Mitsubishi S6R, S6R2 Service Manual

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Page 1

SERVICE MANUAL

199419-12120

August 2010

Pub. No. 99419-12120

Page 2

FOREWORD

This service manual describes the maintenance and adjustment procedures, and specifi-

cations for Mitsubishi diesel engines.

To maintain the performance of the engine for many years and to ensure safe operation,

it is important to use the engine correctly and conduct scheduled inspection and mainte-

nance, and it may also be necessary to take appropriate measures which involve in disas-

sembly, inspection, repair and assembly work of the engine and engine parts.

Read through this manual carefully and understand the work procedures fully before dis-

assembling, inspecting, repairing or assembling the engine.

The contents of this manual are based on the engine model produced at the time of publi-

cation. Please note that the contents of this manual may change due to improvements made

thereafter.

Page 3

FOREWORD

HOW TO USE THIS MANUAL

This service manual consists of several chapters, which will give you quick references to specifications, maintenance standards,

adjustment and service procedures including practices to disassemble, inspect, repair and assemble the Mitsubishi diesel

engines.

A short summary describing the contents of each chapter is given in the CHAPTER INDEX page, and there is also a detailed

table of contents at the beginning of each chapter.

Regarding the procedures for operation and scheduled maintenance of the engine, refer to the Operation and Maintenance Man-

ual. For information on the engine components and ordering of service parts, refer to the Parts Catalogue. Structure and func-

tion of the engine are described in the relevant training manuals.

If you have an inquiry, please check the engine model and serial number, and contact our service department.

Description format

(1) Index numbers allotted to parts in exploded views are not only a call-out of part names listed in the text but also an indica-

tion of the sequence of disassembly.

(2) Inspections to be conducted during disassembly process are indicated in boxes in the relevant exploded views.

(3) Maintenance standards required for inspection and repair works are indicated in the appropriate positions in the text. They

are also collectively indicated in the Chapter 2.

(4) The tightening torque with engine oil applied on the thread, is specified [Wet]. Unless otherwise specified, the tightening

torque is of dry condition.

(5) In this manual, important safety or other cautionary instructions are emphasized with the following head marks.

Note

Indicates an immediately hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Indicates a potentially hazardous situation which, if not avoided, may result in property damage.

Emphasizes important matter, or indicates information useful for operation or maintenance of the engine.

Page 4

FOREWORD

Terms used in this manual

Nominal value

means the basic nominal size of a part to be measured.

Standard value

means the quantitative requirement for dimension of a part, clearance between parts and performance. The values are rounded

off for the inspection job, and do not necessarily conform to the design values.

Limit value

means the limit value, which the measured value reaches, the part needs repair or replacement with a new one.

Abbreviations and Standards

BTDC : Before Top Dead Center

ATDC : After Top Dead Center

BBDC : Before Bottom Dead Center

ABDC : After Bottom Dead Center

TIR : Total Indicator Reading

API : American Petroleum Institute

ASTM : American Society for Testing and Materials

JIS : Japanese Industrial Standards

LLC : Long Life Coolant

MIL : Military Specifications and Standards (U.S.A.)

MSDS : Material Safety Data Sheet

SAE : Society of Automotive Engineers (U.S.A.)

P/N : Part Number

Unit of Measurement

Measurements are based on the International System of Units (SI), and their converted metric values are indicated in { } and

U.S. customary values are in [ ]. For metric conversion, the following rates are used.

Pressure :1 MPa = 10.197 kgf/cm

Torque :1 N•m = 0.10197 kgf•m

Force :1 N = 0.10197 kgf

Output power :1 kW = 1.341 HP = 1.3596 PS

Pressure (mercury column) :1 kPa = 0.7 cmHg

Pressure (watercolumn) :1 kPa = 10.197 cmH

-1

Rotation speed: 1 min

= 1 rpm

2O (cmAq)

III

Page 5

FOREWORD

Safety Cautions

Fire and Explosion Precautions

Keep Flames Away

Do not use flames near the engine (in

the engine room). The flame is dan-

gerous to ignite combustibles and

cause a fire. Wipe off spilled fuel, oil

and LLC immediately and thoroughly.

Spilled fuel, oil and LLC may ignite and cause a fire.

Store the fuel and engine oil in a well ventilated area.

Make sure that the fuel and engine oil container caps

are tightly fastened.

Keep Engine Surrounding Area Tidy and Clean

Do not place combustible or explosive material, such

as fuel, engine oil, LLC or explosive powder near the

engine. Such substances can cause a fire or explo-

sion. Thoroughly remove dust, dirt and other foreign

material collected on the engine and the area around

the engine. Such material can cause a fire or the

engine to overheat. In particular, clean the top surface

of the battery thoroughly. Dust can cause a short-cir-

cuit. Always place the engine at a position at least 1 m

[3.28 ft.] apart from buildings and other equipment to

prevent a possible fire caused by engine heat.

Do Not Open Side Covers Until Engine Cools

Do not try to open the side cover of crankcase before

the engine cools down. Wait at least 10 minutes after

stopping the engine. Opening the cover when the

engine is hot allows fresh air to flow into the crank-

case, which can cause oil mist to ignite and explode.

Pay Attention to Fuel, Oil and Exhaust Gas Leak

If any fuel, oil or exhaust gas leakage is found, imme-

diately take corrective measures to stop it. Such leak-

ages, if left uncorrected, can cause fuel or engine oil to

reach hot engine surfaces or hot exhaust gas to con-

tact flammable material, may results in a fire, personal

injury and damage to the equipment.

Use Explosion-proof Light

When inspecting fuel, engine oil, coolant, battery elec-

trolyte, etc., use an explosion-proof light. If the lighting

is not an explosion-proof type, it may ignite and cause

an explosion.

Prevent Electrical Wires From Short Circuit

Avoid inspecting or servicing the electrical system with

the battery cable connected to the battery. Otherwise,

a fire could result from short circuit. Be sure to discon-

nect the battery cable from the negative (-) terminal

before starting work. A loose terminal and a damaged

cable or wire may result in a short circuit and a fire.

Inspect, and if any defect is found, repair or replace it

before starting work.

Keep Fire Extinguishers and First-aid Kit Handy

Keep fire extinguishers handy, and

become familiar with their usage.

Keep a first-aid kit at the designated

place to be ready for use in an emer-

gency. Make counteract procedures

against a fire or an accident. Provide the contact per-

son and means of communication in case of emer-

gency.

Page 6

Stay Away From Rotating and Moving Parts

FOREWORD

Install Protective Covers Over Rotating Parts After Inspection and Maintenance Work

Check the covers over engine rotating

parts for correct installation. Repair

any damaged or loosed covers. Never

remove the protective covers over

rotating parts during operation. When

the engine is coupled to a radiator or other equipment,

install protective covers over the exposed connecting

belt and coupling.

Check Work Area for Safety Before Starting

Before starting the engine, make sure that no one is

near the engine and that tools are not left on or near

the engine. Verbally notify persons within the immedi-

ate area when starting the engine. When the starter

device is tagged with the warning sign saying DO NOT

RUN, never start the engine.

Lockout and Tagout

Be sure to lockout and tagout before starting inspec-

tion and maintenance. Lockout and tagout are effec-

tive methods of cutting off machines and equipment

from energy sources. To accomplish the lockout/

tagout, remove the starter switch key, set the battery

switch to OFF position and attach a DO NOT RUN or

equivalent caution tag to the starter switch. The starter

switch key must be kept by the person who performs

inspection and maintenance work.

Be Sure to Stop the Engine Before Inspection and Maintenance

Be sure to stop the engine before proceeding to

inspection and maintenance work. Never try to make

adjustments on the engine parts while the engine is

running. Rotating parts such as belt can reel in your

body and cause serious injuries.

Always Put Back Engine Turning Tool After Stay Away From Moving Parts While Engine Operates

Keep away from the rotating parts

during operation. Do not leave any

objects that may get caught in rotating

parts. If clothes or a tool gets caught

in rotating parts, serious injury will

result.

Use

Be sure to remove the turning tool used for inspection

and maintenance work. Make sure to pull back the

turning gear to the engine running position before

starting the engine. If the engine is started with a turn-

ing tool inserted or turning condition, it can not only

cause damage to the engine, but also lead to a per-

sonal injury.

Page 7

FOREWORD

Be Careful of Exhaust Gas Poisoning

Be Careful of Ventilation to Operate Engine

If the engine is installed in an

enclosed area, and the exhaust gas is

ducted outside, make sure that duct

joints are free from gas leak. Exhaust

gas from the engine contains harmful

components such as carbon monoxide. Operating the

engine in an ill-ventilated area can cause gas poison-

ing.

Be Careful of Hearing Loss

Wear Ear Plugs

Always wear ear plugs when entering

the machine room (engine room).

Combustion sound and mechanical

noise of engine can cause hearing

loss.

Be Careful of Falling

Lift Engine Carefully

Use slings or wire ropes strong

enough to lift the load considering the

engine weight. To lift the engine, hitch

the proper slings to the lifting hangers

prepared on the engine. To lift the

engine, keep the engine in a well-bal-

anced position, thinking carefully of the engine center

of gravity.

The hangers prepared on the engine are designed for

lifting the weight of engine only. In the case where the

generator, marine gear, and others are installed to the

engine, consideration that the additional weight will not

affect the hangers of the engine.

Keep the angle formed by slings attached to hangers

within 60°. If the angle exceeds this limit, excessive

load may be applied to the hangers and damage the

hangers. If the wire rope contacts the engine directly,

place a cloth or other soft pad to avoid damage to the

engine and sling.

Do Not Climb Onto the Engine

Do not climb onto the engine, nor step on any engine

parts on the engine sides. To work on parts located

high on the engine, use a ladder, footing, and others to

prevent from slipping and falling. Climbing onto the

engine may result in engine part damage and your

injury by falling down.

Always Prepare a Stable Footing

When working on the upper part of

the engine and other hard-to-reach

places, use a stable footing. Stand-

ing on an old footstool or parts box

may result in personal injury. Do not

put any unnecessary objects on a footing.

Page 8

FOREWORD

Be Careful When Handling Fuel, Engine Oil or LLC

Use Specified Fuel, Engine Oil and LongLife Coolant (LLC) Only

Use the fuel, oil and LLC specified in this manual only, and handle them carefully. Use of any other fuel, oil or LLC, or improper handling may cause various engine defects and malfunctions. Get the MSDS issued by the fuel, oil and LLC suppliers, and follow the directions in the MSDS for proper handling.

Handle LLC Carefully

When handling LLC, wear rubber gloves and a protective face mask. If LLC or coolant containing LLC comes into contact with your skin or eyes, or if it is swallowed, you would suffer from inflammation, irritation or poisoning. If LLC is accidentally swallowed, induce vomiting immediately and seek medical attention. If LLC enter your eyes, flush them immediately with plenty of water and seek medical attention. If LLC contact your skin or clothing, wash it away immediately with plenty of water. Keep flames away from LLC. LLC can catch flames and cause a fire. Drained coolant containing LLC is a hazardous material. Do not discard it in an unauthorized procedure. Practice the applicable law and regulations when discard drained coolant.

Proper Discarding of Waste Oil, LLC and Coolant

Do not discard waste engine oil, LLC and coolant in an unauthrized procedure. Such a way of disposal is strictly prohibited by laws and regulations. Discard waste oil, LLC, coolant and other environmentally hazardous waste in accordance with the applicable laws and regulations.

Be Careful of Burns

Do Not Touch the Engine During or Immedi-

ately After Operation

Do not touch any parts of the engine

during or immediately after operation.

You can get burned. Before starting

the maintenance and inspection work,

check the water temperature meter to make sure that

the engine is cooled down.

Be Careful to Open and Close the Radiator

Cap

Never open the radiator cap while the engine is run-

ning or immediately after the engine stops. Stop the

engine and give a sufficient time to allow the coolant to

cool down before opening the cap. When opening the

radiator cap, slowly open the cap so as to release

internal pressure. To prevent hot steam scalds, wear

thick rubber gloves or cover the cap with a cloth. When

closing the radiator cap, tightly close the cap. Do not

open the radiator cap during engine running or imme-

diately after engine stop. Otherwise hot steam and

coolant gush out and can cause burns.

Refill Coolant Only After the Coolant Tem-

perature Dropped

Do not refill coolant immediately after the engine

stops. Wait until the coolant temperature lowers suffi-

ciently to avoid risk of burns.

Do Not Remove Heat Shields

The exhaust system, which becomes extremely hot

while the engine is operating, is provided with various

heat shields. Never remove the heat shields. If any of

these heat shields were inevitably removed for the

inspection and maintenance, be sure to install them

after the work.

Be Careful of Burns When Changing Oil

Wear gloves when draining oil or changing oil filters. If

your skin contacts hot oil or hot parts, you get burn

injury.

VII

Page 9

FOREWORD

Battery

Be Careful with Battery

Never use flames or generate

sparks near the battery. The battery gives off highly flammable hydrogen gas and oxygen gas. Any flame or spark near a battery may cause an explosion.

Do not use the battery if its fluid level is below the

lower limit line. Long use of the battery may result in an explosion.

Do not short the battery terminals with a tool or other

metal object.

When disconnecting battery cables, always remove

first from negative (-) terminal first. When reconnecting the cables, always connect first to the positive (+) terminal.

Charge the battery in a well-ventilated area, with all

battery plugs removed.

Make sure the cable clamps are securely fastened to

the battery terminals. A loose terminal can cause sparks that may result in an explosion.

Before servicing electrical components or conducting

electric welding, set the battery switch to the [Open/ OFF] position or disconnect the cable from the negative (-) battery terminal to cut off the electrical current.

Electrolyte (battery fluid) contains dilute sulfuric acid.

Careless handling of the battery may lead to the loss of sight and/or skin burns. Also, do not swallow battery fluid.

Wear protective goggles and rubber gloves when

working with the battery (such as adding water or charging).

If battery electrolyte is spilled onto the skin or cloth-

ing, immediately wash it away with lots of water. Use soap to clean thoroughly.

Battery fluid can make you blind if splash into your

eyes. Immediately flush it away with plenty of clean water, and seek immediate medical attention.

If battery fluid is accidentally swallowed, gargle with

plenty of water, then drink lots of water, and seek immediate medical attention.

When Abnormality Occurs

Do Not Add Coolant Immediately After a

Sudden Stop Due to Overheating

If the engine stops suddenly due to overheating, or

you suddenly stop the engine by any reason, do not

add coolant immediately. If water is added immedi-

ately, parts such as cylinder heads can be damaged

due to the sudden drop of temperature. Add coolant

slowly after the engine becomes cool.

Be Careful to Restart After Abnormal Stop

If the engine stops abnormally, do not restart the

engine immediately. If the engine stops giving an

emergency alert, inspect the engine and correct the

cause of the defect before restarting. If the engine is

kept operating in such a condition, it can result in seri-

ous engine failure.

Immediately Stop the Engine When Engine

Oil Pressure Drops

If the engine oil pressure drops significantly, stop the

engine immediately, and inspect the lubrication sys-

tem to find the cause. Continuous engine operation

with low oil pressure may cause bearings and other

parts to seize.

Stop the Engine Immediately When the Belt

Break

If the belt breaks, stop the engine immediately. Contin-

uous engine operation with the broken belt can cause

the engine to overheat. Steam of boiled coolant may

gush out from the reserve tank or radiator, and results

in burns.

VIII

Page 10

Other Cautions

FOREWORD

Do Not Tamper

If tampered, the warranty is totally void even in the

warranty period. Tampering with the engine can not

only damage the engine but also may lead to personal

injury.

Perform All Specified Pre-operation Inspections and Scheduled Inspections

Conduct the daily inspection and scheduled inspec-

tion/maintenance as described in this manual.

Failure to conduct the specified inspections may cause

various engine problems, damage to parts, and a seri-

ous accident.

Wear Proper Work Clothing and Protective Gears

Wear a hard hat, face shield, safety shoes, dust mask,

gloves and other protective gears as needed. When

using compressed air, wear safety goggles, a hard

hat, gloves and other necessary protective gear.

Works without wearing proper protective gears may

result in serious injury.

Never Break the Seals

To ensure the proper engine operation, the fuel control

link is provided with seals that protect the fuel injection

volume and rotation speed settings against tampering.

If the seal is tampered, no guarantee will be provided.

If the seal is tampered, the defects shown below can

occure.

Rapid wear of moving and rotating parts

Engine troubles such as seizure and damage of

engine parts

Sudden increase of fuel and lubricating oil consump-

tion

Deterioration of engine performance due to improper

balance between fuel injection volume and governor

control, or a serious accident due to overrunning of

the engine

Inspect the Engine After Operation

After the engine operation, inspect each part of engine

once again. If any defect is found, correct immediately.

Break-in the Engine

To break-in a new engine or overhauled engine, oper-

ate the engine at a speed lower than the rated speed

in a light load condition during the first 50 hours of

operation. Operating a new engine or overhauled

engine in a severe condition during the break-in period

shortens the service life of the engine.

Page 11

FOREWORD

Warm-up the Engine Before Use

After starting the engine, run the engine at a low idling

speed for 5 to 10 minutes for warming-up. Start the

work after this operation is completed. Warm-up oper-

ation circulates lubricant in the engine, and works for

the longer service life and economical operation. Do

not continue the warm-up operation for a longer time

than necessary. Long warm-up operation causes car-

bon deposits in the cylinders, and may lead to incom-

plete combustion.

Do Not Operate the Engine in an Overloaded Condition

If the engine shows an overloaded condition such as

black exhaust smoke, reduce the load immediately to

an appropriate load condition. Overloading causes not

only high fuel consumption but also excessive carbon

deposits inside the engine. Carbon deposits cause

various problems and will shorten the service life of the

engine.

Cool Down the Engine Before Stop

Cool down the engine at low idling for five to six min-

utes before stopping it. Stopping the engine immedi-

ately after high-load operation will cause local heat up

of engine parts and shorten the service life of the

engine. During the cooling operation, check the engine

for abnormalities.

Do Not Continue Low Load Operation

Low load continuous operation (less than 30%) must

be limited within one hour. Long warm-up operation

causes carbon deposits in the cylinders, and may lead

to incomplete combustion. Also, after low load opera-

tion for approx one hour, run the engine at a 30% or

higher load for five minutes or more.

Use Care to Protect Engine From Water

Use care to protect engine from water such as rain

entering through the air inlet or exhaust openings. Do

not wash the engine while it is running. Cleaning fluid

or water can be sucked into the engine. Starting the

engine with water inside the combustion chambers

can cause the water hammering, and may result in

engine inner parts damage and serious accident.

Air Cleaner or

Pre-cleaner is to be Properlly Maintained.

With foreign material in the intake air, excessive wear

of the engine can result. Worn parts produce many

problems such as increase of oil consumption,

decrease of output and starting difficulties. For effec-

tive removal of dust from intake air, maintain the air

cleaner/pre-cleaner according to the following instruc-

tions.

Never perform maintenance of the air cleaner or pre-

cleaner during operation. Foreign material enters the

turbocharger and may result in a serious failure.

When removing the air cleaner or pre-cleaner, be

careful to prevent dust and foreign material collected

on the cleaner from entering the engine. After

removing the air cleaner or pre-cleaner, immediately

cover the opening (inlet port of engine or turbo-

charger silencer) with plastic sheet or similar means

to prevent foreign materials from entering the

engine.

An air cleaner with a dust indicator gives an alarm

when it is clogged. Conduct maintenance when the

alarm is given.

Page 12

FOREWORD

Observe Safety Rules at Work Site

Observe the safety rules established at the workplace

when operating and maintaining the engine. Do not

operate the engine if you are in bad health. Consult

your supervisor about your condition. Operation of the

engine with decreased attention may cause improper

operation and results in an accident. When working in

a team of two or more people, use specified hand sig-

nals to communicate among workers.

Use Proper Tools for Maintenance Work

Always keep in mind to select most appropriate tools

for the work and use them correctly. If a tool is dam-

aged, replace with new tool.

