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Mitsubishi Fuso 1996-2001

Mitsubishi Mitsubishi Fuso 1996-2001 Service Manuals All Models (FE, FG, FH, FK, FM)

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Page 1
10
◆ Service procedure
3
Removal of engine assembly C B
3
A
A
3
• Hook lifting gear B to two hangers A on engine assembly 3 and lift the engine using crane C until the lifting gear becomes taut.
• Make sure that wiring and hoses are disconnected.
• Lower engine assembly 3 slowly so that it does not hit the frame or cab.
• When the lower part of engine assembly 3 appears from the frame, turn the engine assembly 90° to remove it.
10-7
Page 2
Group 11
Table of Contents
BACK
HOME
Engine
Pub No. TWME9502-11
Page 3
GROUP 11 ENGINE
SPECIFICATIONS .................................................................................. 2
STRUCTURE AND OPERATION ........................................................... 3
TROUBLESHOOTING ........................................................................... 6
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
• Inspection of Engine Compression ................................................................. 7
• Inspection and Adjustment of Valve Clearance .............................................. 9
CYLINDER HEAD AND VALVE MECHANISM ................................... 10
11
TIMING GEAR ..................................................................................... 24
CAMSHAFT .......................................................................................... 28
PISTON, CONNECTING ROD AND CYLINDER SLEEVE .................. 34
FLYWHEEL .......................................................................................... 48
CRANKSHAFT AND CRANKCASE .................................................... 52
11-1
Page 4
SPECIFICATIONS
Item Specifications
Engine model 6D34T2 Type 6-cylinder in-line, water-cooled 4-cycle diesel Combustion chamber type Direct injection type Valve mechanism Overhead valve (OHV) type Maximum output HP/rpm 175/2900
(SAE Gross)
Maximum torque lbs.ft/rpm 325/2000
(SAE Gross) Bore×stroke mm {in.} ø104×115 {4.09×4.53} Total displacement cm3 {cu. in.} 5861 {357.7} Compression ratio 18
11-2
Page 5
STRUCTURE AND OPERA TION
Engine Body
11
4
13
12
11
14
3
2
1
A
8
9
10
5
6
7
1 Rocker arm 2 Valve spring 3 Camshaft 4 Cylinder sleeve 5 Cylinder head 6 Flywheel 7 Crankshaft 8 Exhaust valve
9 Piston 10 Connecting rod 11 Timing gear 12 Tappet 13 Inlet valve 14 Push rod
A : Direction of rotation
11-3
Page 6
STRUCTURE AND OPERA TION
Connecting Rod
Piston
B
“▲”
1
2
4
5
A
6
A
C
B 3
1 Connecting rod bushing 2 Connecting rod 3 Connecting rod cap 4 Connecting rod bolt 5 Upper connecting rod bearing 6 Lower connecting rod bearing
A : Alignment mark B : Mass mark
(A, B, C, D, E, F, G)
A : Stamped mass B : Stamped “T” C : Part number D : Free space for piston cooling
▲ : Front mark
D
11-4
Page 7
Timing Gear
10
11
1 Camshaft gear 2 Injection pump gear 3 Crankshaft gear
5
1
9
8
2
4
3
A
6
7
4 Oil pump gear 5 Idler gear 6 Idler shaft 7 Idler bushing 8 Bolt 9 Thrust plate
10 Power steering oil pump gear
A : Oil hole
Alignment marks “1”, “2”, “3” are punch-marked on each timing gear to ensure proper engage­ment of the gears at installation.
11-5
Page 8
TROUBLESHOOTING
Symptoms
Decrease of power
Possible causes
Oil viscosity unsuitable ● ^ Gr 12 Fuel incorrect or unsuitable ● Valve clearance faulty ● ● Head gasket faulty ● ● Valve and valve seat worn, and carbon deposits ● ● Valve spring fatigued ● ● Piston ring worn or damaged ● ● Piston ring grooves worn or damaged ● ● Injection timing faulty ● ● ^ Gr 13 Injection pump malfunctioning ● ● ^ Gr 13 Cooling system malfunctioning ● ^ Gr 14 Injection nozzle malfunctioning ● ● ^ Gr 13 Fuel system sucking air ● ^ Gr 13 Air cleaner mesh clogged ● ^ Gr 15 Muffler clogged ● ^ Gr 15 Pipe and hose installation faulty ● Ancillary equipment (injection pump, alternator, etc.) or installation faulty ^ Gr 13
V-belt loose or damaged ● ^ Gr 14 Crankshaft pulley mounted incorrectly ● Air cleaner or muffler malfunctioning ● ^ Gr 15 Rocker shaft and bracket faulty ● Rocker shaft bracket lubrication faulty ● Timing gear backlash faulty ● Timing gear system and idler shaft lubrication faulty ● Connecting rod small end bushing worn and piston pin worn ● Crankshaft pin and big end bearing of connecting rod worn or damaged ● Crankshaft journal and main bearing worn or damaged ● Crankshaft and camshaft end play excessive ● Tappet and camshaft worn ●
Engine noise abnormal
●
^ Gr 54
Remarks
11-6
Page 9
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
11
Inspection of Engine Compression
Service standards
Location Maintenance item Standard value Limit Remedy
—
Engine Each cylinder (200 rpm) 2550 kPa {370 lbf/in2, 26 kgf/cm2} 1960 kPa Inspect Compression {285 lbf/in
20 kg/cm
Pressure difference between each — within Inspect cylinder 390 kPa
{57 lbf/in 4 kgf/cm
2
,
2
}
2
,
2
}
0 Special tools Unit : mm {in.}
Location Tool name and shape Part No. Application
— Compression gauge MH061460 Measurement of engine compression
adapter
M14×1.5
The decrease of engine compression is a signal that it is time to overhaul the engine. It is strongly recommended that this item is inspected periodi­cally and that you record the history of deterioration in engine perform­ance as this will help you to diagnose causes of future irregularities. When the vehicle is still new or immediately after installation of new parts, there may be a slight increase in engine compression, but normal performance will be restored soon.
• Before inspection make sure that engine oil, starter and battery are in normal condition.
• Before inspecting the vehicle do the following:
• Run the engine to bring the temperature of the coolant up to
approximately 75 to 85°C {167 to 185°F}.
• Turn all the lights and accessory equipment OFF.
• Put transmission in neutral. (N range for automatic transmission)
• Set the steering wheel at center and straight position.
11-7
Page 10
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
• Remove fuse 2 for the fuel-cut motor from fuse box 1 inside the cab to prevent the fuel from being injected when the engine is cranked by the starter.
1
A
0
3
A
2
• Remove all the injection nozzles. ^ Gr 13
B
• Check that no foreign particles are sticking to waste cloth B covering injection nozzle mounting hole A after cranking the engine.
WARNING–
You must stay clear of injection nozzle mounting hole A when you crank the engine during this inspection. Assume that all cylinders have cracked, and that coolant, engine oil, fuel, etc. have seeped into the cylinder chambers. If this is the state when
C
4
the engine is cranked, there is an extreme danger of these sub­stances being injected out of the injection nozzle mounting hole at high temperature.
• Mount gasket 3 and 0 compression gauge adaptor in injection nozzle mounting hole A and fasten them with nozzle bridge 4, then mount compression gauge C.
• Measure engine compression while cranking the engine.
• Measure engine compression of cylinders and calculate the difference among the cylinders.
• If the engine compression and pressure difference between each cylinder deviate from the limit, reinspect by pouring a small amount of engine oil into injection nozzle mounting hole A.
• When pressure is high : It is likely that either wear or damage of the
slide-contact area of both the piston ring and the cylinder inner surface has taken place.
• When pressure is low : It is likely that burning of the valve, faulty
contact of valve surfaces and/or faults in the cylinder head gasket have developed.
11-8
Page 11
11
Inspection and Adjustment of Valve Clearance
Service standards Unit : mm {in.}
Location Maintenance item Standard value Limit Remedy
— Valve clearance (When engine is cold) 0.4 {0.016} — Adjust
Inspect and adjust the valve clearance while the engine is cold in the
“1, 6”
1
following way. [Inspection]
• Crank the engine to move No.1 or No.6 piston to top dead center, and align stamped marks “1, 6” on the flywheel with pointer 1 on the flywheel housing.
NOTE
The cylinder whose push rod is not pushing up the inlet/outlet rocker is the one whose piston is at top dead center.
• Measure valve clearance A when either No.1 or No.6 piston is at top dead center in accordance with the following tabulated sequence of
A
2
each valve.
Piston No. 1 2 3 4 5 6
Valve In- Ex- In- Ex- In- Ex- In- Ex- In- Ex- In- Ex­arrangement take haust take haust take haust take haust take haust take haust
No.1 piston at top dead center ● ● ● ✕✕● ● ✕✕● ✕✕
No.6 piston at top dead center ✕✕✕● ● ✕✕● ● ✕ ● ●
NOTE
Be sure when taking measurements using feeler gauge 2 that some resistance is felt when inserting the gauge. If the gauge can be inserted freely without any resistance, an accurate measure­ment cannot be obtained.
• If the measured value deviates from the limit, adjust as follows:
4
5
3
2
A
[Adjustment]
• Adjust valve clearance A so that feeler gauge 2 encounters some resistance when it is inserted. Do this by loosening lock nut 3 and turning adjusting screw 4.
• After adjusting, tighten adjusting screw 4 using screwdriver 5 and tighten lock nut 3. Reinspect valve clearance A using feeler gauge 2.
11-9
Page 12
CYLINDER HEAD AND VALVE MECHANISM
● Disassembly sequence
3
1
-Ê 4
- 6
A
2 Ù
5
4 Ê-
● Assembly sequence
Ù
1 Oil filler cap 2 Rocker cover gasket 3 Rocker cover 4 Cylinder head bolt 5 Rocker and bracket assembly
Õ P11-14
6 Push rod 7 Cylinder head and valve
assembly Õ P11-16
8 Cylinder head gasket 9 Tappet
* : Crankcase Õ P11-52
A : Positioning pin
Ù : Non-reusable parts
Follow the disassembly sequence in reverse.
-
A
Service standards Unit : mm {in.}
Location Maintenance item Limit Remedy
6 Push rod deflection — 0.4 {0.016} Replace
9, * Clearance between tappet and crankcase [28] 0.05 to 0.09 0.2 {0.0079} Replace
tappet hole {[1.10] 0.0020 to 0.0035}
Standard value
(Basic diameter in [ ])
Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}
Location Parts to be tightened Tightening torque Remarks
4 Cylinder head bolt 145 {110, 15}+90° Wet
Reuse up to
three times
- Lubricant
Location Points of application Kinds Quantity
4 Thread area of cylinder head bolt Engine oil As required 6 Both ends of push rod Engine oil As required 9 External periphery of tappet Engine oil As required
11-10
Page 13
0 Special tools
Location Tool name and shape Part No. Application
7 Socket wrench MH061560 Installation of cylinder head and valve
assembly
9 Tappet extractor MH063329 Removal of tappet
◆ Service procedure
11
6
Push rod deflection
If the measured value is higher than the limit, replace push rod 6.
6
7
C
4
A
Cylinder head and valve assembly
[Removal]
• Before undoing cylinder head bolts 4, first loosen adjusting screw C of rocker A that pushes down valve spring B.
7
B
• First loosen cylinder head bolts 4 in the numbered order as illustrated, then remove them.
1
5
3
7
17
9252010
11
23
13
19
15
21
22 14 6
16
24 18
12
8
2
4
11-11
Page 14
CYLINDER HEAD AND VALVE MECHANISM
[Installation]
• Center punch the heads of cylinder head bolts 4 before installation.
9
17
25
23
13
21
19
15
11
1
3
5
7
6
12
4
10
2
8
ÀÀÀÀÀÀÀ
16
24
20
22
18
14
CAUTION–
If there are already three center-punch marks, replace the cylinder head bolt with a new one.
• After tightening cylinder head bolts 4 at specified torque in the
numbered order as illustrated, tighten further as follows: À : Tightened simultaneously with rocker and bracket assembly
• Turn 0 socket wrench holder D counterclockwise and keep the
E
0
spring in the wrench compressed.
E : Socket
D
F : Rod G : Rod (for connection)
F
G
• Set 0 socket wrench holder D so that the repercussive force of the spring presses rod G (for connection) against adjacent parts such as,
5°
J
G
H
the rocker shaft bracket or the injection pipe.
• Select a scale that is convenient for reading graduation H on holder D.
• Tighten further by turning socket H clockwise by 90° (setting is in 5°
increments), referring to graduation J on the selected scale.
11-12
Page 15
0
“UP”
8
*
11
8
Cylinder head gasket
[Removal]
CAUTION–
Be careful not to scratch the cylinder head or crankcase * when you remove cylinder head gasket 8.
[Installation]
• Install cylinder head gasket 8 onto crankcase * in the direction as illustrated.
CAUTION–
Be sure to measure the amount of protrusion whenever a piston or connecting rod is replaced, since replacement changes the amount of protrusion.
9
Removal of tappet
9
9*
If the measured value is higher than the limit, replace the faulty parts.
9
*
Clearance between tappet and crankcase tappet hole
11-13
Page 16
CYLINDER HEAD AND VALVE MECHANISM
Rocker and Bracket Assembly
● Disassembly sequence 1 Set bolt
2 Rocker shaft bracket
-
5 6
7
3 Rocker assembly 4 Rocker bushing 5 Lock nut 6 Adjusting screw 7 Rocker 8 Rocker shaft spring 9 Rocker shaft
1
8
3
2
● Assembly sequence
Follow the disassembly sequence in re­verse.
