Mitsubishi S4S, S6S, S6S-DT, S4S-DT Service Manual

SERVICE

MANUAL

MITSUBISHI
DIESEL

ENGINES

S4S

ses

March

2002

J..

!!!!I'D'!S~~!~!.

Foreword

This service manual is written to familiarize you with the maintenance of your S4S and S6S Diesel Engine. If
the engine is carefully maintained it will deliver a long productive life and efficient performance marked by
power and economy.

Before you attempt to inspect, disassemble, or repair the engine, read this manual carefully to leam more about
the engine and how to care for it properly. AHdescriptions, illustrations, specifications and serial numbers in
this manual are effective as of the date printing of this manual.

The information contained in this manual applies to the engine model produced at the time of publication.
It should be noted that specifications and design may change due to improvements made thereafter.

For

items other than those in this publication, refer to the operation

manual

for a unit on which the

engine is mounted,

How to Use This Manual

1. Parts in illustrations are numbered to correspond with references to these numbers in text.

2. Items or conditions to be inspected during disassembly are enclosed in a box in the disassembIed views:

I Clogged oil hole I

3. Maintenance standards for inspeetion and repair are described in text wherethey are relevant. For a quick
summary of maintenance standards refer to group 2 of this manual.

4. The sequence in which parts are to be reassembled is summarized below eaeh assembIed view.
Sueh as:

@

.....~.....

@

.....

@

.....

CD

5. Tightening torqueunder wet conditions is indieated as "(wet)" in text, drawings, andtables.When so indieated
as (wet), apply engine oil to the threaded portion of the fastener. Unless indieated as such, the tightening
torque is to be assumed in the dry condition.

6. Pay attention to the special notes, cautions and wamings.

Pub. No. 99616-10170

Notes, Cautions, Warnings, Dangers

Notes, cautions, wamings, dangers are used in this manual to emphasize important or critical instructions or
advice.

(&OANGER)

&WARNING

(&CAUTION)

(NOTE)

'Ierms Used in This

Manual

Indicates the most serious specific potential hazard
resulting in serious bodily injury or death.

Indicates a specific potential hazard resulting in
bodily injury.

Indicates operating procedure, practice,etc., resulting
in personal injury or damage to or destruction

of

engine.

An operating procedure, condition, etc. that will help
you work more efficiently.

Beforeyou read this manual, note that the following special terms are used indimensional and otherspecifications.

Assembly Standard Indicates the dimension of a part, the dimension to be attained at the

time of reassembly or the standard performance. The value is rounded
to the nearest whole number needed for inspeetion and is different from
the design value.

Nominal Value Indicates the standard dimension of a part.

Repair Limit.. A part which has reached this limit must be repaired.

Service Limit A part which has reached this limit must be replaced.

Standard Clearance Indicates the clearanceto be obtained betweenmating parts atreassembly.

SummaryofManual

Contents

Group

1.

General

2.

Maintenance

Standards

3.

Special

Tools

4.

Overhaul

Instructions

5. Adjustments,

Bench

Test,

Performance

Tests

6.

Engine

Auxiliaries

Removal

and

Installation

7.

Engine

Main Parts

8. Inlet

and

Exhaust

System

9. Lubrication

System

lO.Cooling

System

11.Fuel

System

12.Electrical

System

13.Workshop Tips

Contents

External

view,

engine

serial

number

location,

engine

model

and

application codes, specifications, tips on disassembly and reassembly.

Maintenance standards, tightening torques, sealants and lubricants.

A list

of

special tools required.

Determining when to overhaul the engine, testing compression pressure

Adjustment of valve clearance, fuel system bleeding, fuel injection
timing, no-load

minimum

and maximum speed setting, V-belt, bench

testing, performance tests.

Removal and installation of turbocharger, fuel injection pump, alternator,
water

pump,

starter, etc.

Disassembly, inspeetion and reassembly of the main parts, to include
cylinderhead and valve mechanism, flywheel, damper, timing gears and
camshaft, pistons, connecting rods, crankshaft, crankcase and tappets.

Disassembly, inspeetion and reassembly of inlet and exhaust system
(exhaust manifold).

Disassembly, inspeetion and reassembly oflubrication system, to inlcude
oil

pump,

oil filter, oil cooler, oil pressure relief valve and safety valve.

Disassembly, inspeetion and reassembly of cooling system, to include
water

pump

and thermostat.

Disassembly, inspeetion and reassembly

offuel

systern, to include fuel

filter

and

injection nozzles.

Disassembly, inspeetion and reassembly of electrical system, to include
starter, alternator, glow plugs and stop solenoid (option).

Basic

recommended

assembly procedures: oil seals, O-rings, bearings,

split pins and spring pins.

GENERAL

1. Outline 1- 2

1.1 External View 1- 2

1.2 Engine Serial NumberLocation 1- 6

1.3 Engine Model andApplication Codes 1- 6

2. Specifications 1- 7

3. Tips on Disassembly and Reassemb1y 1-13

3.1 Disassembly 1-13

3.2 Reassembly 1-13

Di

GENERAL

1. Outline

1.1 External View

[848 -

Standard]

Fuel filter Fuel injection pump

Fan

IFront I

Fuel feed pump

C'-I)

n

Inlet manifold

Fuel injection nozzle

ETR

stop solenoid

Governor

Coolant drain plug

Dipstick

IRear I

<>-tt-++--Flywheel

Oil drain plug

ILeft view

Oil filler

onfilter

Exhaust manifold

IRear I

Starter

n

I-I:)

Thermostat

Alternator

IFront I

V-belt

üil

pan

I

Right

viewl

Remark: Direction of rotation of this engine is counterclockwise as seen from flywheel side.

1-2

GENERAL

[S4S-DT - Standard]

IRear I

::n

"

.'

(I~I\

Fuel injection pump n

Fuel filter \

<,

I/In,

let manifold

h--.rT,----1JI

Fuel injection nozzle

Fan

~

rr-.

~

tJUI fT"i"T"i:

~

r~~

~?n'\~

I

hl

vETRstopsolenoid

Water

pump~

F -\.lIJ

11

(( --r

~Governor

I

~

;:,

Ip,~

-~

!

:;::

p

"/

/ Coolant drain plug

):

[l.l.AF::J"1"-

~

~

:::"

f'\f

r~

'Q

,

~

_

~!::L-

~.\

K"

Q.r-

~

~

I

",-

'"

Tb.

y

~

V Dipstick

13

--1.

~

~

___

0:/

ra

11

:

~

"\

V

~

(0

,0

/1, 0

ol--

~0,,~

,-'-

h>'

• F

;:;

:

I1

\

'--'-ol

Fuel feed pump -:

rUi;!=~~o?J;»-~~'-.-i~0Ë=Q:~~:

jl~~,

\~~r-~-dn

1111

~f--Ij'---H--FI

ywheel

IFront I

ondrain

PIL

I

Left

view I

on

filter

IFront I

Altemator

Thermostat

V-belt

Oil pan

Turbocharger

(1-1\

n

onfiller

Starter

Exhaust manifold

------.11ll-

~~~~~~

I

Rear

I

IRignt viewl

Remark: Direction of rotation

of

this engine is counterclockwise as seen from flywheel side.

1-3

GENERAL

[868 - Standard]

uel filter Fuel injection pump lnlet manifold

I

Rear

I

Flywheel

Oil filter

Dipstick

Governor

t:~~~ah~~::~~r

Coolant drain plug

Oil drain plug

%~-1----le:::::~I-~e:::::~~--:v:

Fuel injection nozzle

1NI"bb!l;a

ETR stop solenoid

Fan

Water pump

I

Front

I

I

Left

view

Oil filler

Exhaust manifold

IRear I

Starter

Oilpan

Thermostat

Alternator

I

Front

I

V-belt

I

Right

viewl

Remark: Directionofrotation of this engine is counterclockwise as seen from flywheel side.

1-4

GENERAL

[S6S-DT-

Standard]

Fan

Water pump

IFront I

Gil filler

Exhaust manifold

IRea.. I

Starter

Fuel injection nozzle

ETR stop solenoid

).F~~~~~~

Governor

IRear I

Flywheel

Gil drain plug Dipstick

ILef! view I

Turbocharger

Thermostat

Alternator

IFront I

V-belt

Gil pan

IRight viewl

Remark:

Direction of rotation of this engine is counterclockwise as

seen

from flywheel side.

1-5

GENERAL

1.2 Engine Serlal Number Location

The engine serial number is located on the side of
the crankcase.

1.3 Engine Model

and

Application Codes

s D s -

[Q][ïJ

~

1-6

T : Equipped with turbocharger
D : Direct injection type

Series code
Number of cylinders
Manufactured by Sagamihara machinery works

2. Specifieations

GENERAL

Model designation

S4S

S4S-DT

Type

Water-cooled, 4-stroke cycle

No. of cylinders

- arrangement

4-

in line

Combustion chamber type

Swirl chamber

Direct injection

Valve mechanism

Overhead

Cylinder bore

x stroke

mm[in.] 94

x 120 [3.70 x 4.72]

Piston displacement liter [cu in.]

3.331 [203]

";J

Compression ratio

22:

1

17:

1

...

<Ll

I:

Firing order

1-3-4-2

<Ll

0

Direction of rotation

Counterclockwise as viewed from flywheel side

Overall1ength

781 [30.7]

mm[in.]

Dimension

Overall width

593 [23.3]

mm[in.]

Overall height

710 [28.0]

821 [32.3]

mm[in.]

Weight (dry)

kg [Ib]

245 [540] 250[551]

Type of cylinder sleeve

Integral with cylinder block

Ol:>

No. of piston ring

Compression ring

2

~

0..

Oilring

1 (w/spring expander)

I:

Open BTDC 30° BTDC 18°

.e;

InIet valve

a

<Ll

Valve timing

Close

ABDC 50°

ABDC 54°

I:

·So

Open BBDC 74°

BBDC 66°

I:

Exhaust

valve

p:l

Close ATDC 30°

ATDC 22°

Starting system

Electric-starter

Starting aid

G10wplugs

"0_",

Air cleaner Type

Paper-element

§~e

"t).2

*

Turbocharger

Model TD04HL

-><>-.

-

~lUtI'.:l

Type

Force feed by oil pump

Specification

Class CD oil (API Service Classification)

Engine oil

Capacity (engine) Approx. 10 [2.6]

liter [U.S. gal] (Oil pan: 9 [2.4], Filter: 1 [0.3])

Type

Trochoid

a

Speedratioto

crankshaft

0.74

~

Oil pump

Ol:>

Capacity

28.6 [7.6] at 0.3MPa (3 kgf/cm") discharge pressure

;>,

Ol:>

I:

liter [U.S gal] of pump running at 2 230 min:'

0

.~

Type

Piston valve

u

·C

Re1iefva1ve

Opening pressure

..0

::l

0.35 ± 0.05 (3.5±0.5) [50±7]

....:l

MPa (kgf/cm") [psi]

Oil Cooler

I

Water-cooled

Type

-

multi-plate

Oil filter

Type Cartridge of paper element

Safety valve

Opening pressure

-

I

1.1

(11)

[156]

MPa (kgf/cm") [psi]

1-7

GENERAL

Model designation

S4S S4S-DT

Refill capacity (engine water jacket)

5.5 [1.5] 5 [1.3]

liter [U.S. gal.]
Type Centrifugal

Water

pump

Speedrationto

crankshaft

1.3

Ei

Capacity 160 [42.3] at 0.075 MPa [0.75 kgf/cm'] discharge pressure

2

liter [U.Sgalj/min/mirr'

of

pump running at 3600

min'

'Jl

;>,

'Jl

Fan belt

Type Low-edge B type V-belt x 1

eo

.S

Type Wax pellet

0

0

Thermostat

U

Valve

opening

temperature

°C

[OF]

76.5±1.5 [170±2.7]

Type Pusher (PP)

Fan

No.ofblade

6

Diameter

mm [in.]

440 [17.3]

Type Bosch A

Injection

pump

Diameter of plunger

7 [0.276] 9 [0.354]

mm [in.]

Type Bosch, piston

Feedpump

Cam

lobe lift

8 [0.315] 9 [0.354]

mm [in.]

Ei

Governor

Type Bosch RSV, centrifugal

2

co

;>,

Typeofnozz1e

Bosch throttle Bosch hole

'Jl

Q)

No.ofspray orifice

1 4

::l

~

Diameterof sprayorifice

1.0 [0.039]

0.28 [0.011] (for D/G)

Injection nozz1e

mm [in.]

0.24 [0.009] (for Power Unit)

Sprayangle

0° 155°

Valve opening pressure

11.77

(I20)

[1707] \7.65 (I 80) [2561]

MPa

(kgf/cm") [psi]

Fuel filter Type Cartridge of paper element

Ei

Voltage - polarity 12V - e ground

2

Model M008T75171

'Jl

;>,

'Jl

Type

Pinion shift

ë<i

Cl

Starter Output

V-kW

12 - 2.2

'5

Cl

Cl)

No.ofpinion teeth/

ü3

flywheel ring gear teeth

lO/l22

1-8

GENERAL

Model designation

S4S

I

S4S-DT
Type 3-phase, with rectifier
Output

V-A

12-50

Working

speed

min:'

1000 to 18000

Altemator

Rated output generating

5000

Ei

speed

min:'

s

<IJ

Maximum

perrnissib1e>-.

22000

co

C;;

speed

min:'

o

oE

Speed ratio to crankshaft 2.0

o

Il.l

iii

Type

Sheathed

G10w plug

Rated voltage - current Direct injection: 11

- 5.5 (30 sec. rating)

V-A

Swir1 chamber: 10.5 - 9.7 (30 sec. rating)

Stop solenoid

Rated voltage V 12

(option)

Rated temp.

oe

[OP]

20 [68]

1-9

GENERAL

Model designation

S6S

S6S-DT

Type

Water-cooled, 4-stroke cycle

No. of cylinders

- arrangement

6-in

line

Combustion chamber type

Swirl chamber Direct injection

Valve mechanism

Overhead

Cylinder bore x stroke mm [in.]

94 x 120 [3.70 x 4.72]

Piston displacement liter [cu in.]

4.996 [305]

~

Compression ratio

22:

1

17:

1

...

Q)

:::

Firing order

I - 5

- 3 - 6 -2-4

Q)

Cl

Direction of rotation

Counterclockwise as viewed from flywheel side

Overall length

1033 [40.7] SG type, 1029 [40.5] SP type

mm[in.]

Dimension

Overall width

593 [23.3] 626 [24.6]

rum [in.]

Overall height

748 [29.4] 896 [35.3]

mm[in.]

Weight (dry) kg [Ib]

340 [750] 350 [772]

Type of cylinder sleeve

Integral with cylinder block

I!J

No. of piston ring

Compression ring

2

...

0::1

Oil ring I (w/spring expander)

0..

:::

Open

BTDC 30° BTDC 18°

.;:;

Inlet valve

8

Q)

Valve timing

Close

ABDC 50° ABDC 54°

:::

·öo

Open BBDC 74°

BBDC 66°

:::

Exhaust

valve

"'-l

Close

ATDC 30° ATDC 22°
Starting system Electric-starter
Starting aid

Glow plugs

"0_",

Air cleaner Type

Paper-element

a~E

~~*

Turbocharger Model

TE06H

-><>,

-

,.5CUoZl

Type

Force feed by oil pump

API

Service

Classification

CD

Engine oil

Refill capacity

Whole system: Approx. 12 liters [3.2 U.S. gal];

liter [U.S. gal.] Oil pan: II liters [2.9 U.S. gal]; Filter: I liters [0.3 U.S. gal]

Type

Trochoid

8

Speedratioto crankshaft

0.74

2

Oil pump

<J)

Capacity 38.7 [10.2] at 0.3 MPa (3 kgf/cm') discharge pressure

>.

<J)

e

liter [U.S gal]/min

of pump running at 2230

min'

0

.~

Type

Piston valve

o

Oil pressure

.e:

Opening pressure

.D

relief valve

::l

0.35±0.05 (3.5±0.5) [50±7]

....:l

MPa (kgf/cm") [psi]

Oil Cooler Type

Water-cooled

-

multi-plate

Oil filter Type Cartridge of paper element
Safety valve

Opening pressure

-

1.1(11)[156]

MPa (kgf/cm') [psi]

1-10

GENERAL

Model

designation

S6S

S6S-DT

Refill

capacity

(engine water jacket)

9 [2.4]

8 [2.1]

liter [U.S. gal.]

Type Centrifugal

Water

pump

Speedrationto

crankshaft

1.3

Ei

Capacity 160 [42.3] at 0.075

MPa

[0.75 kgf/cm"] discharge pressure

B

liter [U.S

gall/rnin/mirr'

of

pump

running at 3600 min'!

CI:l

;>,

CI:l

Fan belt Type

Low-edge B typeV-belt x I

en

.5

Type Wax pellet

Ö

0

Thermostat

U

Valve

opening

temperature

°C

[OF]

76.5±1.5 [170±2.7]

Type Pusher (PP)

Fan

No.

of

blades

7

Diameter mm [in.]

500

[19.7]

Type

Bosch A

Injection

pump

Diameterofplunger

7 [0.276] 9 [0.354]

mm[in.]

Type Bosch, piston

Feed

pump

Cam lobe lift

8 [0.315]

9 [0.354]

mm [in.]

Ei

Governor

Type Bosch RSV, centrifugal

B

CI:l

;>,

Typeofnozzle Bosch throttle Bosch hole

CI:l

03

No.of dischargeorifice

I

4

;:l

"'"

Diameterofdischarge

1.0 [0.039]

0.28 [0.011] (for

D/G)

Injection

nozzle

orifice

mm [in.]

0.24

[0.09] (for

Power

Unit)

Discharge angle 0°

155°

Valve opening pressure

11.77

17.65 (180) [2561]

MPa

(kgf/cm') [psi]

(120) [1707]

Fuel filter

Type Cartridge

of

paper element

Ei

Voltage -

polarity

12V - 8 ground

B

Model

M008T5027I

CI:l

;>,

CI:l

Type Pinion shift

ca

o

Starter Output

V-kW

12 - 3

"5

o

<I)

No.ofpinion teeth/

W

flywheel ring gear teeth

10/122

1-11

GENERAL

Model designation

S6S

I

S6S-DT
Type 3-phase, with rectifier
Output

V-A

12

-50

Working speed

min-I

1000 to 18000

a

Altemator

Rated output generating

5000

B

speed

min-I

'"

>.

Maximum permissible

'"

22000

'<'J

speed

min-I

.~

::

Speedratio tocrankshaft 2.0

o

<l.l

m

Type Sheathed

Glow plugs Rated voltage- current Direct injection:

11- 5.5 (30 sec. rating)

V-A

Swirl chamber: 10.5

-9.7

(30 sec. rating)

Stop solenoid Rated voltage V

12

(option) Rated temp.

°C

[OF]

20 [68]

1-12

3. Tips on Disassembly

and

Reassembly

This

service

manual

covers

recommended
procedures to be followed when servicing diesel
engines. It also contains information on special
tools required and basic safety precautions.

It is the responsibility

of

service personnel to be

familiar with these requirements, precautions and

potential hazards and to discuss these points with
their foreman or supervisor.

Study this manual carefully and observe the
following general precautions to prevent serious
personal injury and to avoid

damagetothe

engine, equipment and parts.

3.1 Disassembly

(1) Use the correct tools and instruments. Serious

injury or damage to the engine can result from
using the wrong tools and instruments.

(2) Use an

overhaul

standorwork

bench

if
necessary. Also, use assembly bins to keep the
engine parts in order of removal.

(3) Lay down disassembiedorc1eanedparts in the

order in which they were removed. This will
save you time at reassembly.

(4) Pay attention to the marks on

assemblies,

components and parts for positionsordirections.
Put on your own marks, if necessary, to aid
reassembly.

(5) Carefully

check

each part for faults during

removal or cleaning. Signs of abnormal wear

will tell if parts or assemblies are functioning
improperly.

(6) When

liftingorcarrying

heavy

parts,

get
someone to help you if the part is too awkward
for one person to handle. Use jacks and chain
blocks when necessary.

GENERAL

3.2 Reassembly

(1)

Wash all engine parts, except oilseals,O-rings,

rubber seals, etc. in c1eaning solvent and dry
them with compressed air.

(2) Use only the correct tools and instruments.

(3) Use only

good

quality lubricating oils and
greases. Be sure to apply a coat of oil, grease,
or sealanttoparts as specified.(Referto section
3, of Group 2, "Maintenance Standards".)

(4) Use a torque wrench to tighten parts when

specified tightening torquesare required.(Refer
to

section2,of

Group2,"Maintenance

Standards".)

(5)

Replace

all

gaskets

and

packing.

Apply
appropriate amountof adhesiveor liquid gasket
when required.

1-13

MAINTENANCE STANDARDS

1. Maintenance Standards Table 2- 2

2. Tightening Torques , 2- 9

2.1 Important Bolts and Nuts 2- 9

2.2 Standard Bolts 2-10

2.3 Standard Studs 2-10

2.4 Standard Plugs .. 2-10

3. Sealants and Lubricants Table

2-11

MAINTENANCE STANDARDS

1. Maintenance Standards Table

Unit: mm [in.]

Nominal

Assembly

Standard

Repair

Service

Group Inspeetion Point

Limit

Limit Remark

Value (Standard Clearance)

(Clearance)

(Clearance)

Maximum min-I, (no-load)

According to engine

Adjust governor

Minimum min", (no-lead)

specification setting.

DI

2.9 (30) [427]

2.6
Oil and water temp.

Compression

at 300 min:'

(27) [384]

20 to

30°C

pressure

3.2 (33) [469]

2.8

[68 to 86°F]

Ml'atkgf/cm') [psi]

SC

at 300 min-I

(29)

[413]

0.3 to 0.5 (3 to 5) [43 to 71] 0.15 (1.5)
üil

temperature

Engine oil pressure

at 1500 min:'

[21.3]

70 to 90°C

0.1

(1) [14.2] or

more

at

0.05

(0.5)

[158 to 194°F]

MPa (kgf/cm") [psi] idling [7]

DI SC

Inlet

valves open

BTDC

18°

BTDC

30°

C;

Valve timing

Inlet

valves close

ABDC

54°

ABDC

50°

....

Exhaust

valves open

BBDC

66°

BBDC

74°

(1)

c

Exhaust

valves close

ATDC

22°

ATDC 30°

(1)

c

± 3°

(crank

angle) ± 3° (crank angle)

Valve clearance (cold)

Both

in1et and exhaust

0.25 [0.0098]
valves

The

timing for each

model

of

engine varies

according to its speci-

Fuel injection timing fication. Be sure to

verify the timing by
referring to the speci-

fications

of

each

model.

Push beIt inward with

V-belt deflection 12 [0.5], approx.

thumb

pressure and

measure

deflection.

,

"""'(1)

Warpage of gasket 0.05 [0.0020]

0.20

Regrindifwarpage

<=:",

~~

contact surface

or 1ess [0.0079]

is minor.

Uu

Inside diameter

94

94,000 to 94,035

94.200 94.700 Refinish cylinder to

...

[3.70] [3.7008to 3.7022]

[3.7087]

[3.7283] 0.25 [0.0098] or 0.50

(1)

[0.0197] oversize of

"0

0.01 [0.0004]

.5

Circularity

>..

or less

normal value by

U

honing and use the

Taper

0.015 [0.0006]

same

oversize pistons

(1)

or less

and piston rings.

'"

<:Il

u

~

If repair limit is

<=:

<:Il

reached, replace

...

U

-0.09

bearings.Ifis

01)

<=:

[-0.035] exceeded, regrind

.t:

Clearance between

(0.050 to 0.110)

~

(0200)

asjoumal

journals

and

use(1)

.D

bearing and journal ([0.0020 to 0.0043]) ([0.0079])

diameter undersize bearings.

<=:

'ca

which is Bearing undersizes:

::E

78 [3.07]

0.25 [0.0098]

0.50

[0.0197]

0.75 [0.0295]

DI - Direct injection SC - Swirl chamber

2-2

MAINTENANCE STANDARDS

Unit: mm [in.]

Nominal Assembly Standard

Repair

Service

Group Inspeetion Point

Limit Limit

Remark

Value (Standard Clearance)

(Clearance) (Clearance)

~

14.000 to 14.018 14.100

...

Inside diameter

0

..0

[0.5512 to 0.5519]

[0.5551]

Q)

0..

Clearance between

(0.016 to 0.052) (0.08)

If

it exceeds the repair

0..

~

tappet and bore

([0.0006 to 0.0021)) ([0.0031))

limit, replace tappets.

~

Front (0.070 to 0.118)

'"

and

([0.0028 to 0.0047))

<Il

If it exceeds the repair

~

~

midd1e

(without bushings)

(0.15) limit, refinish bores

§

5

...

..0

Clearance

(0.070 to 0.110) ([0.0059)) and install bushings,

U