Do Not Operate Starter for a Long Time

Do not use the starter for more than 10 seconds at a

time. If the engine does not start, wait for at least 1

minute before starting again. Continuous operation of

the starter to start a stubborn engine may lead to a flat

battery or starter burning out.

Cautions for Engine Trans portation

To road-transport the engine, consider the engine

weight, width and height, and obey applicable laws

and regulations such as road traffic laws, vehicle road

acts and vehicle restriction ordinances.

Be Careful of Engine Room Ventilation

Always keep the engine room well-ventilated. Insuffi-

cient intake air amount of the engine can cause an

increase in the engine temperature, and could result in

a decrease in the output power and poor performance.

It is highly recommended to calculate the required

amount of air supply to the engine and install an ade-

quate ventilation system before installing the engine.

Do Not Touch High Pressure Fuel Jet

Do not touch fuel jet leaked or sprayed from the high

pressure injection pipe. Fuel in the fuel injection pipe

has a high pressure and if the fuel impinges your skin,

it goes through the skin and can cause serious injury.

Do Not Turn Off the Battery Switch During Operation

If the battery switch is turned OFF when the engine is

running, not only various meters will stop working but

also the diodes and transistors in the starter can be

damaged.

Page 13

FOREWORD

Warning Labels

Maintenance of Warning Labels

Make sure all warning/caution labels are legible.

Clean or replace the warning or caution label when the description or illustration is not clear to read.

For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvent, gasoline or other

chemicals to prevent the label from fading and peering.

Replace a damaged or missing label with a new one.

If any engine part sticked with a warning label is replaced with a new one, attach a new identical warning label to the

new part.

To get new warning labels, contact our approved dealer.

XII

Warning labels

Page 14

Points on Disassembling and Assembling

This service manual contains the recommended practices to

service the engine. The manual also contains dedicated spe-

cial tools made for the work, and the basic safety cautions to

obey when working. Note that this manual does not cover

all potential hazards that could occur during maintenance,

inspection and service works of the engine.

When working on the engine, follow the related instructions

in this manual and also be careful of the following:

Points on Disassembling

 Use correct tools and instruments. Or serious damage or

accident may result.

Do not use jack bolts having sharp edge, as they may cause

damage to the surface.

Use a footing and workbench to place disassembled parts if

necessary, and obey the disassembling procedures

described in this manual. Do not place the parts on the

floor directly. Place them on a workbench or the like.

Place the engine parts in the order of removal to prevent

from missing. Place the parts in the serial order for reas-

sembling.

When reusing the engine parts, unless there are special rea-

sons, install them to their original positions.

Pay attention to assembling marks. Put your marks on the

parts, if necessary, to ensure correct assembling.

Carefully check each part for defects during disassembling

or cleaning. Do not miss symptoms which can not be

found after disassembling or cleaning.

Pay attention to the safety, especially for the balancing of

disassembled parts and carrying of heavy parts. (Get help,

and use jacks, chain blocks and guide bolts as necessary.)

Use protective gloves when you touch overheated or fro-

zen parts. Touching the part with a bear hand can cause

burns.

Points on Assembling

 Wash all engine parts, except such parts as oil seals, O-

rings and rubber seats, in cleaning oil and dry them with

compressed air.

 Use correct tools and instruments.

Use only high-quality lubricating oil and grease of the

appropriate type. Be sure to apply oil, grease or adhesive

to specified surfaces.

Use a torque wrench to tighten parts correctly when their

tightening torques are specified. Refer to "Tightening

torque table."

Replace Gaskets, packings and O-rings with new ones.

Apply adhesive as required. Do not apply adhesive too

much.

Use protective gloves when you touch overheated or fro-

zen parts. Touching the part with a bear hand can cause

burns.

FOREWORD

XIII

Page 15

GENERAL CONTENTS

Chapter 1 GENERAL

1. External View

2. Outline of Systems

3. Contents of Plate and Label

4. Specifications

Chapter 2 SERVICE DATA

1. Maintenance Service Data

2. Tightening Torque Table

Chapter 3 SERVICE TOOLS

1. Special Tools

Chapter 4 OVERHAUL INSTRUCTIONS

1. Determining Overhaul Timing

2. Compression Pressure - Measure

Chapter 5 DISASSEMBLY OF BASIC ENGINE

1. Cylinder Heads and Valve Mechanisms - Disassemble and Inspect

2. Rear Mechanism - Disassemble and Inspect

3. Front Mechanism - Disassemble and Inspect

4. Cylinder Liner, Piston and Connecting Rod - Disassemble and Inspect

5. Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

1. Cylinder Head and Valve Mechanism - Inspect and Repair

2. Rear Mechanism - Inspect and Repair

3. Front Mechanism - Inspect and Repair

4. Piston and Connecting Rod - Inspect and Repair

5. Crankcase and Crankshaft - Inspect and Repair

Chapter 7 ASSEMBLY OF BASIC ENGINE

1. Crankshaft and Main Bearing - Install

2. Cylinder Liner, Piston and Connecting Rod - Assemble

3. Front Mechanism - Assemble

4. Rear Mechanism - Assemble

5. Cylinder Head and Valve Mechanism - Assemble

Page 16

Chapter 8 FUEL SYSTEM

1. Fuel System - Remove and Inspect

2. Fuel System - Disassemble, Inspect and Assemble

3. Fuel System - Install

Chapter 9 LUBRICATION SYSTEM

1. Lubrication System - Remove and Inspect

2. Lubrication System - Disassemble, Inspect and Assemble

3. Lubrication System - Install

Chapter 10 COOLING SYSTEM

1. Cooling System - Remove and Inspect

2. Cooling System - Disassemble, Inspect and Assemble

3. Cooling System - Install

Chapter 11 INLET AND EXHAUST SYSTEMS

1. Inlet and Exhaust Systems - Remove and Inspect

2. Inlet and Exhaust Systems - Disassemble, Inspect and Assemble

3. Inlet and Exhaust Systems - Install

Chapter 12 AIR START SYSTEM

1. Air Start System - Remove and Inspect

2. Air Start System - Disassemble, Inspect and Assemble

3. Air Start System - Install

Chapter 13 ADJUSTMENT AND OPERATION

1. Engine - Adjust

2. Break-in Operation

3. Engine-Test and Adjustment

Page 17

Chapter 1 GENERAL

1. External View ...........................................................................................................1-3

2. Outline of Systems................................................................................................1-13

2.1 Outline of Fuel System ........................................................................................................... 1-13

2.2 Outline of Lubrication System................................................................................................. 1-13

2.3 Outline of Cooling System ...................................................................................................... 1-14

2.4 Outline of Inlet and Exhaust System....................................................................................... 1-17

3. Contents of Plate and Label .................................................................................1-19

3.1 Name Plate ............................................................................................................................. 1-19

3.2 Caution Plate .......................................................................................................................... 1-19

3.3 Emissions Certification Label.................................................................................................. 1-19

4. Specifications ........................................................................................................1-20

1-1

Page 18

Chapter 1 GENERAL

Tension pulley

Engine coolant outlet

Water pump

S6R-PTA with fan spec

Thermostat case

Oil pan

Note: Configuration varies depending on the destination and specifications.

Damper

Flywheel

Engine oil discharge port

Rotation direction

Timing gear case

S6R-PTA with fan spec

Note: Configuration varies depending on the destination and specifications.

Rotation direction

1. External View

Chapter 1 GENERAL

Engine Front View

Engine Rear View

1-3

Page 19

Chapter 1 GENERAL

Oil level gauge

Governor

Governor oil filter

Fuel injection pump

Fuel filter

Oil cooler

Engine coolant inlet

Oil filler

Stop solenoid

Fuel outlet

Fuel inlet

Rear

Front

Damper

Oil filter

Bypass oil filter

Front hanger

Fuel feed pump

Breather

Rear hanger

Water pump

S6R-PTA with fan spec

Note: Configuration varies depending on the destination and specifications.

Engine coolant outlet

Starter

Air cooler

Turbocharger

Front

Rear

Air inlet

Exhaust manifold

Exhaust pipe, exhaust outlet

Relief valve

Alternator

S6R-PTA with fan spec

Note: Configuration varies depending on the destination and specifications.

Left Side View

1-4

Right Side View

Page 20

Chapter 1 GENERAL

Tension pulley

Engine coolant outlet

Thermostat case

Oil pan

S6R-PTK

Note: Configuration varies depending on the destination and specifications.

Water pump

Damper

Flywheel

Timing gear case

Note: Configuration varies depending on the destination and specifications.

S6R-PTK

Engine oil drain port

Rotation directionRotation directionRotation direction

Engine Front View

Engine Rear View

1-5

Page 21

Chapter 1 GENERAL

Governor

Governor oil filter

Fuel injection pump

Fuel filter

Oil cooler

Oil filler

Rear

Front

Front hanger

Breather

Rear hanger

Water pump

Note: Configuration varies depending on the destination and specifications.

S6R-PTK

Fuel feed pump

Stop solenoid

Oil level gauge

Fuel return port

Fuel inlet

Damper

Oil filter

Bypass oil filter

Starter

Engine air cooler coolant outlet

Air cooler

Engine air cooler coolant inlet

Turbocharger

Front

Rear

Exhaust manifold

Alternator

S6R-PTK

Note: Configuration varies depending on the destination and specifications.

Exhaust pipe, exhaust outlet

Air inlet

Relief valve

Left Side View

Right Side View

1-6

Page 22

Chapter 1 GENERAL

Tension pulley

Engine coolant outlet

Thermostat case

Oil pan

Note: Configuration varies depending on the destination and specifications.

S6R-Y2PTAW

Water pump

Damper

Water pump for air cooler cooling

Flywheel

Timing gear case

S6R-Y2PTAW

Note: Configuration varies depending on the destination and specifications.

Engine oil drain port

Rotation directionRotation direction

Rotation direction

Engine Front View

Engine Rear View

1-7

Page 23

Chapter 1 GENERAL

Oil level gauge

Governor

Fuel injection pump

Fuel filter

Oil cooler

Engine coolant inlet

Oil filler

Fuel return port

Fuel inlet

Rear

Front

Front hanger

Breather

Rear hanger

Water pump

S6R-Y2PTAW

Note: Configuration varies depending on the destination and specifications.

Fuel feed pump

Stop solenoid

Damper

Oil filter

Bypass oil filter

Alternator

Starter

Air cooler coolant outlet

Air cooler

Turbocharger

Front

Rear

Exhaust manifold

S6R-Y2PTAW

Note: Configuration varies depending on the destination and specifications.

Exhaust pipe, exhaust outlet

Air inlet

Relief valve

Air cooler coolant inlet

Left Side View

Right Side View

1-8

Page 24

Chapter 1 GENERAL

Thermostat case

Note: Configuration varies depending on the destination and specifications.

S6R2-PTAA

Water pump

Damper

Coolant inlet

Coolant outlet

Air outlet for air cooler

Air inlet for air cooler

Flywheel

Timing gear case

S6R2-PTAA

Note: Configuration varies depending on the destination and specifications.

Engine oil drain port

Rotation directionRotation direction

Rotation direction

Turbocharger

Engine Front View

Engine Rear View

1-9

Page 25

Chapter 1 GENERAL

Fuel return port

Oil level gauge

Fuel inlet

Breather

Stop lever

Actuator (governor)

Fuel injection pump

Fuel feed pump

Stop solenoid

Water pump

Damper

Bypass oil filter

Oil filter

Oil filler

Oil cooler

Fuel filter

Fan

Front hanger

Front

Rear

Exhaust pipe, exhaust outlet

S6R2-PTAA

Note: Configuration varies depending on the destination and specifications.

Starter

Relief valve

Radiator

Air cooler

Air duct

Front

Rear

Rear hanger

S6R2-PTAA

Note: Configuration varies depending on the destination and specifications.

Oil pan

Left Side View

Right Side View

1-10

Page 26

Chapter 1 GENERAL

Tension pulley

Thermostat case

Oil pan

Water pump

Damper

Note: Configuration varies depending on the destination and specifications.

S6R-Z3MPTAW

Engine coolant outlet

Flywheel

Timing gear case

Silencer

S6R-Z3MPTAW

Note: Configuration varies depending on the destination and specifications.

Engine oil drain port

Rotation directionRotation directionRotation direction

Engine Front View

Engine Rear View

1-11

Page 27

Chapter 1 GENERAL

Oil level gauge

Governor

Governor oil filter

Fuel injection pump

Fuel filter Oil cooler

Engine coolant inlet

Oil filler

Fuel return port

Fuel inlet

Rear

Front

Damper

Front hanger

Fuel feed pump

Breather

Rear hanger

Water pump

S6R-Z3MPTAW

Note: Configuration varies depending on the destination and specifications.

Starter

Oil filter

Bypass oil filter

Air cooler coolant outlet

Air cooler

Air cooler coolant inlet

Turbocharger

Front

Rear

Pre-cleaner air inlet

Exhaust manifold

Exhaust pipe, exhaust outlet

Alternator

S6R-Z3MPTAW

Note: Configuration varies depending on the destination and specifications.

Left Side View

1-12

Right Side View

Page 28

2. Outline of Systems

Fuel injection nozzle

Fuel leak-off pipe

Fuel injection pump

Fuel feed pump

From fuel tank

To fuel tank

Fuel filter

Fuel injection pipe

Oil pressure governor spec

Governor

Turbocharger

Camshaft

Oil thermostat

Oil cooler

Timing gear

Fuel injection pump

Oil pump

Safety valve

Bypass oil filter

Oil strainer

Oil filter

Relief valve

Crankshaft

Water pump

Piston cooling nozzle

Piston

Rocker shaft

Oil filter

Governor oil filter

2.1 Outline of Fuel System

Chapter 1 GENERAL

2.2 Outline of Lubrication System

Outline of Fuel System

Outline of Lubrication System

1-13

Page 29

Chapter 1 GENERAL

Turbocharger

Camshaft

Oil thermostat

Oil cooler

Electronic governor spec

Timing gear

Fuel injection pump

Oil pump

Safety valve

Bypass oil filter

Oil strainer

Oil filter

Relief valve

Crankshaft

Water pump

Piston cooling nozzle

Piston

Rocker shaft

Oil filter

Water outlet pipe (rocker case)

Oil cooler

Air cooler

PTA spec

Thermostat

Radiator

Water pump

2.3 Outline of Cooling System

Outline of Lubrication System

1-14

Outline of Cooling System

Page 30

Chapter 1 GENERAL

Water outlet pipe (rocker case)

Oil cooler

PTK spec

Thermostat

Air cooler

Water pump

Air cooler, Engine coolant inlet

Air cooler, engine coolant outlet

Water outlet pipe (rocker case)

Oil cooler

PTAW spec (Outside of water pump for air cooler cooling)

Thermostat

Air cooler

Water pump

Exhaust manifold

Air cooler coolant inlet Air cooler coolant outlet

Engine coolant outlet

Outline of Cooling System

1-15

Page 31

Chapter 1 GENERAL

Water outlet pipe (rocker case)

Oil cooler

Thermostat

Air cooler

Water pump

Air cooler water pump

Engine coolant inlet

Air cooler coolant outlet

Engine coolant outlet

Air cooler coolant outlet

PTAW spec (Water pump for air cooler cooling mounted)

Water outlet pipe (rocker case)

Oil cooler

Air cooler

PTAA spec

Thermostat

Radiator

Water pump

Outline of Cooling System

1-16

Outline of Cooling System

Page 32

Chapter 1 GENERAL

Water outlet pipe (rocker case)

Oil cooler

Marine gear oil cooler

MTK, MPTK spec

Thermostat

Heat exchanger

Water pump

Sea water pump

Sea water outlet port

Sea water inlet port

Exhaust manifold

Exhaust outlet

Air cooler

Exhaust air

Charging air

Turbocharger

Exhaust pipe

Internal air cooler spec

From air-cleaner

Cylinder

2.4 Outline of Inlet and Exhaust System

Outline of Cooling System

Outline of Inlet and Exhaust System

1-17

Page 33

Chapter 1 GENERAL

Exhaust outlet

Air cooler

Exhaust air

Charging air

Turbocharger

Exhaust pipe

External air cooler spec

From air-cleaner

Cylinder

Outline of Inlet and Exhaust System

1-18

Page 34

3. Contents of Plate and Label

3.1 Name Plate

The name plate is attached on the lateral side of the engine,

and shows the following information:

Engine serial number

Manufactured date

Total displacement

Engine output

Rated speed



Right side







Chapter 1 GENERAL



RearFront

3.2 Caution Plate

The caution plate is attached to the top face of the rocker

cover of No. 1 cylinder and shows the following informa-

tion:

Valve clearance

Firing order

Fuel injection timing

Connecting rod weight rank

3.3 Emissions Certification Label

The emission certification label that shows compliance with

emission requirements is attached to the engine.

Left side

Cylinder No.

Name Plate











VALVE CLEARANCE(COLD)

INLET

FUEL INJECTION TIMING

0.6

FIRING ORDER

1-5-3-6-2-4

CON-ROD RANK

EXHAUST

0.8

BTDC

Caution Plate

1-19

Page 35

Chapter 1 GENERAL

4. Specifications

Engine model S6R S6R2

Type Water cooled, four stroke cycle diesel, turbo charged

No. of cylinders - Arrangement 6 cylinders, in-line

Combustion system Direct injection system

Valve mechanism Overhead

Cylinder bore × stroke 170×180 mm [6.69×7.09 in.] 170×220 mm [6.69×8.66 in.]

Total displacement 24.51 L [1495.9 cu in] 29.96 L [1828.5 cu in.]

Firing order 1-5-3-6-2-4

Direction of rotation Counterclockwise as viewed from flywheel side

Engine oil Class CF or CH-4 (API service classification)

Specification table

The mark "○" in the table represents the installed equipment of each engine type.

Note:(a) This table shows the general information. The installation of equipment differs in accordance with the customization

and specifications.

(b) The specification and part number may be changed with the design progress without prior notice.