Service standards Unit : mm {in.}
Location Maintenance item Limit Remedy
4, 9 Clearance between rocker bushing and rocker shaft [19] 0.06 to 0.11 0.2 {0.0079} Replace
Standard value
(Basic diameter in [ ])
{[0.75] 0.0024 to 0.0043}
- Lubricant
Location Points of application Kinds Quantity
4 Inner surface of rocker bushing Engine oil As required
0 Special tools Unit : mm {in.}
Location Tool name and shape Part No. Application
ø19 {0.75}
4 Rocker bushing puller MH061378 Removal and installation of rocker bushing
ø21 {0.83}
ø19 {0.75}
11-14
Page 17
◆ Service procedure
11
49
[Inspection] If the clearance is higher than the limit, replace the faulty parts.
9
4
0
4
Rocker bushing
[Removal]
Rocker bushing and rocker shaft
[Press-fitting]
• Align oil hole A of rocker bushing 4 with oil hole B of rocker 7.
0
D
E
7
C
B
4
C
A
B
C
A
9
• Position clinch C and split D of rocker bushing 4 in the direction as illustrated.
• Press-fit rocker bushing 4 from chamfered side E of rocker 7.
9
Installation of rocker shaft
When installing rocker shaft 9, bring oil passage hole for lubrication A to front side B.
C : Fixing hole of the set bolt.
11-15
Page 18
CYLINDER HEAD AND VALVE MECHANISM
Cylinder Head and Valve Assembly
● Disassembly sequence 1 Valve cap
2 Valve cotter 3 Upper retainer 4 Outer valve spring 5 Inner valve spring 6 Valve stem seal 7 Inlet valve 8 Exhaust valve 9 Nut
10 Connecting plate 11 Glow plug ^ Gr 54 12 Bolt 13 Nozzle bridge 14 Nozzle tip gasket 15 O-ring 16 Injection nozzle ^ Gr 13 17 Inlet valve guide 18 Exhaust valve guide 19 Inlet valve seat 20 Exhaust valve seat 21 Water director 22 Stud 23 Cylinder head
Ù-
-
-
9
10
1
3
-
22
11 Ê
Ù15
Ù14
16
12 Ê
13
Ù : Non-reusable parts
CAUTION–
Be careful of the protrusion of glow plug 11 and injection nozzle 16 from
● Assembly sequence
Follow the disassembly sequence in reverse.
the bottom surface of cylinder head
23.
NOTE
When inlet valve 7 and exhaust valve 8 have been removed, replace valve stem seal 6.
11-16
Page 19
11
Service standards Unit : mm {in.}
Location Maintenance item Limit Remedy
4 Outer valve Without load 66.1 {2.60} 63.0 {2.48} Replace
spring
Installed load 273±12 N 230 N {52 lbf, Replace (Installed length 47.25 {1.86}) {62±2.6 lbf, 27.9±1.2 kgf} 23.7 kgf}
Tilt — 2.5 {0.098} Replace
5 Inner valve Without load 60.0 {2.36} 52.1{2.05} Replace
spring
7 Inlet valve Stem diameter 8.96 to 8.97 {0.3529 to 0.3531} 8.85 {0.348} Replace
Installed load 119±4.4 N 79 N {18 lbf, Replace (Installed length 40.3 {1.59}) {27±1.0 lbf, 12.1±0.45 kgf} 8.1 kgf}
Tilt — 2 {0.079} Replace
Valve recess from the cylinder 0.75 to 1.25 {0.030 to 0.049} 1.5 {0.059} Inspect head bottom surface each part
Valve margin 1.5 {0.059} 1.2 {0.047} Correct or
Valve seat angle 45°±15' — Correct or
7, 17 Clearance between inlet valve stem and inlet valve [9] 0.04 to 0.06 0.15 Replace
guide {[0.35] 0.0016 to 0.0024} {0.0059}
8
Exhaust valve
Outer diameter of stem 8.93 to 8.94 {0.3515 to 0.3519} 8.85 {0.348} Replace Valve recess from the cylinder 0.75 to 1.25 {0.030 to 0.049} 1.7 {0.067} Inspect
head bottom surface each part Valve margin 1.5 {0.059} 1.2 {0.047} Correct or
Valve seat angle 45°±15' — Correct or
8, 19 Clearance between exhaust valve [9] 0.07 to 0.1 0.2 Replace
stem and exhaust valve guide {[0.35] 0.0028 to 0.0039} {0.0079}
19 Seat width of inlet valve seat 2±0.2 {0.079±0.0079} 2.8 {0.11} Correct or
20 Seat width of exhaust valve seat 2±0.2 {0.079±0.0079} 2.8 {0.11} Correct or
23
Cylinder head
Distortion of bottom 0.05 {0.0020} or less 0.2 {0.0079} Correct or
Height from top to bottom 95±0.1 {3.74±0.0039} 94.6 {3.72} Replace
Standard value
(Basic diameter in [ ])
replace
replace
replace
replace
replace
replace
replace
Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}
Location Parts to be tightened Tightening torque Remarks
11 Glow plug 15 to 20 {11 to 14, 1.5 to 2.0} — 12 Bolt (Nozzle bridge mounting) 25 {18, 2.5} —
- Lubricant
Location Points of application Kinds Quantity
1 Slide contact areas of valve cap and rocker Engine oil As required 6 Lip of valve stem seal Engine oil As required
7, 8 Valve stem Engine oil As required
11-17
Page 20
CYLINDER HEAD AND VALVE MECHANISM
0 Special tools Unit : mm {in.}
Location Tool name and shape Part No. Application
2 Valve lifter 30091-08500 Removal and installation of valve cotter
ø47 {1.85}
6 Valve stem seal MH061293 Installation of valve stem
installer
ø28 {1.10}
ø9 {0.35}
7, 8 Valve lapper 30091-07500 Fitting of valve and valve guide
{0.51}
Valve guide remover MH061066 Removal of valve guide
ø9 {0.35}
17, 18
ø28.5 {1.12}
Valve guide installer MH061998 Press-fitting of valve guide
ø15 {0.59}
18 {0.71}
A : Caulking tool body B : Caulking ring
19, 20 (Inlet) Press-fitting of valve seat
Inlet ø47.6 {1.87} Exhaust ø40.6 {1.60}
C dimension
ø9 {0.35}
C
A
B
A : MH061067 B : MH061275
MH061069 (Exhaust)
11-18
Page 21
11
◆ Service procedure
2
0
3
2
4
5
6
2
Valve cotter
[Removal] Remove valve cotter 2 making sure that valve springs 4, 5 are squarely and evenly pressed down by 0 valve lifter.
[Installation] Follow the removal procedure in reverse.
CAUTION–
Be sure not to press down on valve springs 4, 5 too hard because this would cause upper retainer 3 to contact valve stem seal 6 and damage it.
45
Install outer springs 4 and inner springs 5 in cylinder head 23 in the direction as illustrated.
A : Closely wound area
6
• Apply engine oil to lip A of valve stem seal 6.
• Tap down 0 valve stem seal installer until it hits cylinder head 23.
78
[Inspection]
0
A 6
23
4 5
A
A
23
Installation of outer and inner valve springs
Installation of valve stem seal
Inlet valve and exhaust valve
7, 8
(1) Inspection of stems
If the measured value is lower than the limit or in the case of excessive wear, replace valves 7, 8.
CAUTION–
Be sure to lap valve seats 19, 20 when valves 7, 8 are replaced with new ones. Õ P11-21
11-19
Page 22
CYLINDER HEAD AND VALVE MECHANISM
(2) Valve seat angle and valve margin
If the measured value is higher than the limit, correct or replace valves
7, 8
7, 8. A : Valve seat angle B : Valve margin
A
B
[Correction]
NOTE
• Be sure to keep the grinding work as light as possible.
• Be sure to replace valves 7, 8 after grinding if valve margin deviates from the limit.
• Be sure to lap valve 7, 8 and valve seats 19, 20 after grinding. Õ P11-21
7, 8
0
78MN
[Inspection] When the clearance is higher than the limit, replace the faulty parts.
17, 18
Valve guide
[Removal]
Valve and valve guide
11-20
23
17, 18
0
10 mm{0.39 in.}
17, 18
[Installation]
• Tap down valve guides 17, 18 with 0 valve guide installer until it hits cylinder head 23.
CAUTION–
• The length of fit of valve guides 17, 18 is standardized. Be sure to use 0 valve guide installer.
• Be sure to distinguish between valve guides 17, 18. Exhaust valve guide 18 is longer.
Page 23
11
78OP
[Inspection]
0
A
• Apply red lead evenly to entire surface A of valve seats 19, 20 that contact valves 7, 8.
• Fit valves 7, 8 to valve seats 19, 20 and tap once without rotating.
Valve and valve seat
NOTE
Be sure to carry out inspection under the condition that valves 7,
7, 8
B
8 and all parts of valve guides 17, 18 are normal.
• Check how much red lead has transferred to valves 7, 8 to determine the contact of the valve and the seat. According to the degree of abnormality, take proper measures to correct it.
Contact conditions Correction measures
Minor fault Valve lapping Major fault Repair of valve and seat or replacement of both
[Correction] Valve polishing is done in the following manner:
• Apply valve lapping compound thinly to contact surface A of valves 7,8 with valve seats 19, 20.
CAUTION–
A
Take care not to smear stems B of valves 7, 8 with the compound.
0
NOTE
• Start with medium grit compound (120 to 150 grit) and for finish­ing up, use finer grit (200 grit or finer).
• Mixing with a small amount of engine oil will make the compound consistent and make even application easier.
• Tap valves 7, 8 against valve seats 19, 20 several times while rotating the valves slightly at each strike.
• Clean off the compound with gas oil.
• Apply engine oil to contact surface A of valve seats 19, 20 and smooth
the surface.
• Check the contact of valves 7, 8 and valve seats 19, 20.
• If contact does not take place completely around the seat, replace
valve seats 19, 20.
11-21
Page 24
CYLINDER HEAD AND VALVE MECHANISM
OP
7, 8
19, 20
A
[Inspection]
(1) Valve seat width
If the measured value is higher than the limit, replace valve seats 19,
20. A : Valve seat width
Valve seat
NOTE
Be sure to lap and fit valves 7, 8 and valve seats 19, 20 after correction or replacement.
(2) Extent of valve recess from the bottom surface of cylinder
head
If the measured value is higher than the limit, correct or replace the faulty parts. B : Extent of valve recess
[Correction]
• Grind valve seats 19, 20 using valve seat cutter or valve seat grinder.
• After grinding, do another light abrasion using 400 grit emery paper
placed between the cutter and the seat.
• Adjust the seat width A of valves 7, 8 using 15° or 75° cutter to make seat width conform to the standard value.
C : Valve seat angle
7, 8
B
CB
A
19, 20
7, 8
19, 20
CAUTION–
Be sure that as a result of grinding, recess B of valves 7, 8 does not become higher than the limit.
11-22
0.5 to 1.0 mm
D
{0.020 to 0.0039 in.}
19, 20
• After correction is done, be sure to carry out lapping and fitting on valves 7, 8 and valve seats 19, 20.
[Removal]
• Valve seats 19, 20 have been set in by the cooling-off-process, and have to be thinned by grinding off the inner side for removal under normal temperature. D : Part to be ground
Page 25
23
ø46
{1.81
+0.025
0 +0.00098
0
G
11
[Installation]
• Make sure that the diameter of valve seat hole of cylinder head 23 conforms to the standard value.
E : Inlet valve seat hole diameter F : Exhaust valve seat hole diameter
E
mm
in.}
ø39
{1.54
F
+0.025
0
mm
+0.00098
0
1
2
19, 20
in.}
• Immerse valve seats 19, 20 in liquid nitrogen and cool them substan- tially. Press-fit into the cylinder head using 1 caulking tool body and 2 caulking rings inlet and exhaust.
CAUTION–
Be sure, when press-fitting, to place the chamfered side G of 2 caulking rings inlet and exhaust against valve seats 19, 20.
• After installation of valve seats 19, 20, work until they contact valves 7, 8 smoothly.
21
Q
Installation of water director
A
4mm {0.16 in.}
23
• With indent A set in the direction as illustrated, press-fit water director 21 into cylinder head 23 to the specified depth.
S
Inspection of cylinder head
Measure the extent of distortion of the bottom of cylinder head 23, and if the measured value is higher than the standard value, grind using a surface grinder.
CAUTION–
Be sure to keep the amount of grinding within the limit of the height of cylinder head 23.
23
11-23
Page 26
TIMING GEAR
-Ê1
*3
17
*2
*3
14 -
16
21
21
*4
*1
*5
*2
*1
Ê18
19
Ù-20
-
5
4
3
­Ù
8
­Ù
­Ê
10
7
6
Ê
*4
● Inspection before disassembly
Õ P11-26
● Disassembly sequence 1 Nut
2 Taper cone 3 O-ring 4 Crankshaft pulley 5 Bolt 6 Eye bolt 7 Air and water suction pipe
^ Gr 12
8 Front oil seal 9 Timing gear case
10 Bolt 11 Thrust plate
● Assembly sequence
Follow the disassembly sequence in reverse.