~

between

<Il

Rear ([0.0028 to 0.0043)) or replace camshaft.

..0

camshaft

co

(without bushings)

a

journa1 and

<Il

U

(0.040 to 0.119)

If

it exceeds the repair

bore

(0.15)

([0.0016 to 0.0047))

([0.0059))

limit, rep1acebushings.

(with bushings)

Ream if necessary.

'0

Warpageofgasket 0.05 [0.0020]

0.20

Regrind if warpage is

<Il

<)

..c

contact surface

or less

[0.0079]

minor.

...

<)

'0

Compressed thickness

1.2

±0.05

.5

>-,

of gasket [0.05]

[±0.002]

U

Diameter

Inlet

7.940 to 7.955 7.900

va1ve

8 [0.3126 to 0.3132]

[0.3110]

~

ofva1ve

'0

Exhaust

[0.31]

7.920 to 7.940 7.850

'5 stern

co

va1ve

[0.3118 to 0.3126] [0.3091]

~

;>

(;J

Clearance

Inlet (0.065 to 0.095) (0.150)

;>

'0

between

valve

([0.0026 to 0.0037))

([0.0059])

=

<Il

guide and

Exhaust

(0.080 to 0.115)

(0.200)

~

;>

stern

va1ve

~

([0.0032 to 0.0045))

([0.0079))

Height to top

of

11.5
±0.1 [±0.004]

va1veguide

[0.45]

'0

Ang1e

30°

<Il

~

..0

Inlet 0.4

...

~

~

Valve

va1ve [0.016]

1.0

'0

±0.1 [±0.004]

.:::

sinkage [0.039]

è

;;,

ê<I

Exhaust

0.5

':l

U

~

va1ve'"[0.020]

~

;>

1.8

~

Width

IA

±0.14 [±0.0055]

Valve

[0.055] [0.071]

margin

Valve seat

Va~e

Up to 1.83

angle

sin age

Valve margin

2.13 [0.0839]

[o.onO] by

refacing

Free length

48.85 47.60

[1.92] [1.87]

eo

Squareness of ends

=

Squareness 1.50or less with respect to center

.t::

0..

line

'"

~

;>

Set length 43 [1.69]

~

Set force

176 to 196

147

N (kgf) [lbf]

(18 to 20)

(15)

[40 to 44]

[33]

2-3

MAINTENANCE 8TANDARD8

Unit: mm [in.]

Nominal

Assembly Standard

Repair

Service

Group Inspeetion Point Limit

Limit Remark

Value

(Standard Clearance)

(Clearance)

(Clearance)

Inside diameter

of

19.010 to 19.030

S

rocker bushing

19

[0.7484 to 0.7492]

"0

a

Diameter of rocker

[0.75]

18.980 to 19.000

....

0::1

Q.}

Q.}

~

shaft [0.7472 to 0.7480]

.!:

u

à:3

0

"0

0:::

Clearance between

(0.010 to 0.050)

(0.070)

.S

;;.,

bushing and shaft

([0.0004 to 0.0020)) ([0.0028))

U

"0

Q.}

0

0.3 [0.012]

1/2

of

dial indicator

;;.-

....

Deflection

~

.!:

'"

or less

reading

:::s

0..

Deflection

0.02 [0.0008]

0.05

or less [0.0020]

Journal

78

77.955 to 77.970

77.850

77.100

diameter [3.07]

[3.0691 to 3.0697]

[3.0650]

[3.0354]

Crankpin

58

57.955 to 57.970

57.800

diameter [2.28] [2.2817 to 2.2823] [2.2756]
Center to center

60

distance between ±0.04 [±0.0016]

journal and crankpin

[2.36]

Parallelism between

Runout:

0.01

[0.004]

journal and crankpin

or

less

(over

crankpin

length)

<:i=:

Circularity of

""

journal and crankpin

.c

0.01 [0.0004]

0.03

'"

~

Taperofjournal and

or less [0.0012]

""

....

U

crankpin
Fillet radius

of

journal

3

±0.2 [±0.008]

.'!i

and crankpin [0.12]

....

0::1

If thrust plate clearance

0..

eo

exceeds the repair limit,

I:

.;;

replace thrust plates.

0

S

33

(0.100 to 0.264)

(0.300)

If it is exceeded, use

:::

End

play oversize thrust plates.

'ca

[1.30]

([0.0039 to 0.0104))

([0.0118))

::E

Thrust plate oversizes:

0.15 [0.0059]

0.30 [0.0118]

0.45 [0.0177]

....

93.955 to 93.985 93.770

Q.}

Standard

d)

[3.6990to

3.7002]

[3.6917]

S

~

0::1

....

0.25 [0.0098] 94 94.205 to 94.235 94.020

:a~

Q.}

'"

oversize [3.70] [3.7089to

3.7100]

[3.7016]

:9

:g

'"

"El

0.50 [0.0197] 94.455 to 94.485

94.270

I:

0

oversize

[3.7187to3.7199]

[3.7114]

.8

'"

p::;

DI

0.05 to 0.45

Protrusion

[0.0020 to 0.0177]

Check bearing

-0.25

to 0.15

clearance.

SC

[-0.0098 to 0.0059]

Clearance between

(0.000 to 0.016)

(0.050)

piston pin and bore ([0.0000 to 0.0006))

([0.0020]

Piston weight

5g[0.180z]

difference per engine

orless

DI - Direct injection SC - Swirl chamber

2-4

MAINTENANCE STANDARDS

Unit: mm [in.]

Graup

Inspeetion Point

Repair Service

Nominal Assembly Standard Limit Limit

Value (Standard Clearance) (Clearance) (Clearance)

Remark

1.50

[0.0591]

(0.200)

([0.0079])

(0.150)

([0.0059])

(0.150)

([0.0059])

0.30 to 0.50

[0.0118 to 0.0197]

(0.07 to 0.11)

([0.0028to 0.0043])

(0.045 to 0.085)

([0.0018to 0.0034])

(0.025 to 0.065)

([0.0010to 0.0026])

2.0

[0.079]

4.5

[0.177]

No.1 ring

No.2 ring

Gil ring

~

g]

No.

1,2

rings

~

~

-

~

Gil

ring

U]

I::

Q) Cl)

~

.S

v~f-----~---+':':--------::+-----j-':'::------=':+----------j

..0

I::

Q) o:l

U Q)

§>t-------j-"--..........::.-+--------..........::.+----+-----+-----------i

~

g

~

5i:J

U

"0

o

...

Cl)

.S

~

I::
I::

o

U

Diameter

Clearance between
pin and bushing

Inside diameter

of

bushing

Bend

and twist

Clearance between
crankpin

and

conneet-

ing rad bearing

Endplay

30

[U8]

30

[U8]

33

[1.30]

29.994 to 30.000
[l.l809 to

l.l8

II]

(0.020 to 0.051)

([0.0008to 0.0020])

30.020 to 30.045
[l.l819 to l.l829]

0.10/100

[0.0039/3.94]

or less

(0.030 to 0.090)

([0.0012to 0.0035])

(0.15 to 0.35)

([0.0059to 0.0138])

0.15

[0.0059]

(0.080)

([0.0032])

(0.200)

([0.0079])

(0.50)

([0.020])

Replace connecting
rad.

Rad

weight difference

per

engine

JO

g [0.35 oz]

orless
Flatness
Face runout

Deflection

0.15 [0.0059]
or less

0.02 [0.0008]
or less

0.50

[0.020]

0.05

[0.0020]

Straighten by cold
working or replace.

DI

U

E

o:l

U

Inlet
valve

SC

DI

Exhaust
valve

SC

A

=46.918:'2)

[1.847:ti~1

A=

46.916:'2)

[1.8471:'2~1

A=

46.878::;N

11.8456:'2~1

A=

46.880:'2)

[1.8457:'2~1

6.682

[0.2631]

6.684

[0.2632]

6.722

[0.2647]

6.720

[0.2646]

6.182

[0.2434]

6.184

[0.2435]

6.222

[0.2450]

6.220

[0.2450]

Tcr

B

No.l,

2 (S4S)

No.l,

2,3

(S6S)

No.3 (S4S)
No.4

(S6S)

54

[2.13]

53

[2.09]

53.94 to 53.96

[2.1236 to 2.1244]

52.94 to 52.96

[2.0842 to 2.0850]

53.90

[2.1220]

52.90

[2.0827]

End

play

5

[0.20]

(0.JOto 0.25)

([0.0039 to 0.0098])

(0.30)

([0.0118])

Replace thrust plates.

2-5

MAINTENANCE STANDARDS

Unit:mm

[in.]

Nominal Assembly Standard

Repair

Service

Group

Inspeetion Point

Limit

Limit

Remark

Value (Standard Clearance)

(Clearance) (Clearance)

Clearance between

(0.009 to 0.050) (0.100) Replace bushing.

shaft and bushing ([0.0004 to 0.0020]) ([0.0040])

~

30

(0.05 to 0.20) (0.35)

til

<l.l

End play

...

co

Replace thrust plates.

t'l

[1.18]

([0.0020 to 0.0079])

([0.0138])

<l.l

...

co

<l.l

co

::a

Fit (interference) of

l:

......

ï§

bushing in crankcase

30

(0.035T to 0.076T)

~

bore

[1.18]

([0.0014Tto0.0030T])

Backlash

(0.03 to 0.18) (0.25)

Replace gears.

([0.0012 to 0.0071]) ([0.0098])

Clearance between (0.20 to 0.30) (0.50)
outer rotor and case ([0.0012 to 0.0018]) ([0.0197])

Diameter of main

16 15.985 to 16.000

shaft (case side) [0.63]

[0.6293 to 0.6299]

Diameterof mainshaft

14 13.957 to 13.975

(oilpump bushingside) [0.55]

[0.5495 to 0.5502]

0..

Clearance between (0.032 to 0.074) (0.15)

Replace

pump

case

E

::>

main shaft and case ([0.0013 to 0.0029]) ([0.0059])

or pump assembly.

E

0..

.2

(5

Clearance between

til

(0.025 to 0.111) (0.200)

Replace bushing or

;..,

main shaft and oil

til

l:

pump bushing

([0.0010 to 0.0044]) ([0.0079])

pump assembly.

0

.~

.::l Clearance between

(0.13 to 0.15) (0.20)

...

..0

outer and inner rotors ([0.0051 to 0.0059]) ([0.0079])

::I

....l

Clearance between

(0.04 to 0.09)

(0.15)

Replace

cover

or

rotors and cover ([0.0016 to 0.0035]) ([0.0059])

case.

Valve

0.35±0.05

Reliefvalve

opening

(3.5±0.5)

[50±7]

pressure,

Safety valve

MPa

(kgfïcm')

1.1 (11) [156]

With oil

cooler

[psi]

E

g

Temp. at which valve

76.5±I.soC

.2

til

starts opening [170±2.7°F]

;..,

til

til

0

co

E

Temp. at which valve

.=

...

<l.l

lift is more than 8 90°C [194°F]

0

.J::

E-<

0

[0.3]

U

2-6

MAINTENANCE STANDARDS

Unit: mrn [in.]

Nominal

Assembly Standard

Repair Service

Group Inspeetion Point

Limit

Limit Remark

Value (Standard Clearance)

(Clearance)

(Clearance)

17.65

18.14 to 19.12

Make

shirn adjustrnent.

DI

(180)

(l85

to 195)

Pressure varies by I

Valve opening

[2560]

[2632 to 2774]

(l0)

[142] per 0.1 mrn

pressure

11.77

II.77to

12.75

[0.004 in.] thickness

MPa

(kgf/cm')

SC

(120)

(l20

to 130)

ofshim.

[psi]

[1706]

[1707 to 1849]

Cl)

Test by meansofhand

a

N

N

DI

155°

tester, using diesel

s

0

'fJ

I:::

fuel, at 20°C [68°P]. If

>-.

I:::

o:

.S

Spray cone

Q)

Ü

angle

discharge pattern is

&;

Cl)

bad even after nozzle

ï?

.....

SC

0°

is washed in clean
diesel fuel, replace
nozzle tip.

Seat shallhold a testpressure

üil

tightness of

2 MPa (20

kgf/cm")

Wash or replace

needie valve seat

[284psi] lower thanvalve nozzle tip.

opening pressurefor 10seconds.

Diameter of

32

31.4

commutator [1.26] [1.24]
Runout of

0.03

0.\

commutator [0.0012]

[0.004]

Depth of

0.4

to 0.6

0.2 [0.008]

[0.016 to

commutator mold

0.024]

or less

Length

18

11

[0.71] [0.43]

~

Brush

Spring 30.4

19.6

a

""

force,

to 38.2

(2.0)

2:l

N

N (kgf) (3.1to 3.9)

'fJ

M

[4.4]

>-.

[Ibf]

[6.8to8.6]

'fJ

I

C;; :>

Thrust clearance of 0.5

u

N

oor more

OE

-

pinion shaft [0.020]

u

'-'

<1)

...

G:l

~

0.5 to 2.0

en

Pinion clearance

[0.020 to

0.079]

No-load characteristics

Locked

characteristics Magnetic switch

Voltage

Current

Speed Voltage Current

Torque

Switch-in

Nrn (kgf-m)

V A

min:'

V

A

[lbfft]

voltage V

130

3800

1120

31.36 (3.2)

11

3

[23.1]

8 or Iess

or less or

more

or less

or more

DI - Direct injection SC - Swirl chamber

2-7

MAINTENANCE 8TANDARD8

Unit: mm [in.]

Nominal

Assembly Standard

Repair

Service

Group

Inspeetion Point

Limit

Limit

Remark

Value (Standard Clearance)

(Clearance)

(Clearance)

Diameter

of

38.7

38.1

commutator

[1.S2]

[I.SO]

Runout

of

0.03

0.1

commutator

[0.0012]

[0.004]

Depth

of

004

to 0.6

0.2 [0.008]

[0.016 to

commutator

mold

0.024]

or Iess

Length

17

11

[0.67]

[0.43]

,-..

Brush

Spring

33.3

17.7

~

force,

to

4S.1

..;.:

N (kgf) (3.4to 4.6)

(1.8)

c<)

[4.0]

I [Ibf] [7.5to

10.1]

Ei

>

Thrust clearance

of

O.S

~

C'1

oor more

on

-

pinion shaft

[0.020]

>-.

'-"'

on

....

-a

~

O.S

to 2.0

o

l§

oE

CZJ

Pinion clearance [0.020 to

()

0.079]

Il.l

~

No-laad

characteristics Locked characteristics Magnetic switch

Voltage

Current

Speed

Voltage

Current

Torque

Switch-in

Nrn

(kgf.m)

V

A

min:'

V

A

[lbf.ft]

voltage V

180

3800

lOS0

2S.0(2.S5)

11 2

[1804]

8 or less

or less or more

or less

or more

~

Brush spring 3.0 to 4.2

2.1

0

force, (310 to 430)

(210)

lr)

I

>

N (gf) [Ibf] [0.7 to 0.9]

[0.5]

N

'-"'

Brush height

18.S 7

....

[0.73]

[0.28]

~

E

Resistance in

B

2AQ

at 20°C [68°F]

~

slip rings

2-8

2. Tightening Torques

2.1 Important Bolts and Nuts

MAINTENANCE 8TANDARD8

Thread Width

Tightening Torque

Description

Dia. x Pitch

across flats,

Remark

(M-thread) mm

N·m

kgf-rn

IbHt

Cylinder head

M12 x 1.75

19 113 to 123

11.5 ta 12.5

83 ta 90

Rocker cover M8 x 1.25

12

10.0 to 13.0 1.0 ta 1.3

7.23 to 9.40

Rocker shaft brackets M8 x 1.25

12

10.0 ro 20.0 1.0 to 2.0 7.23 ta 14.5

Main bearing caps

M14x2

22

98 to 108

10.0 to 11.0 72 ta 80

Connecting rod caps

MlO

x 1.25

14

49.0 ta 59.0 5.0 to 6.0 36.2 ta

43.4

Flywheel

M12x

1.25

17 78.5 ta 88.3

8.0 ta 9.0 57.9 to 65.1

Camshaft thrust plate

M8 x 1.25

12 10.0 to 13.0 1.0 ta 1.3 7.23 ta

9.40

Front plate

M8 x 1.25

12 10.0 ta 13.0

1.0 to 1.3 7.23 to

9.40

Timing gear case M8 x 1.25

12 10.0 ta 13.0

1.0 to 1.3 7.23 to 9.40

Crankshaft pulley

M30

x 1.5

46 480 to 500

49 ro 51 354 to 369

Idler gear thrust plate

MlO x 1.25

14 29.0 to 39.0

3.0 to 4.0 21.7 ta 28.9

Oil pan

M8 x 1.25

12 10.0 to 13.0 1.0 ta 1.3 7.23 ro

9.40

Press product

Cast oil pan

Oil pan

M8 x 1.25

12 27.5 ta 33.4 2.8 to 3.4 20.3 to 24.6 for agricul-

tural tractor

Rear plate

MlO

x 1.25 14 54.0 ta 65.7 5.5 ta 6.7 39.8 to 48.5

Agricultural

tractor use

Oil pan drain plug

M14

x 1.5

22 34.0 ta 44.0

3.5 to 4.5

25.3 to 32.5

M20x

1.5

24 73.0 to 83.0 7.5 to 8.5

54.2 to 61.5

Fuel injection nozzle

M8 x 1.25

12 21.0 ta 23.0

2.0 ta 2.4 14.5 to 17.4

glands (direct injection type)
Fuel injection nozzles

M20x

1.5

21 53.0 to 64.7

5.4 ta 6.6 39.1 ta 47.7

(swirl chamber type)
Fuel injection pump

22 34.0 to 39.0

3.5 to 4.0 25.3 ta 28.9

delivery valve holders
Fuel leak-off pipe nut

M12

x 1.5

17 20.6 to 24.5

2.1 ta 2.5 15.2 ta 18.1

Fuel injection pump gear

M14

x 1.5

22 76.5 to 86.3

7.8 ta 8.8

56.4 to 63.7

(distribution type)
Fuel injection pump gear

(in-line, swirl chamber type)

M12

x 1.75 19 58.8 ta 68.6 6.0 ta 7.0 43.4 ta 50.6

(in-line, direct injection type)

M14

x 1.5

22 83.4 to 98.0 8.5 to 10.0 61.5 ta 72.3

Glow plug
(swirl chamber type)

MlO

x 1.25

12

15.0 to 20.0 1.5 to 2.0 10.8 ta 14.5
(direct injection type) M12 x 1.25 12 20.0 to 30.0 2.0 ta 3.0 14.5 to 21.7
(terminal)

M4xO.7

8

1.0 ta 1.5 0.10 ta 0.15 0.72 ta 1.08

Exhaust manifold
(balt only) M8 x 1.25

12 27.5 to 33.3

2.8 ta 3.4 20.3 to 24.6

(with spacer) M8 x 1.25

12 15.0 to 22.0

1.5 ta 2.2

10.8 to 15.9

Oil pressure reliefvalve

M22

x 1.5

27

44.1 ta 53.9 4.5 to 5.5

32.5

to 39.8

Safety valvearblind plug M18

x2

24 64.0 to 74.0 6.5 to 7.5 47.0 to

54.2

Coolant drain plug 1/4 - 18NPTF 14 35.3 to 43.1

3.6 to 4.4

26.0 ta 31.8

Fuel injection pipe nuts

M12

x 1.5

19 26.5 to 32.4 2.7 to 3.3 19.5 ta 23.9

Fuel return pipe nuts

MlO

x 1.25

14 17.7 ta 21.6

1.8 to 2.2 13.0 ta 15.9

Oil pump gear

MlO

x 1.25 14 28.0 ta 38.0 2.9 ta 3.9 21.0 to 28.2

2-9

MAINTENANCE STANDAROS

Thread Width

Tightening Torque

Description Dia. x Pitch across flats,

Remark

(M-thread)

mm

N·m

kgf-m lbf-ft

Overheat warning unit

M16 x 1.5 19 20.6 to 24.5

2.1 to 2.5 15.2 to 18.1

(thermostat)
Starter terminal B M8 x 1.25 12 9.81 to 11.8 1.0 to 1.2

7.23 to 8.68

Plug

M16 x 1.5 24 39.2 to 49.0

4.0 to 5.0 28.9 to 36.2 Cylinder head

Balancer

M8 x 1.25

12

27.5 to 33.4

2.8

to 3.4 20.3 to 24.6

Fuel injection

pump

M12 x 1.0

17

16.0 to 23.0 1.6 to 2.3

11.6

to 16.6

feed pipe (flare)

Fuel injection

pump

eye bolt

M14x

1.5 22 15.0 to 20.0

1.5 to 2.0 10.8 to 14.5

Fuel injection

pump

17

15.0 to 20.0

1.5 to 2.0 10.8 to 14.5

overflow valve

Oil level sensor

1-1/16-12

24 49.0 to 58.8

5.0 to 6.0 36.2 to 43.4

2.2

Standard

BoUs

Thread

Diameter

Torque

(mm)

4T

7T

N·m