Equipment name Specification name

Single spring

Valve mechanism

Camshaft

Cylinder liner

Piston cooling nozzle

Oil pan

Connecting rod Rod

(Inlet side)

Double spring (Exhaust side)

Overlap 61° (37505-40100)

Overlap 93° (37505-34100)

Overlap 93° advanced by 4° (37505-04300)

(37507-22700) ○○○○○○○○○○○○○○○○

(37507-55600) ○○○○○○○○○○○○

One jet ○○○ ○○○○○○○○○○○○○○○○○○○○○○

Two jets ○○○○

Standard oil pan (37513-60101)

Deep type oil pan (Hi 145L, Low114L) [38.3, 30.1 USgal] (37513-20602)

Bolt identification mark "AU""AL" (37519-31020)

Bolt identification mark "2" (37519-75020 to 76010)

S6R S6R2

V2PTK-1

Y2PTAW

Y1PTA-4

Y1PTA-5

PTA-S

PTA

○○○○○○○○○○○○○○○○○○○○○○○○○○○○

○ ○○○○○ ○ ○ ○○○

○○○ ○ ○○ ○○○ ○○○○○○○○○○

○ ○○○○○ ○ ○ ○ ○

○○○○○○○○○○ ○○○○○○○○

○ ○ ○○○○○○○ ○ ○○○○○○○

○○○○○○○○○○○○○○○○

PTK

Z3MPTAW

MPTA

Y1MPTA-3

Y1MPTK-3

MPTK

Y2MPTK-3

MPT

PTA

○○○○○○○○○○○○

PTAA

PTA-S

PTAA-S

PTK

MPTA

MPTK

MTK

MTK2

MTK3

○○

MTK2L

1-20

Page 36

Chapter 1 GENERAL

Equipment name Specification name

Overlap 61° Compression ratio 14 (37517-30101)

Overlap 93° Compression ratio 15 (37517-10401)

Overlap 93° Compression ratio 14.5 (37517-00900)

Piston

Flywheel

Front pulley, Crankshaft pulley

Overlap 61° Compression ratio 14 (37517-25100)

Overlap 91° Compression ratio 14 (37517-05300)

Overlap 93° 4°advance, compression ratio14 (37517-05500)

Standard (37521-00012) ○○○○○○○○ ○○○○○○

FCD spec (37521-00060) ○○○○○○○ ○○○○○○

Land clutch (37521-12012) ○

(37525-12201) ○○○○○ ○○○○○○○○○○○○○○○○○○○○○○

(37525-04501) ○

(37525-18800) ○○

(37320-22600) ○○○

(37525-28101) ○ ○○ ○○○○○○

(37525-18600) ○○

(37525-02800) ○

S6R S6R2

V2PTK-1

Y2PTAW

Y1PTA-4

Y1PTA-5

PTA-S

PTA

○○○ ○ ○○ ○○○ ○

○○○○○

PTK

○○○

Z3MPTAW

MPTA

Y1MPTA-3

Y1MPTK-3

MPTK

Y2MPTK-3

MPT

PTAA-S

PTA-S

PTAA

PTA

○○○○○○○○○

PTK

MPTK

MPTA

MTK

MTK2L

MTK2

MTK3

○○

1-21

Page 37

Chapter 1 GENERAL

Equipment name Specification name

TD10L-42F-34 ○

TD10L-42F-43 ○○○○

TD13L-47F-40 ○○○○○○○

TD13L-47F-47 ○○○○○ ○○○

TD13L-47F-55 ○○

TD13L-54QRC-47 ○○

TD13L-54QRC-47 Water cool exhaust manifold

TD13L-57V-55 ○

TD13M1-48QRC-40 ○

TD15-50B-49 ○○ ○○

TD15-50B-54 ○○○

TD15-55B-54 ○○○

Turbocharger

Fan

TD15-55B-54 Classification JG

TD15-55B-54 Classification NK

TD15-55B-59 ○○

TD15-55B-66 ○

TF15L-60QV-49 ○

TF15M-60QV-49 ○○○○

TF15M-60QVRC-49 ○○○

TF15M-67QVRC-49 (Flange connection type)

TF15M-67QVRC-54 ○○

TF15M1-67QVRC-49 ○

TF15M1-60QVRC-49 Water cool exhaust manifold

D1010, PUSHER (46648-02300)

D1016, PUSHER (46648-22600)

S6R S6R2

V2PTK-1

Y2PTAW

Y1PTA-4

Y1PTA-5

PTA-S

PTA

○○○○ ○○ ○○○ ○ ○

PTK

Z3MPTAW

MPTA

○

Y1MPTA-3

Y1MPTK-3

MPTK

Y2MPTK-3

MPT

PTA-S

PTAA

PTA

○○

PTAA-S

PTK

MPTA

MPTK

○

MTK

MTK2

MTK3

○○

MTK2L

1-22

Page 38

Chapter 1 GENERAL

Equipment name Specification name

Fresh water (internal cooling) air cool exhaust manifold (37555-30030)

Fresh water (external cooling) air cool exhaust manifold (37555-30040)

Fresh water (internal cooling) Water cool exhaust manifold (37555-10054)

Sea water (37555-30083) ○○ ○○

Air cooler

Fuel injection nozzle

Fresh water (internal cooling) air cool exhaust manifold Classification JG (37555-30J30)

Fresh water (two system) air cool exhaust manifold (37555-30030)

Fresh water (two system) Water cool exhaust manifold (37555-00060)

MTK2(37555-33013) ○○

MTK3(37555-05012) ○○

MPTK(37555-30083) ○

T model, screw adjust opening pressure type (37560-35000)

T model, screw adjust opening pressure type (37560-37000)

T model, screw adjust opening pressure type (37560-39000)

T model, screw adjust opening pressure type (37560-22010)

T model, screw adjust opening pressure type (37560-41000)

T model, screw adjust opening pressure type (37561-44000)

T model, shim adjust opening pressure type (37560-32000)

TE model, screw adjust opening pressure type (37860-06000)

S model, screw adjust opening pressure type (37760-22001)

S6R S6R2

V2PTK-1

Y2PTAW

Y1PTA-4

Y1PTA-5

PTA-S

PTA

○○○○ ○○ ○○ ○ ○

○○○○○

○○ ○ ○ ○

○ ○ ○○ ○○○ ○○○ ○○○○

○○ ○○○○○○ ○○○

PTK

○○ ○

○

○○

Z3MPTAW

MPTA

○○ ○

○○

Y1MPTA-3

Y1MPTK-3

MPTK

Y2MPTK-3

MPT

○

PTAA-S

PTA-S

PTAA

PTA

○

MPTK

MPTA

PTK

○○○○

MTK

MTK2

MTK2L

MTK3

○

1-23

Page 39

Chapter 1 GENERAL

Equipment name Specification name

Diesel oil ○○○○○○○○ ○ ○○ ○○○○

Diesel oil, changover type ○○ ○ ○○

Fuel filter

Governor

Starter

Alternator

Stop solenoid

Start restriction solenoid

A diesel oil ○○ ○○○○○○○○○○○○○

Diesel oil, changeover type ○○ ○○

Primary filter ○○ ○

Changeover type (VOLVO) ○○

Woodward make PSG type governor

Woodward make SG type governor

TOHO SEISAKUSHO Co., LTD . SG4017 type actuator

Woodward make DYNA8000 type Actuator

Woodward make PROACT type Actuator

Land use self starter motor (37566-30200)

Land use self starter motor (37566-40300)×2

Marine use self starter motor (37566-45200)

Marine use self starter motor (37566-45200)×2

Air motor (04065-61001) ○○○

30A (04343-38000) ○○○○○○○○ ○○○○○○

35A, brushless (04343-35500)

35A, brushless, JG (04343-35600)

35A, JG (04344-05100) ○ ○ ○ ○ ○○○○

130A (04344-08001) ○

RUN-OFF ○○ ○ ○○○○○○○○○○ ○○○○○○○

RUN-ON ○○○○○○○ ○○○○○

RUN-OFF ○○

S6R S6R2

V2PTK-1

Y2PTAW

Y1PTA-4

Y1PTA-5

PTA-S

PTA

○○ ○ ○○○○○○○ ○○ ○○○○○○○

○○ ○ ○○○○○

○○

○○○○

○○○○○○○○○ ○○○○○○

○ ○○ ○○○ ○○

PTK

Z3MPTAW

MPTA

○○ ○

○○○○○○○ ○○○○○○

○○○ ○○

Y1MPTA-3

Y1MPTK-3

MPTK

Y2MPTK-3

MPT

PTAA-S

PTA-S

PTAA

PTA

PTK

MPTK

MPTA

MTK

○

MTK2

MTK3

MTK2L

1-24

Page 40

Chapter 2 SERVICE DATA

1. Maintenance Service Data ......................................................................................2-3

1.1 Maintenance Service Data of Engine General.......................................................................... 2-3

1.2 Maintenance Service Data of Basic Engine.............................................................................. 2-4

1.3 Maintenance Service Data of Fuel System............................................................................... 2-9

1.4 Maintenance Service Data of Lubrication System .................................................................. 2-11

1.5 Maintenance Service Data of Cooling System ....................................................................... 2-12

1.6 Maintenance Service Data of Electrical System ..................................................................... 2-14

1.7 Air Start System...................................................................................................................... 2-17

2. Tightening Torque Table.......................................................................................2-18

2.1 Tightening Torque Spec for Basic Engine .............................................................................. 2-18

2.2 Tightening Torque Spec for Fuel System ............................................................................... 2-19

2.3 Tightening Torque Spec for Lubrication System..................................................................... 2-19

2.4 Tightening Torque Spec for Cooling System.......................................................................... 2-20

2.5 Tightening Torque Spec for Inlet and Exhaust System .......................................................... 2-20

2.6 Tightening Torque Spec for Electrical System........................................................................ 2-21

2.7 Tightening Torque Spec for Air Start System ......................................................................... 2-21

2.8 Tightening Torque for Standard Bolts..................................................................................... 2-22

2.9 Tightening Torque for Standard Eyebolts ............................................................................... 2-23

2.10 Tightening Torque for Standard Union Nuts........................................................................... 2-23

2.11 Tightening Torque for Fuel Injection Pipe............................................................................... 2-23

2-1

Page 41

Chapter 2 SERVICE DATA

1. Maintenance Service Data

1.1 Maintenance Service Data of Engine General

Item

Compression pressure

At rated

Engine oil pressure

When idling

Open BTDC 37°

Close ABDC 44°

Open BBDC 57°

Close ATDC 24°

Open BTDC 2.5°

Close BBDC 13°

Open BBDC 26°

Close BTDC 10.5°

Open BTDC 53°

Close ABDC 44°

Open BBDC 57°

Close ATDC 40°

Open BTDC 14°

Close ABDC 12.5°

Open BBDC 25.5°

Close ATDC 1°

Open BBDC 57°

Close ABDC 40°

Open BBDC 61°

Close ABDC 36°

Open BTDC 18°

Close ABDC 8.5°

Open BBDC 29.5°

Close BTDC 3°

Overlap 61° camshaft P/N:37505-40100

Overlap 93°

Valve timing

camshaft P/N:37505-34100

Overlap 93° advanced by 4° camshaft P/N:37505-04300

Valve clearance (when cold)

Fuel injection timing

Inlet

Exhaust

Inlet

Exhaust

Inlet

Exhaust

Inlet

Exhaust

Inlet

Exhaust

Inlet

Exhaust

Inlet 0.6 mm [0.024 in.]

Exhaust 0.8 mm [0.031 in.]

Nominal

value

Standard value Limit value Remarks

}

1.27 MPa

{13 kgf/cm2}

[189 psi]

0.29 MPa

{300 kgf/cm2}

[4267 psi]

0.15 MPa

{300 kgf/cm2}

[4267 psi]

Cranking (approx 120 min

When oil temperature is 90 to 100º C [194 to 212°F]

1.8 MPa

{18.5 kgf/cm

[263 psi]

0.49 to 0.64 MPa {300 kgf/cm

[4267 psi]

0.20 to 0.29 MPa {300 kgf/cm

[4267 psi]

Valve clearance 0 mm

±2°(Crank angle)

Valve clearance 2 mm [0.08 in.]

Valve clearance 0 mm

±2°(Crank angle)

Valve clearance 2 mm [0.08 in.]

Valve clearance 0 mm

±2°(Crank angle)

Valve clearance 2 mm [0.08 in.]

Check the caution plate on No. 1 rocker cover.

-1

Chapter 2 SERVICE DATA

)

2-3

Page 42

Chapter 2 SERVICE DATA

1.2 Maintenance Service Data of Basic Engine

Item

Rocker bushing inside diameter ø36 [1.42]

Rockers

Rocker shaft outside diameter ø36 [1.42]

Valve stem outside diameter ø10 [0.39]

Valve guide inside diameter ø10 [0.39]

Va l ve

Clearance

Intake side between the bottom face of valve bridge and top face of valve rotator

Exhaust

side

Single valve spring spec

Double valve spring spec

Valve seat angle 30°

Valve sinkage 0

Seat width

Valve margin

Valve seat

Inside diameter of valve seat counterbore

and valve

Standard

Valve seat outside diameter

0.03

0.06

Valve seat interference

Free length 73 [2.87] 71 [2.80]

Single valve spring

P/N: 37504-10400

Squareness

Installed length/load

(mm [in.]/N {kgf} [lbf])

Free length

P/N: 37504-10600

Inner

spring

Squareness

Set length / load

Double valve spring

P/N: 37504-20500

Outer

spring

(mm [in.]/N{kgf} [lbf])

Free length 96.57

Squareness

Set length / load (mm [in.]/N{kgf} [lbf])

Push rod Runout 0.50 [0.0197] or less TIR

Nominal

value

2.3

[0.091]

3.0

[0.118]

Standard value Limit value Remarks

36.000 to 36.040

[1.4173 to 1.4189]

35.966 to 35.991

[1.4160 to 1.4170]

9.940 to 9.960

[0.3913 to 0.3921]

10.000 to 10.015

[0.3937 to 0.3943]

2.1

[0.083]

36.090

[1.4209]

35.940

[1.4150]

9.910

[0.3902]

10.060

[0.3961]

Same for both inlet and exhaust valves.

Single valve spring spec only

3.4

[0.134]

2.1

[0.083]

- 0.1 to 0.1

[-0.004 to 0.004]

2.18 to 2.42

[0.0858 to 0.0953]

2.8 to 3.2

[0.110 to 0.126]

60.000 to 60.030

[2.3622 to 2.3634]

60.100 to 60.130

[2.3661 to 2.3673]

60.130 to 60.160

[2.3673 to 2.3685]

60.160 to 60.190

[2.3685 to 2.3697]

1.0

[0.039]

2.8

[0.110]

2.5

[0.098]

60.09

[2.3657]

Valve seat angle

2 lines, brown

3 lines, brown

4 lines, brown

0.070 to 0.130

[0.0028 to 0.0051]

A=1.5° or less B=1.9 [0.075] or less Lf=73 [2.87]

B=2.2 [0.087] over entire length

66.0 [2.60]/289 to 319 {29.45 to 32.55}

[65 to 72]

90.6

[3.567]

A=2.0° or less B=3.2 [0.126] or less Lf=90.6 [3.567]

88.12

[3.469]

B=3.7 [0.146] over entire length

56.0 [2.20]/137 to 152

{14 to 15.5}

[31 to 34]

93.92

[3.8020]

A=2.5° or less B=4.2 [0.165] or less Lf=96.57 [3.8020]

[3.698]

B=4.9 [0.193] over entire length

62.0 [2.44]/496 to 549

{50.6 to 56.0}

[112 to 123]

Unit: mm [in.]

Seat width

Valve sinkage

Valve margin

2-4

Page 43

Cylinder head

Cylinder liner

Piston

Cylinder head gasket

Piston cooling nozzle

Piston and cylinder head

Piston ring End gap

Distortion of bottom surface 0.03 [0.0012] or less

Height (reference)

Inside diameter

Roundness 0.02 [0.0008] or less

Cylindricity 0.02 [0.0008] or less

Flange protrusion

Flange thickness

Top ridge height

Outside diameter

Weight difference per engine

Piston pin bore inside diameter ø70 [2.76]

protrusion

Thickness when tightened

Valve opening pressure

Top clearance

Item

P/N: 37507-22700 (S6R)

P/N: 37507-55600 (S6R2)

P/N: 37517-30101 ("30101" stamp) 37517-10401 ("10401" stamp) 37517-00900 ("00900" stamp) 37517-25100 ("25100" stamp) 37517-05500 ("05500" stamp) 37517-05300 ("05300" stamp)

P/N: 37517-07800 ("07800" stamp) 37517-07900 ("07900" stamp)

P/N: 37517-00800 ("00800" stamp)

P/N: 37517-30101 ("30101" stamp) 37517-10401 ("10401" stamp) 37517-00900 ("00900" stamp) 37517-25100 ("25100" stamp) 37517-05500 ("05500" stamp) 37517-05300 ("05300" stamp) 37517-07800 ("07800" stamp) 37517-07900 ("07900" stamp)

P/N: 37517-00800 ("00800" stamp)

One jet spec

Two jet spec

No. 1 compression

No. 2 compression

Oil

Nominal

value

ø170

[6.69]

ø170

[6.69]

ø170

[6.69]

ø170

[6.69]

ø170

[6.69]

1.8

[0.071]

Chapter 2 SERVICE DATA

Unit: mm [in.]

Standard value Limit value Remarks

0.07

[0.003]

154.9 to 155.1

[6.098 to 6.106]

170.02 to 170.04

[6.6937 to 6.6945]

170.00 to 170.04

[6.6929 to 6.6945]

0.11 to 0.20

[0.0043 to 0.0079]

14.16 to 14.20

[0.5575 to 0.5591]

0.16 to 0.24

[0.0063 to 0.0094]

169.760 to 169.800 [6.6835 to 6.6850]

169.739 to 169.779 [6.6826 to 6.6842]

169.760 to 169.780 [6.6835 to 6.6842]

within 10 g [0.35 oz]

within ±15 g [0.53 oz]

70.002 to 70.015

[2.7560 to 2.7565]

0.04 to 0.64

[0.0016 to 0.0252]

1.77 to 1.83

[0.0697 to 0.0720]

0.26 to 0.32 MPa

{2.7 to 3.3 kgf/cm

[38 to 47 psi]

0.10 to 0.15 MPa

{1.0 to 1.5 kgf/cm

[14 to 21 psi]

1.24 to 1.99

[0.0488 to 0.0783]

0.6 to 0.8

[0.024 to 0.032]

0.6 to 0.8

[0.024 to 0.032]

0.3 to 0.45

[0.0118 to 0.0177]

170.100

[6.6968]

Measure the outside

169.660

[6.6795]

169.639

[6.6787]

169.660

[6.6795]

70.040

[2.7575]

}

1.0

[0.039]

0.6

[0.024]

diameter from lower end of piston at 40 mm [1.57 in.] with right angles to the piston pin.

2-5

Page 44

Chapter 2 SERVICE DATA

Item

Piston pin Outside diameter ø70 [2.76]

Inside diameter of connecting rod bushing ø70 [2.76]

Bend and twist

End play

Connecting rod

Connecting rod rod bearing

Flywheel

Damper

Rear mechanism

Camshaft

Inside diameter of big end bore

Roundness for inside diameter of big end bore

Big end side (Width)

Standard

0.25

Thickness at center

Face runout (Reference) 0.285 [0.0112] or less

Radial runout (Reference) 0.127 [0.0050] or less

Face runout (Reference) 0.5 [0.0197] or less

Radial runout (Reference) 0.5 [0.0197] or less

Backlash between crank gear and idler gear

Backlash between idler gear and camshaft gear

Backlash between idler gear and fuel injection pump gear

Idler bushing inside diameter ø50 [1.97]

Idler shaft outside diameter ø50 [1.97]

Idler gear end play

Cam lift (Major axis minor axis)

Runout 0.05 [0.0020] or less

Journal diameter ø84 [3.30]

Camshaft bushing inside diameter (As installed in crankcase)

End play

Under size

37505-34100 (Overlap 93°)

37505-40100 (Overlap 61°)

0.50

0.75

1.00

Nominal

value

ø131

[5.16]

3.000

[0.1181]

3.125

[0.1230]

3.250

[0.1280]

3.375

[0.1329]

3.500

[0.1378]

ø84 [3.30]

Unit: mm [in.]

Standard value Limit value Remarks

69.987 to 70.000

[2.7554 to 2.7559]

70.020 to 70.040

[2.7567 to 2.7575]

0.05/100 [0.0020/3.94] or less

0.4 to 0.6

[0.016 to 0.024]

131.000 to 131.025 [5.1575 to 5.1585]

66.7 to 66.8

[2.626 to 2.620]

2.957 to 2.970

[0.1164 to 0.1169]

3.082 to 3.095

[0.1213 to 0.1219]

3.207 to 3.220

[0.1263 to 0.1268]

3.332 to 3.345

[0.1312 to 0.1317]

3.457 to 3.470

[0.1361 to 0.1366]

0.11 to 0.28

[0.0043 to 0.0110]

0.12 to 0.18

[0.0047 to 0.0071]

0.12 to 0.18

[0.0047 to 0.0071]

50.000 to 50.025

[1.9685 to 1.9695]

49.950 to 49.975

[1.9665 to 1.9675]

0.2 to 0.4

[0.008 to 0.016]

9.207 to 9.287

[0.3625 to 0.3656]

9.207 to 9.287

[0.3625 to 0.3656]

83.92 to 83.94

[3.3039 to 3.3047]

84.020 to 84.095

[3.3079 to 3.3108]

0.10 to 0.25

[0.0039 to 0.0098]

69.970

[2.7547]

70.070

[2.7587]

1.0

[0.039]

Minimum:

130.950

[5.1555]

Maximum:

131.050

[5.1594]

0.100

[0.0039]

2.930

[0.1154]

3.055

[0.1203]

3.180

[0.1252]

3.305

[0.1301]

3.430

[0.1350]

0.50

[0.197]

0.50

[0.197]

0.50

[0.197]

50.060

[1.9709]

49.900

[1.9646]

0.6

[0.0236]

8.45

[0.3327]

8.45

[0.3327

0.08

[0.0031]

83.87

[3.3020]

84.100

[3.3110]

0.40

[0.0157]

TIR

2-6

Page 45

Crank shaft

Item

Standard

0.25

Crankpin outside diameter

Crank main journal outside diameter

Parallelism of journal and crankpin

Circularity of journal and crankpin

Cylindricity of journal and crankpin

Fillet radius of pin

Fillet radius of journals

Hardness of journals and crankpins Hv > 620

Finishing surface roughness Ra 0.2 μm [0.008 µin.]