12 Idler gear assembly 13 Idler gear bushing 14 Idler gear 15 Idler gear shaft 16 Clamp 17 Oil hose ^ Gr 37 18 Bolt 19 Oil hose ^ Gr 37 20 O-ring 21 Power steering oil pump
^ Gr 37
*1 : Crankshaft gear Õ P11-52 *2 : Oil pump gear ^ Gr 12 *3 : Camshaft gear Õ P11-28 *4 : Air compressor gear ^ Gr 35 *5 : Front oil seal slinger Õ P11-52
Ù : Non-reusable parts
NOTE
Do not remove front oil seal 8, un­less it is faulty.
11-24
Page 27
11
Service standards Unit : mm {in.}
Location Maintenance item Limit Remedy
— Backlash of Idler gear assembly and crankshaft 0.07 to 0.15 {0.0023 to 0.0059} 0.3 {0.012} Replace
gears gear
Idler gear assembly and camshaft 0.07 to 0.17 {0.0023 to 0.0067} 0.3 {0.012} gear
Idler gear assembly and injection 0.07 to 0.17 {0.0023 to 0.0067} 0.3 {0.012} pump gear
Crankshaft gear and oil pump gear 0.10 to 0.18 {0.0039 to 0.0071} 0.3 {0.012} Camshaft gear and power steering 0.08 to 0.16 {0.0031 to 0.0063} 0.3 {0.012}
oil pump gear
— End play of idler gear 0.05 to 0.15 {0.0020 to 0.0059} 0.3 {0.012} Inspect
13, 15 Clearance between idler gear bushing and [45] 0.03 to 0.06 0.1 {0.0039} Replace
idler shaft {[1.77] 0.0012 to 0.0024}
Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}
Location Parts to be tightened Tightening torque Remarks
1 Nut (Taper cone mounting) 490 {360, 50} Wet
6 Eye bolt (Air and water sunction pipe mounting) 25 {19, 2.6} — 10 Bolt (Thrust plate mounting) 24 {17, 2.4} — 18 Bolt (Oil hose mounting) 125 {94, 13} —
Standard value
(Basic diameter in [ ])
- Lubricant and sealant
Location Points of application Kinds Quantity
1 Thread area of nut Engine oil As required
3, 20 Entire body of O-ring Engine oil As required
8 Front oil seal lip Engine oil As required
9 Mounting surface of timing gear case THREEBOND 1207C As required 10 Thread area of bolt Engine oil As required
0 Special tools Unit : mm {in.}
Location Tool name and shape Part No. Application
2 Cone puller MH062496 Removal of taper cone
M44×1.5
13 Idler gear bushing puller MH062224 Removal and installation of idler gear
ø49 {1.93}
bushing
ø44.5 {1.75}
11-25
Page 28
TIMING GEAR
◆ Service procedure
● Inspection before disassembly
(1) Backlash of each gear
Measure three or more locations on the pairing gears and if the measurements are higher than the limit, replace the faulty parts.
(2) End play of idler gear
If the measured value is higher than the limit, replace the faulty parts.
0
2
ø1 to 1.5 mm {0.039 to 0.059 in.}
A
2
Removal of taper cone
9
Installation of timing gear case
Apply sealant A to the mounting surface of timing gear case 9 evenly without break. After applying sealant, within three minutes, mount to the front plate.
CAUTION–
• Be sure to clean and wipe off oily substances from the surface where sealant A is to be applied.
• Make sure that sealant A is not transferred to other areas while the mounting work is being done.
• Be sure to reapply sealant A if the bolts are loosened or removed by any cause whatsoever after mounting.
• Do not start the engine within an hour of mounting.
11-26
Page 29
*2
11
G
A
11
10
12
*1
*3
Installation of thrust plate
A : Chamfered side
H
Installation of idler gear assembly
Install idler gear assembly 12 by matching alignment marks “1”, “2”, “3” on the gears that engage with those on the assembly.
*1 : Crankshaft gear *2 : Camshaft gear *3 : Air compressor gear
NOTE
When aligning each gear with its alignment mark, make sure that pistons No.1, 6 are higher than top dead center.
IK
[Inspection] If the clearance is higher than the limit, replace the faulty parts.
A
0
13
A
0
13
B
14
Idler gear bushing
[Removal]
A : Press
[Press-fitting]
• Press-fit idler gear bushing 13 from chamfered side B of idler gear 14 and align oil holes C of the idler gear and the bushing.
• After press-fitting, finish the fitting by bringing the clearance between idler gear bushing 13 and the idler shaft to the standard value.
Idler gear bushing and idler shaft
C
11-27
Page 30
CAMSHAFT
-
-
1
● Disassembly sequence 1 Bolt
2 Camshaft assembly 3 Bolt 4 Washer 5 Camshaft gear
NOTE
Do not remove camshaft gear 5 unless it is faulty.
6 Thrust plate 7 Key 8 Camshaft 9 No.1 camshaft bushing
10 No.2 camshaft bushing
-
Ê
-
*
-
7
Ù
4
3
11 Sealing cap 12 No.4 camshaft bushing 13 No.3 camshaft bushing
* : Crankcase Õ P11-52
Ù : Non-reusable parts
● Assembly sequence
Follow the disassembly sequence in reverse.
Service standards Unit : mm {in.}
Location Maintenance item Limit Remedy
— End play of camshaft 0.05 to 0.22 {0.0020 to 0.0087} 0.3 {0.012} Inspect
8 Camshaft Difference between Inlet 7.195±0.05 {0.28±0.0020} 6.70 {0.26}
long and short
diameters
Exhaust 7.321±0.05 {0.29±0.0020} 6.82 {0.27}
Bend 0.02 {0.00079} or less 0.05 {0.0020} Replace
9, 10, Clearance between camshaft and
No.1 to No.3
12, 13 camshaft bushing {[2.15] 0.0012 to 0.0031} or replace
No.4 [53] 0.03 to 0.08 0.15 {0.0059}
Standard value
(Basic diameter in [ ])
[54.5] 0.03 to 0.08 0.15 {0.0059} Repair
{[2.09] 0.0012 to 0.0031}
Long diameter
47.105 {1.85}
Short diameter
39.910 {1.57}
Long diameter
Replace
46.979 {1.84}
Short diameter
39.658 {1.56}
Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}
Location Parts to be tightened Tightening torque Remarks
3 Bolt (Camshaft gear mounting) 175 {130, 18} Wet
11-28
Page 31
11
- Lubricant
Location Points of application Kinds Quantity
3 Thread area of bolt Engine oil As required
9, 10 Inner surface of camshaft bushing Engine oil As required
12, 13
0 Special tools Unit : mm {in.}
Location Tool name and shape Part No. Application
Gear puller MH061326 Removal of camshaft gear
5
9, 10,
12, 13
Plug MF665004 Blind plug for removal of camshaft gear
Camshaft bushing installer and extractor
A, CB
Dimension Dimension No. 1 ø58.5 {2.30} ø54.5 {2.15} No. 2
ø58 {2.28} ø54.5 {2.15} No. 3
No. 4 ø57 {2.24} ø53 {2.09}
M14×1.5
C
B
A
MH061276 Removal and press-fitting of camshaft
bushing
◆ Service procedure
● Inspection before disassembly
Camshaft end play If the measured value is higher than the limit, replace the faulty parts.
2
Camshaft assembly
5
1
[Removal] Remove camshaft assembly 2 by undoing bolts 1 through the holes in camshaft gear 5.
CAUTION–
2
Be careful not to damage the camshaft bushings when you remove camshaft assembly 2.
11-29
Page 32
CAMSHAFT
2
1
5
6
8
5
2
“2”
[Installation]
• Before installing camshaft assembly 2, measure the end play be- tween thrust plate 6 and camshaft 8.
• If the measured value is higher than the limit, replace the faulty parts.
• Install the camshaft assembly by matching the alignment mark on
camshaft gear 5 with the alignment mark on the idler gear. Õ P11-
5
Camshaft gear
[Removal]
• Never remove camshaft gear 5 by striking, hitting, or hammering it.
[Installation]
• Install camshaft gear 5 onto camshaft 8 in the direction as illustrated.
• Be sure when finishing the installation to install key 7.
5
7
8
6
“F”
6
8
Installation of thrust plate
Install thrust plate 6 onto camshaft 8 in the direction as illustrated.
11-30
Page 33
8
Inspection of camshaft
11
8
(1) Difference between long diameter and short diameter
If the measured value is lower than the limit, replace camshaft 8.
D
7.5 mm {0.30 in.}
7.5 mm {0.30 in.}
A
A
B
C
NOTE
Measure at point A, as illustrated, because the cam is tapered. B : Long diameter
C : Short diameter D : Front of the engine
(2) Degree of bend
To measure deflection, support camshaft 8 at area E of No.1 journal,
E
F
and area F of No.4 journal . Then, measure the amount of deflection at area G of No.2 journal, and area H of No.3 journal. If any of the measured values is higher than the limit, replace the camshaft.
NOTE
G
H
Degree of bend of camshaft 8 is a half of the indicated value of the gauge after rotating the shaft 360
8
to
FHI
Camshaft and camshaft bushing
°.
[Inspection] If the clearance is greater than the limit, replace the faulty parts.
Camshaft bushing
9, 10, 12, 13
0
[Removal] Remove No.3 camshaft bushing 13, and No.4 camshaft bushing 12 from the rear end of the crankcase.
“1”, “2”, “3”, “4”
[Press-fitting]
• Identify, by referring to the table below, No.1 to No.4 camshaft bush­ings by noting marks “1”, “2”, “3”, “4” on camshaft bushings 9, 10,
12, 13. If you cannot identify the mark, measure outer diameter A of
A
9, 10, 12, 13
the bushing and refer to the table below.
Bushing No. (from the front of the engine) Mark
No.1 1 ø58.50 {2.30} No.2 2 ø58.06 {2.28} No.3 3 ø57.5 {2.26} No.4 4 ø57.06 {2.25}
Outer diameter A (mm {in.})
11-31
Page 34
CAMSHAFT
9, 10, 12, 13
0
• For press-fitting, mount guide B to 0 camshaft bushing installer and extractor.
• Install camshaft bushings 9, 10, 12, 13 in descending order, from No.4 to No.1.
• Install No.4 camshaft bushing 12 from the rear end of the engine, and No.3 to No.1 camshaft bushings 9, 10, 13 from the front end of the engine.
B
12
C
40°
• Align oil hole C of No.4 camshaft bushing 12 in the direction as illustrated.
• Press in until surface D of No.4 camshaft bushing 12 is flush with chamfered part E of crankcase *.
*
D
F
12
0
F : Front of the engine
E
10, 13
11-32
0
G
40°
10
13
• Align oil hole G, of No.2 to No.3 camshaft bushings 10, 13, in the direction as illustrated, and press-fit in the order of No.3, 2.
• Press in until surface H of No.2 to No.3 camshaft bushings 10, 13 is
*
flush with surface J of crankcase *. F : Front of the engine
F
H
J
10, 13
Page 35
11
200 mm {7.37 in.}
ø17.5 mm {0.69 in.}
9
L
15°
40°
M
0
K
50 mm {1.97 in.}
ø30 mm {1.18 in.}
0
• For press-fitting of No.3 camshaft bushing 13, use tool K as illustrated.
• Align oil holes L, M of No.1 camshaft bushing 9 in the direction as
*
illustrated.
L : ø3 mm {0.11 in.} M : ø8 mm {0.31 in.}
* : Crankcase
• Align oil hole M of No.1 camshaft bushing 9 with oil hole N of crank-
*
P
F
Q
case * and press in until camshaft bushing surface P is flush with crankcase surface Q.
F : Front of the engine
9
11
*
2.5 mm {0.098 in.}
9
M
F
*
N
G
*
A
Installation of sealing cap
Press-fit sealing cap 11 into crankcase * to the specified depth.
A : Front of the engine
11-33
Page 36
PISTON, CONNECTING ROD AND CYLINDER SLEEVE
-
*2
-
*1
-
3
-Ê1
● Disassembly sequence 1 Bolt
2 Lower connecting rod bearing 3 Connecting rod cap 4 Upper connecting rod bearing 5 Piston and connecting rod assembly
Õ P11-42
6 Cylinder sleeve
● Assembly sequence
Follow the disassembly sequence in reverse.