kgf-rn lbf-ft N·m

kgf-rn

Ibf-ft

M6

2.94 to 4.90 0.3 to 0.5

2.17t03.62

7.89 to 9.80 0.8 to 1.0

5.79 to 7.23

M8

9.80 to 12.7 1.0 to 1.3 7.23 to 9.40

14.7 to 21.6 1.5 to 2.2

10.8 to 15.9

MlO

17.7t024.5

1.8 to 2.5

13.0 to 18.1 29.4 to 41.2

3.0 to 4.2

21.7 to 30.4

M12

29.4 to 41.2 3.0 to 4.2

21.7 to 30.4 53.9 to 73.5 5.5 to 7.5 39.8 to 54.2

2.3

Standard

Studs

Thread

Diameter

Torque (tap end)

(mm)

Fordriving in aluminummaterials

Fordrivinginferrousmaterials

N-m

kgf-m

lbf-ft

N·m

kgf-rn lbf-ft

M8 4.90 to 5.90 0.50 to 0.60 3.62 to 4.34

11.8to 13.7 1.2 to 1.4 8.68 to 10.1

MlO

12.7 to 14.7 1.3 to 1.5

9.40 to 10.8 21.6 to 25.5 2.2 to 2.6 15.9 to 18.8

2.4

Standard

Plugs

Torque

Thread

Diameter

For aluminum materials

For ferrous materials

N·m

kgfm

lbf-ft N·m

kgf-rn lbf-ft

NPTF

1/l6

4.90 to 7.85

0.5 to 0.8 3.62 to 5.79

7.85 to 11.8 0.8 to 1.2 5.79

to 8.68

PT 1/8 7.85 to 11.8 0.8 to 1.2 5.79 to 8.68

14.7 to 21.6 1.5 to 2.2 10.8 to 15.9

PT 1/4,

NPTF

1/4 19.6 to 29.4 2.0 to 3.0

14.5 to 21.7 34.3 to 44.1 3.5 to 4.5 25.3 to 32.5

PT3/8

-

-

- 53.9 to 73.5

5.5 to 7.5 39.8 to 54.2

Remarks: 1.

The

torque values shown above are for the balts with spring washers.

2. Do not apply any oil to the bolt threads.

2-10

3. Sealants

and

Lubricants Table

MAINTENANCE STANDARDS

Apply to Mating part Sealant or Lubricant How to Use

üil

pan Crankcase Three Bond

12Ü?C

Apply to seal.

Rear bearing cap

Rear bearing cap Three Bond 1212

Apply to corners befare

seat on crankcase installing cap.
Side seals

Crankcase rear bearing cap

Three Bond 1212 Apply to side seals.

Cylinder head

Cylinder head Three Bond 1386D Apply to plug hole.

coolant hole plug
Crankcase coolant

Crankcase Three Bond l386D Apply to plug hole.

hole plug
Crankcase oil hole

Crankcase

Three Bond 1386D Apply to plug hole.

plug
Return oil hole

blind plug or pipe Crankcase Three Bond 1344 Apply to blind plug or pipe.
of crankcase

Crankshaft threads Crankshaft pulley nut Three Bond 1212

Apply to crankshaft thread before

tightening nut.

2-11

SPECIAL

rOOlS

Special

TooI

List 3-2

SPECIAL TOOLS

Special

Tooi List

Taal name

Valve spring pusher

Valve guide remave

Valve guide installer

Stem seal installer

Valve seat insert

caulking

taal

Piston ring pliers

Part No.

30691--04500

32A91--o0300

3

2A91--o0

100

32A91-10200

Inlet valve:

36791--00200

Exhaust valve:

34491-03020

31391-12900

Shape

Use

Valve spring removal/
installation

Valve guide removal

Valve guide installation

Valve stem installation

Valve seat installation

Piston ring removal/
installation

Piston installer

34491--00200

®

Piston installation

Idler shaft puller

MH061077 Idler gear shaft removal

3-2

SPECIALTOOLS

Tooi name Part No.

Shape

Use

Oil seal sleeve installer

30691-13010

set

Crankshaft rear oil seal sleeve
installation

Engine tuming

Compression pressure
measurement

Compression pressure
measurement

Compression pressure
measurement

58309-73100

Gage

adaptor 32A91-01100

(direct injection)

~

Gage adaptor

30691-21100

(swirl chamber)

~

Compression gage

33391-02100

Turning socket

Socket

34491-00300

Camshaft thrust plate and rocker
bracket installation

Connecting

rad

bushing puller

Camshaft bushing
instal1er set

MH061236

30691-00010

< ,

~

r

/-<~

j. / .,-'

Connecting rad bushing
rernoval/installation

Camshaft bushing removal!

installation

Oil

pump

bushing

instal1er

32A9]-00400

Oil pump bushing installation

3-3

OVERHAUL INSTRUCTIONS

1.

DeterminationofOverhaul

Timing

4-2

2.

Testing

the

Compression

Pressure

4-3

OVERHAUL INSTRUCTIONS

1. Determlnation of OverhaulTiming

In most cases the engine should be overhauled when
the engine's compression pressure is low. Other
factors that indicatethe necessity of engineoverhaul
are as follows:

(a) Decreased power

(b) Increased fuel consumption

(c) Increased engine oil consumption

(d)

Increased

blow-by

gas volume

through

the
breather due to abrasion at the cylinder liner and
the piston ring

(e) Gas leakage due to poor seating of the inlet and

the exhaust valves

(f)

Starting problems

(g) Increased noise from engine parts

(h) Abnormal color of exhaustgas from engine after

warm-up

Any one or a combination of these symptoms may
indicate thatengine overhaul is required. Of the items
listed above some are not directly related to the
necessity of engine overhaul. Items (b) and

(f)

are

more likely to be affected substantially by

• Injection volume of the fuel injection pump

• Fuel injection timing

• Wearofinjection-pump plunger

• Fitting of the injection nozzle

• Condition of electrical equipment: battery,
starter, or altemator

Item

(d)

above,

however,

requires

special
consideration becausedecreased pressure due to wear
at the cylinder liner and the piston ring is one

ofthe

most

obvious

signs

that

the

engine

requires
overhauling.
The most effective way to make a decision is by
testing the compression pressure; other factors are
to be considered secondarily.

4-2

2. Testlag the Compression Pressure

(1) Remove the injection nozzle from the cylinder

head where the compression pressure is to be
measured.

(2) On the direction injection type engine, attached

gage adaptor (32A9l-01100)tothecylinder, and
conneet thecompression gage (33391-02100) to

the adaptor.

On the swirlchambertype engine, attachthe gage
adaptor

(30691-21100) to the cylinder, and
conneetthecompression gage (33391-02100) to
the adaptor.

(3) Crank the engine by means of the starter, with

the governor stop lever pulled (the fuel supply
shut

off),

and

read

the

compression

gage

indication

when the

engine

running at the

specified speed.

(4)

If

the compression pressure is lower than the

repair limit, overhaul the engine.

r------

&CAUTION

1------

(a) Measure the compression pressure on all

cylinders.Itis

notagood

practice to
measure the compression pressure on only
few cylinders, andpresurnethe compression
on the remaining cylinders.

(b) Compression pressure varies with engine

speed. Check engine speed when measuring

the compression pressure.

Unit:

MPa

(kgf/cm") [psi]

Item

Assembly Repair

Standard Limit

Direct

2.9 2.6

injection

(30) (27)

Compression

[427] [384]

pressure

3.2 2.8

Swirl

(33) (29)

chamber

[469] [413]

.--------4

l

NOTE

Jr--------,

Measure the compression pressure with the
engine running at 300 min-I.

OVERHAUL INSTRUCTIONS

Measuring compression pressure (direct injection type)

Measuring compression pressure (swirl chamber type)

4-3

OVERHAUL INSTRUCTIONS

......-------i[&CAUTION

JI-------.

(a) Measure the compression pressure atregular

intervals to obtain correct data.

(b) The compression pressure will be slightly

higher

ina new or overhauled engine due to

new piston rings, valve seats, etc. Pressure
will drop gradually by the wear of parts.

4-4

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

1. Adjustments 5- 2

1.1 Valve Clearance 5- 2

1.2 Fuel System Bleeding 5- 3

1.3 Fuel Injection Timing 5- 4

1.4 No-load Minimum (Idling) Speed and Maximum Speed Setting 5- 5

1.5 V-belt Inspeetion and Adjustment 5-10

2. BenchTesting .. 5-11

2.1 Starting Up 5-11

2.2 Inspeetion After Starting Up 5-11

2.3 Bench Testing (Dynamometer) Conditions 5-11

2.4 Inspeetion and Adjustment After Bench Testing 5-11

3. Performance Tests 5-12

3.1 Engine Equipment Condition 5-12

3.2 Tests and Their Purposes 5-12

3.3 Other Inspections 5-12

3.4 Adjustment Engine Output 5-12

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

1. Adjustments

1.1 ValveClearance

Valve clearance should be inspected and adjusted
when the engine is cold.

Unit: mm [in.]

Item Assembly Standard

Valveclearance

InIet

0.25 [0.0098]

(cold setting)

Exhaust

(l)

Inspeetion

(a) Inspeet the valve clearance in the injection

sequence.Tocheck, turn thecrankshaft by the
specified crank angle in the normal direction
to bring the piston to the top dead center of
the compression stroke.

Injection sequence

Crank angle

S4S

1-3-4-2

180

0

S6S

1-5-3-6-2-4

120

0

(b) Put socket (58309-73100) and ratchet handle

on the crankshaft pulley nut and turn the
crankshaft in the normal direction (clockwise

as seen from the front end).

Unit: mm [in]

Width across flats of

crankshaft pulley nut

46

[1.81]

(c) The top dead center on compression stroke

ofNo.1piston is identified by the timing mark

"0" (on the crankshaft pulley) being aligned
with the pointer on the gear case. With the

pistonsopositioned, boththe inlet and exhaust

valverocker anns are not being pushed up by

their pushrods.

(d) Insert afeeIer gage in between the rocker arm

and valve cap, and check the clearance.

5-2

ol

I!

I I I I

1401

Checking va1veclearance (turning)

(2) Adjusting

(a) Loosen the loek nut of the adjusting screw.

Adjust the clearance by tuming the screw in
either direction to the extent that the gage is
slightly gripped between the rocker arm and
valve cap.

(b) After adjusting the clearance, tighten the loek

nut.Inspeet the clearance again and make sure
that it is correct.

1.2 Fuel System Bleeding

(l)

Fuel filter

(a) Loosen air vent plug on the fuel filter by

tuming it about 1.5 rotations.

(b) Unlock bleeding pump plunger by tuming it

counterclockwise, and operate the pump.

(c) Tighten the air vent plug when the fuel flows

without bubbles.

(2) Fuel injection pump

(a) Loosen air vent plug on the injection pump

by tuming it 1.5 rotations

(b) Unlock bleeding pump plunger by tuming

counterclockwise, and operate the pump.

(c) Tighten the air vent plug when the fuel flows

without bubbles.

,---------i(

&DANGER

11--

---,

When fuel overflows from the air vent plug, wipe

thoroughly with a cloth. Spilled fuel is a fire
hazard.

,----------1

NOTE

f----------,

If the vent plug is tightened before the bleeding
pump plunger is locked, fuel pressure acts on the

feed pump, making it difficult to restore the

plunger.

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

Adjusting valve clearance

Air vent plug

5-3

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

1.3 Fuel Injection Timing

The injection timing varies according to the output,
speed and specifications of the engine. Be sure to
verify the timing by referring to the specifications.

(1) Bringing the No.l cylinder piston to thetop dead

center on compression stroke

(a) Put socket (58309-73100) on the crankshaft

pulley nut and turn the crankshaft in the
normal direction (clockwise as seenfrom the
front end).

(b) Stop turning the crankshaft when the timing

the mark

"0"

on the crankshaft pulley is

aligned with the pointer.

(c) Push down on the inlet and exhaust valve

rockerarms fortheNo.l cylinder tomake sure
they are not being pushed up by the pushrods
(the inlet and exhaust valves have some
clearance).

(2) Checking injection timing

(a) Remove delivery valve holder from the No.l

plungerofthe

injection

pump. Remove
delivery valve and spring from the holder.
Restore the holder to the pump.

(b) Conneet a spare injection pipe to the No.1

plunger, with its free end held downward so
that you can observe the fuel flow from that
end.

(c) Turn the crankshaft to bring the No.1 piston

to 60° position before top dead center on

compression stroke.

(d) While operating the priming pump to allow

the fuelto flowfrom theinjectionpipe, slowly
turn the crankshaft in the normal direction.

Stop turningthe crankshaft when thefuelflow
stops.

(e) Make sure the timing mark on the crankshaft

pulley is aligned with the pointer.

5-4

Ol

I I I I I

14Ql

Finding top dead center on compression stroke

Delivery valve

hOlde'--t

"""'

Spring

Delivery valve

_.=

,,,-,

Checking injection timing - I

(Removing delivery valve)

Checking injection timing

- 2

(3) Adjusting injecting timing

(a) If the injection timing is retarded, move the

injection pump toward the crankcase. If the
timing is advanced, move the pump away
from the crankcase.

(b) One graduation of the scale on the injection

pump coupling changes the timing by 6° in
terms of crank angle.

1.4 No-lead

Minimum

(Idling) Speed

and

Maximum

Speed Setting

.-----------I(

&CAUTION

)f---------.

a)

The

no-Ioad minimum (idle) speed and
maximum speed are set for each engine on
the test bench at the factory. The set bolts
are sealed. These settingsareto be inspected
and adjusted at our authorized service shop
only.

b) After adjusting the govemorby breaking the

seals, be sure to re-seal all visible stoppers,
making them appear as if they were sealed
at the factory.

c)

When

inspecting

and

adjusting

these
settings, be on standby to operate the engine
stop lever manually in the event of engine
overrun.

For inspeetion and adjustment, warm up the engine
thoroughly until the coolant and oil temperature are
above 70°C [l58°F].

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

......

To retard

injection

timing

--~,.,.

Adjusting injection timing - I

Adjusting injection timing - 2

5-5

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

(1) Starting engine

(a) Pull speedcontrollevertothe high speed side.

Operatethe starterswitch to crank the engine.

(b)

The

engine

will

fire up at 150

min-lof

cranking speed. When the engine fires, hold

the engine speed between 800 and 1000

min-I.

(c) When the engine runs with a steady speed,

move the speedcontrollever back to the idle

speed position.

(2) Setting no-Ioad minimum (idle) speed

Govemor

setbolt

-

Speed control lever

Low idle speed
set screw

Idlesub-spring
adjustingscrew

(a) Hold the speed control lever at the position

for no-Ioad minimum (idle) speed and setlow
idle speed set screw.

...----------JLt,CAUTION

1-----

__

If

a critical speed (the speed at which the engine
excessively vibrates due to torsional resonance)
might exist, shift the setting to a lower or higher
idle speed level.

(b) The engine speed will increase when the low

idle speed set screw is turned clockwise.

(c) Ifthe engine speedtends to fluctuate, turn idle

sub-spring adjusting screwclockwise to bring
this spring into slight contact with the tension
lever for eliminating fluctuation.

...----------JLt,CAUTION

1-----

__

Tightening the idle sub-spring adjusting screw
is likely to cause the engine to overspeed when
the load is removed during operation. Be sure to
tighten