Angular deviation between pins ±20'

Crankpin width

Rearmost crank main journal width

Runout 0.04 [0.0016] or less

End play (width between web and thrust bearing)

Under size

Standard

Under size

Standard

Over size

0.50

0.75

1.00

0.25

0.50

0.75

1.00

0.25

0.50

0.75

1.00

1.25

1.50

Nominal

value

ø125

[4.92]

ø140

[5.51]

[0.28]

[2.64]

[2.60]

Standard value Limit value Remarks

124.930 to 124.950 [4.9185 to 4.9193]

124.680 to 124.700 [4.9084 to 4.9094]

124.430 to 124.450 [4.8988 to 4.8996]

124.180 to 124.200 [4.8890 to 4.8898]

123.930 to 123.950 [4.8791 to 4.8799]

139.930 to 139.950 [5.5090 to 5.5098]

139.680 to 139.700 [5.4992 to 5.5000]

139.430 to 139.450 [5.4894 to 5.4901]

139.180 to 139.200 [5.4795 to 5.4803]

138.930 to 138.950 [5.5090 to 5.5098]

Deviation of 0.01 [0.0004] or less over entire pin length

Diameter difference

0.01 [0.0004] or less

Diameter difference

0.01 [0.0004] or less

6.8 to 7.0

[0.268 to 0.276]

6.8 to 7.0

[0.268 to 0.276]

67.20 to 67.30

[2.6457 to 2.6496]

66.00 to 66.05

[2.5984 to 2.6004]

66.25 to 66.30

[2.6083 to 2.6102]

66.50 to 66.55

[2.6181 to 2.6201]

66.75 to 66.80

[2.6279 to 2.6299]

67.00 to 67.05

[2.6378 to 2.6398]

67.25 to 67.30

[2.6476 to 2.6496]

67.50 to 67.55

[2.6575 to 2.6594]

0.300 to 0.520

[0.0118 to 0.0205]

Chapter 2 SERVICE DATA

Unit: mm [in.]

124.890

[4.9169]

124.640

[4.9071]

124.390

[4.8972]

124.140

[4.8874]

123.890

[4.8775]

139.890

[5.5075]

139.640

[5.4976]

139.390

[5.4878]

139.140

[5.4779]

138.890

[5.4681]

0.03

[0.012]

0.03

[0.012]

0.03

[0.012]

0.10

[0.0039]

0.600

[0.0236]

TIR

2-7

Page 46

Chapter 2 SERVICE DATA

Item

Standard

Main bearing

Trust plate

Crankcase

Thickness at center

Thickness

Distortion of top surface 0.1 [0.004] or less

Inside diameter of main bearing bore

Depth of counterbore in crankcase

Height from journal center to top face (Reference value)

Under size

Standard

Over size

0.25

0.50

0.75

1.00

0.25

0.50

0.75

Nominal

value

3.500

[0.1378]

3.625

[0.1427]

3.750

[0.1476]

3.875

[0.1526]

4.000

[0.1575]

5.00

[0.1969]

5.25

[0.2067]

5.50

[0.2165]

5.75

[0.2264]

ø147

[5.79]

Unit: mm [in.]

Standard value Limit value Remarks

3.467 to 3.480

[0.1365 to 0.1370]

3.592 to 3.605

[0.1414 to 0.1419]

3.717 to 3.730

[0.1463 to 0.1469]

3.842 to 3.855

[0.1513 to 0.1518]

3.967 to 3.980

[0.1562 to 0.1567]

4.78 to 4.85

[0.1882 to 0.1909]

5.03 to 5.10

[0.1980 to 0.2008]

5.28 to 5.35

[0.2079 to 0.2106]

5.53 to 5.60

[0.2177 to 0.2189]

147.000 to 147.025 [5.7874 to 5.7884]

14.00 to 14.05

[0.5512 to 0.5531]

549.45 to 549.55

[21.6318 to 21.6358]

3.425

[0.1348]

3.550

[0.1398]

3.675

[0.1447]

3.800

[0.1496]

3.925

[0.1545]

4.71

[0.1854]

4.96

[0.1953]

5.21

[0.2051]

5.46

[0.2150]

0.2

[0.008]

147.035

[5.7888]

2-8

Page 47

1.3 Maintenance Service Data of Fuel System

Item Nominal value Standard value Limit value Remarks

Free length of nozzle spring

Squareness of nozzle spring

Nozzle spring parallelism of top and bottom surfaces

Fuel injection starting pressure

Orifice cone angle

Fuel injection nozzle

Orifice diameter

Number of orifices

P/N:37561-26400

P/N:48726-00402

P/N:37561-26400 0.6 [0.0236] or less

P/N:48726-00402 1.25°or less

P/N:37561-26400 0.1 [0.004] or less

P/N:48726-00402 0.65°or less

P/N: 37760-14001 37760-22001

P/N: 37560-32000

P/N: 37561-44000 37860-06000 37560-35000 37560-39000 37560-22010

P/N: 37561-44000 ("K" mark)

P/N: 37860-06000 ("XX" mark) 37760-14001 ("SS" mark) 37760-22001 ("RS" mark)

P/N: 37560-35000 ("M" mark) 37560-37000 ("F" mark) 37560-39000 ("H" mark) 37560-32000 ("N" mark) 37560-22010 ("N" mark)

P/N: 37760-14001 ("SS" mark)

P/NP/N: 37860-06000 ("XX" mark)

P/N: 37560-35000 ("M" mark) 37760-22001 ("RS" mark)

P/N: 37560-32000 ("N" mark) 37561-44000 ("K" mark) 37560-22010 ("N" mark)

P/N: 37560-39000 ("H" mark)

P/N: 37560-37000 ("F" mark)

P/N: 37760-14001 ("SS" mark) 37760-22001 ("RS" mark)

P/N: 37860-06000 ("XX" mark) 37560-35000 ("M" mark) 37560-32000 ("N" mark) 37561-44000 ("K" mark) 37560-22010 ("N" mark) 37560-39000 ("H" mark) 37560-41000 ("P" mark) 37560-37000 ("F" mark)

30.40 MPa

{310 kgf/cm

[4267 psi]

34.32 MPa

{350 kgf/cm

[4978 psi]

34.32 MPa

{350 kgf/cm

[4978 psi]

155°

158°

160°

ø0.26

[0.012]

ø0.27

[0.0106]

ø0.29

[0.0114]

ø0.31

[0.0122]

ø0.325

[0.0128]

ø0.35

[0.0138]

[1.18]

26.8

[1.055]

30.40 to 30.89 MPa

{310 to 315 kgf/cm

}

[4409 to 4480 psi]

(the value when it is new)

33.83 to 35.79 MPa

{345 to 365 kgf/cm

}

[4907 to 5192 psi]

(the value when it is new)

34.32 to 34.81 MPa

{350 to 355 kgf/cm

}

[4978 to 5049 psi]

(the value when it is new)

Chapter 2 SERVICE DATA

Unit: mm [in.]

}

2-9

Page 48

Chapter 2 SERVICE DATA

Inside diameter of case bearing housing

Fuel injection pump accessory drive

Governor drive

For injection pump drive shaft bearing

Outside diameter of drive shaft bearing fit

Inside diameter of drive shaft case bearing housing ø52 [2.05]

Drive shaft side bearing

Outside diameter of drive shaft bearing fit ø25 [0.98 in.]

Outside diameter of drive shaft gear fit ø26 [1.02]

Inside diameter of drive gear fit ø26 [1.02]

Inside diameter of idler shaft case bearing housing ø47 [1.85]

Idler shaft side bearing

Outside diameter of idler shaft bearing fit ø20 [0.79]

Outside diameter of idler shaft gear fit ø24 [0.94]

Inside diameter of idler gear fit ø24 [0.94]

backlash

Unit: mm [in.]

Item Nominal value Standard value Limit value Remarks

ø90 [3.54]

ø100 [3.94]

Small ø90 [3.54]

outside diameter

Large ø100 [3.94]

Small ø45 [1.77]

Inside diameter

Large ø50 [1.97]

ø45 [1.77]

ø50 [1.97]

outside diameter ø52 [2.05]

Inside diameter ø25 [0.98 in.]

outside diameter ø47 [1.85]

Inside diameter ø20 [0.79]

89.987 to 90.022

[3.5428 to 3.5442]

99.987 to 100.022 [3.9365 to 3.9379]

89.985 to 90.000

[3.5427 to 3.5433]

99.985 to 100.000 [3.9364 to 3.9370]

44.988 to 45.000

[1.7712 to 1.7717]

49.988 to 50.000

[1.9680 to 1.9685]

45.002 to 45.013

[1.7717 to 1.7722]

50.002 to 50.013

[1.9686 to 1.9690]

51.988 to 52.018

[2.0468 to 2.0479]

51.987 to 52.000

[2.0467 to 2.0472]

24.990 to 25.000

[0.9839 to 0.9843]

25.002 to 25.011

[0.9843 to 0.9847]

26.035 to 26.048

[1.0250 to 1.0255]

26.000 to 26.013

[1.0236 to 1.0241]

46.989 to 47.014

[1.8500 to 1.8509]

46.989 to 47.000

[1.8500 to 1.8504]

19.990 to 20.000

[0.7870 to 0.7874]

20.002 to 20.011

[0.7875 to 0.7878]

24.035 to 24.048

[0.9463 to 0.9468]

24.000 to 24.013

[0.9449 to 0.9454]

0.12 to 0.18

[0.0047 to 0.0071]

0.4

[0.0157]

2-10

Page 49

1.4 Maintenance Service Data of Lubrication System

Item

Backlash between oil pump gear and idler gear

Drive gear and driven gear backlash

Top clearance between gear teeth and case

Side clearance between gear width and case depth

Drive shaft outside diameter

Oil pump

Oil filter alarm Differential pressure for activation of alarm

Relief valve Spring free length 115 [4.53]

Oil thermostat

Oil pump idler gear and crankshaft gear backlash

Driven shaft outside diameter

Bushing inside diameter

Spindle outside diameter

Idler gear bushing inside diameter

Safety valve opening pressure

Valve opening temperature 80 to 84°C [176 to 183.2°F]

Temperature at which valve lift becomes 11 [0.43] or more

Nominal

value

ø25

[0.98]

ø25

[0.98]

Standard value Limit value Remarks

0.087 to 0.316

[0.0034 to 0.0124]

0.100 to 0.200

[0.0039 to 0.0079]

0.100 to 0.196

[0.0039 to 0.0077]

0.050 to 0.114

[0.0020 to 0.0045]

24.947 to 24.960

[0.9822 to 0.9827]

24.947 to 24.960

[0.9822 to 0.9827]

25.000 to 25.021

[0.9843 to 0.9851]

24.949 to 24.960

[0.9822 to 0.9827]

25.000 to 25.021

[0.9843 to 0.9851]

1.4 ± 0.1 MPa

{14 ± 1 kgf/cm²}

[203 ± 14 psi]

0.15 to 0.18 MPa

{1.5 to 1.8 kgf/cm²}

[21 to 26 psi]

95°C [203°F]

0.11 to 0.38

[0.0043 to 0.0150]

Chapter 2 SERVICE DATA

Unit: mm [in.]

0.500

[0.0197]

0.400

[0.00157]

0.350

[0.0138]

0.250

[0.0098]

24.900

[0.9803]

24.900

[0.9803]

25.100

[0.9882]

24.900

[0.9803]

25.100

[0.9882]

2-11

Page 50

Chapter 2 SERVICE DATA

1.5 Maintenance Service Data of Cooling System

Item

Inside diameter of pulley bearing fit ø52 [2.05]

Tension pulley

P/A: 37546-21700 (For jacket water)

Thermostat

Wat e r p u m p

For air cooler water pump

P/A: 35C46-05200 (For air cooler)

P/A: 37546-40700 (For air cooler)

Bearing

Outside diameter of bracket bearing fit ø20 [0.79]

Valve opening temperature

Temperature at which valve lift becomes 9 [0.35] or more

Valve opening temperature

Temperature at which valve lift becomes 10 [0.433] or more

Valve opening temperature

Temperature at which valve lift becomes 11 [0.43] or more

Outside diameter of case bearing housing

Bearing

Outside diameter of shaft fit to bearing

Impeller front clearance

Impeller water pump shaft interference

Case bearing inside diameter of counterbore

Bearing

Outside diameter of shaft fit to bearing

Impeller front clearance

Outside diameter

Inside diameter

Outside diameter

Inside diameter

Pump case

Bearing cover

Outside diameter

Inside diameter

Nominal

value

ø52 [2.05]

ø20 [0.79]

ø80

[3.15]

ø90

[3.54]

ø80

[3.15]

ø90

[3.54]

ø40

[1.57]

ø40

[1.57]

0.72

[0.0283]

ø20

[0.79]

ø62

[2.44]

ø68

[2.6]

ø28

[1.10]

ø68

[2.6]

ø28

[1.10]

0.8

[0.031]

Standard value

51.970 to 52.000

[2.0461 to 2.0472]

51.987 to 52.000

[2.0467 to 2.0472]

19.988 to 20.000

[0.7869 to 0.7874]

19.987 to 20.000

[0.7869 to 0.7874]

69 to 73ºC

[156 to 163ºF]

85ºC

[185ºF]

33 to 37°C

[91.4 to 98.6°F]

50°C

[122ºF]

69 to 73ºC

[156 to 163ºF]

85ºC

[185ºF]

79.988 to 80.018

[3.1494 to 3.1503]

89.987 to 90.022

[3.5428 to 3.5442]

79.985 to 80.000

[3.1490 to 3.1496]

89.985 to 90.000

[3.5427 to 3.5433]

39.988 to 40.000

[1.5743 to 1.5748]

40.002 to 40.013

[1.5749 to 1.5753]

0.14 to 1.30

[0.0055 to 0.0445]

0.024 to 0.060

[0.0009 to 0.0024]

61.988 to 62.018

[2.4405 to 2.4416]

67.961 to 67.991

[2.6756 to 2.6768]

27.990 to 28.000

[1.1020 to 1.1024]

67.987 to 68.000

[2.6766 to 2.6772]

28.002 to 28.015

[1.1024 to 1.1030]

0.5 to 1.1

[0.0197 to 0.0433]

Limit

value

80.025

[3.1506]

90.025

[3.5443]

39.995

[1.5746]

Unit: mm [in.]

Remarks

Valve open temperature stamp: 71ºC [160ºF]

Opening temperature stamp 35ºC [95ºF]

Valve open temperature stamp: 71ºC [160ºF]

2-12

Page 51

Sea water pump for air cooler

Fan drive

Item

Inside diameter of case bearing housing

Outside diameter

Bearing

Outside diameter of shaft fit to bearing

Inside diameter of case bearing housing

Bearing

Outside diameter of shaft fit to bearing

Inside diameter

Outside diameter

Inside diameter

Nominal

value

ø90

[3.54]

ø90

[3.54]

ø30

[1.18 in.]

ø40

[1.57]

ø30

[1.18 in.]

ø40

[1.57]

ø100

[3.94]

ø110

[4.33]

ø100

[3.94]

ø110

[4.33]

ø45 [1.77]

ø50 [1.97]

ø45 [1.77]

ø50 [1.97]

Standard value

89.9825 to 90.0175 [3.5426 to 3.5440]

90.000 to 90.015

[3.5433 to 3.5439]

29.990 to 30.000

[1.1807 to 1.1811]

39.988 to 40.000

[1.5743 to 1.5748]

30.002 to 30.018

[1.1812 to 1.1818]

40.002 to 40.018

[1.5743 to 1.5749]

99.987 to 100.022

[3.9365 to 3.9379]

109.987 to 110.022 [4.3302 to 4.3316]

99.985 to 100.000

[3.9364 to 3.9370]

109.985 to 110.000 [4.3301 to 4.3307]

45.002 to 45.013

[1.7717 to 1.7722]

50.002 to 50.013

[1.9686 to 1.9690]

44.988 to 45.000

[1.7712 to 1.7717]

49.988 to 50.000

[1.9680 to 1.9685]

Chapter 2 SERVICE DATA

Unit: mm [in.]

Limit

value

Remarks

2-13

Page 52

Chapter 2 SERVICE DATA

1.6 Maintenance Service Data of Electrical System

Item

Dia ø43 [1.69] ø42 [1.65]

Starter

P/N: 37566-30200 (Single wire type) 37566-45200 (2-wire type)

Armature

Shaft

Metal

Bearing outside diameter to fit

Brush

Thrust cap

Commutator

Shaft outside diameter

Front pinion metal

Outside diameter of bearing to fit

Front bracket

Pinion

Internal shaft

Armature front

Armature rear

Brush length

Brush spring load 4.5 [0.177]

Armature

Internal shaft

Runout 0.06 [0.0024] 0.1 [0.004]

Undercut depth

Front ø20 [0.79]

Rear ø10 [0.39]

Outside diameter

Clearance between metal and shaft

Outside diameter

Inside diameter ø19 [0.75]

Clearance between metal and shaft

Inside diameter ø19 [0.75]

Clearance between metal and shaft

Bearing inside diameter

Item name 6006

Bearing inside diameter

Item name 6204

Bearing inside diameter

Item name 6200

P/N: 37566-30200

P/N: 37566-45200

Nominal

value

Unit: mm [in.]

Standard value Limit value Remarks

0.7 to 0.9

[0.028 to 0.035]

ø19 [0.75]

ø30 [1.18]

ø55 [2.17] ø55.1 [2.17]

ø47 [1.85] ø47.1 [1.85]

ø30 [1.18] ø30.1[1.19]

22 to 23

[0.87 to 0.91]

0.15 to 0.75

[0.0059 to 0.0295]

0.2 to 0.7

[0.008 to 0.028]

0.2 to 0.8

[0.008 to 0.032]

0.2 [0.008] or less

0.25 [0.01]

less than 13

[0.51] lefts

less than 4.1

[0.161]

Replace if it does not rotate smoothly or an abnormal noise is generated.

With brush installed

Adjust with the adjust washer

2-14

Page 53

Starter

P/N: 37566-30200 (Single wire type) 37566-45200 (2-wire type)

Magnetic switch

Insulating resistance

Item

P/N:

Pressure

Coil resistance (Ω)

Holding

Contactor deflection

Armature Commutator to earth

Yoke assy M terminal lead to earth

Brush holder

Positive brush box to holder ring

37566-30200

P/N: 37566-45200

P/N: 37566-30200

P/N: 37566-45200

P/N: 37566-30200

P/N: 37566-45200

Nominal

value

Chapter 2 SERVICE DATA

Unit: mm [in.]

Standard value Limit value Remarks

0.127 [0.0050]

0.066 [0.0026]

0.92 [0.0362]

1.07 [0.0421]

1.5 to 2.5

[0.06 to 0.1]

1.35 to 2.05

[0.0531 to 0.0807]

100MΩor higher

(Room temperature

and humidity at 500

V megger)

10MΩor higher

(Room temperature

and humidity at 500

V megger)

10MΩor higher

(Room temperature

and humidity at 500

V megger)

0.6 [0.023]

0.02MΩor higher

(Room

temperature

and humidity

at 500 V

megger)

0.02MΩor higher

(Room

temperature

and humidity

at 500 V

megger)

0.02MΩor higher

(Room

temperature

and humidity

at 500 V

megger)

(Reference at 20°C [68°F])

2-15

Page 54

Chapter 2 SERVICE DATA

P/N:04343-35500 04343-35600

Alternator

P/N:04343-38000

Belt tension (cogged type)

Alternator P/N:04343-38300

Item

Output current

Initial

(at 27 V) exciting type (brushless)

Regulator adjusting voltage

(Alternator 5000 min

load at 5 A or lower)

Field coil resistance

(20 °C [68 °F])

Output

current

(at 27 V)

Self exciting type

Regulator adjusting voltage

(Alternator 5000 min

load at 5 A or lower) (with brush)

Height of brushes 21.5 8.0 [0.36]

Pressure of brush springs

Output

current

(at 27 V)

Regulator adjusting voltage

External exciting type (with brush)

(Alternator 5000 min

load at 5 A or lower)

Rotor slip ring

outside diameter

Height of brushes

Belt tension (ribbed type)

Rotation speed (min

Unit: mm [in.]