*3
*1 : Crankshaft Õ P11-52 *2 : Crankcase Õ P11-52 *3 : Oil pan ^ Gr 12
11-34
Page 37
11
Service standards Unit : mm {in.}
Location Maintenance item Limit Remedy
— Extent of piston protrusion 0.43 to 0.69 {0.017 to 0.027} — Inspect — End play of connecting rod 0.15 to 0.45 {0.0059 to 0.018} 0.6 {0.024} Inspect
2, 4 Connecting rod bearing Oil clearance [60] 0.04 to 0.09 0.2 {0.0079} Replace
Expansion — Upper :
5, 6 Clearance between piston and connecting rod [104] 0.07 to 0.11 — Adjust or
assembly and cylinder sleeve {[4.094] 0.0028 to 0.0043} replace with
6 Cylinder sleeve Inner 104 to 104.03 {4.094 to 4.095} 104.25 {4.10} Adjust or
diameter replace with Circular 0.01 {0.00039} or less —
accuracy Cylindrical 0.03 {0.0012} or less —
accuracy
6, *2 Interference between cylinder Standard 0.17 to 0.23 {0.0067 to 0.0091} — Replace with
sleeve and crankcase oversizes
Oversize 0.19 to 0.21 {0.0075 to 0.0083} — Replace
Standard value
(Basic diameter in [ ])
{[2.36] 0.0016 to 0.0035}
less than 64.5
{2.54}
Lower :
less than 64.27
{2.53}
oversizes
oversizes
Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}
Location Parts to be tightened Tightening torque Remarks
1 Bolt 30 {22, 3}+90°±5° Wet
- Lubricant
Location Points of application Kinds Quantity
1 Thread area of bolt Engine oil As required
2, 4 Inner surface of bearing Engine oil As required
*2 Sleeve hole of crankcase Spindle oil (ISO VG 32) As required
11-35
Page 38
PISTON, CONNECTING ROD AND CYLINDER SLEEVE
0 Special tools Unit : mm {in.}
Location Tool name and shape Part No. Application
Socket wrench MH061560
5 Installation of piston and connecting
A : Piston guide clamp A : MH061890 B : Piston guide lever B : MF061658
6 Cylinder sleeve installer MH062228 Installation of cylinder sleeve
A
B
ø103 {4.06}
rod assembly
◆ Service procedure
● Inspection before disassembly
A
*2
(1) Extent of piston protrusion from the upper surface of
crankcase *2
NOTE
Always inspect the extent of piston protrusion because it af­fects the engine performance greatly.
11-36
• Measure piston protrusion at two points on the top of the piston, and produce the average value. A : Front of the engine
• If the average valve deviates from the limit, inspect clearance of the related parts.
(2) End play of connecting rod
• Measure the end play of each connecting rod.
• If the measured value is higher than the limit, replace the faulty
parts.
Page 39
11
2
A
4
B
A
24
[Installation] Install connecting rod bearings 2, 4 by matching lugs A to the connecting rods.
Connecting rod bearing
CAUTION–
Be sure to distinguish between upper and lower connecting rod bearings 2, 4. The upper bearing has oil opening B while the lower bearing has no oil opening.
[Inspection]
CAUTION–
• Do not forcibly open or expand connecting rod bearings 2, 4.
• When either upper or lower connecting rod bearings 2, 4 needs replacing, replace as a set.
(1) Expansion at free state
If the measured value is lower than the limit, replace connecting rod bearings 2, 4.
(2) Clearance between connecting rod bearing and crankshaft
If the clearance between connecting rod bearing 2, 4 and crankshaft *1 is lower than the limit, replace the faulty parts.
11-37
Page 40
PISTON, CONNECTING ROD AND CYLINDER SLEEVE
5
B
A
C
Installation of piston and connecting rod assembly
CAUTION–
• Be sure to fit piston ring A in the correct position. Õ P11-46
• Be careful not to scratch or damage head B of the piston (a part of the combustion chamber).
• Make sure that the connecting rod does not hit oil jet C.
1
2
“▲”
D
E
2
1
• Install piston front mark “▲” directed towards the front of the engine using the following procedure. D : Front of the engine
• Match the inner diameter of 1 piston guide clamp to the outer diameter of the piston skirt by turning adjusting bolt E of 2 piston guide lever.
• After adjusting, set 1 piston guide clamp and 2 piston guide lever at the top of the piston so that the clamp is flush with the top of the piston.
11-38
1
3 F
• After the piston is inserted, align alignment marks F on the connecting rod with the alignment marks on connecting rod cap 3 and tighten bolt 1 at specified torque. Then tighten the bolt further as follows:
Page 41
*1
11
• Turn 0 socket wrench holder G counterclockwise and keep the
H
0
G
J
K
K
M
5°
L
spring in the wrench compressed.
H : Socket J : Rod K : Rod (for connection)
• Set 0 socket wrench holder G so that the repercussive force of the spring presses rod K (for connection) against crankshaft *1.
• Select a scale that is convenient for reading graduation L on holder G.
• Tighten further by turning socket H clockwise by 90°±5° (setting is in
5° increments), referring to graduation M on the selected scale.
NOTE
After installation of connecting rod cap 3, inspect the following points :
• End play of the connecting rod : Õ P11-36
• Piston protrusion : Õ P11-36
*2
6
56
20 mm {0.79 in.} or more
B
A
[Inspection]
• If the inner diameter of cylinder sleeve 6 is higher than the limit, bore the cylinder sleeve oversize and use an oversized piston.
Piston and connecting rod assembly, and cylinder sleeve
A : In the direction of the crankshaft axis
60 mm {2.36 in.} or more
B : At right angles to the crankshaft axis
• If the clearance between piston 5 and cylinder sleeve 6 deviates from the standard value, even when the inner diameter of the cylinder sleeve is within the limit, replace the piston.
72.15 mm {2.84 in.}
[Selection of oversized piston] Extent of oversize : 0.50, 1.00 mm {0.020, 0.039 in.}
C
• Determine the extent of oversize by measuring the inner diameters of all the cylinders and calculating the maximum wear amount of all the cylinders.
• Measure the outer diameter of the oversized piston to be used.
C : Position to measure the outer diameter of the piston
• Bore cylinder sleeve 6 and hone it to make the clearance between piston 5 and the cylinder sleeve conform to the standard value.
NOTE
• Even if only one cylinder sleeve 6 requires boring, all the other cylinder sleeves must be bored to the identical oversize.
• Piston rings must be replaced with the corresponding oversized ones.
11-39
Page 42
PISTON, CONNECTING ROD AND CYLINDER SLEEVE
*2
D1
D2
D3
D
Cylinder sleeve
[Removal]
• Mount a boring machine on crankcase *2 and center. Centering must
E
be done at the lower part of cylinder sleeve 6 which is less unevenly worn.
• Bore until the thickness of cylinder sleeve 6 is approximately 0.5 mm {0.020 in.}.
• Insert tool D (a modified screwdriver) between crankcase *2 and cylinder sleeve 6, break the sleeve by tapping it gently, then remove.
6
*2
CAUTION–
Make sure when inserting tool D that round part E is facing crankcase *2.
[Installation]
• Inspect sleeve hole of crankcase *2 before installing cylinder sleeve
15 mm
{0.59 in.}
6. If there are irregularities, such as defects or insufficient interfer­ence, correct them by boring.
NOTE
99 mm
{3.90 in.}
183 mm {7.20 in.}
B
A
• Pull out cylinder sleeve 6 of all cylinders and bore the sleeve holes perfectly round when you bore the sleeve holes of crank­case *2.
• Apply spindle oil (ISO VG 32) when you push cylinder sleeve 6 into the sleeve hole of crankcase *2.
6
15 mm
{0.59 in.}
D1
99 mm
D2 D3
{3.90 in.}
183 mm {7.20 in.}
B
A
Inspection of interference must be carried out as follows.
• Measure the inner diameter of the sleeve hole of crankcase *2 and the outer diameter of cylinder sleeve 6 at the specified positions illustrated.
• Take the average value at the top, middle and bottom (D1, D2, D3) and across the diameter (A, B). If the interference is lower than the limit, bore the sleeve hole of crankcase *2 oversize.
11-40
Page 43
11
*2
0
6
< If interference is sufficient >
• Press-fit cylinder sleeve 6 into crankcase *2 from the chamfered end using 0 cylinder sleeve installer.
NOTE
Align the top of cylinder sleeve 6 with the top of crankcase *2 when press-fitting.
• After press-fitting, make the inner diameter of cylinder sleeve 6 con- form to the standard value by honing the surface.
< If interference is insufficient >
• Prepare cylinder sleeve 6 which is 0.5 mm {0.020 in.} oversize in diameter.
• Hone crankcase *2, making the clearance between the outer diam- eter of cylinder sleeve 6 and the sleeve hole of crankcase *2 conform to the standard value.
• Press-fit cylinder sleeve 6 into crankcase *2 from the chamfered end using 0 cylinder sleeve installer.
NOTE
Align the upper face of cylinder sleeve 6 with the upper face of crankcase *2 when press-fitting.
• After press-fitting, make the inner diameter of cylinder sleeve 6 con- form to the standard value by honing the surface.
11-41
Page 44
PISTON, CONNECTING ROD AND CYLINDER SLEEVE
Piston and Connecting Rod Assembly
● Disassembly sequence 1 Snap ring
2 Piston pin 3 Connecting rod bushing 4 Connecting rod
-
1
-
-
5 1st compression ring 6 2nd compression ring 7 Oil ring 8 Piston
● Assembly sequence
Follow the disassembly sequence in re­verse.
Service standards Unit : mm {in.}
Location Maintenance item Limit Remedy
2, 3 Clearance between piston pin and [36] 0.03 to 0.04 0.1 {0.0039} Replace
connecting rod bushing {[1.42] 0.0012 to 0.0016}
2, 8 Clearance between piston and piston pin [36] 0.007 to 0.021 0.05 {0.0020} Replace
4 Degree of bend and distortion of connecting rod — 0.05 {0.0020} Repair or
5 to 7 Deviation of piston ring 1st compression ring 0.3 to 0.45 {0.012 to 0.018} 1.5 {0.059} Replace
fitted position
5 to 8 Clearance between piston 1st compression ring 0.02 to 0.10 {0.00079 to 0.0039} 0.2 {0.0079} Replace
ring and piston ring groove
2nd compression ring 0.4 to 0.55 {0.016 to 0.022} Oil ring 0.25 to 0.45 {0.0098 to 0.018}
2nd compression ring 0.05 to 0.08 {0.0020 to 0.0031} 0.15 {0.0059} Oil ring 0.03 to 0.06 {0.0012 to 0.0024}
Standard value
(Basic diameter in [ ])
{[1.42] 0.00028 to 0.00083}
replace
- Lubricant
Location Points of application Kinds Quantity
2 Exterior of piston pin Engine oil As required 3 Exterior of connecting rod bushing Engine oil As required 4 Bushing attachment area of connecting rod Engine oil As required
11-42
Page 45
11
0 Special tools Unit : mm {in.}
Location Tool name and shape Part No. Application
3 Connecting rod bushing puller kit MH062225 Removal and installation of connecting
rod bushing
ø60 to 120 {2.36 to 4.72}
5 to 7 Piston ring tool MH060014 Removal and installation of piston ring
◆ Service procedure
0
23
[Inspection] If the clearances are higher than the limit, replace the faulty parts.
2
3
Connecting rod bushing
Use 0 connecting rod bushing puller kit to replace connecting rod bushing 3. (Components of 0 connecting rod bushing puller kit)
Nut [Pulling-out]
C
D
3
4
B
E
• Remove upper connecting rod bearing from the big end of connecting rod 4.
• Place connecting rod 4 on base A and fix it to the base at two points, bracket B and plate E.
• Fit collar D in puller C in the direction as illustrated, and pull out connecting rod bushing 3 with a gradual load of approximately 49 kN {11020 lbf, 5000 kgf}.
Piston pin and connecting rod bushing
A : Base B : Bracket C : Puller D : Collar
E : Plate F : Collar G :
A
11-43
Page 46
PISTON, CONNECTING ROD AND CYLINDER SLEEVE
[Press-fitting]
• Apply engine oil to the exterior peripheral area of connecting rod
4
C
F
3
D
G
3
H
bushing 3 and the inner area of the bushing fitting ring of connecting rod 4.
• Fit collar F, connecting rod bushing 3 and collar D in puller C in the arrangement and direction as illustrated and mount them with nut G.
• Align oiling holes H of connecting rod bushing 3 and connecting rod 4, and gradually press in the bushing with approximately 49 kN {11023 lbf, 5000 kgf} load.
• After press-fitting, ream connecting rod bushing 3 to make its clear­ance with piston pin 2 conform to the standard value.
NOTE
After press-fitting bushing 3, insert piston pin 2 and make sure that the rod moves smoothly without any excessive play.
“▲”
248
8
A
8
2
C
4
B
2
[Disassembly]
• Drift out piston pin 2 using a rod.
• When removal of piston pin 2 is difficult, warm piston 8 using a piston heater or hot water.
[Installation]
• Apply engine oil to piston pin 2 and assemble connecting rod 4 and piston 8 in the direction as illustrated.
A : Piston mass (Mass of piston is marked) B : Connecting rod mass mark (Alphabetical: A, B, C, D, E, F, G)
C : Mounting base of connecting rod cap
▲ : Front mark
• When piston pin 2 insertion is difficult, warm piston 8 using a piston heater or hot water.
Piston pin and connecting rod and piston
CAUTION–
• Make sure that the total mass error of all pistons 8 in one engine is 10 g {0.35oz} or less.
• Be sure to install connecting rods 4, to be used in one engine, that have identical mass mark B.
• Be sure that after inserting piston pin 2 the connecting rod operates smoothly without excessive play.
11-44
Page 47
11
8
2
100 mm {3.94 in.}
100 mm {3.94 in.}
28
Clearance between piston pin and piston
If the clearance is higher than the limit, replace the faulty parts.
4
C
A
Degree of bend or distortion of connecting rod
• Mount connecting rod bushing 3 and piston pin 2 to connecting rod 4.
• Measure degree of bend A and distortion B of connecting rod 4. If the measured value is higher than the limit, repair or replace the connect-
2
ing rod.
C : Connecting rod aligner (Measuring instrument)
NOTE
• When making measurements by mounting connecting rod 5 to
B
connecting rod aligner C, make sure that the upper connecting rod bearing and the lower connecting rod bearing are mounted on the rod.