this

adjusting

screw

just

enough

to

eliminate the unstable condition.

5-6

Low idle speed

set screw

Setting no-Ioad minimum (idle) speed

Idle sub-spring
adjusting screw

Setting idle sub-spring adjusting screw

(3) Setting rack (maximum output)

(a) Hold the speed controllever at the position

for the indicated output and speed.

(b) Under this condition, check to be sure that

the engine is running in a steady state.

(c) With the engine running in a steady state,

adjust the ful1-load stopper bolt. Tighten or
loosen this bolt to find out the position where
the engine delivers the rated output.

(d)

Af

ter adjusting the stopper bolt, back it off

slowly

while

observing

the speed. Stop
backing off the stopper bolt just when the
engine speed begins todecreasefromthe rated
level and secure itin thatposition with itsloek
nut.

(e) At this time, the speed control lever should

be in the maximum speed position.

(f)

Tuming the fuIl-load stopper bolt clockwise
will increase the injection quantity (engine
output), and vice versa.

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

Settingrack

(maximum

output)

(4) Setting govemor (maximum speed)

(a) Apply fuIl load to the engine and hold the

speed control lever at the position for the
indicated maximum speed.

(b) Set govemor set bolt (maximum speed set

bolt) at the position for the indicated speed.

Governor

set bolt

Settinggovernor

(maximum

speed)

5-7

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

(5) Deterrnining speed regulation (speed droop)

[I] Speed regulation upon removing load
(a) Run the engine with the speed control lever

set atthe position for the rated load and speed.

(b) Vnder this condition, remove the load to bring

the engine into no-load condition. Do not
move the speed contral lever.

(c)

The

engine

speed

will

increase

once

and
decrease and settle at a new steady state level
as

shown.

Read

the

highest

speed

(N2)

occurring in this transition and the speed

(N3)

af

ter

settling,

and

the

time

(tr)

from

the
momentofremoving the load at the initial
speedtbli) to the settling at the new level

(N3).

[2] Speed regulation upon applying load

With the engine runningunderno-loadcondition
subsequentto the condition mentionedin (b), [1],
above, and with the speed control lever held in
the same position as above, apply the prescribed
load instantaneously to the engine: the engine
speed will decrease once and increase, as shown,
and settle at a new steady state level. Read the
lowest speed (Ns) occurring in this transition and
the speed

(N6)

after settling, and the time (ts) from

N4toN6.

[3] Calculate the speed regulation

From the values obtained in [1]

and

[2], above,

compute

the

speed

regulation

for

each

load
change. A totaloffour percent values of speed
regulation are to be determined by using the
indicated forrnulas.

If the computer values are at varianee with the
prescribed values, "governor notch adjustment"
should be made to eliminate the varianee.

5-8

Speed regulation upon removing load

N,

Instantaneous speed Steady-state speed

regulation

(%)

regulation (%)

Nz-

NI

N3-NI

NI

X 100

NI

X 100

NI =initial speed, min-I, before load is

removed

N, = highest speed, min-I,during transitional

period

N3

=speed, min-I,at which the engine settles

after load is removed

ti =stabilization time

Speed

regUlatiO~n

upqn,applying load

N.

N,

Instantaneous speed Steady-state speed

regulation

(%)

regulation

(%)

N4-

Ns

N4-N6

N4

X 100

N4

X 100

N4

= initial speed, min-I, before load is

applied

Ns = lowest speed, min-I, during transitional

period

N6

=speed, min-I,at which the engine settles

after load is applied

tz = stabilization time

(6) Setting no-load maximum speed (make governor

notch adjustment)

(a) This adjustment is to be made by turning the

adjustingscrew for theswivellevertoincrease
ordecrease the preload ofthe govemor spring.

(b) Togainaccess to the adjusting screw, remove

the plug at the top of the governor housing.
Turn the speed control lever all the way to
the low idle position: this will turn up the
swivellever, pointing the head oftheadjusting
screw toward the plug hole. Insert a flat-tip
screwdriver through the hole to catch the
screw head.

(c) Tightening the adjusting screw will increase

the preload of the governor spring to narrow
the

speed

regulation;

loosening

it will

decrease the preload to widen the regulation.

One notch corresponds to 1/4 turn

of

the

adjusting screw and to 3 to 5 speed change of

the engine speed.

(d) Changing the setting of this adjusting screw

changes the governorsetting (for limiting the

maximum speed). After making a governor

notch adjustment, be sure to readjust the

governor setting, as explained in (4), above.

(e) Tightening the adjusting screw, mentioned

above, will increase the maximumspeed, and
vice versa.

,---------i!h

CAUTION

1---------,

Never loosen the adjusting screw by more than
20 notches (5 turns) frorn the fully tightened
position, or the control action of the governor
will become hazardous.

(7) Seal the set bolts.

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

Adjusting speed reguJation

5-9

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

1.5 V-belt Inspeetion

and

Adjustment

Push the belt inward with thumb pressure exerted
midway between the pulleys, as shown, to check the
belt tension (deflection).

If

the tension is incorrect,
loosen the adjusting bracket bolt and mounting bolt,
and move the altemator in or out.

Item

V-belt deflection

5-10

Unit: mm [in.]

Assembly Standard

12 [0.5]

Checking V-belt

2. Bench Testing

An

overhauled

engine

should

be

tested

for
performance on a dynamometer. This test is also for
breaking in the major running parts of the engine.

To test the engine, follow the procedures described

below:

2.1

Starting

Up

(l)

Inspeetthe levels in the radiator, oil pan, and fuel
tank. Prime the fuel and cooling systems to bleed
air out.

(2) Crank the engine with the starter for 15 seconds

to permit lubricating oil to circulate through the
engine. Por this cranking, do not supply fuel to
the engine, placingthe stop lever in stop position.

(3)

Move

the

speed

control lever slightly in the
direction of increasing fuel injection, and turn
the starter switch to START to start the engine.
Do not move the control lever to the "full fuel
injection" position.

(4)After the engine starts, let it idle under no load

by operating the speed control lever.

2.2 Inspeetion

After

Starting

Up

Af

ter starting up

the

engine, check the foIlowing

points.

Ifyou

find anythingwrong, immediately stop

the engine, then investigate the cause.

(1) Lubricatingoil pressureshould be 0.3 to0.5 MPa

(3 to 5 kgf/cm") [43 to 71 psi] at rated speed or

0.1

MPa(lkgf/cm") [14.2 psi] at idling speed.

(2) Coolant temperature should be 75 to 85°C [167

to 185°P].

(3)

Lube

oil temperature should be 60°C to 95°C

[l40oP

to 203"F], (Varies according to engine

specifications.)

(4) Checkfor leakage of oil, coolant, fuel, especiaIly

oil

leakage

from

oil

pipe

connections

for

turbocharger lubrication.

(5) Knocking shoulddie away as coolant temperature

rises. No other defective noise should be heard.

(6)

Check

for exhaust color and abnormal odors.

ADJUSTMENTS, BENCH TEST,

PERFORMANCE

TESTS

2.3 Bench Testlng (Dynamometer)

Conditions

Step

Speed (min-I)

Load (PS) Time (min.)

1

1000

No-load

30

2 1500

25%

30

3

25%

10

-

(According to

4

engine specifi-

50%

10

-

5

cation)

75% 30

-

6

100%

20

2.4 Inspeetion

and

Adjustments Af

ter

Bench Testing

(a) Adjusting valve clearance

(b) Adjusting injection timing

(c) Re-tightening external bolts and nuts

5-11

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

3. Performance Tests

There are various performance test procedures, and here the procedures for "Earth moving machinery
Engines, Part 1 : Test code

of

net power (JIS D 0006-1)" and "Earth moving machinery Engines, Part 2 :
standard format of specifications and tests methods of diesel engines (JIS D 0006-2)" are described. Other
test items may be required on application. Engine performance isjudged with integrated test results.

3.1 Engine Equipment Condition

Engine must be equipped with such standard auxiliaries as cooling fan, air cleaner and altemator.

3.2 Tests

and

TheirPurposes

(1) Operation load test

Conduct this test to evaluate engine output, torque, fuel consumption rate and governor performance under
various load conditions.

(2) Continuous load test

Operate the engine continuously for 10 hours at 90% load (continuous load application) of nominal net
brake power while engine speed is maintained at revolutions corresponding to the nominal brake power. In
this test, evaluate fuel consumption rate and operating condition and confinn continuous engine operation.

(3) No-load minimum idle speed test

Conduct this test to confinn that the engine can operate stably at the specified no-load minimum idle
speeds.

3.3 Other Inspeetiens

During performance testing, inspeet for leakage of gases, coolant, lubricating oil, or fuel, and for noise or
hunting. Make adjustment, as needed.

3.4 Adjustment Engine

Output

Diesel engine output is affected by atmospheric pressure, temperature, and humidity. Therefore, the engine

output should be set for standard atmospheric conditions.

(1) Standard atmospheric conditions

Base temperature

298 K (25°C)

[nOp]

Atmospheric pressure

WO

kPa [750 mmHg]

Atmospheric vapor pressure

99 kPa [743 mmHg]

5-12

ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS

(2) Calculation of corrected power

Multiply the measured brake power or torque by the calculated diesel engine correction factor (see below)
to obtained a corrected value.

Corrected output

=Correction factor

(ac)

x Measured brake power

•Atmospheric conditions for test
Temperature (T): 283

K (l0°C)

[SOap]

~T~

313 K (40°C) [104°P]

Dry atmospheric pressure (Pd): 80 kPa (600 mmHg)

~Pd~

110 kPa (825 mmHg)

(3) Calculation of correction factor

(oe)

cc=(fa)fm

fa: Atmospheric factor fm: Engine factor

(a) Calculation of atmospheric factor (fa)

CD

Natural aspiration engine and engine with mechanically driven air charger

fa

=(

~)

•(

l)

0.7

Pd 298

@ Turbocharged engine without air cooler (after cooler) or with air-to-air cooler

99

T

fa = (

_)

0.7 • (

_)

1.2

Pd 298

@ Turbocharged engine with air-to-liquid cooler

99 T

fa =

(_)0.7.

(_)07

Pd 298

(b) Calculation of engine factor (fm)

fm

= 0.036 qc - 1.14

q

CD

qc (Corrected fuel supply volume) =-

r

(z) x (Fuel flow rate gIs)

q =(Stroke volume

f)

x (Engine idle speed min-I)

z

= 120000 (4-cycle engine)

r: Ratio of pressure at turbocharger or air cooler to atmospheric pressure

(r

=1 for natural aspiration engine)

@ Applicable range of engine factor (fm)

37.2

~qc~

65 mg/(f-cycle)

• qc

~

37.2 mg/(f-cycle) : fm =0.2 (Constant)

• 65

mgl(f-cycle)

~

qc : fm =1.2 (Constant)

(c) Range of correction equation use

The range of correction factor

(oe)

use is as follows: 0.9~ac

~

l.I.

If this range is exceeded, indicate the corrected value and record the test conditions on the test record sheet.

5-13

ENGINE

AUXlllARIES

REMOVAl

AND

INSTAllATION

1. Preparation 6- 2

2. EngineAuxiliaries Removal 6- 2

3. Engine Auxiliaries Installation 6- 7

ENGINEAUXILIARIE8 REMOVAL AND IN8TALLATION

This section explains the procedures and tips for
removal and installation of the auxiliaries - the
pre1iminary process to go through for overhauling
the engine.

1. Preparation

(a) Shut off the

fue1

supply, and disconneet the

starting system from the engine.

(b) Loosen the drain plugs on the left-rear side

of crankcase, and drain coolant.

(c) Loosenthe oilpan drain pluganddrain engine

oil.

Hot engine oil can cause personal injury if it
contacts the skin. Use caution when draining the
oil.

.-------....,(

NOTE

)1--------,

Check the drained oil for contamination.

2. Engine Auxiliaries Removal

(1) Turbocharger (engines with turbocharger)

(a) Disconneet pipe from the turbocharger and

inlet manifold.

(b) Disconneet oil pipe and drain pipe from the

turbocharger.

(c) Remove

turbocharger

from

the

exhaust

manifold.

6-2

üil

pipe

Turbocharger

Removing turbocharger

Return
pipe

(2) Exhaust manifold

Remove the bolts that hold exhaust manifold to
the cylinder head. Remove the manifold and
gasket from the head.

(3) Fuel filter

(a) Disconneet fuel pipes and from the fuel filter.
(b) Remove fuel filter complete with bracket

from the inlet manifold.

(4) Fuel injection pipes

(a) Remove pipe clamps and disconneet injection

pipes from the injection pump and nozzle

holders.
(b) Disconneet leak-off pipe.
(c) Disconneet return pipe.

,-------llLtCAUTION

)f--------.

Be sure to put rubber caps over the openings of
the injection pump and nozzle holders to prevent
dust from getting inside the fuel system.

(5) Inlet manifold

Remove the bolts that hold inlet manifold to the
cylinder head. Remove the manifold and gasket
from the cylinder head.

ENGINE AUXILlARIES REMOVAL AND INSTALLATION

Exhaust
manifold

Removing exhaust manifold

Removing fuel filter

Removing fuel injection pipes

Removing inlet manifold

6-3

ENGINE AUXILIARIE8 REMOVALAND IN8TALLATION

(6) Fuel injection nozzles (direct injection type)

Remove gland, then remove nozzle and gasket
from the cylinder head.

(7) Fuel injection nozzles (swirl chamber type)

Remove nozzle and gasket.

(8) Glow plugs (direct injection type)

Remove nuts, then remove conneetion plate and
glow plug.

(9) Glow plugs (swirl chamber type)

Loosen nuts, then remove conneetion plate and
glow plug.

6-4

Removing fuel injection nozzles (direct injection type)

~

./~

Nozzle

Gasket

Removing fuel injection nozzles (swir! ehamber type)

Removing glow plug (direct injection type)

1liIIP---Nut

;"--Conneetion

plate

---Glow

plug

Removing glow plug (swirl ehamber type)

(10) Fuel injection pump

(a) Remove oil pipe.

(b) Remove bolts that hold the gear case cover.

(c) Remove bolts that hold the flange plate.

Remove pump with gear and flange from the
front plate. (Some engines are not equipped
with pump bracket.)

(11) Oil cooler (engines with oil cooler)

Remove bolts that hold oil cooler cover to the
crankcase. Remove the cooler, complete with