Nominal

value

2500

5000

-1

)

-1

2500

5000

-1

)

-1

[1.3]

3.7N

{0.38kgf}

[83.78

lbf]

2500

5000

-1

)

-1

33 [1.3]

21.5

[0.847]

3.7N

{0.38kgf}

[83.78

lbf]

Standard value Limit value Remarks

30 A or more

(when cold)

35 A or more

(when engine is hot)

28.5 ± 0.5 V

7.3 to 8.5 Ω

26 A or more

(when engine is hot)

30 A or more

(when engine is hot)

28.5 ± 0.5 V

32.8 to 33.2

[1.291 to 1.307]

32.4 [1.276]

The part shows a limit line.

3.1N to 4.3N

{0.32 to 0.44kgf}

[0.70 to 0.97 lbf]

1.8N

{0.18kgf}

[0.40 lbf]

When the center of the belt is pushed

10 to 15

[0.4 to 0.6]

with a force of approx 98 to 147 N {10 to 15 kgf} [22 to 33 lbf]

29 A or more

(when engine is hot)

35 A or more

(when engine is hot)

28.5 ± 0.5 V

32.8 to 33.2

[1.291 to 1.307]

3.1N to 4.3N

{0.32 to 0.44kgf}

[0.70 to 0.97 lbf]

32.4 [1.276]

8.0 [0.36]

1.8N

{0.18kgf}

[0.40 lbf]

The part shows a limit line.

Refer to the table below

2-16

Page 55

Chapter 2 SERVICE DATA

1.6.1 Belt tension

Item

When a new belt is installed:

When re-adjusted:

Number

of ribs

Unit N {kgf} [lbf]

Belt straight distance (mm) [in.]

300 [11.81]

or below

3 74 {7.55} [16.64] 49 {5.00} [11.02] 37 {3.77} [8.32] 29 {2.96} [6.52] 25 {2.55} [5.62]

4 88 {8.97} [19.78] 59 {6.02} [13.26] 44 {4.49} [9.89] 35 {3.57} [7.87] 29 {2.96} [6.52]

5 103 {10.50} [23.16] 69 {7.04} [15.51] 51 {5.20} [11.47] 41 {4.18} [9.22] 34 {3.47} [7.64]

6 118 {12.03} [26.53] 79 {8.06} [17.76] 59 {6.02} [13.26] 47 {4.79} [10.57] 39 {3.98} [8.77]

7 132 {13.46} [29.67] 88 {8.97} [19.78] 66 {6.73} [14.84] 53 {5.40} [11.91] 44 {4.49} [9.89]

8 147 {14.99} [33.05] 98 {9.99} [22.03] 74 {7.55} [16.64] 59 {6.02} [13.26] 49 {5.00} [11.02]

9 162 {16.52} [36.42] 108 {11.01} [24.28] 81 {8.26} [18.21] 65 {6.63} [14.61] 54 {5.51} [12.14]

10 176 {17.95} [39.57] 118 {12.03} [26.53] 88 {8.97} [19.78] 71 {7.24} [15.96] 59 {6.02} [13.26]

11 191 {19.48} [42.94] 127 {12.95} [28.55] 96 {9.79} [21.58] 76 {7.75} [17.09] 64 {6.53} [14.39]

12 206 {21.01} [46.31] 137 {13.97} [30.80] 103 {10.50} [23.16] 82 {8.36} [18.43] 69 {7.04} [15.51]

3 51 {5.20} [11.47] 34 {3.47} [7.64] 26 {2.65} [5.85] 21 {2.14} [4.72] 17 {1.73} [3.82]

4 62 {6.32} [13.94] 41 {4.18} [9.22] 31 {3.16} [6.97] 25 {2.55} [5.62] 21 {2.14} [4.72]

5 72 {7.34} [16.19] 48 {4.89} [10.79] 36 {3.67} [8.09] 29 {2.96} [6.52] 24 {2.45} [5.40]

6 82 {8.36} [18.43] 55 {5.61} [12.36] 41 {4.18} [9.22] 33 {3.37} [7.42] 27 {2.75} [6.07]

7 93 {9.48} [20.91] 62 {6.32} [13.94] 46 {4.69} [10.34] 37 {3.77} [8.32] 31 {3.16} [6.97]

8 103 {10.50} [23.16] 69 {7.04} [15.51] 51 {5.20} [11.47] 41 {4.18} [9.22] 34 {3.47} [7.64]

9 113 {11.52} [25.40] 75 {7.65} [16.86] 57 {5.81} [12.81] 45 {4.59} [10.12] 38 {3.87} [8.54]

10 123 {12.54} [27.65] 82 {8.36} [18.43] 62 {6.32} [13.94] 49 {5.00} [11.02] 41 {4.18} [9.22]

11 134 {13.66} [30.12] 89 {9.08} [20.01] 67 {6.83} [15.06] 54 {5.51} [12.14] 45 {4.59} [10.12]

12 144 {14.68} [32.37] 96 {9.79} [21.58] 72 {7.34} [16.19] 58 {5.91} [13.04] 48 {4.89} [10.79]

more than 300 to 400

[11.81 to 15.75]

more than 400 to 500

[15.75 to 19.69]

more than 500 to 600

[16.69 to 23.62]

more than 600

[23.62]

The force when the middle of belt straight line is pushed and deflected by 15 mm [0.5906 in.]

1.7 Air Start System

Item Nominal value Standard value Limit value Remarks

Sterter valve

DIstributer valve

Clearance between valve and valve guide

Valve spring free length

Distributer valve height

Clearance between shaft and bushing

ø15

[0.59]

0.016 to 0.052

[0.0006 to 0.0020]

[1.42]

21.85 to 21.95

[0.8602 to 0.8642]

0.050 to 0.091

[0.0020 to 0.0036]

Unit: mm [in.]

0.100

[0.004]

[1.34]

21.75

[0.8563]

0.150

[0.0059]

2-17

Page 56

Chapter 2 SERVICE DATA

2. Tightening Torque Table

2.1 Tightening Torque Spec for Basic Engine

Description

Cylinder head bolt M 22 × 2.5 539 ± 27 55 ± 2.75 397.55 ± 19.91

Cylinder head nozzle gland (studs) M 14 × 2.0 73.5 ± 4.5 7.5 ± 0.5 54.21 ± 3.31

Rocker case M 12 × 1.25 108 ± 5.4 11 ± 0.55 79.66 ± 3.98

Rocker shaft M 14 × 2.0 147 ± 7.4 15 ± 0.75 108.42 ± 5.45

Rocker arm (lock nut) M 12 × 1.25 64 ± 3.2 6.5 ± 0.33 47.20 ± 2.36

Bridge (lock nut) M 10 × 1.25 55 ± 2.8 5.6 ± 0.28 40.57 ± 2.06

Camshaft gear M 14 × 1.5 176 ± 8.8 17.9 ± 0.9 129.81 ± 6.49 Use 12T bolt w/hard washer

Camshaft thrust plate M 12 × 1.25 59 ± 5.9 6 ± 0.6 43.52 ± 4.35

Main bearing cap M 22 × 2.5 490 ± 24.5 50 ± 2.5 361.41 ± 18.07 [Wet], Note (b)

Hanger M 12 × 1.25 108 ± 5.4 11 ± 0.55 79.66 ± 3.98

Piston cooling nozzle M 12 × 1.75 34 ± 1.7 3.5 ± 0.18 25.08 ± 1.25 Note (c)

Timing gear case M 16 × 1.5 255 ± 12.8 26 ± 1.3 188.08 ± 9.44 Use hard washer

Rear plate M 12 × 1.25 108 ± 5.4 11 ± 0.55 79.66 ± 3.98

Front mounting bracket M 12 × 1.25 108 ± 5.4 11 ± 0.55 79.66 ± 3.98

Rear mounting bracket M 16 × 1.5 216 ± 10.8 22 ± 1.1 159.31 ± 7.96

Connecting rod cap M 22 × 1.5 Note (e) [Wet]

Flywheel M 22 × 1.5 539 ± 27 55 ± 2.75 397.54 ± 19.91 [Wet]

Damper M 22 × 1.5 490 ± 24.5 50 ± 2.5 361.40 ± 18.07

Idler shaft M 12 × 1.25 108 ± 5.4 11 ± 0.55 79.66 ± 3.98 Apply MOLYKOT

Idler shaft thrust collar (nut) M 18 × 1.5 196 ± 9.8 20 ± 1.0 144.56 ± 7.22

Fuel injection Accessory drive

Governor drive case M 12 × 1.25 108 ± 5.4 11 ± 0.55 79.66 ± 3.98

Case M 12 × 1.25 108 ± 5.4 11 ± 0.55 79.66 ± 3.98

Gear (nut) M 30 × 1.5 490 ± 24.5 50 ± 2.5 361.40 ± 18.07

Dia x Pitch (M-thread)

Tightening torque

N·m kgf·m lbf·ft

Remarks

[Wet] 2-time tightening method, Note (a)

Apply Loctite 272 to the internal screw thread of the cylinder head

Front end lower bolt of right front mounting bracket only

Note:(a) For torque-angle tightening method of cylinder head bolts, follow the steps in sequence given below:

1) Tighten the bolts with a snug torque of 294 ± 14.7 N·m {30 ± 1.5 kgf·m} [217±11 lbf·ft].

2) Tighten to the angle 65± 3°.

3) Loosen all bolts, and then retighten them in the sequence shown in the above 1) and 2).(2-time tightening) For tightening procedure, refer to "Cylinder Head Bolt - Tighten" of "ASSEMBLY OF BASIC ENGINE".

(b) Tighten the main bearing cap bolt in specified sequence. Tighten them to the half of specified torque, then tighten them

to the specified torque.

For tightening procedure, refer to "Main bearing cap - Install" of "ASSEMBLY OF BASIC ENGINE."

(c) Tighten piston cooling nozzle check valves to the specified torque. Do not over-tighten. If the tightening torque exceeds

the specified torque, it could cause the check valve to malfunction, which may result in piston seizure.

(d) When [Wet] is indicated, apply engine oil to the threads and bolt seat surface.

(e) Connecting rod cap bolts should be tightened as shown below.

Bolt mark

AL Snug torque 294 ± 14.7 N·m {30 ± 1.5 kgf·m} [217 ± 11 lbf·ft] → 60 ± 3°

Torque method

(2-time tightening method)

539 ± 27 N·m {55 ± 2.75 kgf·m}

[398 ± 20 lbf·ft]

637 ± 31.9 N·m {65 ± 3.25 kgf·m}

[470 ± 24 lbf·ft]

Angle controlled method (2-time tightening method)

Snug torque 245 ± 12.3 N·m {25 ± 1.25 kgf·m} [180 ± 9 lbf·ft] → 60 ± 3°

2-18

Page 57

2.2 Tightening Torque Spec for Fuel System

Chapter 2 SERVICE DATA

Description

Accessory drive case M 12 × 1.25 108 ± 5.4 11 ± 0.55 79.66 ± 3.98

Accessory drive gear (nut)

Coupling shaft M 14 × 1.5 172 ± 5 17.5 ± 0.5 126.86 ± 3.68 Tighten the slit portion.

Fuel injection pump

Plunger assembly M 12 × 1.25 80.5 ± 2.5 8.25 ± 0.25 59.37 ± 1.84

Delivery valve holder M 30 × 1.5 245 ± 10 25 ± 1 180.70 ± 7.38

Fuel injection pipe (nozzle and pump side) M 18 × 1.5 59 ± 10 6 ± 1 43.52 ± 7.38

Fuel rack control lever M 8 × 1.25 25 ± 1.25 2.5 ± 0.13 18.44 ± 0.92 2-time tightening method

Fuel filter air vent plug M 8 × 1.25 9 ± 1 0.9 ± 0.1 6.64 ± 0.74

Nozzle tip retaining nut

Nozzle inlet connector M 16 × 1.5 69 ± 5 7 ± 0.5 50.84 ± 3.68

Nozzle holder cap nut M 14 × 1.5 73.5 ± 4.5 7.5 ± 0.5 54.21 ± 3.32

Nozzle holder set screw M 10 × 1.5 39 ± 5 4 ± 0.5 28.76 ± 3.69

Short plug M 14 × 1 73.5 ± 4.9 7.5 ± 0.5 54.21 ± 3.61

Nozzle gland (nut) M 14 × 1.5 98 ± 4.9 10 ± 0.5 72.28 ± 3.61

Laminated plate

Pump mounting bolt M 12 × 1.25 108 ± 5.4 11 ± 0.55 79.66 ± 3.98

Bracket M 12 × 1.25 108 ± 5.4 11 ± 0.55 79.66 ± 3.98

Flywheel (nut) M 24 × 1.5 392 ± 19.6 40 ± 2.0 289.12 ± 14.45

Air vent plug M 8 × 1.25 15 ± 2 1.5 ± 0.2 11.06 ± 1.47

Nut M 30 × 1.5 490 ± 24.5 50 ± 2.5 361.40 ± 18.07

Speed pick-up M 30 × 1.5 392 ± 19.6 40 ± 2.0 242.65 ± 14.46

ThreadsDia

- Pitch (mm)

M 14 × 1.5 118 ± 5 12 ± 0.5 87.03 ± 3.68 2-time tightening method

M 12 × 1.25 108 ± 5 11 ± 0.5 79.66 ± 3.68

M 28 × 1.5 186.5 ± 9.5 19 ± 1 137.56 ± 7 T type, TE type

M 28 × 1.5 127.5 ± 5.0 13 ± 0.5 94.04 ± 3.68 S type

N·m kgf·m lbf·ft

Tightening torque

Remarks

10T bolt + Nut with washer, 2-time tightening method

2.3 Tightening Torque Spec for Lubrication System

Description

Oil pump M 12 × 1.25 108 ± 10.8 11 ± 1.1 79.66 ± 7.96

Oil pump idler gear (nut) M 12 × 1.25 69 ± 3.5 7 ± 0.35 50.89 ± 2.58 Apply Loctite 262 to threads

Oil pump cover M 10 × 1.25 33 ± 6.7 3.4 ± 0.68 24.34 ± 4.94

Governor oil filter air vent plug M 8 × 1.25 9.8 ± 2.0 1 ± 0.2 7.23 ± 1.48

Governor oil filter drain plug M 8 × 1.25 9.8 ± 2.0 1 ± 0.2 7.23 ± 1.48

Governor oil filter center bolt M 14 × 1.5 34.3 ± 6.9 3.5 ± 0.7 25.30 ± 5.09

Oil pan M 12 × 1.25 59 ± 5.9 6 ± 0.6 43.52 ± 4.35

Dia x Pitch (M-thread)

Tightening torque

N·m kgf·m lbf·ft

Remarks

2-19

Page 58

Chapter 2 SERVICE DATA

2.4 Tightening Torque Spec for Cooling System

Tightening torque

Wat e r p u m p

Water pump for air cooler cooling

Water pump for sea water pump

Fan drive

Description

Pump M 12 × 1.25 59 ± 5.9 6 ± 0.6 43.52 ± 4.35

Pump shaft pulley (nut) M 24 × 1.5 245 ± 12.3 25 ± 1.25 180.70 ± 9.07 For alternator driving

Pipe - 22.5 ± 2.25 2.29 ± 0.23 16.59 ± 1.66 R 1/4

Pump shaft pulley (nut) M 20 × 1.5 112 ± 4.9 11.5 ± 0.5 82.61 ± 3.61

Pipe - 22.5 ± 2.25 2.29 ± 0.23 16.59 ± 1.66

Pump M 10 × 1.25 18.6 ± 2.95 1.9 ± 0.3 13.72 ± 2.18

Pump shaft pulley (nut) M 24 × 2.0 220 ± 10 22.4 ± 1.0 162.26 ± 7.38

Camshaft gear (front) M 24 × 1.5 176 ± 8.8 17.9 ± 0.9 129.81 ± 6.49

Drive shaft gear (nut) M 30 × 1.5 392 ± 19.6 40 ± 2.0 289.12 ± 14.46

Plate fan M 12 × 1.25 108 ± 10.8 11 ± 1.1 79.66 ± 7.97

Dia x Pitch (M-thread)

N·m kgf·m lbf·ft

2.5 Tightening Torque Spec for Inlet and Exhaust System

Description

Mounting nut for turbocharger M 12 × 1.25 108 ± 5.4 11 ± 0.55 79.66 ± 7.97

Exhaust pipe V clamp 1/4-28 UNF 9 ± 0.45 0.9 ± 0.04 11.80 ± 1.48

Air cooler M 12 × 1.25 108 ± 10.8 11 ± 1.1 79.66 ± 7.97

Air cooler cover M 8 × 1.25 16 ± 2 1.6 ± 0.2 11.80 ± 1.48

Air cooler element M 10 × 1.5 49 ± 5 5 ± 0.5 36.14 ± 3.69

Dia x Pitch (M-thread)

Tightening torque

N·m kgf·m lbf·ft

Remarks

2-20

Page 59

2.6 Tightening Torque Spec for Electrical System

Chapter 2 SERVICE DATA

Starter

Alternator

Description

P/N: 37766-20200 (Single wire type) 37766-30300 (2-wire type)

P/N: 04343-35500 04343-35600

P/N: 04343-38000

Dia x Pitch (M-thread)

Starter - Install M 12 × 1.25 59 ± 5.9 6.0 ± 0.60 43.5 ± 4.35

Magnetic switch assembly M 6 × 1.0 4.5 ± 0.6 0.46 ± 0.06 3.32 ± 0.44

Lever assembly M 8 × 1.25 10.9 ± 1.3 1.1 ± 0.14 8.04 ± 0.96

Front bracket M 6 × 1.0 5.85 ± 0.75 0.60 ± 0.07 4.31 ± 0.55

Safety switch M 6 × 1.0 4.2 ± 0.3 0.43 ± 0.03 3.10 ± 0.22

Center bracket M 8 × 1.25 14 ± 1.7 1.4 ± 0.17 10.3 ± 1.25 Hexagon socket bolt

Brush holder M 5 × 0.8 3.2 ± 0.4 0.33 ± 0.04 2.36 ± 0.30

Through bolt M 6 × 1.0 8.7 ± 1.1 0.9 ± 0.11 6.42 ± 0.81

B terminal nut M 10 × 1.25 17.7 ± 1.9 1.8 ± 0.19 13.05 ± 1.40

E terminal nut M 10 × 1.25 22.6 ± 2.9 2.3 ± 0.3 16.67 ± 2.14 2- wire type only

Pulley nut M 20 × 1.5 147 ± 15 14.99 ± 1.53 108.4 ± 11.1

Retainer tightening screw M 5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.88 ± 0.73

Through bolt M 6 × 1.0 5.4 ± 1.5 0.55 ± 0.15 3.98 ± 1.11

Regulator assembly tightening screw

Rectifier assembly tightening screw

B terminal nut M 5 × 0.8 6.9 ± 0.9 0.07 ± 0.09 5.09 ± 0.66

E terminal nut M 5 × 0.8 6.9 ± 0.9 0.70 ± 0.09 5.09 ± 0.66

Coil assembly tightening screw

Screw connecting field coil and regulator

Connector assembly tightening bolt

Pulley nut M 20 × 1.5 147 ± 29 14.99 ± 2.95 108.4 ± 21.4

Retainer tightening screw M 5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.88 ± 0.73

Through bolt M 5 × 0.8 4.4 ± 1 0.45 ± 0.1 3.25 ± 0.73

Regulator assembly tightening screw

Rectifier assembly tightening screw

B terminal nut M 5 × 0.8 6.9 ± 1.9 0.7 ± 0.19 5.09 ± 1.40

M 5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.88 ± 0.73

M 6 × 1.0 5.4 ± 1.5 0.55 ± 0.15 3.98 ± 1.1

M 5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.88 ± 0.73

Tightening torque

N·m kgf·m lbf·ft

Remarks

2.7 Tightening Torque Spec for Air Start System

Description

Starter valve nut M 8 × 1.25 19 ± 0.95 1.94 ± 0.09 14 ± 0.7

Starter valve cap nut M 36 × 1.5 117.6 ± 5.88 12 ± 0.6 86.7 ± 4.34

Dia x Pitch (M-thread)

N·m kgf·m lbf·ft

Tightening torque

Remarks

2-21

Page 60

Chapter 2 SERVICE DATA

2.8 Tightening Torque for Standard Bolts

Threads

Metric automobile screw thread

Metric course screw thread

Thread size

Dia. x Pitch

Width across

flats

(mm)

7T 10.9

Strength classification

N·m kgf·m lbf·ft N·m kgf·m lbf·ft

M 8 × 1.25 12 17 1.7 12.5 30 3.1 22.1

M 10 × 1.25 14 33 3.4 24.3 60 6.1 44.3

M 12 × 1.25 17 60 6.1 44.3 108 11.0 79.7

M 14 × 1.5 22 97 9.9 71.5 176 17.9 129.8

M 16 × 1.5 24 145 14.8 106.9 262 26.7 193.2

M 18 × 1.5 27 210 21.4 154.9 378 38.5 278.8

M 20 × 1.5 30 291 29.7 214.6 524 53.4 386.5

M 22 × 1.5 32 385 39.3 284.0 694 70.8 511.9

M 24 × 1.5 36 487 49.7 359.2 878 89.5 647.6

M 27 × 1.5 41 738 75.3 544.3 1328 135.5 979.5

N·m kgf·m lbf·ft N·m kgf·m lbf·ft

M 10 × 1.5 14 32 3.3 23.6 58 5.9 42.8

M 12 × 1.75 17 57 5.8 42.0 102 10.4 75.2

M 14 × 2 22 93 9.5 68.6 167 17.0 123.2

M 16 × 2 24 139 14.2 102.5 251 25.6 185.1

M 18 × 2.5 27 194 19.8 143.1 350 35.7 258.1

M 20 × 2.5 30 272 27.7 200.6 489 49.9 360.7

M 22 × 2.5 32 363 37.0 267.7 653 66.6 481.6

M 24 × 3 36 468 47.7 345.2 843 86.0 621.8

M 27 × 3 41 686 70.0 506.0 1236 126.0 911.6

Note:(a) The tightening torque listed in this table is for standard bolts and nuts.

