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