the cover, from the crankcase. Remove gasket
and O-ring.

(12) Oil filter

(a) Remove oil filter with a filter wrench.

C13)Altemator

Ca)

Disconneet hamess from alternator. Remove
adjusting bolt.

(b) Remove bolts to remove the altemator.

Cc)

Remove V-belt.

ENGINE AUXILIARIE8 REMOVAL AND IN8TALLATION

Fuel injection pump

Removing fuel injection pump

Removing oil cooler

üil

filter

Removing oil filter

Removing alternator

6-5

ENGINEAUXILIARIE8 REMOVALAND IN8TALLATION

(14) Water pump

(a) Remove the bolts that holdfan andpulley and

remove them.

(b) Remove the bolts that hold water pump and

remove the pump and gaskets.

(15) Starter

Disconneet harness from starter. Remove nuts
to remove the starter.

(16) Thermostat

(a) Remove water by-pass hose.

(b) Remove the bolts that hold thermostat case

to remove the termostat case.

(17)

ûil

pan

Remove bolts to remove oil pan.

6-6

Removing water pump

<;

<>

\~rter~

Removing starter

Removing thermostat

L

~

~Bolt

onpan

Removing oil pan

3. Engine Auxiliaries Installation

To install the engine auxiliaries, follow the
removal procedures in reverse. After installation,
service them as follows:

(a) Refill the engine with the recommended oil

up to the specified level.

(b) Refill the cooling system with coolant.

(c) Check each pipe conneetion for oil or coolant

leaks.

(d) Prime the fuel system.

(e) To installation of the fuel injection pump is

described below. After installing the fuel
injection pumps, be sureto inspeet and adjust
the injection timing. (Refer to Section 1.3 of
Group 5, "Adjustment, Bench Testing, and
Performance Tests."

ENGINE AUXILlARIES REMOVALAND INSTALLATION

6-7

ENGINE MAIN PARTS

1. Cylinder Heads and ValveMechanism

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2.1 Disassembly

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7-16

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7-21

3.3 Reassembly

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4. Pistons, Connecting Rods, Crankshaft, Crankcase and Tappets

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4.3 Reassembly

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7-48

ENGINE MAIN PARTS

1. Cylinder

Head

and

Valve Mechanism

1.1 Disassembly

Check valve cap contact face

for wear.

Check

oil hole for

clogging.

Check for cracks.

or'carbon

or scale deposits,

Check

face for pitringorridging

(exhaust valve),

Check

stem

for

serarches or

scuff

marks.

Check for uneven

WeM.

IDisassembly sequence I

CD

Rocker cover

® Adjusting screw
® Bolt (short)

@ Bolt (long)

Remove @ through(@as an
assembly.
@ Rocker shaft bracket

@ Snap ring

(j) Inlet valve rocker arm

7-2

@ Exhaust valve rocker arm

® Rocker shaft spring

(@

Rocker shaft

(jJ)

Valve cap

© Valve pushrod

(j])

Cylinder

head

bolt

Remove ® through @ as an
assembly.

® Cylinder head

@ Valve cotter
@ Valve retainer

® Valve spring

@ Valve

® Valve stem seal

®>

Cylinder head gasket

(1) Removing rocker shaft assembly

(a) Loosen the adjusting screw one rotation.

(b) Loosen the bolts, short and long, that holdthe

rocker shaft bracketto the cylinder head. Be
sure to loosen the short bolt first. Remove the
rocker shaftassembly from the cylinder head.

,-------l,&CAUTION

1--------,

If the long bolt is loosened first, the rocker shaft
bracket might suffer damage.

(2) Disassembling rocker shaft assembly

Put a mark on the rocker arm and shaft so that
the arm can be installedon the same shaft position
from which it was removed.

(3) Removing cylinder head

(a) Remove the cylinder head bolts.

(b) Lift the

head

off

the crankcase.

,--------1

NOTE

}--------,

(a)

Whenremoving

the

gasket

from

the

crankcase,

be careful not to

damage

the

gasket contact surface of the crankcase

(b)Ifany cylinder head parts are faulty, check

the

cylinder

head

bolts for torque with a

torque wrench before removing them.

ENGINE MAIN PARTS

Removing rocker shaft assembly

Disassembling rocker shaft assembly

7-3

ENGINE MAIN PARTS

(4) Remove valve and valve spring

(a)

Use

valve spring pusher (30691-04500) to
compress the valve spring, then remove the
valve cotters.

(b) Remove the valves and valve springs.

,.....-------I[

NOTE

ÎI-

-,

If the original valves are to be reused, mark them
for their locations to ensure the originallocation
and combinations of the valve, valve seat and
valve guide.

1.2 Inspeetion

Rocker arms, rocker bushings

and

rocker shafts

(1) Measuring rocker arm bushing and rocker shaft

Measurethe inside diameterof the rockerbushing

and the diameter of the rocker shaft as shown in
the illustration. Determine the clearance between
the

bushing

and

shaft

on

the

basisofthe

measurements.

If

the clearance does not exceed

the

repair limit, replace the rocker arm. If it
exceeds the repair limit, replace the shaft and
rocker arm.

Unit: mm [in.]

Item

Nominal

Assembly

Service

Value Standard

Limit

Inside diameter

19.010

of rocker

to 19.030

bushings

[0.7484

19

to 0.7492]

[0.75]

18.980

Diameter of to 19.000

rocker shaft

[0.7472

to 0.7480]

Clearance 0.010
between rocker to 0.050

0.070

bushing and [0.0004 [0.0028]
shaft to 0.0020]

7-4

Removing valve and valve spring

Measuring rocker arm bushing and rocker shaft

Valves, valve guldes

and

valve seats

(1)

Measuring

valve

stem

Measure

the

diameterofthe valve stem as

shown

in

the

illustration.Ifthe stem is

wom

beyond

the

service

limitorunevenly

wom

excessively,

replace

the valve.

Unit: mm [in.]

Item

Nominal Assembly

Service

Value

Standard Limit

lniet

7.940 to 7.955

7.900

[0.3126

Diameter

valve

8

to 0.3132]

[0.3110]

ofvalve

I----

Exhaust

[0.31]

7.920 to 7.940

stem

valve

[0.3118

7.850

to 0.3126]

[0.3091]

(2)

Checking

clearance

between

valve

stem

and

valve guide

The

valve guide wears more rapidly at its

both

ends

than at any

other

parts. Measure the

inside

diameterofthe

guide

at its ends as shown in

the

illustration to

determine

the clearance

between

the

guide

and

stem.Ifclearance

exceeds

the

service

limit,

replace

the

valve

or

guide

whichever

is excessively wom. Unit: mm [in.]

Item

Nominal Assembly

Service

Value Standard

Limit

InIet

0.065 to 0.095

0.150

Clearance

valve

-

[0.0026

[0.0059]

between

to 0.0037]

valve

stem

Exhaust

0.080 to 0.115

and

guide

valve

-

[0.0032

0.200

to 0.0045]

[0.0079]

Height to top of

11.5

±O.I

valve guide [0.45]

[±0.004]

ENGINE MAIN PARTS

Measuring diagram

+

Measuring valve stem

Measuring
diagram

e

~

Measuring valve guide

(3) Replacing valve guide

(a)

Use

the valve guide remover(32A91-OO300),

to

remove

the

valve guide for replacement.

Valve

guide

remover

-~.

Removing valve guide

7-5

ENGINE MAIN PARTS

(b) To install areplacement guide, use valveguide

installer (32A91-o0100).

Press

Valve guide instalIer

.....--------iLLCAUTION

1-------,

The installation depth for the valve guide is

specified; be sure to usethe valve guide instalIer

to insure the correct depth.

Installing valve guide

Valve margin

Valve sinkage

Bad

Inspecting valve face

Valve contact pattern

Good

Coatthe valve face lightly with red lead. Use the
Valve lapper to inspeet the valve contacts with
its seat. If the contact is not uniform, or if the
valve isdefectiveoriftherepair limit is exceeded,
repair or replace the valve and valve seat.

Unit: mm [in.]

a) Inspeetthe valve faceafter the inspeetion or

replacement of the valve guide.

b) Do not rotate the valve when checking its

contact.

c)

Af

ter refacing or replacing the valve or the
valve seat, be sure to lap the valve in the
seat. (See (8) Valvelapping.)

(4) Inspecting valve face

Item

Assembly

Repair

Standard

Limit

Angle 30° -

Inlet

0.4±0.1

ce

Valve

[0.016 ± 0.004]

Q)

Valve

(inlet)

1.0

'"

Q)

sinkage

0.5±0.1

[0.039]

;>

Exhaust

~

Valve

[0.020±0.004]

(exhaust)

1.4±O.14

1.8

Width

[0.O55±0.OO55]

[0.071]

2.13

Up to 1.83

Valve margin

[0.0839]

[o.onO]

by refacing

,..---------1

NOTE

1--------,

7-6

(5) Refacing valve face

If

the valve face is badly wom, reface it with a

valve refacer.

NOTE

1---------,

a) Set a valve refacerto an angle of 30°
b)

The

valve has a stellate facing. This facing

will be gone

if

the valve margin exceeds the

service limit.

If

the margin seems to be less
than the service limit when ground, replace
the valve.

(6) Refacing valve seat

Use

the Valve seat cutter or valve seat grinder to

reface the valve seat.

Af

ter refacing, grind the

seat lightly using #400 grade sandpaper inserted

between the cutter and valve seat.

NOTE

1---------,

a) Cut or grind the valve seat only as needed

for refacing.

b) Replace the valve seat

if

the seat width is
more than the repair limit as a result of wear
or cutting.

(7) Replacing valve seat

(a) Weld a stud to the valve seat. Insert a shaft

into the valve guide holder from the upper
side of the cylinder head. Drive the seat off
from the cylinder head as shown .

.--------I(

NOTE

11--

---,

When

you weld the stud, do not to permit splatter

to come in contact with the machined surfaces

of cylinder head.

ENGINE MAIN PARTS

Refacing valve face

Refacing valve seat

Stud

Removing valve seat

7-7

ENGINE MAIN PARTS

(b) Before installing replacement valve seats in

the cylinder head, measure the bores in the
cylinder head for the valve seats.

(c) Chill the valve seat in liquid nitrogen of -

l70DC[-274

DF]

for more than4 minutes with

the cylinder head kept at normaltemperature,

or heat the cylinder head up to 80

DC

to 100

DC

[176DFto 212

DF]

with the valve seat chilled

in ether or alcohol containing dry ice.

(d) Using insertcaulkingtaal, drive the seat into

position.

Tools needed

Insert caulking tooI

36791-00200

(for inlet valve seat)
Insert caulking tooI

34491-03020

(for exhaust valve seat)

(8) Lapping valve in va1veseat

Be sure to lap the valve inthe valve seat after the
valve or the seat have been replaced.

(a) Coat the valve face lightly with a lapping

compound.

,---------j(

NOTE

If--

--,

(a) Do not permit the compound to come in

contact with the valve stem.

(b) Use a compound of 120 to 150 mesh for

initiallapping and the compound finer than
200 mesh for finish lapping.

(c) Mixing the compound with a small amount

of

engine oil will facilitate coating.

7-8

46~~·OO25

[1.8II

-;;"'~']

Inlet valve Exhaust valve
seat bore seat bore

Valve seat dimensions

Installing valve seat

Coating valve with lapping compound

(b) Using lapping tool, hold the valve against the

seat and rotate it only a part of a turn, then
raisethe valve off the seat, rotating it to anew
position. Then press the valve against the seat
for another part of aturn. Repeatthis operation
untilthe compound wears and loses itcutting
particle.

(c) Wash off the compound with diesel fuel.

(d) Apply the valve face to the engine oil, and

again lap the valve.

(e) Check the valve face for contact.

(9) Measuring valve spring perpendicularity andfree

length

Measure the free length and perpendicularity of
each

valve

spring.Ifthe

free

length

or

perpendicularity

exceeds

the

service

limit,

replace the spring.

Unit: mm [in.]

Item

Assembly Service

Standard Limit
Free length 48.85 [1.92] 47.60 [1.87]
Perpendicularity

1.5°or less

-

Set

length 43 [1.69] -

Set force

176to 196 147

N (kgf) [lbf]

(18 to 20) (15)
[40 to 44] [33]

ENGiNE MAiN PARTS

Valve lapping

tooI

Lapping valve in valve set

Perpendicularity

Measuring valve spring perpendicularity and free length

7-9

ENGINE MAIN PARTS

(10) Measuring cylinder head warpage

Using a heavy accurate straight edge and feeler
gages, check

the

gasket

contact

surface for

warpage in

two

positions

lengthwise,

two
crosswise and two widthwise as shown in the
illustration.

If

the warpage exceeds the repair

limit, reface the head with a surface grinder.

Unit: mm [in.]

Item

Assembly Repair

Standard Limit

Warpage of gasket

0.05 [0.0020] 0.20

contact surface or less [0.0079]

Measuring cylinder head warpage

(11) Measuring valve pushrod deflection

Measure the pushrod deflection with a V-block
and a dial indicator as shown in the illustration.
Ifthedial indicatorreading exceeds the assembly
standard, replace the pushrod.

Item

Deflection (dial indicator
reading) of valve pushrod

Unit: mm [in.]

Assembly Standard

0.3 [0.012] or less
Measuring valve pushrod deflection

Installing valve stem seal

1.3 Reassembly

(1) Installing valve stem seal

After installing the valve in position, install the

seal to the valve guide with stem seal installer
(32A91-10200).

..-------l(

LÏ:,CAUTION11---------,

a) Do not put any oil or sealant on the face of

the stem seal that comes in contact with the
valve guide. When installing the seal, put
engine oil on the seal contact surface of the
stemto ensure initiallubrication ofthe stem
seallip.

b) Do not remove the valve after the seal has

beeninstalledin position to prevent damage
to the seallip.

7-10

Stem seal instalIer

Valve

Valve

stem seal

Valve

guide

(2) Installing valve and valve spring

(a) Put the valve spring and retaineron the valve

guide. Using valve spring pusher

(30691-

04500), compressthe valve spring and install
the valve cotters.

(b) Tap

the

valve stem top with a soft-faeed

hammer

several times to make sure the valve

spring and cotters are properly installed.

(3) Installing cylinderhead

(a) Put the gasket on the top of the crankcase,

making sure the two dowel pins enter their
holes in the gasket.

(b)

Put

the

cylinder

headonthe

crankcase,
making sure the two dowel pins enter their
holes in the head. Tighten the head bolts.

...------I&CAUTION

1------

Do not use any sealant. Make sure the gasket
contact surface

ofthe

crankcase is free from any

defects.

ENGINE MAIN PARTS

Installing valve cotters

Installing cylinder head

(c)

Tighten

the

cylinder

head

boltstothe
specifiedtorque in the sequence shown in the
illustration.

Tightening torque for
cylinder head bolts

113

to 123Nrn

(11.5to12.5

kgf-m)

[83 to90 lbHt]

~

/'

0

0

0

0

Front

12

0

4

Ol

5

13

0

0

0

<?

16

8

9

1:"-

-

14

0

0

0 0 0 0

0

0

15

11

7

3

2

6

10

No. of bolts: 17

Cylinder head bolt tightening sequence (S4S)

7-11

ENGINE

MAIN PARTS

No.ofbolts: 25

Cylinder head bolt tightening sequence (565)

(4) Reassembling rocker shafts

Af

ter reassembling the rocker shafts, make sure

the

rocker arms

move

smoothly.

Reassembling rocker shafts

(a) Install the valve caps in position.

(5) Installing rocker shaft assembly

(b) Put the roeket shaft assembly on the cylinder

head and tighten the bolts to the specified
torque.

Long bolt

10.0 to 20.0 N·m

(1.0 to 2.0 kgf.m)

[7.23

to

14.5

IbHt]

Tightening torque for
rocker shaft bolts

r---------j

NOTE

1---------,

Installing rocker shaft assembly

Be sure to tighten

the

long bolt first.

(6) Adjusting valve clearance

Refer

to 1.1, Group 5.

Adjusting valve clearance

7-12

2. Flywheel

2.1 Disassembly

Replace gasket.

Checks for cracks or
defective dowel hole.

I

Disassembly

sequence

I

CD

Flywheel

Check for wom or

defective lip.

Check for cracks or defective
dowel hole. Check ring gear
for wom or detective teeth.

Remove ® and

CID

as an assembly.

® Flywheel housing

CID

Oil seal

3

ENGINE MAIN PARTS

@ Rear gasket

7-13

ENGINEMAIN

PARTS

(1) Removing flywheel

(a) Removeone

ofthe

bolts that hold theflywheel

to the crankshaft.

(b) Run safety bar (M12 x 1.25) in the holefrom

which the bolt was

removed

in Step (a).

Remove the remaining flywheel bolts.

(c) Remove the flywheel from the crankshaft by

puIling

it straight.

.---------J&CAUTION

f------,

When removing the flywheel, wear heavy gloves
to avoid injury.

(2) Removing flywheel housing

Remove the bolts that hold the flywheel housing
to the crankcase. Remove the housing.

...-------l[&CAUTION

JI-------.

Do not cause damage to the oil seal.

2.2 Inspeetion

Flywheel

and

ring

gear

(1) Flatness (difference between lower and higher

measurements) of flywheel

Put the flywheel on the surface plate. Set a dial
indicator at one side

of

the friction surface and
move it over to the opposite side of that surface
asshown inthe illustration.

If

the surface flatness

is over the repair limit, regrind it.

Unit: mm [in.]

Item

Assembly Repair

Standard

Limit

Flatnessof flywheel 0.15 [0.0059] 0.50
friction surface or less

[0.020]

7-14

Removing flywheel

Removing flywheel housing

Measuring flywheel flatness

(2)

Face

runout

and

circular

runout

(radial

eccentricity)offlywheel

Set

adia! indicatorat the friction(vertical) surface

and

turn the flywheel one full revolution to check

the

face

run

out.

Set

a dial

indicatoratthe
horizontal surface of the pilot bearing bore and
turn the flywheel one full revolution to check the
circularrunout. Excessive runout of theflywheel
in either position will probably be causedby dirt
in the mounting face or improper tightening of

the

bolts. Unit:mm

[in.]

Item

Assernbly Repair

Standard

Limit

Face and bore

0.15 [0.0059]

0.50

runouts of flywheel or less [0.020]

(3)

Ring

gear replacement

Check

the

ring

gear

teeth and,ifthey

are

defective, replace the gear as outlined below.

(Removal)

(a) Heat the ring gear evenly with an burner.

(b) Hit the ring gear all the way around with a

bar

and a hammer to remove it.

(Installation)

Heat a replacement ring gear up to 100°C [212°F]

with a heater,

and

install the gear to the flywheel

placing

the

unchamfered side of the teeth to the

flywheel.

.---------l(

Lh

CAUTION

)1-------,

Do

not

heat the ring gear excessively.

ENGINE MAIN PARTS

Measuring flywheel runouts

Removingring gear

7-15

ENGINE MAIN PARTS

2.3 Reassembly

(1)

Installing

oil

seal

(According

to

engine

specification)

Apply a thin coat of grease to the oil seal and
install the oil seal to the flywheel housing with
an installer.

..-------1

NOTE

1---------,

If the oil seal contact surface of the crankshaft is
excessively worn, use an oil seal with sleeve.

Apply grease,

Engine side

<;::::J

F1ywheel

housing

F1ywheel

side

c:::)

I ""H--_Oil seal

Installing oi! sea!

(2) Installing flywheel housing

(a) Put the new rear gasket in position.

(b) Apply engine oil to the oil seallip.

(c) Installtheflywheel housing, making sure the

dowelsenter their holes, andtighten the bolts.

,-----,..-------I(

NOTE

If--

---,

Install the starter to the housing to facilitate
installation work.

(3) Installing flywheel

(a) Install safety bar (M12 x 1.25) in the rear end

of the crankshaft.

(b) Install the flywheel to the crankshaft, making

sure the safety bar enters the hole in the
flywheel.

(c) Tighten the bolts (five) finger tight only.

(d) Remove the safety bar and install the last one

bolt.

(e) Have someone hold the crankshaft pulley nut

with a wrench.

(f)

Tighten the bolts that hold the flywheel to the
specified torque.

Tightening torque for

78.5 to 88.3 N·m

flywheel bolts

(8.0 to 9.0 kgf-m)

[57.9

to65.1lbHt]

(illCAUTION

During installation, signal to each otherto avoid
personal injury.

7-16

Installing flywhee! housing

Safety bar

Installing flywhee1

3. Damper, Timing Gears

and

Camshaft

3.1 Disassembly

ENGINE MAIN PARTS

Replace

gasket

Check for wear
or damage.

Check teeth for wear,

nicks, burrs or chips.
Check keyway

apçl

bushing for damage
or wear.

Check for

we:n"

Check for stripped
threads.

IDisassembly sequence I

CD

Damper (S6S)

® Crankshaft pulley

@ Cover
@ Fuel injection pump

®

Oilpan

Check for wom heil
grooves.

Check for cracks or
defective dowel holes.

@ Timing gear case

(J) Oil pump gear

@ Thrust plate

® Idler gear

Remove

(j])through © as an

assembly.

(j]) Camshaft

® Camshaft gear

© Thrust plate

Cl])

Front plate

7-17

ENGINE MAIN PARTS

(I)

Removing damper

(S6SIDT)

(a) Install two safety bars

(MI2

x 1.25)in therear

end of the crankshaft to hold the crankshaft.

(b) Remove the damper.

llliWARNING

Be to install the safety bars securely.

(2) Removing crankshaft pulley

Removethepulley from the crankshaftas shown.

(3) Removing oil pan

Remove the bolts and remove the oil pan.

(4) Removing timing gear case assembly

Removethetiming gear case assembly as shown.

.--------1illCAUTION

1-------,

Do not cause damage to the oil seal.

(5) Measuring backlash and end play

Make

a recordofthe backlash and end play
measurements to be referred to for reassembly.
(Refer to 3.2)

7-18

Removing damper

Removing crankshaft pulley

Removing timing gear case assembly

Measuring backlash and end play

(6) Removing oil pump gear

Loosen the nut and remove the gear.

(7) Removing idler gear

Remove the thrust plate and remove the gear as
shown.

(8) Removing camshaft

(a) Turn the crankcase upside down.

(b)

Position

the

camshaft

gearsothat

its
lightening holes come to top and bottom.
Remove the bolts that hold the thrust plate.
Remove the camshaft from the crankcase.

~-------I&CAUTION

)1-----------,

Do not cause damage to the Iobe faces of the

camshaft and the bushings.

ENGINE MAIN PARTS

Removing oil pump gear

Removing idler gear

Removing camshaft

7-19

ENGINEMAIN

PARTS

(9) Removing camshaft gear

Removethe gear from the camshaft with a puller.
Now the thrust plate can be removed.

r-------1(

NOTE

11-

---,

Do not remove the camshaftgear and thrust plate
unless they are damagedto the extent of requiring
replacement.

(10) Removing front plate

Remove the bolts that hold the front plate to the
crankcase. Remove the front plate.

7-20

Removing camshaft gear

Removing front plate

3.2 Inspeetion

Camshaft

and

camshaft bushlngs

(1) Measuring camshaft end play

Measure the camshaft end play as shown in the

illustration. If the end play exceeds the service
limit, replace the thrust plate.

Unit: mm [in.]

Item

Assembly

Service

Standard Limit

End play of 0.10 to 0.25 0.30
camshaft [0.0039 to 0.0098] [0.0118]

(2) Measuring cam lift

To find the cam lift, use the procedure that
follows:

(a) Measure lobe height (A).

(b) Measure base circle (B).

(c) Subtract base circle (B) from the lobe height

(A). The difference is lobe lift

(C).

Ifthecam liftis lessthan the servicelimit,replace
the camshaft.

ENGINE MAIN PARTS

Measuring camshaft end play

Measuring diagram

-9-~

Measuring cam lift

Unit: mm [in.]

Item

Nominal Assembly Service

Value Standard

Limit

A=

6.62 6.182

DI

46.918tii:~1

[0.2631] [0.2434]

Inlet

[1.8472tii:8?i]

valve

A=

SC

46.916tii:~1

6.684 6.184

Cam

[1.8471tii:~]

[0.2632]

[0.2435]

liftC

A=

DI

46.878tiiS

l

6.722 6.222

Exhaust

[1.8456tii:~]

[0.2647] [0.2450]

valve

A=

SC

46.88

otiiS

1

6.720

6.220

[1.8457tii:8?i]

[0.2646] [0.2450]

DI - Direct injection SC - Swirl chamber

A

7-21

ENGINE MAIN PARTS

(3) Measuring camshaft deflection

Support

the

camshafton its front and rear journals

in

V-blocks. With the dia! indicator set at 0.00

mm [0.0000 in.] at the

center

joumal,

turn the

camshaft

full

one

revolution

and

read

the
indicator, as shown in the illustration. 1/2ofthe
reading on

the

indicator is

the

deflectionofthe

camshaft.

If

deflection exceeds

the

repair limit,

straighten

the

camshaftbycold

working, or

replace it.

Unit: mm

[in.]

Item

Assembly

Repair

Standard Limit

Camshaft 0.02[0.0008] 0.20

detlection

or less

[0.0020]

(4)

Clearance

between

camshaft

journals

and

bushings

Measure

the

diameterofthe

camshaft

journals

and the inside diameter

of

the

bushings in the

crankcase to

check

the

clearance

between the

joumal

and

bushing.

Ifthe

clearanceexceeds the

service limit, replace the bushings.

Unit: mm [in.]

Item

Nominal Assembly Service

Value

Standard Limit

No.l,2

53.94

(S4S)

54

to 53.96

53.90

Diameters

No.l,

2,3

[2.13]

[2.1236

[2.1220]

of cam-

(S6S)

to 2.1244]

shaft

52.94

journals

No.3

(S4S)

53

to 52.96 52.90

NoA

(S6S)

[2.09] [2.0842 [2.0827]

to 2.0850]

0.070

to 0.118
Front and [0.0028
middle to 0.0047]

(without

bushings)

Clearance

0.070

between

to 0.110

0.15

camshaft

Rear

[0.0028

[0.0059]

journals to 0.0043] (Repair

and bore

(without

limit)

bushings)

0.040
to 0.119
[0.0016

to 0.0047]

(with bush-

ings)

7-22

Measuring camshaft detlection

Measuring diagram

-Q-W

Measuring camshaftjournals

Measuring camshaft bushings

(5) Replacing camshaft bushings

(a)

Ifthe

clearancebetween the camshaftjoumal
and bore in the crankcase exceeds the service
limit,

refinish

the

boreto57H6

("'8019)

3.125 Ra. and install bushings.

(c) To replace or install bushings, use camshaft

bushings installer set (30691-00010).

(d) Install bushings with their oil holes aligned

with the holes leading to the oil gallery.

Timing

gears

Backlash

Put a dial indicatoron the gear along its pitch circle

as shown. Hold it tightly in place. Move one of the
mating gears back and forth to check the backlash.

If the backlash exceeds the service limit, replace the

wom gears.

Unit: mm [in.]

Item

Assembly Service

Standard Limit

Backlash

0.03 to 0.18 0.25

[0.0012 to 0.0071]

[0.0098]

NOTE

f-----------,

Install the injection pump drive gear to the front
plate in the state

of

being installed onthe injection

pump.

Idler

gear,

bushing

and

shaft

(l)

Measuring idler gear end play

Measurethe idler gear end play with feeIergages

or a dial indicator as shown in the illustration.

If

the end play exceeds the service limit, replace
the thrust plate.

Unit: mm [in.]

Item

Assembly

Service

Standard Limit

End play

of

idler

0.05 to 0.20 0.35

gear

[0.0020 to 0.0079]

[0.0138]

ENGINE MAIN PARTS

Removal

Replacing camshaft bushings

Measuring timing gear backlash

Measuring idler gear end play

7-23

ENGINEMAIN

PARTS

(2) Measuring clearancebetween idler

gear

bushing

and shaft

Measure the inside diameter

of

the

bushing and

the

diameterofthe

shafttodetermine

the

clearance

between

the two.Ifthe

clearance

exceeds the service limit, replace the idler

gear

or shaft.

Unit:

rnrn [in.]

Item

Assembly Service

Standard Limit

Clearancebetween

0.009 to 0.050

0.100

idler gearbushing [0.0004

[0.0039]

and shaft to 0.0020]

(3) Removing idler gear shaft

To remove the idler gear shaft for replacement,
use idler shaft puller (MH061077).

Crankshaft

pulley

Check

the V-belt groove for wear.

Wrapanew

belt

around the pulley, pressing it in the

groove

as far as

it goes, and see if the top surface

of

the

belt is above

the top of the pulley.

If

the top surfaceofthe new belt is uniformly above
the top of the pulley all the way around, it is not
necessary to replace the pulley.

If

the top surface of the new belt sinks intothe groove
more than 1.6 mm [0.06 in.], replace

the

pulley.

7-24

Measuring

diagram

-$-

-sr

Measuringclearancebetween idlergear bushingand shaft

Removing idler gear shaft

1.6 mm [0.06 in.]

InspectingV-beltgroove

ENGINE MAIN PARTS

(1) Installing front plate

3.3 Reassembly

(b) Tighten the bolts that hold the front plate to

the crankcase to the specified torque.

Installing front plate

10.0 to 13.0 N·m

(1.0 to 1.3 kgf-m)

[7.23

to9.40

lbf-ft]

Tightening torque for
front plate bolts

(a) Put the gasket on the crankcase, making sure

the dowels enter the holes in the gasket.

(c) Cut off the excess of the gasket with a cutter.

(2) Installing camshaft gear and thrust plate

(a) Heat the camshaft gearfor installation.

(b) Have the thrust plate installed in advance.

Installing camshaft gear and thrust plate

(3) Installing camshaft

(a) Apply engine oil to the lobes

andjoumals

of

the camshaft.

(b) Carefully put the camshaft in the bore in the

crankcase.

Installing camshaft

10.0 to 13.0 N·m

(1.0 to 1.3 kgf-m)

[7.23

to 9.40IbHt]

Tightening torque for
front plate bolts

(c) Tighten the bolts that hold the thrust plate to

the specified torque.

r-------1&,CAUTION

1-------.,

Do not cause damage to the lobes and bushings.

7-25

ENGINE MAIN PARTS

(4) Installing idler gear

(b) Tighten the thrust plate mounting bolts to the

specified torque.

(a) Install the idler gear by aligning its matching

mark with

those

on the crankshaft gear,
injection pump gear and camshaft gear and
install the thrust plate.

Installing idler gear

29.0 to 39.0 N·m

(3.0 to 4.0 kgf.m)

[21.7 to 28.9IbHt]

Tightening torque for
thrust plate bolts

(c) The marks on the gears will be aligned as

shown when the No.1 piston is at top dead

center of compression stroke.

Injection pump

Marks on timing gears

(a) Install the gear to the oil pump shaft.

(b) Tighten the jam nut to the specified torque.

(5) Installing oil pump gear

28.0 to 38.0 N·m

(2.9

to 3.9 kgf-m)

[21.0 to 28.2 lbf-ft]

Tightening torque for

jam

nut

Installing oil pump gear

(6) Inspecting and adjusting after reassembly

Timing gear backlash and end play

After installing the timing gears,

check

the
backlash and end play and, if necessary, adjust
them. (Refer to 3.2.)

Inspecting backlash and end play

7-26

(7) Inspecting valve timing

It is not necessary to inspeet the valve timing,

provided that all matchmarks on thetiminggears
are aligned. Inspeet thetiming for verification as

explained below:

(a) Using a 3 mm [0.12 in.] thick smooth steel

plate, add 3 mm [0.12 in.] clearance to the
inlet and exhaust valves of the No.l cylinder.

ENGINE MAIN PARTS

Exhaust valve

t

Rotatien

Bottom

dead

center

Valve timing diagram (direct injection type)

Valve timing diagram with 3 mm [0.12 in.] clearance

added (direct injetion type)

(b)

Puta0.05

mm [0.0020 in.] feeler gage
between the top of the valve cap and the
rocker.

(c) Slowly turn the crankshaft to find a position

where the feeler gage is firmly gripped (the
valve starts opening) and aposition where the
gage is

just

ungripped

(the

valve starts

closing).

(d) Checktomake surethesepositions agreewith

the angular positions shown in the valve
timingdiagram with3mm [0.12 in.]clearance
added to the valves.

Exhaust valve

t

Rotatien

Bottom

dead

center

Inlet valve

Rotatien

Exhaust valve

500

74°

Bottom

dead

center

Valve timing diagram (swirl chamber type)

Rotation

Inlet valve

Bottom

dead

center

Valve timing diagram with 3 mm [0.12 in.] clearance

added (swirl chamber type)

7-27

ENGINE MAIN PARTS

(8) Installing oil seal (if necessary)

Apply a small amount of grease to the oil seal
and install it to the timing gear case with an
installer.

Installingoil seal

(b) Apply oil to the lip of the oil seal.

(9) Installing timing gear case

(c) Tighten the boltsthat hold thetiming gear case

to the specified torque.

Installingtiminggear case

10.0 to 13.0 N·m

(1.0 to 1.3 kgf.m)

[7.23

to9.40

lbf-ft]

Tightening torque for
timing gear case bolts

(a) Put the gasket on the front plate, making sure

the dowels enter their holes in the gasket.

(10) Installing oil pan

(a) Clean the mounting surfaces

ofthe

crankcase,

timing gear case and oil pan.

(b) Squeeze out

a4

mm [0.2 in.] thickness of
Three Bond 1207C (32A91-05100) from the
tube and put it on the oil pan flange.

./

Put Three Bond 1207C along heavy line.

-:

'~

,J

(c) Install the oil pan to the crankcase within 5

minutes after putting Three Bond 1207C.

Oil panflange

to becoated

with

ThreeBond 12Ü7C

(d) Tighten the bolts to the specified torque.

Tightening torque for

oil pan bolts

10.0 to 13.0 N·m
(1.0 to 1.3 kgf-m)
[7.23

to9.40 IbHt]

7-28

.---------1

NOrf

'1--

---,

To squeeze outa4mm [0.2 in.] thickness

ofThree

Bond, cut the first node of the nozzie.

ENGINE MAIN PARTS

Nozzle for Three Bond 12Ü7Ctube

(11) Installing crankshaftpulley

Install two safety bars

(MI2 x 1.25) to the rear

end

of

the crankshaft.

Put

a bar between the safety bars
to hold the crankshaft. Under this condition, install
the

crankshaft

pulley

and tighten

the

nuttothe

specified torque.

Tightening torque for
crankshaft pulley nut

Î!\WARNING

480to500

Nrn

(49 to 51 kgf-m)

[354 to 369 lbf-ft]

Installing crankshaft pulley

Be on standby to act when the safety

bar

comes

off

inadvertently.

(12) Installing

damper

(S6S/-DT)

Hold the crankshaft with safety bars and install
the damper.

Installing damper

7-29

ENGINE MAIN PARTS .

4. Pistons, Connecting Rods, Crankshaft, Crankcase and Tappets

4.1 Disassembly

Check

for scratching, pitting,

flaking. chipping or lossofoverlay.

NOTE: When replacing the crankcase, carefully

rernove the components (such as an

oil

pressure reliefvalve, etc.) to reuse them,

Check

for c10gged oil hole.

Check

for stripped

thread,

@ Main bearing (lower halt)

@ Crankshaft
@ Main bearing (upper halt)

(j]) Check valve

(direct injection with turbocharger)

(j]) Tappet

® Crankcase

Check for wear, scoring, cracking, damaged or

widened ring grooves, clogged oil drain holes or

carbon deposits,

Check

for fatigue.

Check

for

wear

or darnage.

rJ)

Snap ring

@ Piston pin

CID

Piston

®l

Connecting rod

® Bearing cap bolt
® Main bearing cap
® Side seal

CID

Thrust plate

Check

for

scale

deposits,

corrosionorother

defects.

Check

for pitting,

flaking, chipping.
eracking,

105s

of

overlay

or

signs

ofoverheating.

Check

for cracking, scoring, wear

or clogged oil hole.

Check

for nicking,

chipping

or

abnormal

tooth

contact

Check for

wear or

clogged oil

hole.

IDisassembly sequence I

CD

Nut

® Connecting

rad

cap

@ Connecting

rad

bearing

Remove

@ through

®l

as an

assembly.

@ Top compression ring
@ Second compression ring
@ ou ring

7-30

(l)

Removing connecting rod cap

(a) Remove the nuts that hold the cap to the

connecting rod. Tap the bolts squarely and
evenly with a hammer and, after the cap
comes off the reamer bolts, remove the cap.

(b) Mark the bearings for cylinder number and

location.

(2) Preparation before removing pistons

(a) Lay the crankcase on its side.

(b) Use a cloth or oil paper to remove all carbon

deposits from the upper areas of the cylinder

liner. If any carbon deposits are present, this
will make it difficult to pull a piston upward.

(3) Removing piston

(a) Turn the crankshaft to bring the piston (from

which the

connecting

rod

cap

has been

removed) to top dead center.

(b) Put the handle of a hammer on the big-end of

the

connecting

rod

and

push

the

piston

assembly off the cylinder.

(4) Removing piston rings

Use piston ring pliers (31391-12900) to remove
the piston rings.

ENGINE MAIN PARTS

Removing connecting rad cap

Removing carbon from cylinders

Removing piston

Removing piston rings

7-31

ENGINE MAIN PARTS

(5) Removing piston pin

Using snap ring pliers, remove the snap rings
from the piston.

Removethepiston pin to separate thepiston from
the connecting rad.

If it is difficult to pull out the pin, heat the piston
with a piston heater or in hot water to expand the
pin bore.

(6) Removing main bearing caps

Remove the

bolts

that

hold the cap to the

crankcase. Remove the cap with lower main

bearing. To remove the rearmost bearing cap,

use a puller as shown in the illustration.

.-----------l(

NOTE

11--------,

When removing the caps, do not cause damage
to the bearings. After removing the caps and
bearings, mark each combination of the cap and
bearing for its location so that it can be restored
to the original position at reassembly.

(7) Removing crankshaft

Fasten a hoist to the crankshaft. Remove the
crankshaft by lifting it in horizontal position.

(8) Removing tappets

Remove the tappets.

NOTE

1-------,

Put a mark on

each

tappet so that it can be

installed in the same position.

7-32

Removing piston pin

Removing main bearing caps

Removing crankshaft

4.2 Inspeetion

Crankcase

(1) Gasket contact surface

Measure flatness of the gasket contact (top)
surface with a heavy accurate straight edge and
feeler gages, in three positions lengthwise, two
crosswise and two widthwise, as shown in the
illustration. If flatness exceeds the repair limit,
grind the crankcase.

Unit: mm [in.]

Item

Assembly Repair

Standard

Limit

Flatness of gasket 0.05 [0.0020] 0.20
contact surface or less [0.0079]

ENGINE MAIN PARTS

Checking crankcase f1atness

(2) Inside diameter of cylinders

(a) Measure the inside diameter of the cylinder

atthe top (ridged portion),middle and bottom,
each in two directions parallel and transverse
to the crankshaft, as shownin the illustration.

Unit: mm [in.]

Item

Assembly

Repair Service

Standard Limit Limit

Inside

94.000

diameter of

to 94.035 94.200 94.700

cylinder

[3.7008 [3.7087] [3.7283]

to 3.7022]

0.01

Circularity [0.0004]

or less

0.015

Taper

[0.0006]

or less

(b)Ifthe cylinder has reached the repair limit,

with the wear far less than the service limit,
bore it to 0.25 mm [0.0098 in.] or 0.5 mm
[0.0197

in.]

oversize.

(c) Hone the cylinder withinan accuracy of 0.035

mm [0.00138 in.], and use the piston and
piston rings

of

the same oversize.

Measuring diagram

E9

~

~

«)

lr)

7-

sti

-0

- oe

~]

Measuring cylinder

Unit: mm [in.]

7-33

ENGINE MAIN PARTS

(d) If any cylinder is unevenly worn, determine

the oversizeonthebasis ofthe maximumwear
noted to ensure perfect roundness in the

oversized bore.

..----------J[

NOrE

JI----------..,

(a) Refinish all cylinders to the same oversize.

(b) If the cylinder is found in good condition,

with the wear far less than the repair limit,
replace the piston ring and ream off "ridge"
at the top of the cylinder. Hone

the

bore if

necessary.

-------

Ridge-reaming cylinder

Pistons

and

piston rings

(l)

Measuring piston diameter

(a) Measure the diameter

ofthe

piston at skirt in
the direction transverse to the piston pin with
a micrometer, as shown in the illustration. If
the piston is wom beyond the service limit,

replace it.

Measuring diagram

~

Measuring piston diameter

Service

Limit

Unit: mm [in.]

Assembly

Standard

Item

FRONT mark

94.270

[3.7114]

93.770

[3.6917]

94.020

[3.7016]

5

g [0.18 oz]

or less

94.455 to 94.485

[3.7187 to 3.7199]

93,955 to 93.985

[3.6990

to 3.7002]

94.205

to 94.235

[3.7089 to 3.7100]

Standard

0.25
[0.0098]
oversize

0.50
[0.0197]
oversize

Piston weight
difference per :
engine

<IJ

2

Ë

o:l

:a

~

:9

~

1----+---------+-----1

<IJ

.-

'Sc

o 0

(b) When installing the piston, make sure the

weight difference of the piston per engine is

in the assembly standard.

FRONT mark and WEIGHT mark on piston

(direct injection type)

7-34

ENGINE MAIN PARTS

WEIGHTmark

FRONTmark

(2) Measuring cut clearancebetween endsofpiston

ring

Put

the piston ring in the gage or a new cylinder
sleeve and measurethe cut clearance with feeler
gages as shown in the illustration.

Ifthe

clearance

exceeds the service limit, replace all pistonrings.

Inside diameter of gage:

94"'2.

035

[3.7011.

001

38]

NOTE

1---------,

Use the piston to

put

the ring in the gage or the

cylinder sleeve squarely.

Unit: mm [in.]

Item

Assembly Service

Standard Limit

No.l
Cut and No.2 0.30 to 0.50 1.50
clearance rings [0.0118 to 0.0197] [0.0591]

Oi! ring

Forward

FRONT

mark and WEIGHT mark on piston

(swirl chamber type)

Measuring cut clearance between ends of piston ring

7-35

ENGINE MAIN PARTS

(3) Measuring clearance between groove and piston

ring

Put

a new piston ring in the groove. Measure the
clearance between the groove and piston ring
with a straight edge andfeeler gages as shown in
the illustration.

If

the clearance exceeds the

service limit; replace the piston.

Unit: mm [in.]

Item

Assembly

Repair

Standard Limit

No.1 0.07 to 0.11 0.200

Clearance

ring [0.0028 to 0.0043]

[0.0079]

between

No. 2 0.045 to 0.085 0.150
groove and ring [0.0018to 0.0034] [0.0059]
piston ring

üil

0.025 to 0.065 0.150

ring

[0.001

0 to0.0026] [0.0059]

(4) Measuringclearancebetween piston pin and bare

Measuretheinside diameterof the pistonpin bare
and the diameter of the pin as shown in the
illustration to check the clearance between the
piston and pin.

If

the clearance exceeds the
service limit, replace the pin or piston whichever
is excessively wom.

Unit: mm [in.]

Item

Nomina1 Assembly Service

Value

Standard

Limit

29.994 to

Diameter of

30

30.000

piston pin [1.18] [1.1809 to

1.18ll]

Clearance 0.000 to
between

0.016 0.050
piston pin [0.0000 to [0.0020]
and bare

0.0006]

7-36

Measuring clearance between groove and piston ring

Measuring clearance between piston pin and bore

(5) Measuring piston protrusion

If the piston protrusion is not correct, check the
various parts for clearance. Measure the piston
protrusion as outlined below.

(a) Measure the top dead center of the pistons

with a dial gage.

(b) Install the dial indicator on the top of the

crankcase. Set the indicator to read 0.0

mm

[0.000 in.].

(c) Measure the piston protrusion at least three

locations on the top

ofthe

piston and average

the

three

measurements

to

check

the
protrusion. Subtract the projection from the
compressed thickness of the cylinder head
gasket to check the clearance between the
piston top and the cylinder head.

Unit: mm [in.]

Item

Assembly Standard

Direct

0.05 to 0.45

Piston

injection [0.0020 to 0.0177]

protrusion

Swirl

-0.25

to 0.15

chamber [-0.0098 to 0.0059]

Compressed thickness

1.2±0.05

of cylinder head gasket [0.05±0.002]

.--------4

l

& CAUTION

f-------,

Incorrect

piston

protrusion

affects

engine
performance and causes valve interference with
the piston.

ENGINE MAIN PARTS

Measuring piston protrusion

7-37

Measuring connecting rad bearing

ENGINE MAIN PARTS

Connecting rods, conneetion

rod

hearings and

piston

pin

bushings

(1) Clearance between connecting rod bearing and

crankpin

Measure the diameter of the crankpin and the
inside diameter

of

the connecting rod bearing as

shown in the illustration to check the clearance

between the two.

If

the clearance exceeds the

service limit, replace the bearing. Ifthecrankpin
is badly or unevenly wom, grind the crankpin
and use an undersize bearing.

0.25 mm [0.0098 in.], 0.50mm [0.0197 in.] and

0.75 mm [0.0295 in.] undersize connecting rod
bearings are available for service.

.--

---!r

NOrE

11--

......,

To measurethe inside diameter ofthe connecting
rod bearing, install the upper and lower halves
in the connecting rod and tighten the cap bolts to
the specified torque.

Unit: mm [in.]

Item

Nominal Assembly

Service

Value Standard Limit

57.955

57.800

Diameter of

58

to 57.970 [2.2756]

crankpin

[2.28] [2.2817 (Repair

to 2.2823]

limit)

Clearance

0.030

between

to 0.090 0.200

connecting

[0.0012 [0.0079]

rad

bearing and

to 0.0035]

crankpin

Measuring diagram

EBttE

49.0to 59.0

Nrn

(5.0to

6.0

kgf-m)

[36.2to43.4

Ibf-ft]

(2) Clearance between connecting rod bushing and

piston pin

Measure the inside diameter of the connecting
rod bushing and the diameter of the piston pin as
shown in the illustration

tocheck

the clearance
between the two. If the clearance exceeds the
service

limit,

replace

the

pinorbus

hing

whichever is badly wom.

7-38

Measuring diagram

Measuring connecting rad bushing