(b) The numerical values in the table are the values when spring washers are used.

(d) Use the tightening torque in this table unless otherwise specified.

(e) Do not apply oil to threaded portions.(Dry)

2-22

Page 61

2.9 Tightening Torque for Standard Eyebolts

Chapter 2 SERVICE DATA

Thread size Dia. × Pitch

(M-thread)

8 × 1.25 12 [0.47] 8 ± 1 0.8 ± 0.1 5.90 ± 0.73

10 × 1.25 14 [0.55] 15 ± 2 1.5 ± 0.2 11.06 ± 1.47

12 × 1.25 17 [0.67] 25 ± 3 2.5 ± 0.3 18.44 ± 2.21

14 × 1.5 19 [0.75] 34 ± 4 3.5 ± 0.4 25.08 ± 2.95

16 × 1.5 22 [0.87] 44 ± 5 4.5 ± 0.5 32.45 ± 3.68

18 × 1.5 24 [0.94] 74 ± 5 7.5 ± 0.5 54.58 ± 3.68

20 × 1.5 27 [1.06] 98 ± 10 10.0 ± 1.0 72.28 ± 7.37

24 × 1.5 32 [1.26] 147 ± 15 15.0 ± 1.5 108.42 ± 11.06

27 × 1.5 41 [1.61] 226 ± 20 23.0 ± 2.0 166.69 ± 14.75

(Dry)

Width across flats

(mm) [in.]

2.10 Tightening Torque for Standard Union Nuts

Nominal

63 14 × 1.5 19 [0.75] 39 4 28.76

80 16 × 1.5 22 [0.87] 49 5 36.14

100 20 × 1.5 27 [1.06] 78 8 57.53

120 22 × 1.5 30 [1.18] 98 10 72.28

150 27 × 1.5 32 [1.26] 157 16 115.80

180 30 × 1.5 36 [1.42] 196 20 144.56

200 30 × 1.5 36 [1.42] 196 20 144.56

220 33 × 1.5 41 [1.61] 245 25 180.70

254 36 × 1.5 41 [1.61] 294 30 216.84

(Maximum tolerance value: ±10%, dry condition)

Cap nut thread size

Dia. × Pitch

(M-thread)

Width across flats

(mm) [in.]

Strength classification

N·m kgf·m lbf·ft

2.11 Tightening Torque for Fuel Injection Pipe

Cap nut thread size

Dia. x Pitch

12 × 1.5 39 ± 5 4 ± 0.5 28.8 ± 3.68

14 × 1.5 49 ± 5 5 ± 0.5 36.1 ± 3.68

18 × 1.5 59 ± 10 6 ± 1.0 43.5 ± 7.37

(Dry)

N·m kgf·m lbf·ft

2-23

Page 62

Chapter 3 SERVICE TOOLS

1. Special Tools............................................................................................................3-3

3-1

Page 63

Chapter 3 SERVICE TOOLS

M10 × 1.25

M12 × 1.25

M10 × 1.5

M14 × 1.5

1. Special Tools

Maintenance

item

Basic engine Rocker bushing tool 37591-02600 Rocker bushing - replace

Tool name Part No. Illustration Usage

Bushing inside diam : ø36 × 40 mm [1.38 ×1.57 in.]

Idler bushing puller 32591-02500 Idler bushing - replace

Bushing inside diam : ø50 × 55 mm [1.97 × 2.17 in.]

Eye bolt 37591-02500 Main bearing cap - remove

Eye bolt 05930-00200 Gear case - lift

Chapter 3 SERVICE TOOLS

Eye bolt 45815-32301 Piston - lift

Eye nut 37591-02400 Cylinder head assembly - install/

Front seal Installer assembly

Rear seal installer assembly

37591-05010 Front oil seal - install

37591-06010 Rear oil seal - install

remove

3-3

Page 64

Chapter 3 SERVICE TOOLS

ø10 × L50

ø17 × L100

M10 × 1.25 M12 × 1.25

Maintenance

item

Basic engine Front slinger - insert 37591-03900 Front oil seal slinger installation

Tool name Part No. Illustration Usage

Valve guide remover 33591-04300 Valve guide - remove

Applicable valve guide inside/outside diam: ø10 × 18 mm [0.39 × 0.71 in.]

Guide and seal installer 37191-11500 Valve guide and stem seal - install

Guide height: 31.5 mm [1.240 in.] Stem seal height: 34.3 mm [1.350 in.] Inlet and exhaust with single valve spring

Guide and seal installer 37591-12300 Valve guide and stem seal - install

Exhaust double valve spring spec

Valve seat installer 37591-04010 Valve seat - press-in

Crankcase grinder

Connecting rod bushing installer

Nozzle remover 33591-10101 Fuel injection nozzle - remove

37591-07010 Crankcase counterbore depth - reface

37591-01010 Connecting rod bushing - install and

Big outside diam: ø59 mm [2.32 in.] Small outside diam: ø48.5 mm [19.095 in.]

remove

3-4

Adapter set 37591-04400 Main bearing cap - remove

M10 × 1.25: 37591-04300 M12 × 1.25: 37591-04411

Page 65

Chapter 3 SERVICE TOOLS

W1 1/8 -18

ø10 mm

W1 1/8 -18 θ＝30°

Maintenance

item

Basic engine Cylinder liner remover 37591-04100 Cylinder liner - remove

Tool name Part No. Illustration Usage

Applicable cylinder liner inner diam: ø170 mm [6.69 in.]

Cam bushing tool assembly

Jack bolt 64362-68500 Water pump plate - remove

37591-08020 Cam bushing installation/removal

M12 × 1.25㨺95mm

Valve spring pusher 33591-04500 Valve spring - install/remove

Valve lapper Suction cup diam:

ø35 mm [1.38 in.] 30091-07500 Suction cup diam: ø40 mm [1.57 in.] 30091-08800

Valve seat cutter Shaft

37591-06400

Cutter 37591-06430

Valve seat puller 32591-04200 Valve seat - remove

Valve lapping

Valve seat - reface Width across flats: 32 mm [1.26 in.] Applicable seat inside/outside diameter: ø45 to 66 [1.77 to 2.60 in.]

Head bolt plate 37598-08900 Cylinder head bolt - tighten with con-

trolled angle

3-5

Page 66

Chapter 3 SERVICE TOOLS

M22 × 2.5 - 115mm

Maintenance

item

Basic engine Projection plate 37598-09201 Depth of counterbore in crankcase -

Tool name Part No. Illustration Usage

measure L230 × W50 × T15 mm [L9.06 × W1.97 × T0.59 in.]

Bolt 37591-06300 Cylinder liner flange

Protrusion - measure (Liner presser jig)

Liner pusher 37591-06200 Cylinder liner flange

protrusion - measure (Liner presser jig)

Ring expander 37191-03200 Piston ring - install/remove

Applicable diam: ø101.6 to 177.8 mm [4.00 to 7.00 in.]

Fuel system

Piston installer 37191-07100 Piston- install

Nozzle tester 83091-03301 Fuel injection nozzle opening pressure

Socket 58309-73100 Fuel injection

Fuel injection pump coupling gauge

37591-06100 Fuel injection pump coupling clear-

Applicable piston diam: ø89 to 178 mm [3.50 to 7.01 in.]

- measure

Pump gear and water pump gear install/remove

ance - adjust GO: 48.75 mm [1.9193 in.] NO GO: 49.25 mm [1.9390 in.]

Cooling system

3-6

Water pump pliers 37591-03100 Water pump cover

Hole snap ring - install/removal Applicable diam: ø180 to 300 [7.09 to

11.81 in.]

Page 67

Chapter 3 SERVICE TOOLS

Maintenance

item

Cooling system

Inspection and measurement

Tool name Part No. Illustration Usage

Impeller remover 37591-03200 Water pump impeller - pull-out

M18 × 1.5 mm

Seal ring

45B91-02100 Water pump unit seal - install

installer guide

Mating ring

45B91-02200 Water pump mating ring - install

installer guide

Compression gauge 33A91-01700 Compression pressure - measure

Measurement range: 0 to 7 MPa {0 to 71 kgf/cm

} [0 to 1015 psi]

Gauge adapter 37591-02200 Compression pressure - measure

U5/8-18

Belt gauge 32591-09100 Belt tension - measure

3-7

Page 68

Chapter 4 OVERHAUL INSTRUCTIONS

1. Determining Overhaul Timing ................................................................................4-3

2. Compression Pressure - Measure..........................................................................4-4

4-1

Page 69

Chapter 4 OVERHAUL INSTRUCTIONS

1. Determining Overhaul Timing

Chapter 4 OVERHAUL INSTRUCTIONS

In most cases, the engine should be overhauled when the compression pressure of the engine decrease. An increase in engine oil

consumption and blow-by gas should be considered when evaluating the engine condition.

Such symptoms as the output decrease, fuel consumption increase, oil pressure decrease, engine starting difficulty and noise

increase should be considered to evaluate overhaul timing, although these symptoms are often affected by various causes, and

are not always effective to consider overhaul timing.

Decreased compression pressure shows a variety of symptoms and engine conditions, thus making it difficult to accurately

determine when the engine needs an overhaul.

The following shows typical symptoms:

(1) Output power decrease

(2) Fuel consumption increase

(3) Engine oil consumption increase

(4) Combustion gas leak increase by cylinder liner and piston ring wear, and as a result, blow-by gas increase through the

breather. (Visually check the blow-by amount.)

(5) Gas leak increase due to poor seating of inlet and exhaust valves

(6) Difficult starting

(7) Noise increase from engine parts

(8) Abnormal exhaust color after engine warm-up

The engine shows these symptoms in various combinations.

Some of these symptoms are directly caused by worn engine parts, while others are not.

Symptoms of items (2) and (6) are affected by improper fuel injection volume and timing of the fuel injection pump, worn

plunger, faulty nozzles and also faulty conditions of electrical devices such as battery and starter.

The most valid reason to overhaul an engine is the compression pressure decrease due to worn cylinder liner and piston ring, as

described in item (4). And once this symptom is shown, it is reasonable to take other symptoms into consideration for making

the final decision.

4-3

Page 70

Chapter 4 OVERHAUL INSTRUCTIONS

2. Compression Pressure - Measure

(a) Be sure to measure the compression pressure of

all cylinders. It is not a clever way to measure

the compression pressure of only two or three

cylinders, and assume the compression pres-

sure of all other cylinders. Cylinders are all inde-

pendent.

(b) Also be sure to check the engine speed when

measuring the compression pressure, as the

compression pressure varies depending on the

engine speed.

sure at regular intervals, and know the change of

the pressure.

(1) Remove the injection nozzle from the cylinder head

where the compression pressure is to be measured.

(2) Attach the compression gauge adapter to the fuel injec-

tion nozzle hole and connect the compression gauge.

(3) Place the fuel injection pump rack at the no-injection

position (rack "0" position), and crank the engine with

the starter.

Read the engine speed and compression pressure while

the engine is running at a stable speed.

Note: Ensure the battery being fully charged when cranking

the engine with the starter.

If the battery voltage is low, the proper compression

pressure can not be measured because of a low crank-

ing speed.

(4) If the measured value exceeds the limit, overhaul the

engine.

Compression gauge P/N: 33A91-01700

Gauge adapter

P/N: 37591-02200

Compression Pressure - Measure

Item

Compression pressure

4-4

Standard

value

1.8 MPa

{18.5 kgf/cm

[263 psi]

Limit value

1.27 MPa

}

{13 kgf/cm2}

[189 psi]

Basic

Rotation speed

-1

120 min

Page 71

Chapter 5 DISASSEMBLY OF BASIC ENGINE

1. Cylinder Heads and Valve Mechanisms - Disassemble and Inspect..................5-3

1.1 Fuel Inlet Connector - Remove................................................................................................. 5-4

1.2 Nozzle Assembly - Remove...................................................................................................... 5-4

1.3 Valve Clearance - Inspect......................................................................................................... 5-4

1.4 Fuel Injection Timing - Inspect.................................................................................................. 5-5

1.5 Rocker Shaft Assembly - Remove............................................................................................ 5-5

1.6 Clearance Between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect... 5-5

1.7 Valve Bridge - Remove............................................................................................................. 5-6

1.8 Rocker Case - Remove ............................................................................................................ 5-6

1.9 Cylinder Head Assembly - Remove.......................................................................................... 5-6

1.10 Valve Sinkage - Measure.......................................................................................................... 5-6

1.11 Valve and Valve Spring - Remove............................................................................................ 5-7

1.12 Nozzle Gland Stud Bolt and Bridge Guide - Remove ............................................................... 5-7

2. Rear Mechanism - Disassemble and Inspect........................................................5-8

2.1 Flywheel Face and Radial Runout - Measure........................................................................... 5-9

2.2 Flywheel - Remove ................................................................................................................... 5-9

2.3 Timing Gear Case - Remove ....................................................................................................5-9

2.4 Timing Gear Backlash - Measure ........................................................................................... 5-10

2.5 Idler Gear End Play - Measure ............................................................................................... 5-10

2.6 Idler Gear - Remove ............................................................................................................... 5-10

2.7 Governor Drive and Fuel Injection Pump Accessory Drive - Remove .................................... 5-10

2.8 Camshaft End Play - Measure................................................................................................ 5-11

2.9 Camshaft Gear - Remove.......................................................................................................5-11

2.10 Camshaft - Remove................................................................................................................ 5-11

2.11 Idler Shaft - Remove............................................................................................................... 5-11

2.12 Rear Plate - Remove .............................................................................................................. 5-12

3. Front Mechanism - Disassemble and Inspect.....................................................5-13

3.1 Coupling - Remove ................................................................................................................. 5-14

3.2 Damper Face and Radial Runout - Measure .......................................................................... 5-14

3.3 Front Pulley, Damper and Crankshaft Pulley - Remove ......................................................... 5-15

3.4 Tension Pulley - Remove........................................................................................................ 5-15

3.5 Front Cover - Remove ............................................................................................................ 5-15

4. Cylinder Liner, Piston and Connecting Rod - Disassemble and Inspect.........5-16

4.1 Piston Protrusion - Measure ................................................................................................... 5-17

4.2 Connecting Rod End Play - Measure ..................................................................................... 5-17

4.3 Hard Carbon Deposits on the Upper Part of Cylinder Liner - Remove ................................... 5-17

4.4 Connecting Rod Cap - Remove.............................................................................................. 5-17

4.5 Piston - Remove ..................................................................................................................... 5-18

4.6 Piston Ring - Remove............................................................................................................. 5-19

4.7 Piston Pin and Piston - Remove ............................................................................................. 5-19

4.8 Cylinder Liner Inside Diameter - Measure .............................................................................. 5-20

4.9 Cylinder Liner Flange Protrusion - Measure ........................................................................... 5-20

4.10 Cylinder Liner - Remove ......................................................................................................... 5-20

5. Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect.............5-21

5.1 Crankcase - Turn Over (Upend) ............................................................................................. 5-22

5.2 Crankshaft End Play - Measure.............................................................................................. 5-22

5.3 Piston Cooling Nozzle - Remove ............................................................................................ 5-22

5.4 Main Bearing Cap - Remove .................................................................................................. 5-22

5.5 Crankshaft - Remove.............................................................................................................. 5-23

5-1

Page 72

Chapter 5 DISASSEMBLY OF BASIC ENGINE

20 24

27 28

Wear at both ends, bend

Cam contact face and outer peripheral contact face wear

Settling, crack

Wear

Wear, oil hole clogging

Stem and seat face wear, corrosion, flaw, carbon deposit

Crack, oil leak, settling

Replace

Crack, carbon deposit, flaw, scale deposit

Replace

Crack, flaw, settling, rubber crack

Contact, wear

Crack, oil leak, scale deposit

Flaw

Exhaust

Double spring spec

1. Cylinder Heads and Valve Mechanisms - Disassemble and Inspect

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the

efficient work.

Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with

any job.

Valve Clearance - Inspect

Fuel Injection Timing - Inspect

Clearance Between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect

Valve Sinkage - Measure

Disassembling Sequence

1 Rocker cover 2 Fuel inlet connector 3 Washer, nut 4 Nozzle gland 5 Fuel injection nozzle 6 Gasket 7 Adjusting screw 8 Bolt

9 Rocker arm 10 Spacer 11 Rocker shaft

Cylinder Heads and Valve Mechanisms - Disassemble and Inspect

12 Bridge cap 13 Valve bridge 14 Push rod 15 Water outlet connector 16 Rocker case 17 Cylinder head bolt 18 Cylinder head (Approx 35 kg [77.2 lb]) 19 Inlet port packing 20 Valve cotter 21 Valve rotator 22 Valve spring

23 Stem seal 24 Valve rotator

(24 to 28 exhaust double spring spec)

25 Inner valve spring 26 Outer valve spring 27 Lower retainer 28 Stem seal 29 Valve 30 Cylinder head gasket 31 Tappet

5-3

Page 73

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Nozzle remover P/N: 33591-10101

Gasket

Nozzle gland

1.1 Fuel Inlet Connector - Remove

Remove the fuel inlet connector.

1.2 Nozzle Assembly - Remove

When removing the nozzle assembly with nozzle

remover, be careful not to get caught your fingers

between the nozzle remover weight, bar and plate.