• Mount the connecting rod cap by tightening the bolt at specified torque. Õ P11-34
2
C
11-45
Page 48
PISTON, CONNECTING ROD AND CYLINDER SLEEVE
5
to
“▲”
0
Piston ring
[Removal]
[Installation]
E
C
B
5, 6
D
A
• Install oil ring 8 so that split D and the butting joint of expander spring
• Compression rings 5 and 6 have a manufacturer’s mark A at the split,
8
E come to the points as illustrated.
and installation should be made with the mark outward.
B : The split of the 1st compression ring C : The split of the 2nd compression ring D : Oil ring slit E : Oil ring expander spring butt joint
▲ : Front mark of piston
Piston ring and piston
8
5 to 7
[Inspection]
(1) Clearance of piston ring slit
• Install piston rings 5 to 7 into the crankcase cylinder sleeve using the head of piston 8 to level the piston ring.
• Measure the clearance of the piston ring split while keeping them level and stationary. If the measured value is higher than the limit, replace the piston ring.
NOTE
• Use piston 8 to ensure that piston rings 5 to 7 are kept level when inserting them into the crankcase cylinder sleeve.
• Insert piston rings 5 to 7 into the lower part of the crankcase cylinder sleeve, where the area is less worn, when measuring clearance of piston ring split 5 to 7.
• Exchange the whole set of piston rings 5 to 7 as a set if any of the rings is faulty.
11-46
Page 49
11
(2) Clearance between piston ring and ring groove
• If the measured value is higher than the limit, replace the faulty parts.
• Measure using feeler gauge F, by pressing 1st compression ring 5 against piston 8 with straight edge G.
NOTE
• Measurement has to be conducted around the whole periphery of piston 8 after removing carbon deposits.
F
8
G
• Be sure to exchange the whole set of piston rings 5 to 7 as a set if any of the rings is faulty.
5
11-47
Page 50
FLYWHEEL
1
< Automatic transmission >
A
*
● Disassembly sequence 1 Flywheel housing adaptor
< Automatic transmission >
2 Bolt 3 Plate < Manual transmission >
Wear plate < Automatic transmission >
4 Flex plate
< Automatic transmission >
9
5
6
10
-
5 Flywheel adaptor
< Automatic transmission >
6 Bearing 7 Flywheel assembly 8 Ring gear 9 Flywheel
10 Washer plate
3
4
2 Ê-
2 Ê-
3
6
< Manual transmission >
9
11 Rear oil seal 12 Flywheel housing
* : Crankshaft assembly Õ P11-52
A : Positioning pin
● Assembly sequence
Follow the disassembly sequence in reverse.
NOTE
Be sure to check wobble of flywheel 9 after installing flywheel assembly 7. Õ P11-49
Service standards Unit : mm {in.}
Location Maintenance item Standard value Limit Remedy
7 Height from bolt mounting surface 20 {0.787} 19 {0.748} Correct
12 Eccentricity of flywheel housing when install — 0.2 {0.008} Inspect
Flywheel assembly < Manual transmission >
to friction surface or replace Distortion of friction surface 0.050 {0.002} or less 0.2 {0.008} Correct
or replace
Wobble of friction surface when — 0.2 {0.008} Correct installed or replace
or replace
11-48
Page 51
11
Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}
Location Parts to be tightened Tightening torque Remarks
o
2 Bolt (Flywheel mounting) 39 {29, 4} +45
- Lubricant and sealant
Location Points of application Kinds Quantity
2 Thread area of bolt Engine oil As required
11 Lip area of rear oil seal Engine oil As required
Crankcase mounting surface of rear oil seal THREEBOND 1207C As required
◆ Service procedure
7
Flywheel assembly
DŽ5
o
Wet
7
2
A
7
A
7
[Inspection]
(1) Wobble
If the measured value is higher than the limit, check the fastening of bolt 2, the attachment surface of crankshaft assembly, and depending on the condition found, either repair or replace flywheel assembly 7.
(2) Height of friction surfaces
If the measured value is lower than the limit, repair or replace flywheel assembly 7.
A : Height from bolt mounting surface to friction surface
(3) Distortion of friction surface
If the measured value is lower than the limit, repair or replace flywheel assembly 7.
NOTE
If any fault is found in ring gear 8, replace it first, then begin the inspection.
8
A
A
B
[Correction] Make sure when grinding the friction surfaces for correction, that height A is not lower than the limit while maintaining the degree of parallel with surface B within 0.1 mm {0.0039 in.}.
11-49
Page 52
FLYWHEEL
8
8
Ring gear
[Inspection] Check and see if there is any damage, wear or other fault, and if any fault is found, replace ring gear 8. [Removal]
• Heat up ring gear 8 evenly using an acetylene torch.
• Hammer the outer edge of ring gear 8 evenly until it drops off.
[Installation]
• Heat up ring gear 8 using a piston heater to approximately 100°C {212°F} for three minutes.
• With the side of the chamfered teeth of ring gear 8 facing you, mount it on flywheel 9. A : Chamfered ring gear side
G
Mounting of rear oil seal
• Apply engine oil to lip area A of rear oil seal 11.
• Install rear oil seal 11 in flywheel housing 12 in the direction as illustrated.
• Apply sealant C along line B on rear oil seal 11 evenly without break
• After applying sealant C, within three minutes, mount rear oil seal 11.
12
8
“UP”
11
A
9
A
A
C
CAUTION–
• Do not start the engine within an hour of installing rear oil seal
11.
11
B
• Be sure to reapply sealant C if the bolts (for mounting rear oil seal 11) are loosened or removed by any cause whatsoever after mounting.
11-50
12
H
Inspection of flywheel housing
Mount of eccentricity
• If the measured value is higher than the limit, reassemble flywheel housing 12.
• After reassembly, if the measured value is still higher than the limit, replace the faulty parts.
Page 53
MEMO
11
11-51
Page 54
CRANKSHAFT AND CRANKCASE
20 Ù
19
*2
*1
-
12
-
● Inspection before disassembly
Õ P11-54
● Disassembly sequence 1 Bolt
2 Main bearing, lower 3 No.1 main bearing 4 No.2 main bearing 5 No.3 main bearing
6 No.4 main bearing
7 No.5 main bearing 8 No.6 main bearing 9 Rear main bearing
-
13
1
Ê
10 Thrust plate 11 Side seal 12 Crankshaft assembly 13 Front oil seal slinger 14 Crankshaft gear 15 Key 16 Rear oil seal slinger 17 Crankshaft
Ù
Ù
-
15 Ù
18 Main bearing, upper 19 Front plate 20 Gasket 21 Crankcase
*1 : Check valve ^ Gr 12 *2 : Oil jet ^ Gr 12
Ù : Non-reusable parts
CAUTION–
Do not remove crankshaft gear 14, check valve *1 or oil jet *2 unless it is faulty.
● Assembly sequence
Follow the disassembly sequence in reverse.
11-52
Page 55
11
Service standards Unit : mm {in.}
Location Maintenance item Limit Remedy
— Camshaft end play 0.10 to 0.26 {0.003 to 0.010} 0.4 {0.010} Inspect
2, 18 Main bearing Oil clearance [78] 0.03 to 0.09 0.15 {0.0059} Replace
Free tension — less than 82.5 Replace
17 Crankshaft Bend 0.02 {0.00079} or less 0.05 {0.0020} Replace
Pin and journal Circular 0.01 {0.00039} or less 0.03 {0.0012} Correct
accuracy or replace Cylindrical 0.006 {0.00024} or less — Correct
accuracy or replace
21 Distortion of crankcase top surface 0.07 {0.0028} or less 0.2 {0.0079} Correct
Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}
Location Parts to be tightened Tightening torque Remarks
1 Bolt (Main bearing cap mounting) 59 {43, 6}+90° Wet
Standard value
(Basic diameter in [ ])
{[3.07] 0.0012 to 0.0035}
{3.25}
or replace
Reuse up to
three times
- Lubricant and sealant
Location Points of application Kinds Quantity
2, 18 Interior of main bearing Engine oil As required
9 Pack side seal driving-in groove of rear main bearing THREEBOND 1207C As required
11 Side seal tip THREEBOND 1207C As required
0 Special tools Unit : mm {in.}
Location Tool name and shape Part No. Application
3 to 9 Socket wrench MH061560 Installation of main bearing cap
9 Bearing cap extractor MH061083 Removal of rear main bearing cap
M8×1.25
60 {2.36}
14 Gear puller MH061326 Removal of crankshaft gear
ø100 {3.94}
16 Rear oil seal slinger installer MH062677 Installation of rear oil seal slinger
ø103 {4.06}
ø15 {0.59}
11-53
Page 56
CRANKSHAFT AND CRANKCASE
◆ Service procedure
● Inspection before disassembly
Crankshaft assembly end play If the measured value is higher than the limit, replace thrust plates 10 with oversized ones. Õ P11-56 < Available oversize ones > +0.15, +0.30, +0.45 mm {+0.0059, +0.012, +0.018 in.}
2N
B
2
A
18
[Installation] When installing main bearings 2, 18, align lugs A.
CAUTION–
A
Be sure to distinguish between main bearings 2, 18. The upper bearing has oil opening B while the lower bearing has no oil opening.
[Inspection]
Main bearing
CAUTION–
• Do not forcibly expand main bearings 2, 18.
• Be sure to replace both upper and lower main bearings 2, 18 as a pair when replacement is necessary.
(1) Expansion at free state
If the measured value is lower than the limit, replace main bearings 2,
18.
(2) Clearance between main bearing and crankshaft
If the measured value is lower than the limit, replace faulty parts.
11-54
Page 57
11
3
to
9
Main bearing cap
[Removal] Use 0 bearing cap extractor to remove rear main bearing cap 9 be-
0
9
4
5
3
A
6
8
7
9
cause side seal 11 is installed between crankcase 21 and the rear main bearing.
[Installation]
• Install main bearing caps 3 to 9 in the direction as illustrated. A : Front of engine
“ ”
12
“R”
• Center punch the head of bolt 1 before installation.
C
B
0
D
E
G
E
5°
F
CAUTION–
If there are already three center-punch marks, replace the cylin­der head bolt with a new one.
• After tightening bolt 1 at specified torque, tighten further as follows:
• Turn 0 socket wrench holder B counterclockwise and keep the spring in the wrench compressed.
C : Socket D : Rod E : Rod (for connection)
• Set 0 socket wrench holder B so that the repercussive force of the spring presses rod E (for connection) against crankshaft assembly 12.
• Select a scale that is convenient for reading graduation F on holder B.
• Tighten further by turning socket C clockwise by 90° (setting is in 5° increments), referring to graduation G on the selected scale.
• After installation, check the following points :
• Crankshaft assembly 12 can be rotated easily by hand.
• The end play of crankshaft assembly 12. Õ P11-54
11-55
Page 58
CRANKSHAFT AND CRANKCASE
F
Installation of thrust plate
Install thrust plates 10 on both ends of rear main bearing 9 and the rear end of crankcase 21 in the direction as illustrated.
A : Oil groove B : Positioning pin
CAUTION–
When installing oversized thrust plates 10, mount them on the front and rear of rear main bearing cap 9. It is not necessary that the thrust plates used are all of the same size, but use the same­size-combination of thrust plates for mounting on the rear of crankcase 21 and on the rear of the rear bearing cap.
G
Installation of side seal
• Supply sealant in side seal mounting groove A of rear main bearing cap 9.
• Apply sealant at end B of side seal 11.
• Press in side seal 11 between rear main bearing cap 9 and crankcase
21 in the direction as illustrated. C : Rear main bearing cap side D : Crankcase side
• After pressing in, apply sealant to side seal mounting E of rear main bearing cap 9.
10
21
21
11
9
B
10
A
B
10
A
D
C
B
E
9
A
A
17
0
16
B
J
Crankshaft gear
[Removal] Never remove crankshaft gear 14 by striking, hitting or hammering it.
15
14
[Installation] Before installing heat up crankshaft gear 14 using a piston heater or similar device to approximately 100°C {212°F}.
NOTE
0
A
Install key 15 to prevent rotation.
L
Installation of rear oil seal slinger
Install rear oil seal slinger 16 using 0 oil seal slinger installer. Strike installer A until it hits guide B positively.
11-56
Page 59
11
M
Crankshaft
[Inspection]
17
17
A
B
C
(1) Cylindrical and circular accuracy of the journal and the pin
If the measured value is higher than the limit, grind and correct crankshaft 17 to convert it to the undersize specifications or replace it.
(2) Degree of bend
The degree of bend of crankshaft 17 is measured at No.4 journal C by supporting No.1 journal A and No.7 journal B. If the measured value is higher than the limit, replace the crankshaft.
NOTE
The degree of bend of crankshaft 17 is half of the indicated value of the gauge after rotating the shaft 360
°.
E
17
H
G
J
J
D
F
NOTE
Be sure to replace main bearings 2, 18 with those that meet the undersize specifications after crankshaft 17 is corrected by grind­ing.
• Set F, distance between the center line of the journal D and that of the pin E, constant. F : 57.5±0.075 mm {2.26±0.0030 in.}
[Correction]
• Set the width of journal G and pin H so they are constant. G : 35 mm {1.38 in.} (32 mm {1.26 in.} for No.1 journal)
+0.2
H : 41
0
{1.61
mm
+0.0079
0
in.}
• Finish the fillet J smoothly. J :R4±0.2 mm {0.0079 in.}
• Check and confirm that there has been no cracking caused by grind­ing using the magnetic particle inspection method (Magnafluxing). Also make sure the surface hardness has not deteriorated (Shore hardness to be maintained at not less than Hs 75).
K
N
• When grinding K, set crankshaft 17 and grinder L so that they both rotate counterclockwise as viewed from the front of the crankshaft.
• To finish grinding M using a grindstone or emery paper N, rotate crankshaft 17 clockwise.
16
M
L
16
11-57
Page 60
CRANKSHAFT AND CRANKCASE
Undersize specifications of crankshaft Unit : mm {in.}
Undersize scales
0.25 {0.0098} 0.50 {0.020} 0.75 {0.030} 1.00 {0.039}
Finish outer diameter of journal 77.69 to 77.70 77.44 to 77.45 77.19 to 77.21 76.94 to 76.95
{3.058 to 3.059} {3.048 to 3.049} {3.038 to 3.039} {3.0291 to 3.0295}
Finish outer diameter of pin 64.69 to 64.71 64.44 to 64.46 64.19 to 64.21 63.94 to 63.96
{2.546 to 2.547} {2.5370 to 2.5377} {2.5271 to 2.5279} {2.517 to 2.518} Circular accuracy 0.01 {0.00039} or less Cylindrical accuracy 0.006 {0.00024} or less
Q
Crankcase top surface distortion
If the measured value is higher than the limit, grind and correct using a surface grinder.
CAUTION–
When grinding crankcase 21 be sure that the extent of piston protrusion does not deviate from the standard value. Piston protrusion : Õ P11-36
21
11-58
Page 61
Group 12
Table of Contents
BACK
HOME
Lubrication
Pub No. TWME9502-12
Page 62
GROUP 12 LUBRICATION
SPECIFICATIONS .................................................................................. 2
STRUCTURE AND OPERATION ........................................................... 3
TROUBLESHOOTING.......................................................................... 11
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
• Replacement of Oil Filter ................................................................................. 12
• Replacement of Engine Oil .............................................................................. 13
• Measurement of Oil Pressure.......................................................................... 14
12
OIL PAN, OIL STRAINER AND OIL JET ............................................. 16
OIL PUMP ............................................................................................. 18
OIL COOLER AND OIL FILTER ........................................................... 22
12-1
Page 63
SPECIFICATIONS
Item Specifications
Mode of lubrication Oil pump type Oil filter type Spin-on filter paper type Oil cooler type Shell and plate type (Multiple-plate type) Engine oil Grade Grade CD or above as per API classification
Quantity of oil Oil pan Approximately 9.5 {10}
L {qts} Oil filter Approximately 1 {1.1}
12-2
Page 64
STRUCTURE AND OPERA TION
Lubrication System (Flow of Oil)
12
1
3
2
1 Main oil gallery 2 Air compressor 3 Crankshaft main bearing 4 Connecting rod bearing 5 Connecting rod busing 6 Idler gear bushing 7 Timing gear 8 Check valve for oil jet
9 Piston 10 Camshaft bushing 11 Rocker bushing 12 Push rod 13 Tappet 14 Injection pump
4
5
10
6
11
12
7
8
9
13
27
14
17
18
15
23
15 Turbocharger 16 Engine oil pressure switch 17 Engine oil bypass alarm switch 18 Bypass valve (Built-in within oil pump) 19 Full-flow filter element 20 Bypass filter element 21 Oil cooler 22 Bypass valve 23 Regulator valve 24 Oil pump 25 Relief valve (Built-in within oil pump) 26 Oil strainer 27 Oil pan
19
21
24
26
16
20
22
25
12-3
Page 65
STRUCTURE AND OPERA TION
Oil Pump
1
A
B
2
3
4
C
1 Crankshaft gear 2 Oil pump gear 3 Oil pump 4 Relief valve
A : To oil cooler B : From oil strainer C : To oil pan
Oil pump 3 is a gear type, driven by rotation of the crankshaft transmitted by crankshaft gear 1 that engages oil pump gear
2. Relief valve 4 is installed on the oil pump and when the oil pump discharge pressure becomes higher than the standard pressure level, part of the engine oil is returned to the oil pan by relief action of the valve, protecting the lubricating system from breakdown caused by excessive oil pressure.
12-4
Page 66
Oil Cooler and Oil Filter
1
A
E
8
D
8
12
1 Engine oil pressure switch
2
B
3
C
D
4
5 6
7
2 Oil cooler 3 Regulator valve 4 Bypass filter element 5 Oil filter 6 Full-flow filter element 7 Bypass valve 8 Bypass valve 9 Engine oil bypass alarm switch
A : Coolant exit port B : Coolant entry port C : To oil cooler D : To oil pan E : To main oil gallery
9
C
8
5
E D
3
5
Operation of bypass valve
When the viscosity of the engine oil is high at low temperatures, or when oil cooler 2 element is clogged, flow resistance is high, and if this happens, bypass valve 8 opens to let the engine oil return directly to oil filter 5 without going through the oil cooler.
Operation of regulator valve
When the oil pressure in the main oil gallery becomes higher than standard, regulator valve 3 opens to let part of the oil return to oil pan D, thereby regulating the oil pressure.
12-5
Page 67
STRUCTURE AND OPERATION
E
D
4
6
● Oil filter element
This oil filter uses a spin-on, filter paper type element, that integrates full-flow filter element 6 and bypass filter element 4. When the filter element is clogged, bypass valve 7, installed at the base of the filter, opens to let the oil bypass the element and flow directly to main oil gallery E, preventing engine sei­zure.
7
E
1
E
9
Operation of engine oil pressure switch
When pressure for delivering the oil to main oil gallery E becomes lower than standard, the built-in electric contact point of engine oil pressure switch 1 closes to light warning lamp in the meter cluster, warning the driver that the oil pressure is abnormal.
Operation of engine oil bypass alarm switch
• When the oil filter element is clogged, the engine oil level becomes low and might cause seizure of engine parts, engine oil bypass alarm switch 9 is installed to prevent this.
• When the oil filter element is clogged, engine oil bypass alarm switch 9 lets the oil flow directly to main oil gallery E, bypassing full-flow filter element 6. When the engine oil bypass alarm switch is activated it lights the warning lamp, warning the driver that the oil filter element is clogged.
12-6
Page 68
Lubrication of Related Parts
1
A
12
● Main bearing and connecting rod bearing 1 Main oil gallery
2 Main bearing 3 Crankshaft 4 Connecting rod bearing
A : Connecting rod oil passage
4
2
1
8
A
2
3
3
6
7
4
5
Engine oil supplied through the oil passage drilled in crankshaft 3 flows through connecting rod oil passage A to lubricate the small end of the connecting rod.
● Timing gear 1 Thrust plate
2 Camshaft 3 Idler gear bushing 4 Air compressor gear 5 Timing gear case 6 Idler gear 7 Idler shaft 8 Camshaft gear
A : From main oil gallery
Engine oil from main oil gallery A flows through the inside of camshaft 2 and idler shaft 6 and lubricates each gear.
12-7
Page 69
STRUCTURE AND OPERATION
A
5
4
3
2
1
B
A
6
7
8 C
9
10
1
● Valve mechanism 1 Crankcase
2 Cylinder head 3 Rocker shaft 4 Rocker shaft bracket 5 Rocker bushing 6 Rocker 7 Push rod 8 Tappet 9 Camshaft
10 No. 1 camshaft bushing
A : Rocker oil hole B : From main oil gallery C : To oil pan
● Oil jet 1 Piston
2 Oil jet 3 Check valve
A : Main oil gallery
An oil jet 2 is installed, in the lower part of main oil gallery A, for each
3
1
A
B
3
2
2
4
3
cylinder and cools piston 1 by injecting engine oil toward the inside of the piston. The oil jet is fitted with check valve 3 which opens and closes at standard oil pressure levels. This prevents a decrease of oil volume at low oil pressure as well as a decrease of oil pressure itself.
● Turbocharger 1 Bearing housing
2 Snap ring 3 Piston ring 4 Bearing
A : From main oil gallery B : To oil pan
Engine oil is delivered from the main oil gallery to bearing housing 1 through the oil pipe to lubricate bearing 4. Piston ring 3 installed at both ends of the turbine wheel shaft works as an oil seal.
12-8
Page 70
12
● Injection pump
1
2
3
B
A
A
B
1
2
1 Injection pump 2 Governor 3 Oil return pipe
A : From main oil gallery B : To oil pan
Engine oil that has lubricated injection pump 1 and governor 2 returns to the oil pan through oil return pipe 3.
● Air compressor 1 Air compressor
2 Timing gear case
A : From main oil gallery B : To oil pan
Engine oil from the main oil gallery lubricates the inside of air compres­sor 1 and returns to the oil pan through timing gear case 2.
12-9
Page 71
STRUCTURE AND OPERATION
Lubrication System Electric Circuit
1 Fuse box 2 Meter cluster 3 Engine oil pressure/clogged oil filter warning
lamp
4 Warning buzzer
(Buzzer does not work when parking brake is engaged.)
5 Parking brake switch 6 Diode 7 Engine oil bypass alarm switch 8 Engine oil pressure switch
12-10
Page 72
TROUBLESHOOTING
Symptoms
Engine hard to start
Overheating
Oil pressure low
Possible causes
Oil cooler element installation faulty ● ● ● Gasket faulty ● ● ● O-ring faulty ● ● ●
Oil cooler Oil cooler element clogged ● ●
Oil cooler element damaged ● ● ● Bypass valve spring fatigued ● Regulator valve spring fatigued ● Malfunctioning ● ●
Oil pump Oil pump gear interfering with oil pump case or cover ● ●
Relief valve spring fatigued ● Installation faulty ●
Oil filter Element clogged ● ●
Gasket faulty ● Oil strainer installation faulty or clogged ● ● Crankshaft front oil seal faulty ● ^ Gr 11 Crankshaft rear oil seal faulty ● ^ Gr 11 Timing gear case installation faulty ● ^ Gr 11 Oil jet for piston cooling faulty ● Oil working its way up into combustion chamber ● Oil working its way down into combustion chamber ● Oil viscosity too high ● Oil quality unsuitable ● Oil deteriorated ● Fuel mixed with oil ●
Oil consumption excessive (Oil leakage)
12
Remarks
12-11
Page 73
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
Replacement of Oil Filter
0 Special tools Unit : mm {in.}
Location Tool name and shape Part No. Application
101.2
2 Oil filter wrench MH061587 Removal of oil filter
{3.98}
WARNING–
• Wipe up any engine oil that has been spilled because it can cause a fire.
• Do not touch the engine while it is hot because it will burn you.
• When replacing oil filter 2, take care not to spill oil on the V-belt.
[Removal]
0
[Installation]
• Clean the surface of oil cooler body 1 that makes contact with oil filter
1
A
2
2.
• Apply engine oil thinly and evenly to gasket area A of oil filter 2.
• Screw in oil filter 2 to oil cooler body 1 until gasket area A sits on the body. From this position, tighten further by rotating by five eighths of a turn.
• After installation, run the engine and check that there is no oil leakage from gasket area A.
• Check the oil level and if it is low, top it up.
12-12
Page 74
12
Replacement of Engine Oil
Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}
Location Parts to be tightened Tightening torque Remarks
2 Oil pan drain plug 69 {51, 7} —
- Lubricant
Location Points of application Kinds Quantity
— Oil pan Engine oil (Grade CD or above as per
API Classification)
— Oil filter Engine oil (Grade CD or above as per
API Classification)
1
[Draining] After warming-up the engine, remove oil filler cap 1 and remove drain plug 2 of the oil pan and drain the engine oil.
[Refilling] Tighten drain plug 2 of the oil pan at specified torque and fill with the specified quantity of engine oil.
WARNING–
• Wipe up any engine oil that has been spilled because it can
cause a fire.
• Do not touch the engine while it is hot because it will burn you.
• When replacing engine oil take care not to spill oil on the V-belt.
Approximately
9.5 L {10 qts}
Approximately
1 L {1.1 qts}
2
12-13
Page 75
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
Measurement of Oil Pressure
Service standards
Location Maintenance item Standard value Limit Remedy
— At no-load minimum revolution 145 kPa {21 lbf/in2, 1.5 kgf/cm2} 49 kPa Inspect
Oil pressure (Oil tempera­ture 70 to 90°C {158 to 194°F})
{7.1 lbf/in
0.5 kgf/cm
At no-load maximum revolution 295 to 490 kPa 195 kPa
{43 to 71 lbf/in
2
, 3 to 5 kgf/cm2} {28 lbf/in2,
2 kgf/cm
2
,
2
}
2
}
Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}
Location Parts to be tightened Tightening torque Remarks
2 Engine oil pressure switch 15 to 22 {11 to 16, 1.5 to 2.2}
When engine is cold
- Sealant
Location Points of application Kinds Quantity
2 Thread area of engine oil pressure switch Teflon tape 3
• Remove oil pressure switch 2 from oil cooler 1.
• Mount the oil pressure gauge after installing adaptor 3 onto oil cooler
1.
2
• Warm up the engine until the oil temperature reaches 70 to 90°C {158 to 194°F}.
• Measure oil pressure at no-load minimum revolution and at no-load maximum revolution. If the measured values are lower than the limit,
1
overhaul the lubricating system.
1
/2 turns
12-14
• After measurement, install engine oil pressure switch 2 and tighten at specified torque.
CAUTION–
Be sure to install oil pressure switch 2 when the engine is cold.
Inspection of engine oil pressure switch
PT1/8
3
^ Gr 54
Page 76
MEMO
12
12-15
Page 77
OIL PAN, OIL STRAINER AND OIL JET
1 Ê
-
2
4
*
Ù-5
6 Ê-
7
● Disassembly sequence 1 Drain plug
2 Bolt 3 Oil pan 4 Oil strainer 5 O-ring 6 Check valve 7 Oil jet
* : Crankcase
Ù : Non-reusable parts
● Assembly sequence
Follow the disassembly sequence in re­verse.
CAUTION –
Make sure that you do not tighten check valve 10 higher than the specified torque. Overtightening will cause damage to the check valve, resulting in serious over­heating damage to the engine.
Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}
Location Parts to be tightened Tightening torque Remarks
1 Drain plug 69 {51, 7} — 6 Check valve 29 {22, 3 } Wet
- Lubricant and sealant
Location Points of application Kinds Quantity
3 Oil pan to crankcase connecting surface THREEBOND 1207C As required 5 Body of O-ring Engine oil As required 6 Thread area of check valve Engine oil As required
◆ Service procedure
3
ø2 mm {0.079 in.}
A
3
Installation of oil pan
< When using sealant >
• Apply sealant A to lower connecting surface of oil pan 3 as illustrated evenly without break.
• After applying sealant A, within three minutes, mount oil pan 3 to crankcase *.
CAUTION–
• Be sure to clean and wipe off oily substances from the surface where sealant A is to be applied.
• Make sure that sealant A is not transferred to other areas while the mounting work is being done.
• Do not start the engine within an hour of mounting oil pan 3.
• Be sure to reapply sealant A if bolts 2 (for mounting oil pan 3) are loosened or removed by any cause whatsoever after mounting.
12-16
Page 78
12
< When not using sealant >
NOTE
If sealant is not available, install oil pan 3 to crankcase * using
3
B
*
sheet gasket B.
12-17
Page 79
OIL PUMP
Ù-10
1
*3
*1
*2
● Disassembly sequence 1 Oil pump assembly
2 Bolt 3 Split pin 4 Seat 5 Spring 6 Relief valve 7 Oil pump cover 8 Driven gear assembly 9 Oil pump case assembly
10 O-ring
*1 : Crankcase ^ Gr 11 *2 : Crankshaft gear *3 : Drive gear
Ù : Non-reusable parts
2 Ê
● Assembly sequence
Follow the disassembly sequence in reverse.
6
5
Ù 3
Service standards Unit : mm {in.}
Location Maintenance item Limit Remedy
— Backlash between oil pump gear and crankshaft 0.09 to 0.18 {0.0035 to 0.0071} 0.3 {0.012} Replace
gear ^ Gr 11
5 Relief valve spring load (Installed length 38 {1.50}) 225 N {51 lbf, 23.15 kgf} — Replace 6 Relief valve opening pressure 1080±98 kPa — —
7, *3 Clearance between gear shaft and oil pump cover
8, 9 Clearance between gear shaft and driven gear
[20] 0.04 to 0.07 {[0.79] 0.0016 to 0.0028} [20] 0.04 to 0.07 {[0.79] 0.0016 to 0.0028}
8, 9, *3 Difference between height of each gear and depth 0.01 to 0.07 {0.00039 to 0.0028} 0.18 {0.0071} Replace
of oil pump case Clearance between tooth tip of each gear and oil 0.10 to 0.19 {0.0039 to 0.0075} 0.2 {0.0079} Replace
pump case
Standard value
(Basic diameter in [ ])
{155±14 lbf/in
2
, 11±1.0 kgf/cm2}
0.15 {0.0059} Replace
0.15 {0.0059} Replace
Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}
Location Parts to be tightened Tightening torque Remarks
2 Bolt (Oil pump cover mounting) 9.8±2.0 {7.2±1.4, 1.0±0.2} —
- Lubricant
Location Points of application Kinds Quantity
10 Body of O-ring Engine oil As required
12-18
Page 80
12
◆ Service procedure
4
Installation of seat
A
6
5
4
3
7
8
A
9
9
A : Oil pump case assembly side
7
to
9
Inspection of oil pump cover, driven gear assembly, and oil pump case assembly
• Measure the clearance between oil pump cover 7 and drive gear shaft B, and between driven gear assembly 8 and driven gear shaft A.
• If the measured value is lower than the limit, replace the faulty parts.
B
79
• Prepare two pins A of 9 mm {0.35 in.} in outer diameter and position oil pump cover 7 and oil pump case assembly 9 as illustrated.
A
8
7
A
2
9
• Tighten the illustrated bolts 2 at specified torque.
Installation of oil pump cover and oil pump case assembly
A
12-19
Page 81
OIL PUMP
• Remove pins A, replacing them with bolts 2 and tighten at specified torque.
2
A
B
2
9
*3
8
Confirm smooth movement by rotating oil pump gear B by hand. If it catches, disassemble and reassemble it.
893
(1) Difference between height of each gear and depth of oil pump
case
If the measured value is higher than the limit, replace the faulty parts.
Inspection of driven gear assembly, and oil pump
*3
case assembly
NOTE
(2) Clearance between tooth tip and oil pump case
If the measured value is higher than the limit, replace the faulty parts.
*3
8
9
12-20
Page 82
MEMO
12
12-21
Page 83
OIL COOLER AND OIL FILTER
Ù 18
*
1
-
2
Ê 12
14
13
Ù
Ù-4
15
16
Ê
7 Ê 8 Ù
9
10
3
Ê
17
Ê 11
6 Ê-
● Disassembly sequence 1 Oil filter Õ P12-12
2 Oil cooler assembly 3 Nut 4 O-ring 5 Oil cooler element 6 Engine oil pressure switch ^ Gr 54 7 Plug 8 O-ring 9 Spring
10 Regulator valve
● Assembly sequence
Follow the disassembly sequence in reverse.
11 Drain plug 12 Plug 13 O-ring 14 Spring 15 Bypass valve 16 Engine oil bypass alarm switch ^ Gr 54 17 Oil cooler body 18 Gasket
* : Crankcase assembly ^ Gr 11
Ù : Non-reusable parts
12-22
Page 84
12
Service standards
Location Maintenance item Standard value Limit Remedy
5 Oil cooler element air leakage (Air pressure 0 cm
980 kPa {140 lbf/in
2
, 10 kgf/cm2}, 15 seconds)
10 Regulator valve opening pressure 440±29 kPa — Replace
{64±4.3 lbf/in
15 Bypass valve opening pressure 390±29 kPa — Replace
{57±4.3 lbf/in
16 Engine oil bypass alarm switch 190+60/-0 kPa — Replace
{27
+8.3/-0 lbf/in
Ê Tightening torque Unit : N-m {lbf.ft, kgf-m}
Location Parts to be tightened Tightening torque Remarks
3 Nut (oil cooler element mounting) 19.5±5 {14±3.6, 2.0±0.5} — 6 Engine oil pressure switch 15 to 22 {11 to 16, 1.5 to 2.2} When engine is cold
7 Plug (Regulator valve spring mounting) 19.5±5 {14±3.6, 2.0±0.5} — 11 Drain plug (Oil cooler) 34 {25, 3.5} — 12 Plug (Bypass valve spring mounting) 19.5±5 {14±3.6, 2.0±0.5} — 16 Engine oil bypass alarm switch 12 to 18 {8.7 to 13, 1.2 to 1.8} —
3
{0 cu. in.} — Replace
2
, 4.5±0.3 kgf/cm2}
2
, 4.0±0.3 kgf/cm2}
2
, 1.9+0.6/-0 kgf/cm2}
- Lubricant and sealant
Location Points of application Kinds Quantity
1 Gasket area of oil filter with thin application Engine oil As required
Õ P12-12
4 Body of O-ring Engine oil As required
6 Thread area of engine oil pressure switch Teflon tape 3
1
/2 turns
◆ Service procedure
● Cleaning
• Check and see if any carbon deposits or sludge have developed in the oil passage of oil cooler element 5 or its bypass. Clean any deposits off thoroughly with cleaning solvent.
• Also clean any water scale or fur found in oil cooler element 5 or oil cooler body 17.
5
Inspection of oil cooler element
• Immerse oil cooler element 5 in a water tank after plugging exit port A and connecting the hose to engine oil entry port B.
• Apply air pressure of 980 kPa {140 lbf/in
A
see if there is any air leakage from any part of oil cooler element 5.
• If you see any leakage, replace oil cooler element 5.
2
, 10 kgf/cm2} via the hose and
5
B
12-23
Page 85
BACK
HOME
Page 86
MITSUBISHI
Table of Contents
BACK
HOME
FUSO
'
99
Minor Change
Pub No. TWME9502-313
Page 87
13
GROUP 13 FUEL AND ENGINE CONTROL
SPECIFICATIONS ............................................................................13 - 2
STRUCTURE AND OPERATION .....................................................13 - 4
TROUBLESHOOTING......................................................................13 -34
READING AND ERASING DIAGNOSIS CODES.............................13 -38
SERVICE PROCEDURES USING MUT -II ........................................13 -44
INSPECTION BASED ON DIAGNOSIS CODE................................13 -46
ON-VEHICLE INSPECTION AND ADJUSTMENT
• Checking and Adjusting Injection Timing................................................ 13 -50
• Bleeding Air from Fuel System ................................................................. 13 -51
• Cleaning Gauze Filter................................................................................. 13 -51
• Replacing Fuel Filter .................................................................................. 13 -52
ENGINE CONTROL..........................................................................13 -53
FUEL T ANK.......................................................................................13 -58
FUEL FILTER....................................................................................13 -59
W A TER SEP ARATOR.......................................................................13 -60
INJECTION PUMP............................................................................13 -62
INJECTION PUMP DRIVE CASE.....................................................13 -68
INJECTION NOZZLE........................................................................13 -72
INSPECTION OF OTHER DEVICES ................................................13 -76
ELECTRIC CIRCUIT AND PART INSTALLA TION LOCATIONS.....13 -88
13-1
Page 88
SPECIFICATIONS
Injection Pump
Item Specifications
Manufacturer ZEXEL Body model MD-TICS (Pre-stroke control type) Governor type RED-III electronically controlled governor Feed pump model KD Automatic timer model SPG mechanical type
Injection Nozzle
Item Specifications
Manufacturer ZEXEL Model and type DLLA hole type 1-spring nozzle Nozzle orifice quantity 5 Orifice diameter mm {in.}
Fuel Filter Type
φ
0.23 {0.0091}
Item Specifications
Filter type Spin-on type
13-2
Page 89
MEMO
13
13-3
Page 90
STRUCTURE AND OPERATION
Fuel System (Flow of Fuel)
1
10
9
8
Supplied fuel Excessive fuel
2
3
7
6
1 Injection nozzle 2 Fuel filter 3 Fuel tank 4 Water separator 5 Governor
Fuel in fuel tank 3 is sucked up by feed pump 6 which is driven by the cam action of injection pump 8 and is filtered through fuel filter 2 which removes dirt and other foreign particles. Filtered fuel is sent to the injection pump where the fuel pressure is boosted and injected through injection nozzle 1 into the combustion chamber. When fuel pressure is higher than the specified value, overflow valve 10 opens to let the fuel return to the fuel tank.
5
4
31102
P
6 Feed pump 7 Automatic timer 8 Injection pump 9 Pre-stroke actuator
10 Overflow valve
13-4
Page 91
Engine Control
13
1 Emergency engine stop handle 2 Starter switch 3 Engine stop lever 4 Engine stop cable 5 Accelerator pedal assembly 6 Lever
2
4
3
7 Accelerator pedal position sensor
* : Electronic governor
B
A
7
6
● Accelerator switch
The accelerator switch is integrated in the accelerator pedal position sensor 7. It detects the pressing of accelerator pedal assembly 5.
● Accelerator pedal position sensor
Accelerator pedal position sensor 7 detects the movement of accelerator pedal assembly 5, and sends an electric signal to the electronic governor control unit. Lever 6 of the accelerator pedal position sensor is constantly pulled by the return spring towards idle position D.
1
C
5
D
A
*
B
P 31103
A : Engine-stop position B : Engine start-up position C : Full-load position D : Idling position
● Emergency engine stop button
In normal condition, turn starter switch 2 to the ACC position to electrically shut down the engine operation. In the case the engine does not stop when the starter switch is turned to the ACC position due to malfunction of the electronic governor system or other cause, stop the engine by pulling emergency engine stop handle 1 to move stop lever 3 of electronic governor * to engine stop position A.
CAUTION –
When the engine is stopped by pulling engine stop handle 1, set starter switch 2 to the ACC or LOCK position to reset the control unit computer. Restarting the engine without resetting the computer results in unstable engine speed control.
13-5
Page 92
STRUCTURE AND OPERATION
Fuel Gauge Electric Circuit
Water Separator
12
5
F
E
3
4
1 Water level ring
1 Fuse box 2 Meter cluster 3 Fuel gauge 4 Fuel gauge sending unit 5 Float
The fuel gauge circuit indicates the amount of fuel remaining in the fuel tank by means of a gauge.
A : From fuel tank
A
B
1
B : To feed pump
The water separator is installed between the fuel tank and the feed pump. Any water present in the fuel is separated by the baffle plate and the screen assembly.
13-6
Page 93
Fuel Filter
13
1 Fuel filter
2
B
A
1
2 Fuel filter head
A : From feed pump B : To injection pump
Pressurized fuel is delivered from the feed pump of the injec­tion pump to the fuel filter which separates water from the fuel. Dirt and other foreign particles are removed from the fuel by fuel filter 1.
13-7
Page 94
STRUCTURE AND OPERATION
Configuration of Electronic Governor and Pre-stroke Control Injection Pump System
7
6
5
4
3
1
A
B
D
C
8
9
10
2
34
e
d
33
32
31
30
b
a
Z
35
Y
E
F
G
H
J
L
M
N
11
12
13
14
15
16
29
17
28
X
P
27
26
W
25
24
23
V
U
22
A : To exhaust brake 3-way magnetic valve ^ Gr 54
13-8
Q R
S
T
18 19
20
21
A
Page 95
13
Part Main function/operation Data signal
1 Starter switch Sensing of start signal e : Start signal 2 Fuse box — — 3 Engine speed sensor Sensing of engine speed D : Engine speed signal 4 Sub control rack position sensor Sensing of control rack position C : Control rack position signal (backup)
Pre-stroke actuator
5
• Pre-stroke position sensor —
• Drive unit —
6 Pre-stroke control type injection pump
Alteration of pre-stroke (advancement of fuel injection timing)
7 Control rack position sensor Sensing of control rack position G : Control rack position signal 8 Backup engine speed sensor Sensing of engine speed F : Engine speed signal (backup) 9 Linear DC motor Activation of rack E : Linear DC motor drive signal
10 Electronic governor — — 11 Boost temperature sensor
Detection of engine intake air temperature
12 Meter cluster — — 13 Tachometer — J : Tachometer drive signal 14 Warning lamp (Orange) 15 Warning lamp (Red)
Indication of system faults and diagnosis codes
16 Indicator lamp — 17 Auxiliary brake switch ON/OFF switching of Exhaust brake P : Exhaust brake ON signal
18 Accelerator pedal position sensor
19 Accelerator pedal switch
Idling speed adjustment
20
potentiometer
Sensing of accelerator pedal depression amount
Turns OFF when accelerator pedal is depressed
Shortening of warmup time S : Warmup time shortening signal
21 Fuel injection rate adjustment resistor Correction of fuel injection rate T : Injection volume correction signal 22 Modulator — — 23 Diagnosis switch Generation of diagnosis codes U : Diagnosis code signal 24 Memory clear switch Eraser of diagnosis codes V : Diagnosis code eraser signal 25 MUT-II connector (16 pin) Connection of MUT-II — 26 Relay box — —
27 Pre-stroke cut relay
28 Transmission neutral relay
29 Exhaust brake relay
30 Accelerator relay
Closes contacts upon plunger pre-stroke operation
Contact closed when transmission is in neutral
Closes contacts upon exhaust brake operation
Contact closed when modulator is activated
31 Boost pressure sensor Sensing of boost pressure a : Boost pressure signal 32 Coolant temperature sensor Sensing of engine coolant temperature
33 Transmission neutral switch
34 Clutch pedal switch
Turns OFF when transmission neutral is selected
Turns OFF when clutch pedal is depressed
35 Electronic governor control unit Control of overall system —
A
: Pre-stroke position signal : Actuator drive signal
B
—
H : Boost temperature signal
L : Lamp illumination signal
M : Lamp illumination signal
N
: Lamp illumination signal
Q : Accelerator pedal position signal
R : Accelerator pedal depression signal
W : Pre-stroke operation signal
X : Transmission neutral signal
Y : Exhaust brake operation signal
Z : Modulator operation signal
b
: Coolant temperature signal
—
d : Clutch pedal depression signal
13-9
Page 96
STRUCTURE AND OPERATION
• The electronic governor and pre-stroke control injection pump system combines an electronic governor 10 with an injection pump 6 that has an electronically controlled pre-stroke adjustment feature.
• The injection pump’s plunger lift speed varies in accordance with the engine speed, causing concomitant variations in the injection pipe pressure.
• Variations in the injection pipe pressure make it difficult to achieve an optimum spray from the injection nozzles and the optimum air/fuel mixture.
• To compensate for changes in the injection pipe pressure, the injection pump plunger pre-stroke is increased at low and mid- range speeds, thus ensuring that fuel injection takes place late in the cam lift, when plunger movement is relatively fast.
• At high speeds, the plunger pre-stroke is decreased, thus ensuring that fuel injection takes place in early in the cam lift, when plunger movement is relatively slow. Excessive increases in injection pipe pressure are thus prevented.
• By adjusting the plunger pre-stroke in this manner, the pre-stroke control injection pump 6 ensures that the spray and air/ fuel mixture are always optimally suited to combustion.
• The overall benefits are higher engine torque and cleaner exhaust emissions than are possible with a conventional injection pump.
• Control operations are performed by the electronic governor control unit 35, which receives data from sensors on the engine and other vehicle components, processes them, and issues appropriate drive signals to the pre-stroke actuator 5 (located at the rear of the injection pump) and to the linear DC motor 9 (located inside the electronic governor).
The system’s control functions (including auxiliary functions) are shown in the following table.
Item Operation
Sensor(s) Data signal(s
Fuel injection rate The fuel injection rate is optimized to match engine operating 3, 7, 18, 19, 21, D , G , Q , R , control conditions. Õ P13-12 31
Pre-stroke control
★
Control rack prelimi­nary operation
★
Warmup time short- In cold weather, the engine’s idling speed is increased to ening function shorten the time required for warmup. Õ P13-14
★
Overrun prevention function
★
Emergency vehicle operation function (used in event of control rack position sensor fault)
★
Auxiliary brake con­trol function
★
Fault diagnosis function
★
Fail-safe function
★
Reverse engine operation prevention function
★
: Auxiliary function
The timing sleeve position is altered, thereby changing the pre-stroke and advancing the fuel injection timing. Õ P13-13
3, 5, 7, 18, 32
In cold weather and other conditions that are unfavorable for engine startup, the control rod is caused to move slightly in the fuel increase direction, thus enhancing startability. This opera-
1, 18, 19, 32 e , Q , R , b
tion takes place when the starter switch is turned ON.
18, 19, 20 Q , R , S
In the event of an abnormal increase in engine speed, the control rack is pulled in the fuel decrease direction to prevent 3 D the engine from overrunning.
In the event of a fault in the control rack position sensor 7, the control rack position is sensed by the sub control rack position sensor 4. If both rack position sensors develop faults, thus preventing detection of the rack position and optimization of
3, 4, 7 D , C , G
the fuel injection rate, the fuel injection rate is controlled in accordance with engine speed signals only. Õ P13-16
The auxiliary braking devices (exhaust brake) are controlled by the electronic governor control unit 35. (In a conventional 3, 16, 18, 19, 28, D , N , Q , R , system, the auxiliary braking devices are controlled by 33, 34 X , d switches, relays, and dedicated controllers.) Õ P13-17
The status of each system sensor is monitored continuously during engine operation. In the event of a fault, a warning lamp is illuminated to alert the driver and data related to the
ALL ALL
fault are stored in memory. Õ P13-36 In the event of a fault, a backup mode is selected and remedial
action is taken in accordance with the type of fault. Õ P13-40 In the event of reverse engine operation, the control rack is
pulled in the fuel decrease direction to stop the engine
ALL ALL
3D
Data source
,
T D
, A , B , G ,
Q , b
)
a
13-10
Page 97
System Block Diagram
13
Injection pump
Engine
Trans­mission
Chassis
Input signals
Backup engine speed sensor 8 Control rack position sensor 5 Pre-stroke position sensor (integral part of pre-stroke actuator 5)
Sub control rack position sensor 4
Engine speed sensor 3 Boost pressure sensor 31 Coolant temperature sensor 32 Boost temperature sensor 11
Transmission neutral switch 33
Starter switch 1 Auxiliary brake switch 17 Accelerator pedal position sensor 18 Idling speed adjustment potentio­meter 20 Fuel injection rate adjustment resistor 21 Diagnosis switch 23 Memory clear switch 24 Clutch pedal switch 34 Accelerator pedal switch 19
Electronic
governor
control unit 35
Output signals
Linear DC motor 9
Drive unit (integral part of pre-stroke actuator 5)
Warning lamp 14, 15
Indicator lamp 16
Fuel injection rate control
Fuel injection
timing control
Fault diagnosis indication
Indication of auxiliary brake
operation
13-11
Page 98
STRUCTURE AND OPERATION
● Fuel Injection Rate Control
Data signals
Fuel injection rate adjustment resistor 21
Starter switch
Sub control rack position sensor 4
Acc
Ne
Acc
N
Ne P
Acc
Ne T
Electronic governor control unit 35
Idling charac-
V
teristics
l
*
Running
e
characteristics
Digital signals
Selection of maximum injec­tion rate value
Selection of minimum injec­tion rate value
Target control rack position
Start mode evaluation
B
Full rack characteristics
Starting
w
characteristics
Feedback control
Servo circuit
Analog signals
Rack
Actuator (linear DC motor 9)
Drive circuit
Servo circuit
D/A converter
Acc: Accelerator pedal position Ne: Engine speed
: Engine coolant temperature
T
w
: Idling speed adjustment potentiometer voltage
V
l
P
: Boost pressure
B
Control rack posi­tion sensor 7
Feedback control
D/A converter: Digital-to-analog converter * Idling speed control limited only to low idling speed control
Operation of electronic governor control unit 35
• During engine operation, control is effected in accordance with the idling characteristics and running characteristics. The maximum fuel injection rate value is selected in accordance with the output signals.
• After this selection, the control unit calculates and determines the minimum injection rate to prevent the injection rate selected in accordance with the full rack characteristics from exceeding the maximum injection rate. The target control rack position is thus determined. (During engine startup, control is effected in accordance with the starting characteris­tics with the target rack position determined directly in accordance with the data signals.)
• The determined control rack position signal is converted into a continuous analog signal. By way of the servo circuit and drive circuit, the signal is applied to the linear DC motor 9, which moves the rack.
Operation of control rack position sensor 7
• The control rack position sensor 7 monitors the operation of the linear DC motor 9. In accordance with the position of the control rack, the sensor determines whether the linear DC motor is operating in accordance with the target, and it transmits feedback signals to the electronic governor control unit 35.
• In accordance with the feedback signals, the electronic governor control unit 35 calculates the actual control rack position. If the actual position differs from the target, the control unit issues a correction command.
• Through repetition of this process, the system ensures that the control rack position complies with the target at all times.
13-12
Page 99
● Pre-stroke control
Data signals
13
Electronic governor control unit 35
Ne
Rac
Ne
T
w
Timing sleeve movement
Rac: Control rack position Ne: Engine speed
: Engine coolant temperature
T
w
D/A converter: Digital-to-analog converter
Basic map
Start map
Drive unit (integral part of pre-stroke actuator 5)
Pre-stroke position sensor (integral part of pre-stroke actuator 5)
START
Drive circuit
ON
Pre-stroke position learning function
Servo circuit D/A converter
Feedback control
Engine in operation
Engine stationary
Target pre-stroke
Analog signals
Operation of electronic governor control unit 35
• During engine operation, control is effected in accordance with the basic map.
• The pre-stroke position learning function compensates for pre-stroke position sensor adjustment errors and other injection pump errors using the pre-stroke position sensor output voltage, thereby enabling determination of the target pre-stroke.
• The determined target pre-stroke value is converted into a continuous analog signal. By way of the servo circuit and drive circuit, the signal is applied to the drive unit. The drive unit moves the timing sleeve to alter the pre-stroke.
• During engine startup, control is effected in accordance with the start map.
Operation of pre-stroke position sensor (integral part of pre-stroke actuator 5)
• The pre-stroke position sensor monitors the operation of the drive unit. In accordance with the position of the timing sleeve, the sensor determines whether pre-stroke control is being performed in accordance with the target, and it transmits feedback signals to the electronic governor control unit 35.
• In accordance with the feedback signals, the electronic governor control unit 35 calculates the actual timing sleeve position. If the actual position differs from the target, the control unit issues a correction command.
• Through repetition of this process, the system ensures that the timing sleeve position complies with the target at all times. The appropriate pre-stroke is achieved as a result.
13-13
Page 100
STRUCTURE AND OPERATION
● Warmup time shortening function
Data signals
Engine coolant temperature
Accelerator pedal position
Comparison
Target control rack position
Idling speed control
Idling speed adjustment potentiometer
The warmup time shortening function increases the engine’s idling speed in accordance with the coolant temperature, thereby shortening the time required for the engine to warm up. Control is effected automatically or manually in accordance with the position of the idling speed adjustment potentiometer 20. Automatic control is selected by pushing the potentiometer, and manual control is selected by pulling it.
Automatic control (Potentiometer pushed)
• Automatic control is selected when the idling speed adjustment potentiometer 20 is pushed.
• When the coolant temperature is low, the engine’s idling speed is automatically increased to shorten the time required for warmup.
• If the coolant temperature increases from T to T’ (see the graph), the engine speed is decreased from N’ to N, thus returning to its standard idling level.
PUSH
N’
N
Engine speed (rpm)
0
Coolant temperature (°C)
TT’
13-14
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