Fuel inlet connector

Fuel Inlet Connector - Remove

Before removing the nozzle assembly, clean the noz-

zle assembly to prevent foreign material from getting

into the cylinder head. Keep the nozzle and the fuel

inlet connector as a set, and handle the nozzle with

care to avoid damage to the nozzle tip.

(1) Remove the nozzle gland.

(2) Remove the nozzle holder with nozzle remover.

(3) Remove the gasket remained inside the cylinder head.

1.3 Valve Clearance - Inspect

Inspect the valve clearance, and know the current condition.

For the inspection procedure, refer to "Valve Clearance -

Inspect and Adjust" of "ASSEMBLY OF BASIC ENGINE.

Nozzle Assembly - Remove

Valve clearance

Valve Clearance - Inspect

5-4

Page 74

1.4 Fuel Injection Timing - Inspect

Inspect the fuel injection timing, and know the current con-

dition.

For the inspection procedures, refer to "Fuel Injection Tim-

ing - Check and Adjust" of "ASSEMBLY OF BASIC

ENGINE. "

1.5 Rocker Shaft Assembly - Remove

(1) Loosen the adjusting screw of rocker arm.

(2) Remove the rocker shaft assembly from rocker case.

Note: Keep the removed rocker shaft assembly and bolts as a

set.

(3) Remove the push rod.

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Pointer

Line mark on the flywheel

Fuel Injection Timing - Inspect

Adjusting screw

Lock nut

Loosen

Rocker Shaft Assembly - Remove

(4) Disassemble the rocker shaft assembly.

Note: Do not remove the rocker bushing unless it is defective

Lock nut

or its inside diameter exceeds the limit.

Adjusting screw

Spacer

Rocker Shaft Assembly - Disassemble

1.6 Clearance Between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect

Inspect the clearance between the bottom face of valve

bridge and the top face of valve rotator, and know the cur-

rent condition.

For the inspection procedure, refer to "Clearance Between

Bottom Face of Valve Bridge and Top Face of Valve Rota-

tor - Measure" of "ASSEMBLY OF BASIC ENGINE. "

Valve bridge

Valve rotator

Hold down the top of bridge by hand.

Bridge cap

Clearance between valve bridge bottom face and valve rotator top face

Rocker arm

Rocker shaft

Clearance Between Valve Bridge Bottom Face and

Rotator Top Face - Check

5-5

Page 75

Chapter 5 DISASSEMBLY OF BASIC ENGINE

1.7 Valve Bridge - Remove

Remove the valve bridge and bridge cap.

Note: Be careful not to drop the bridge cap into the cylinder

head.

1.8 Rocker Case - Remove

(1) Remove the snap ring of water outlet connector.

(2) Slide the water outlet connector to the snap ring groove

side, and separate it from the next rocker case.

(3) Remove the rocker case from the cylinder head.

Valve bridge

Rocker case

Bridge cap

Screw

Valve Bridge - Remove

Water outlet connector

Snap ring groove

1.9 Cylinder Head Assembly - Remove

When removing the cylinder head gasket, be careful

not to damage the cylinder head or crankcase surface

with a screwdriver or the like.

(1) Remove the cylinder head bolt.

(2) Remove the cylinder head by lifting it up using the

sling.

Note: Dowel pins are used to retain the cylinder head in a po-

sition. Therefore, pull the cylinder head vertical to the

mounting surface to remove.

(3) Remove the cylinder head gasket.

1.10 Valve Sinkage - Measure

Measure the valve sinkage, and know the current condition.

For the measurement procedure, refer to "Valve Sinkage -

Measure" of "ASSEMBLY OF BASIC ENGINE."

Rocker Case - Remove

Eye nut P/N: 37591-02400

Cylinder Head Assembly - Remove

5-6

Page 76

1.11 Valve and Valve Spring - Remove

Valve spring pusher P/N:33591-04500

Inlet side

Exhaust side

Exhaust double spring type

Valve cotter

Valve rotator

Valve spring

Stem seal

Inner valve spring

Outer valve spring

Lower retainer

Using a valve spring pusher, compress the valve spring

evenly and remove the valve cotters.

Note: If valves are reusable, mark each valve seat and the

mating valve to identify their original positions. Do not

change the combination of the valve seat and the valve

when reassembling.

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Valve Spring - Compress

1.12 Nozzle Gland Stud Bolt and Bridge Guide - Remove

Do not remove the nozzle gland stud bolt and the bridge

guide from the cylinder head, unless they are defective.

If they are removed, see "Nozzle Gland Stud Bolt and

Bridge Guide - Inspect and Replace" of "INSPECTION

AND REPAIR OF BASIC ENGINE."

Valve and Valve Spring - Remove

Nozzle gland stud bolt

Bridge guide

Nozzle Gland Stud Bolt and Bridge Guide -

Remove

5-7

Page 77

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Wear, flaw, aging

Crack, dowel hole defect

Flaw, wear

Clogging

Flaw, wear

Clogging, wear

Peeling, wear

Crack, dowel hole defect, flaw, abnormal wear

Flaw

Replace

Hour meter spec

Non-attachment spec

Electronic governor spec

Oil pressure governor spec

Electronic governor spec

2. Rear Mechanism - Disassemble and Inspect

Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the

efficient work.

Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with

any job.

Flywheel Face and Radial Runout - Measure

Timing Gear Backlash - Measure

Idler Gear and Camshaft End Play - Measure

Disassembling Sequence

1 Pick up (Electronic governor spec)

2 Hour meter (With hour meter spec)

3 Flywheel (Standard: approx 83 kg [183 lb])

(FCD spec: approx 42 kg [93 lb]) (Land clutch: approx 100 kg [220 lb])

4 Timing gear case (Approx 88 kg [194 lb])

5 Oil seal

6 Thrust plate

7 Idler gear

8 Accessory drive

(Refer to the chapter "FUEL SYSTEM" for disassembly, inspection and assembly.)

Note: The shape of flywheel differs in accordance with the customization and specification.

5-8

9 Governor drive (Oil pressure governor spec)

(Refer to the chapter "FUEL SYSTEM" for disassembly,

Rear Mechanism - Disassemble and Inspect

inspection and assembly.)

10 Camshaft gear 11 Thrust plate 12 Camshaft gear (Approx 32 kg [71 lb]) 13 Idler shaft 14 Rear plate 15 Nozzle plate

Page 78

2.1 Flywheel Face and Radial Runout - Measure

Face runout measuring plane

Radial runout measuring plane

Measure the face and radial runouts of the flywheel, and

know the current condition.

For the measurement procedure, refer to "Flywheel Face

and Radial Runout - Measure" of "ASSEMBLY OF BASIC

ENGINE."

2.2 Flywheel - Remove

(a) Be careful not to drop or bump the flywheel. It can,

not only cause damage to parts, but also lead to

personnel injury.

(b) Be careful not to cut your hands with the ring gear

when pulling-out the flywheel.

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Flywheel Face and Radial Runout - Measure

Be sure to remove the pickups before removing the

flywheel.

(1) Hitch a sling to the flywheel to prevent it from falling.

(2) Screw two jack bolts evenly into the jack bolt holes,

and remove the flywheel.

2.3 Timing Gear Case - Remove

Be careful not to drop or hit the timing gear case. It

can, not only cause damage to parts, but also lead to

personnel injury.

(1) Hitch a sling to the timing gear case to prevent it from

falling.

(2) Lift the timing gear case to disengage the dowel pins,

and remove the timing gear case.

(3) Remove the oil seal from the timing gear case.

Note: Replace the removed oil seal with a new one. Oil seal

can not be re-used.

Flywheel

Jack bolt P/N:64362-68500

Flywheel - Remove

Timing gear case

Timing Gear Case - Remove

5-9

Page 79

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Governor drive (Oil pressure governor spec)

Fuel injection pump accessory drive

2.4 Timing Gear Backlash - Measure

Measure the timing gear backlash, and know the current

condition.

For the measurement procedure, refer to "Timing Gear

Backlash - Measure" of "ASSEMBLY OF BASIC

ENGINE."

2.5 Idler Gear End Play - Measure

Measure the idler gear end play, and know the current con-

dition.

For the measurement procedure, refer to "Idler Gear End

Play - Measure" of "ASSEMBLY OF BASIC ENGINE."

Timing Gear Backlash - Measure

Idler Gear End Play - Measure

2.6 Idler Gear - Remove

(1) Remove the thrust plate from the idler shaft.

(2) Remove the idler gear from the idler shaft.

2.7 Governor Drive and Fuel Injection Pump Accessory Drive - Remove

Remove the governor drive (oil pressure governor spec) and

fuel injection pump accessory drive from the rear plate.

(Refer to the chapter "FUEL SYSTEM" for disassembly,

inspection and assembly.)

Idler gear

Idler Gear - Remove

5-10

Governor Drive, Fuel Injection Pump and

Accessory Drive - Remove

Page 80

2.8 Camshaft End Play - Measure

Measure the camshaft end play, and know the current condi-

tion.

For the measurement procedure, refer to "Camshaft End

Play - Measure" of "ASSEMBLY OF BASIC ENGINE."

2.9 Camshaft Gear - Remove

Remove the camshaft gear from the camshaft.

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Camshaft End Play - Measure

Camshaft gear

2.10 Camshaft - Remove

Support the camshaft with a wood stick or the like

through the side cover. Remove the camshaft paying

attention not to damage the crank case and camshaft

bushing.

(1) Remove the thrust plate.

(2) Support the camshaft through the side cover opening,

remove the camshaft from the crankcase.

Note: Before removing camshaft, remove the oil seal case,

oil seal and coupling from the cam shaft front end.

2.11 Idler Shaft - Remove

Screw two jack bolts evenly into the jack bolt holes, and

remove the idler shaft.

Idler shaft

Camshaft Gear - Remove

Camshaft

Thrust plate

Camshaft - Remove

Jack bolt (M10 × 1.25 mm)

Idler Shaft - Remove

5-11

Page 81

Chapter 5 DISASSEMBLY OF BASIC ENGINE

2.12 Rear Plate - Remove

(1) Remove the rear plate from the crankcase.

(2) Remove the nozzle plate from the crankcase.

Rear Plate - Remove

5-12

Page 82

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Crack, dowel hole defect

Belt groove wear

Crack, oil leak

Lip wear, flaw, aging

Lip wear

Replace

With fan spec

Non-attachment spec

With tachometer spec

3. Front Mechanism - Disassemble and Inspect

Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the

efficient work.

Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with

any job.

Damper Face and Radial Runout - Measure

Front Mechanism - Disassemble and Inspect

Disassembling Sequence

1 Fan (With fan spec)

2 Oil seal case, coupling

(With tachometer spec)

3 Fan drive assembly (With fan spec)

(Refer to the chapter "COOLING SYSTEM" for disassembly, inspection and assembly.)

5 Fan plate (With fan spec) 6 Front pulley 7 Damper (Approx 56 kg [123 lb]) 8 Crankshaft pulley 9 Front cover

10 Oil seal case

4 Fan drive gear (With fan spec)

Note: The shape of front pulley differs in accordance with the customization and specification.

5-13

Page 83

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Jack bolt (M12×1.25 mm)

3.1 Coupling - Remove

(With tachometer spec)

(1) Remove the oil seal case and oil seal from the crank-

case or fan drive case.

Note: Replace the removed oil seal with a new one. Oil seal

can not be re-used.

(2) Screw two jack bolts evenly into the jack bolt holes,

and remove the coupling from the camshaft.

Oil seal case

Oil seal

O-ring

Oil Seal Case - Remove

3.2 Damper Face and Radial Runout - Measure

Measure the face and radial runout of the damper, and know

the current condition.

For the measurement procedure, refer to "Damper Face and

Radial Runout - Measure" of "ASSEMBLY OF BASIC

ENGINE."

Coupling - Remove

Face runout

Radial runout

Damper Face and Radial Runout - Measure

5-14

Page 84

3.3 Front Pulley, Damper and Crankshaft Pulley - Remove

Be careful not to drop or bump the damper. It can,

not only cause damage to parts, but also lead to per-

sonnel injury.

(1) Install the guide bolt to damper mounting thread on the

crankshaft.

(2) Hitch a rope or the like to the groove of front pulley to

support. Screw two jack bolts evenly into the jack bolt

holes, and remove the pulley.

(3) While supporting the damper with a sling, screw two

jack bolts evenly into the jack bolt holes, and remove

the damper.

(4) Remove the crankshaft pulley from the crankshaft.

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Jack bolt (M10×1.25 mm)

Front Pulley - Remove

Jack bolt

P/N:64362-68500

Guide bolt

(M12×1.25 mm)

3.4 Tension Pulley - Remove

Remove the tension pulley and tension plate from the front

cover and bracket.

3.5 Front Cover - Remove

(1) Remove the front cover from the crankcase.

(2) Remove the oil seal from the front cover.

Tension plate

Front cover

Oil seal

Damper

Damper - Remove

Tension pulley

Front cover

Tension Pulley - Remove

Front Cover - Remove

5-15

Page 85

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Wear, flaw

Inner surface wear, flaw, discoloration

Flaw

Serrated portion wear, crack

Inner peripheral surface flaw, seizure, peeling

Crack, oil hole clogging

Outer peripheral surface scratch, crack, flaw, carbon deposit

Replace. Deformation, wear

Inner surface scratch, wear, outer surface/ O-ring groove rust, cavitation

4. Cylinder Liner, Piston and Connecting Rod - Disassemble and Inspect

Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the

efficient work.

Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with

any job.

Piston Protrusion - Measure

Connecting Rod End Play - Measure

Cylinder Liner Inside Diameter - Measure

Cylinder Liner Flange Protrusion - Measure

Cylinder Liner, Piston and Connecting Rod - Disassemble and Inspect

Disassembling Sequence

1 Connecting rod cap bolt

2 Connecting rod cap

3 Lower connecting rod bearing

4 Upper connecting rod bearing

5 No. 1 compression ring

6 No. 2 compression ring

7 Oil ring

8 Snap ring

9 Piston pin 10 Piston 11 Connecting rod 12 Cylinder liner (S6R: approx 16 kg [35 lb])

(S6R2: approx 19 kg [42 lb])

5-16

Page 86

4.1 Piston Protrusion - Measure

Piston protrusion

Cylinder liner

Measure the piston protrusion, and know the current condi-

tion.

For the measurement procedure, refer to "Piston Protrusion

- Measure" of "ASSEMBLY OF BASIC ENGINE."

4.2 Connecting Rod End Play - Measure

Measure the connecting rod end play, and know the current

condition.

For the measurement procedure, refer to "Connecting Rod

End Play - Measure" of "ASSEMBLY OF BASIC

ENGINE."

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Piston Protrusion - Measure

Connecting rod

Connecting Rod End Play - Measure

4.3 Hard Carbon Deposits on the Upper Part of Cylinder Liner - Remove

Be sure to remove hard carbon deposits from the

upper part of the cylinder liner before pulling-out the

piston. Hard carbon deposits, if not removed, cause

damage to the piston and piston rings.

Remove hard carbon deposits from the upper part of cylin-

der liner with carbon remover (scraper, sandpaper, etc.)

Note: Be careful not to damage the inner surface of the cyl-

inder liner.

Hard carbon

Hard Carbon Deposits on the Upper Part of Cylinder

4.4 Connecting Rod Cap - Remove

Using a socket wrench, remove the connecting rod bolts

through the inspection window on the side of the crankcase,

and remove the connecting rod cap and connecting rod bear-

ings.

Note:(a) Be careful not to damage the connecting rod bear-

ings by dropping them into the oil pan.

(b) Make marks, such as cylinder number and upper or

lower, on the removed connecting rod bearings to

ensure the correct reassembly.

Connecting rod end play

Liner - Remove

Connecting rod cap

Cylinder liner

Connecting Rod Cap - Remove

5-17

Page 87

Chapter 5 DISASSEMBLY OF BASIC ENGINE

4.5 Piston - Remove

When holding the connecting rod with your hand to prevent it from swinging, be very careful, as you may suffer

hand injuries from accidental movement of the connecting rod.

(a) When pulling-out the piston, be careful not to drop the upper connecting rod bearing.

(b) When removing piston, be careful not to damage cylinder liner by connecting rod runout.

hold the crankshaft to prevent it from rotating while removing pistons.

(d) Make sure that the connecting rod does not interfere with the piston cooling nozzle when removing the piston.

(e) When pulling the piston out of the cylinder liner, hold the piston by hand so that the piston does not rock. If the

piston rocks the piston skirt will be damaged by the connecting rod.

4.5.1 Removing the Piston With Chain Block Lifting

(1) Remove the connecting rod cap and rotate the crank-

shaft to bring the piston to the top dead center position.

Eyebolt P/N:37591-02500 (M10×1.25 mm)

(2) Install the eye bolt to the threaded hole on the piston

top, and support the piston to prevent it from falling

down.

(3) Rotate the crankshaft to place the crank pin slightly

near to the inspection window so that the connecting

Piston & connecting rod assembly weight: approx 26 kg [57 lb.] (S6R) approx 21 kg [46 lb.] (S6R2)

Crankpin

rod big end does not contact the cylinder liner.

(4) Carefully pull-out the piston by making sure that the

connecting rod big end slides into the cylinder liner.

Removing the Piston With Chain Block Lifting

5-18

Page 88

4.5.2 Removing the Piston With Pushing-up the Con-

Crankpin

Eyebolt P/N:37591-02500 (M10×1.25 mm)

Piston & connecting rod assembly weight: approx 26 kg [57 lb.] (S6R) approx 21 kg [46 lb.] (S6R2)

necting Rod Big End

(1) Remove the connecting rod cap and rotate the crank-

shaft to bring the piston to the top dead center position.

(2) Install the eye bolt to the threaded hole on the piston

top, and support the piston to prevent it from falling

down.

(3) Rotate the crankshaft carefully until the crankpin is dis-

placed from the connecting rod and the lower bolt hole

can be seen trough the inspection window.

(4) Insert a bar wrapped with cloth, and push up the bottom

of connecting rod carefully, with the crankpin as a ful-

crum.

Note: Protect the crankpin and connecting rod big end with

cloth or rubber to prevent them from damage with the

bar.

(5) Push-up the connecting rod and piston while adjusting

the supporting position.

When the oil ring is slid out of the cylinder liner, care-

fully put the piston on the top face of cylinder liner.

(6) Lift the piston with eye bolt on the piston top, and pull-

out the piston from cylinder liner.

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Crankshaft - Rotate

Oil ring

Wrap in cloth

Turning bar

Connecting Rod Big End - Push-up

4.6 Piston Ring - Remove

When removing the piston ring, be careful not to be

pinched your hand between the piston and connecting

rod by piston swing.

A free swing of piston and its bump to connecting rod

may result in piston damage.

Hold the piston and connecting rod in a vise, and remove

the piston rings with ring expander.

4.7 Piston Pin and Piston - Remove

(1) Remove the snap ring with ring pliers.

(2) Place a piece of wood to piston pin end and lightly tap

with hammer to remove the piston pin, and separate the

piston from connecting rod.

Note:(a) Do not tap the piston pin directly with hammer.

(b) If the piston is stubborn, heat the piston with heater

or in hot water.

Ring expander P/N:37191-03200

Piston Ring - Remove

Piston Pin and Piston - Remove

5-19

Page 89

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Cylinder linerCylinder liner

Cylinder liner

4.8 Cylinder Liner Inside Diameter - Measure

Measure the cylinder liner inside diameter, and know the

current condition.

For the measurement procedure, refer to "Cylinder Liner

Inside Diameter - Measure" of "ASSEMBLY OF BASIC

ENGINE."

4.9 Cylinder Liner Flange Protrusion - Measure

Measure the cylinder liner flange protrusion, and know the

current condition.

For the measurement procedure, refer to "Cylinder Liner

Flange Protrusion - Measure" of "ASSEMBLY OF BASIC

ENGINE."

Cylinder Liner Inside Diameter - Measure

Bolt P/N:37591-06300

Tightening torque

98 N·m {10 kgf·m} [72 lbf·ft]

Cylinder liner flange protrusion

4.10 Cylinder Liner - Remove

(1) Set the cylinder liner remover to the cylinder liner.

Note: Use care not to hit the piston cooling nozzle when set-

ting the remover plate to the bottom of cylinder liner.

(2) Rotate the handle, and remove the cylinder liner.

Liner pusher P/N:37591-06200

Cylinder Liner Flange Protrusion - Measure

Cylinder liner remover

P/N:37591-04100

Removing stroke

80 mm [3.15 in.]

Removing stroke

80 mm [3.15 in.]

Cylinder liner

Cylinder Liner - Remove

5-20

Page 90

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Single nozzle hole spec

Double nozzle holes spec

Scale deposit, flaw, crack, oil hole clogging

Valve operation, oil hole clogging, oil injection pipe bend, deformation

Scratch, crack, dent, oil hole clogging, wear

Inner and outer peripheral surface flaw, corrosion, peeling

Flaw

Crack

Peeling, wear, contact

Inner and outer peripheral surface flaw, corrosion, peeling

5. Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect

Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the

efficient work.

Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with

any job.

Crankshaft End Play - Measure

Disassembling Sequence

1 Main bearing cap bolt 2 Main bearing cap 3 Lower main bearing 4 Lower thrust plate

Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect

5 Crankshaft (S6R: approx 285 kg [628 lb])

(S6R2: approx 300 kg [661 lb])

6 Upper main bearing

7 Upper thrust plate

8 Check valve (One jet hole spec)

Eye bolt (Two jet hole spec)

9 Piston cooling nozzle 10 Crankcase (S6R: approx 530 kg [1168 lb])

(S6R2: approx 590 kg [1301 lb])

5-21

Page 91

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Crankcase rotation direction

Crankcase

Wood block

Crankcase weight: approx

530 kg [1168 lb] (S6R)

approx

590 kg [1301 lb] (S6R2)

5.1 Crankcase - Turn Over (Upend)

Using a turnover machine, turn over the crankcase. When

the turnover machine is not available, hitch slings to the

crankcase using wood pieces and cloth pads, and raise the

crankcase with a hoist or crane. Then lay it on the wooden

block with its side facing downward. Then, change the posi-

tions of the slings, and turn over to upend the crankcase.

5.2 Crankshaft End Play - Measure

Measure the crankshaft end play, and know the current con-

dition.

For the measurement procedure, refer to "Crankshaft End

Play - Measure" of "ASSEMBLY OF BASIC ENGINE."

Crankcase - Turn Over (Upend)

5.3 Piston Cooling Nozzle - Remove

Remove the piston cooling nozzle from the crankcase.

5.4 Main Bearing Cap - Remove

When removing the main bearing cap, be careful not

to damage the lower main bearing or the lower thrust

plate attached to the cap. Also be careful not to drop

those parts from the cap, which may result in crank-

shaft damage.

(1) Remove the main bearing cap bolt.

(2) Install the adapter to main bearing cap.

(3) Install the nozzle remover to adapter.

(4) Remove the main bearing cap from crankcase.

(5) Remove the lower main bearing from the main bearing

cap.

(6) Remove the lower thrust plate from the rearmost main

bearing cap.

Crankshaft End Play - Measure

Nozzle remover P/N:33591-10101

Adapter P/N:37591-04300 (M10 × 1.25 mm)

Main Bearing Cap - Remove

5-22

Page 92

5.5 Crankshaft - Remove

Crankshaft assembly

(a) Before removing the crankshaft, remove the front

side upper thrust plate first, and be careful not to

drop it into crankcase.

(b) When placing the crankshaft onto a pallet or other

stands, be careful not to damage the crankshaft.

Once placed on a pallet, place some support to

prevent the crankshaft from moving.

(1) Push a mating face of the front upper thrust plate, and

rotate the thrust plate to remove.

(2) Suspend the crankshaft in a horizontal position, and

slowly lift the crankshaft upward.

Note: Do not hitch a chain directly onto crankshaft, as it

could damage the crankshaft. Place cloth belts or pads

in the positions before lifting crankshaft.

(3) Remove the upper main bearing from crankcase, pay-

ing attention to the lug position, and remove the upper

thrust plate on the rear side.

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Crankshaft - Remove

5-23

Page 93

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

1. Cylinder Head and Valve Mechanism - Inspect and Repair.................................6-3

1.1 Bushing Inside Diameter and Shaft Outside Diameter of Rocker - Measure............................ 6-3

1.2 Rocker Bushing - Replace ........................................................................................................ 6-3

1.3 Valve Stem Outside Diameter and Valve Guide Inside Diameter - Measure ........................... 6-4

1.4 Valve Guide - Replace.............................................................................................................. 6-4

1.5 Valve Face - Inspect ................................................................................................................. 6-5

1.6 Valve Face - Reface ................................................................................................................. 6-5

1.7 Valve Seat - Reface.................................................................................................................. 6-6

1.8 Valve Seat - Replace ................................................................................................................ 6-6

1.9 Valve and Valve Seat - Lap ...................................................................................................... 6-8

1.10 Valve Bridge, Bridge Cap, Valve Cotter and Valve Rotator - Inspect ....................................... 6-8

1.11 Squareness and Free Length of Valve Spring - Measure......................................................... 6-9

1.12 Tappet - Inspect...................................................................................................................... 6-10

1.13 Pushrod Runout - Measure..................................................................................................... 6-10

1.14 Nozzle Gland Stud Bolt and Bridge Guide - Inspect and Replace.......................................... 6-10

1.15 Distortion of Cylinder Head Bottom Surface - Measure.......................................................... 6-11

2. Rear Mechanism - Inspect and Repair.................................................................6-12

2.1 Idler Bushing Inside Diameter and Idler Shaft Outside Diameter - Measure .......................... 6-12

2.2 Idler Bushing - Replace .......................................................................................................... 6-12

2.3 Cam Lift of Cam Shaft Lobe - Measure .................................................................................. 6-13

2.4 Camshaft Runout - Measure................................................................................................... 6-13

2.5 Camshaft Journal Outside Diameter - Measure ..................................................................... 6-13

2.6 Camshaft Bushing - Inspect.................................................................................................... 6-14

2.7 Camshaft Bushing - Replace .................................................................................................. 6-14

3. Front Mechanism - Inspect and Repair................................................................6-16

3.1 Damper - Inspect Visually....................................................................................................... 6-16

3.2 Pulley - Inspect ....................................................................................................................... 6-16

4. Piston and Connecting Rod - Inspect and Repair ..............................................6-17

4.1 Piston - Inspect Visually.......................................................................................................... 6-17

4.2 Piston Weight ......................................................................................................................... 6-17

4.3 Piston Outside Diameter - Measure........................................................................................ 6-17

4.4 Piston Ring Groove - Inspect.................................................................................................. 6-18

4.5 Piston Pin Bore Inside Diameter - Measure............................................................................ 6-18

4.6 Piston Ring - Inspect Visually ................................................................................................. 6-18

4.7 Piston Ring End Gap - Measure ............................................................................................. 6-18

4.8 Piston Pin Outside Diameter - Measure ................................................................................. 6-19

4.9 Connecting Rod Bushing Inside Diameter - Measure............................................................. 6-19

4.10 Connecting Rod Bushing - Replace........................................................................................ 6-20

4.11 Connecting Rod Assembly Weight Rank................................................................................ 6-22

4.12 Bore Diameter and Roundness of Connecting Rod Big End - Measure................................. 6-22

4.13 Side Face Width of Connecting Rod Big End - Measure........................................................ 6-23

4.14 Connecting Rod Big End Serration and Bolt Holes - Inspect.................................................. 6-23

4.15 Connecting Rod Bearing - Inspect.......................................................................................... 6-23

4.16 Connecting Rod Bearing Thickness - Measure ...................................................................... 6-24

4.17 Connecting Rod Bend and Twist - Inspect ............................................................................. 6-24

5. Crankcase and Crankshaft - Inspect and Repair................................................6-25

5.1 Crankcase Top Surface Distortion - Measure......................................................................... 6-25

5.2 Inside Diameter of Main Bearing Housing Bore - Measure .................................................... 6-25

5.3 Cylinder Liner Fitting Bore in Crankcase - Inspect ................................................................. 6-25

6-1

Page 94

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

5.4 Counterbore in Crankcase - Repair........................................................................................ 6-26

5.5 Crankpin and Journal Outside Diameters - Measure.............................................................. 6-27

5.6 Width of Crankpin and Rearmost Crank Main Journal - Measure .......................................... 6-28

5.7 Crankshaft Runout - Measure................................................................................................. 6-29

5.8 Crankshaft Gear - Inspect....................................................................................................... 6-29

5.9 Crankshaft Gear - Replace ..................................................................................................... 6-29

5.10 Oil Seal Slinger - Inspect ........................................................................................................ 6-30

5.11 Oil Seal Slinger - Replace....................................................................................................... 6-30

5.12 Main Bearing - Inspect............................................................................................................ 6-31

5.13 Thickness of Main Bearing Shell - Measure ........................................................................... 6-32

5.14 Thrust Plate - Inspect.............................................................................................................. 6-32

5.15 Thickness of Thrust Plate - Measure ...................................................................................... 6-33

5.16 Piston Cooling Nozzle - Inspect.............................................................................................. 6-33

6-2

Page 95

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

Extract

Rocker bushing tool P/N:37591-02600

Rocker arm

Rocker bushing

Press-fit so that the rocker bushing notch is aligned parallel to the center axis of screw hole.

Rocker bushing

Rocker arm

Rocker bushing notch

Rocker bushing joint

1. Cylinder Head and Valve Mechanism - Inspect and Repair

1.1 Bushing Inside Diameter and Shaft Outside Diameter of Rocker - Measure

Measure the inside diameter of the rocker bushing and the

outside diameter of the rocker shaft. If the measurement

exceeds the limit, replace the rocker bushing or rocker shaft

with a new one.

Item Nominal

Rocker bushing inside diameter

Rocker shaft outside diameter

value

ø36 mm

[1.4 in.]

ø36 mm

[1.4 in.]

Standard value Limit value

36.000 to 36.040 mm

[1.4173 to 1.4189 in.]

35.966 to 35.991 mm

[1.4160 to 1.4170 in.]

36.090 mm

[1.4209 in.]

35.940 mm [1.4150 in.]

1.2 Rocker Bushing - Replace

If rocker bushing notch is not aligned with center axis

of screw hole, oil will not feed from rocker arm to valve,

resulting in wear of rocker arm and bridge, or seizure

of valve.

Bushing Inside Diameter and Shaft Outside Diameter

Measurement direction

of Rocker - Measure

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

Measurement direction

Measurement point

(1) Pull-out the rocker bushing with rocker bushing tool.

(2) Install the new rocker bushing with rocker bushing tool.

With the positioning notch (4mm wide) of rocker bush-

ing facing upward, align the position as shown in illus-

tration. Press-in the rocker bushing into chamfered side

of rocker arm hole.

(3) Check the alignment of the rocker arm and rocker bush-

ing oil holes.

(4) Measure the installed inside diameter of rocker bush-

ing. If the value is smaller than the standard, ream the

inside diameter to the standard.

Rocker Bbushing - Remove

Bushing inner surface roughness

3.2S

ٖٖٖ

Rocker bushing tool P/N: 37591-02600

Rocker bushing

Rocker arm

Rocker Bushing - Insert

Press-fit

Face the notch upward.

Press-fit from chamfered side.

20 mm

[0.79 in.]

15mm

[0.59 in.]

Rocker Bushing - Position

6-3

Page 96

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

Measurement

direction

Measurement

point

Measurement

direction

Measurement

point

1.3 Valve Stem Outside Diameter and Valve Guide Inside Diameter - Measure

Measure the outside diameter of valve stem and the inside

diameter of valve guide at the top and bottom sliding ends in

right-angle directions as shown, as the sliding surface tends

to wear at the top and bottom ends. If the measurement

exceeds the limit, replace the valve guide or valve with a

new one.

Note: Lap the valve and valve seat whenever new valve is in-

stalled.

Item

Val v e s t em outside diameter

Valve guide inside diameter

Nominal

value

ø10 mm

[0.39 in.]

ø10 mm

[0.39 in.]

Standard value Limit value

9.940 to 9.960 mm

[0.0010 to 0.0044 in.]

10.000 to 10.015 mm

[0.3937 to 0.3943 in.]

9.910 mm

[0.3902 in.]

10.060 mm

[0.3961 in.]

1.4 Valve Guide - Replace

Be sure to use the guide and seal installer, and press-

in the valve guide to the specified height.

(1) Remove the valve guide with valve guide remover.

Valve Stem Outside Diameter - Measure

Valve Guide Inside Diameter - Measure

Valve guide remover P/N:33591-04300

(2) With guide and seal installer, press-in the new valve

guide slowly.

6-4

Valve Guide - Remove

31.5 ± 0.3 mm [0.081 ± 0.012 in.]

Valve Guide - Press-in

Guide and seal installer P/N:37191-11500

Valve guide

Cylinder head

Page 97

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

Grind valve face at specified angles.

Valve refacer

1.5 Valve Face - Inspect

Inspect the valve face after the valve guide is inspected or

replaced. Lap the valve and valve seat whenever valve is

refaced or replaced.

1.5.1 Valve Margin - Inspect

Measure the valve margin. If the value exceeds the limit,

reface or replace the valve with a new one.

1.5.2 Seat Width - Inspect

Apply a thin lead-free coloring paste on the valve face, and

tap the valve face against valve seat with valve lapper to

check the contact condition. If the contact is not even, or

any defects are found, or if the value exceeds the specified

limit, reface or replace the valve or valve seat.

Note: Do not rotate the valve when pressing valve face coat-

ed with lead-free coloring paste against valve seat.

Seat width

Valve seat angle

Valve sinkage

Valve lapper P/N:30091-08800

Valve margin

Valve Face - Inspect

Lapping compound

Item

Valve seat angle

Va l ve seat

Seat width

Valve margin

Nominal

value

30° - -

2.3 mm

[0.09 in.]

3.0 mm

[0.12 in.]

Standard value

2.18 to 2.44 mm

[0.0858 to 0.09 in.]

2.8 to 3.2 mm

[0.1102 to 0.1260 in.]

Limit

value

2.8 mm

[0.1102 in.]

2.5 mm

[0.098 in.]

1.6 Valve Face - Reface

When the valve is re-used by refacing, use valve refacer.

Note:(a) Grind the valve face with valve refacer adjusted to

the specified angle.

(b) The valve margin is to be within the specified limit.

If the dimensions after refacing does not meet the

specified values, replace the valve with a new one.

Seat Width - Inspect

Good

Bad

Contact Condition Between Valve Seat and Valve

Valve Face - Reface

6-5

Page 98

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

Valve seat cutter P/N: 37591-06400 37591-06430

Socket (width across flats 32 mm [1.26 in.])

Valve seat

Stud, etc.

Welding

Shaft

1.7 Valve Seat - Reface

If any damage or inclusions are found, grind the sheet face.

(1) Reface the valve seat with valve seat cutter or valve

seat grinder. After refacing, insert sand paper of approx

400 grit between cutter and valve, and glind valve seat

lightly.

If the seat width exceeds the standard, grind the valve

inner seat with 44°50′ valve seat cutter.

(2) Lap the valve and valve seat.

Note:(a) Valve seat refacing depth is to be minimal.

(b) If the seat width cannot be repaired to the standard

value, or line contact on valve seat outer periphery

is shown, replace the valve seat with a new one.

refacing, replace the valve seat with a new one.

Valve Seat - Reface

1.8 Valve Seat - Replace

Select the valve seat with appropriate interference.

Improper interference can result in dropping out of

valve seat or crack in cylinder head.

Be careful not to damage the machined surface of cylinder

head when removing the valve seat.

1.8.1 Valve Seat - Remove (With Valve Seat Puller)

Remove the valve seat with valve seat puller.

1.8.2 Valve Seat - Remove (by Welding)

To remove the valve seat, weld a stud to valve seat as

shown. Then, insert a shaft into valve guide hole from the

top of cylinder head, and punch out the valve seat with

shaft.

Note: Be careful not to allow spatters to adhere to the ma-

chined surface of the cylinder head during welding.

6-6

Valve seat puller P/N:32591-04200

Valve Seat - Remove (With Valve Seat Puller)

Valve Seat - Remove (by Welding)

Page 99

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

1.8.3 Valve Seat - Install (1) Before installing the valve seat, measure the inside

diameter of valve seat counterbore in cylinder head and

the outside diameter of valve seat to make sure that the

interference is within the range of standard value. If the

value exceeds the standard, use the oversize valve seat.

Item Standard value Limit value Remarks

Val v e s e at inside diameter of counterbore

Va l ve seat outside diameter

Valve seat interference

Standard

0.03 mm [0.0012 in.]

0.06 mm [0.0024 in.]

60.000 to 60.030 mm

[2.3622 to 2.3634 in.]

60.100 to 60.130 mm

[2.3661 to 2.3673 in.]

60.130 to 60.160 mm

[2.3673 to 2.3685 in.]

60.160 to 60.190 mm

[2.3685 to 2.3697 in.]

0.070 to 0.130 mm

[0.0028 to 0.0051 in.]

If the inside diameter of valve seat counterbore in cylin-

der head exceeds the limit, replace the cylinder head

with a new one.

Note: Oversized valve seats are available in 0.03 and 0.06

mm [0.0012 and 0.0024 in.] sizes.

60.09 mm

[2.3657 in.]

- 2 lines, brown

- 3 lines, brown

- 4 lines, brown

Inside diameter of

valve seat counterbore

60.03 mm [2.3634 in.] or less Standard

More than 60.03 mm [2.3634 in.] 0.03 mm [0.0012 in.]

More than 60.06 mm [2.3646 in.] 0.06 mm [0.0024 in.]

Applicable valve seat

(2) Cool the valve seat at least for 4 minutes in liquid nitro-

gen and cool the cylinder head to a room temperature.

(3) Install the valve seat into the cylinder head with valve

seat caulking tool.

Cylinder head

8 [0.31]

3.6 [0.14]

60°

Same size on both inlet and exhaust sides

Valve seat fitting

bore inside diameter

outside diameter

+0.004

+0.1

11.6

Valve seat

-0 ]

[0.457

Valve Seat Counterbore

Valve seat

Valve seat installer assembly P/N:37591-04010

Unit: mm [in.]

Valve Seat - Install

6-7

Page 100

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

Compound

Valve lapper P/N:30091-08800

1.9 Valve and Valve Seat - Lap

Lap the valve and valve seat whenever valve seat is refaced

or valve is replaced, or the contact surfaces fail to keep a

pressure in the pressure test after assembling.

(1) Apply a thin coat of lapping compound evenly to the

valve face.

Note:(a) Do not allow the compound to adhere to the valve

stem.

(b) Compound spreads more evenly when it is mixed

with a small amount of engine oil.

for initial lapping, then use fine-grain compound

(200 mesh) for finishing.

(2) Use a valve lapper for lapping.

Tap the valve against valve seat while rotating the valve

little by little.

(3) Clean off the compound using diesel oil.

(4) Apply engine oil to the contact surface of valve, and

finish the lapping.

(5) Apply a thin lead-free coloring paste on the valve face,

and tap the valve face against the valve seat using a

valve lapper to check for contact condition.

Compound - Apply

Valve and Valve Seat - Lap

1.10 Valve Bridge, Bridge Cap, Valve Cotter and Valve Rotator - Inspect

(1) Inspect the contact surfaces between valve bridge and

valve stem, and the sliding surface between valve

bridge and bridge guide. If significant wear or uneven

contact is found, replace them with new ones.

(2) Check the bridge cap for wear. If significant wear is

found, replace the bridge cap with a new one.

(3) Check the valve rotator for rotation. If any defect is

found, replace the valve rotator with a new one.

(4) Inspect the contact surfaces between valve cotter and

valve stem, and valve cotter and valve rotator. If signif-

icant uneven wear or dent is found, replace them with

new ones.

Valve bridge

Valve cotter

Valve stem

Valve Bridge, Bridge Cap, Valve Cotter and Valve

Bridge cap

Bridge guide

Valve rotator

Rotator - Inspect

6-8

Mitsubishi S6R, S6R2 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual