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SD23
Workshop Manual
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NISSAN SD22, SD23, SD25, SD33 Workshop Manual

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Page 1

NISSAN MODEL SD SD22, SD23, SD25 & SD33

Page 2

ENGINE MECHANICAL

CONTENTS

ENGINE COMPONENTS

(Outer parts) EM- 2
ENGINE COMPONENTS
(Internal parts) EM- 3
ENGINE DISASSEMBLY EM- 4
PRECAUTIONS EM- 4
DISASSEMBLY EM- 4
DISASSEMBLING PISTON AND
CONNECTING ROD EM- 7
DISASSEMBLING CYLINDER HEAD EM- 7
INSPECTION AND REPAIR EM- 8
CYLINDER HEAD AND VALVE EM- 8
CAMSHAFT AND CAMSHAFT
BUSHING EM-11
CYLINDER BLOCK EM-12
CYLINDER LINER EM-12
PISTON, PISTON PIN AND PISTON
RINGS EM-13
CONNECTING ROD EM-14
CRANKSHAFT EN 1-14
BEARINGS -15
CRANKSHAFT PILOT BUSHING EN -15
COMBUSTION CHAMBER -16
FLYWHEELEM -16
GEAR TRAIN -16
FRONT PLATE -16
ENGINE ASSEMBLY -17
PRECAUTIONS -17
ASSEMBLING CYLINDER HEAD EM -17
ASSEMBLING PISTON AND CONNECTING
ROD -17
ASSEMBLING ENGINE OVERALL EM -18
SERVICE DATA AND
SPECIFICATIONS -23
INSPECTION AND ADJUSTMENT -23
TIGHTENING TORQUE -29
SPECIAL SERVICE TOOLS EM -31

EM

Page 3

ENGINE COMPONENTS (Outer parts)

Page 4

ENGINE COMPONENTS (Internal parts)

EM-3

181

Page 5

ENGINE DISASSEMBLY

PRECAUTIONS

Arrange the disassembled parts on the parts stand in accordance with their assembled locations, sequence, etc., so that the parts will be reassembled in their original locations. Place mating marks on the parts if necessary.

DISASSEMBLY

MOUNTING ENGINE ON WORK STAND

  • 1. Remove rear and left side parts.
  • Transmission assembly
  • Clutch cover assembly
  • Starter motor
  • Engine mounting bracket
  • Alternator assembly and fan belt
  • Alternator bracket
  • Intake manifold with venturi
  • Exhaust manifold & engine slinger
  • Breather assembly (SD 4-cylinder)

2. Install engine attachment on engine, using engine mounting bracket holes, air breather mounting hole and starter motor mounting holes (SD 4-cylinder). Install engine attachment on engine, using mounting bracket holes and cylinder block water drain cock hole (SD33).

3. Place both engine and attachment on engine stand.

4. Install Tool to prevent crankshaft rotation (SD 4-cylinder).

5. Drain engine oil and coolant.

REMOVING OUTER PARTS

  • 1. Remove front side engine parts.
  • Fan, Tem-coupling and fan pulley
  • Alternator adjusting bar
  • Thermostat housing
  • Water pump

In-line pump

(1) Timer cover

VE pump

  • (1) Drive gear cover
  • (2) Drive gear

C.A.V.-D.P.A. pump

  • (1) Timing gear cover
  • (2) Feed pump camshaft
  • (3) Drive gear

  • Vacuum tube assembly
  • 2. Remove right side parts.
  • (1) Fuel tube assembly

Use double wrench action.

Page 6

  • (2) Spill tube
  • (3) Injection nozzles
  • (4) Nozzle washers

Plug nozzle holes to prevent entry of dust and dirt.

  • (5) Oil cooler
  • (a) SD 4-cylinder
  • Oil filter using Tool.
  • Remove injection pump rear bracket (if equipped) and oil pipe.

Remove main and sub oil cooler (if equipped) assembly.

• Remove oil filter bracket.

  • (b) SD33
  • Fuel filter using Tool
  • Oil cooler and oil filter bracket with oil filter

(6) Injection pump assembly

(7) Diesel pump controller assembly (In-line type only)

(8) Glow plug harness and oil cooler hose.

REMOVING INTERNAL PARTS

  • 1. Remove rocker cover.
  • 2. Remove rocker shaft assembly.

3. Remove push rods and keep them in correct order.

4. Remove cylinder head bolts in the sequence shown below and then remove cylinder head assembly and cylinder head gasket assembly.

SD 4- cylind er
2 4 6 8 7 5 3
0 0 0 0 0 0 0 0
020 )
)
] 		C
C
C 		00
9 13 ) ( 5 1
SD33
2 		4 6 8 10 12 11 97 53 1
0
(16) 		0
0
20 		0
0
(24) 		0
0
26 		0 0
(18) 		0
(14)
Ŏ ŏ ŏ ŏ Ō Ō Ō
13 1 21 ) 25 23 19 (15)
s EM51 1
Page 7

5. Remove oil pump.

(1) Remove spindle support and drive spindle.

  • (2) Remove oil pan.
  • (3) Remove oil pump assembly.

6. Remove flywheel.

(1) Straighten lock plates (if equipped).

(2) Place a wooden block between cylinder block and flywheel to prevent crankshaft from turning (SD33).

  • (3) Remove flywheel.
  • (4) Remove flywheel housing (SD33).

WARNING: When removing flywheel, be careful not to drop it.

7. Crank pulley

If it is difficult to remove cone, tap evenly around the periphery of the crankshaft pulley (with a brass rod and hammer), causing the cone to protrude beyond the pulley (SD33).

  • 8. Remove front cover.
  • 9. Remove camshaft gear.

  • 10. Remove camshaft.
  • (1) Remove camshaft locating plate.

(2) Bring crankshaft to upper side as shown below and remove camshaft.

11. Remove valve lifters and keep them in correct order.

12. Remove crankshaft gear.

If it is difficult to extract crankshaft gear, use a suitable puller.

13. Remove front plate.

14. Remove oil jet bolts and then remove oil jet.

15. Pistons and connecting rod assembly

(1) Remove connecting rod caps and connecting rod bearings.

(2) Take pistons and connecting rods out of cylinder head side.

a. Piston can be easily removed by scraping carbon off top face of cylinder with a scraper.

Page 8

b. Numbers are stamped on connecting rod and cap corresponding to each cylinder. Care should be taken to avoid a wrong combination including bearing.

  • 16. Crankshaft
  • (1) 5 bearings (SD 4-cylinder)
  • a) Remove rear oil seal assembly.

  • b) Remove main bearing cap with bearing.
  • c) Remove crankshaft and main bearings.

Keep main bearing in correct order.

(2) 3 bearings (SD22) & 4 bearings (SD33).

a) Remove main bearing cap with bearing.

Remove rear main bearing cap with Tool.

b) Remove crankshaft and main bearings.

Keep main bearing in correct order.

c) Remove oil seal from crankshaft and rear main cap.

DISASSEMBLING PISTON AND CONNECTING ROD

1. Remove piston ring with a ring remover.

When removing piston rings, be careful not to scratch piston.

2. Remove piston snap rings, and immerse piston in oil of 80°C (176°F), and push out piston pin.

DISASSEMBLING CYLINDER HEAD

1. Remove glow plugs.

2. Remove valves, valve springs and relating parts using Tool.

3. Remove valve stem seals.

Keep valve spring and valves in correct order.

DISASSEMBLING ROCKER SHAFT

1. Remove cotter pin, washer and outer spring.

2. Remove valve rocker and rocker shaft bracket.

If it is difficult to remove rocker shaft bracket, immerse rocker shaft assembly in oil of 70°C (158°F) for a few minutes and then remove bracket.

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INSPECTION AND REPAIR

Clean all removed parts in cleaning oil, eliminating obstacles or dust/dirt from passages or holes. Also check these parts to make sure they are free from cracks or flaws.

CYLINDER HEAD AND VALVE

CHECKING CYLINDER HEAD MATING FACE

Measure the surface of cylinder head (on cylinder block side) for warpage.

Warpage of surface: Less than 0.2 mm (0.008 in)

If beyond the specified limit, correct with a surface grinder.

Cylinder head height should be greater than 89.7 mm (3.531 in) after surface has been ground.

VALVE

1. Check each of the intake and exhaust valve for worn, damaged or deformed valve stems. Correct or replace the valve that is faulty.

For standard size of valve, refer to S.D.S.

2. Valve face or valve stem end surface should be refaced by using a valve grinder.

Valve face angle: 45° - 45° 30'

VALVE LIFTER AND PUSH ROD

Valve lifter

1. Check valve lifters for excessive wear on the face.

2. Replace with new ones if worn beyond repair.

  • a. Valve lifter end should be smooth.
  • b. Valve lifter to lifter hole clearance:
    • Standard 0.016 - 0.052 mm (0.0006 - 0.0020 in) Limit Less than 0.10 mm (0.0039 in)

Push rod

1. Inspect push rod for excessive wear on the face.

2. Replace if worn or damaged beyond repair.

3. Check push rod for bend using a dial gauge.

Maximum allowable bend: Less than 0.5 mm (0.020 in)

VALVE SPRING

1. Check valve spring for squareness using a steel square and surface plate. If spring is out of square "S" more than specified limit, replace with new ones.

Out of square ("S"): Less than 1.3 mm (0.051 in)

2. Measure free length and tension of spring. If measured value exceeds specified limit, replace spring. Refer to S.D.S.

VALVE ROCKER ASSEMBLY

1. Check valve rockers, brackets and rocker shafts for scoring, wear or distortion. Replace if necessary.

Page 10

2. Check clearance between valve rockers and rocker shaft. If specified clearance is exceeded, replace affected valve rockers or shafts.

Specified clearance: Standard 0.02 - 0.05 mm (0.0008 - 0.0020 in) Limit Less than 0.15 mm (0.0059 in)

3. Check rocker shaft bend at its center. If bend is within specified limit, straighten it; and if it is greater than specified limit, replace rocker shaft.

Rocker shaft bend (Total indicator reading): Standard 0 - 0.1 mm (0 - 0.004 in) Limit Less than 0.3 mm (0.012 in)

VALVE GUIDE (SD23 and SD25)

Measure the clearance between valve guide and valve stem. If the clearance exceeds the specified limit, replace the worn parts or both valve and valve guide. In this case, it is

essential to determine if such a clearance has been caused by a worn or bend valve stem or by a worn valve guide.

Determining clearance

1. Precise method

Measure diameter of valve stem in three places: top, center, and bottom. Refer to S.D.S.

(2) Measure valve guide bore at center using telescope hole gauge.

(3) Subtract the highest reading of valve stem diameter from valve guide bore to obtain the stem to guide clearance.

Stem to guide clearance: Standard Intake 0.015 - 0.045 mm (0.0006 - 0.0018 in) Exhaust 0.04 - 0.07 mm (0.0016 - 0.0028 in)

EM-9

Max. tolerance Intake Less than 0.15 mm (0.0059 in) Exhaust Less than 0.20 mm (0.0079 in)

2. Expedient method

Pry the valve in a lateral direction, and measure the deflection at stem tip with dial gauge.

Stem to guide clearance is 1/2 of measured value.

Valve should be moved in parallel with rocker arm. (Generally, a large amount of wear occurs in this direction.)

Replacement of valve guide

To remove old guides, use a press (under a 2-ton pressure) or a hammer, and Tool.

1. Drive them out toward rocker cover side using Tool.

Heating the cylinder head will facilitate the operation.

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INSPECTION AND REPAIR

2. Install new guide onto cylinder head until the guide projects out 13 mm (0.51 in).

3. Ream the bore using Tool ST11032000.

Reaming bore: 8.000 - 8.015 mm (0.3150 - 0.3156 in)

VALVE STEM HOLE (SD22 and SD33)

(Cylinder head)

Measure clearance between valve stem hole (cylinder head) and valve stem. If clearance exceeds specified limit, replace worn parts.

Determining clearance

Refer to Valve Guide for determining clearance check method.

1. If valve stem clearance exceeds limit, grind valve stem hole and use oversize intake and exhaust valves.

Select oversize valve stem so that clearance between valve stem hole and stem is less than 0.15 mm (0.0059 in) at intake side and less than 0.20 mm (0.0079 in) at exhaust side.

Unit : mm (in)
Grinding valve
stem hole
diameter 		Diameter of
oversize valve
stem to be used
8.200 - 8.215
(0.3228 - 0.3234) 		8.2 (0.323)
8.400 - 8.415
(0.3307 - 0.3313) 		8.4 (0.331)

VALVE SEAT INSERTS

1. Check contact width and state of contact between valve and valve seat.

2. Reface valve seat with valve seat cutter.

Valve seat surface: Refer to S.D.S.

  • 2. Install new valve seats.
  • a. Eliminate the old staked lugs (Exhaust side).
  • b. Oversize exhaust valve seats are available as 0.2 and 0.4 mm (0.008 and 0.016 in).

(1) Place new valve seats dry ice and allow it to cool for five minutes.

WARNING: Do not touch cooled valve seats with bare hand.

(2) Heat cylinder head to 80°C (176°F).

(3) Install cooled valve seats on cylinder head with Tool.

Valve seat insert replacement

1. Remove valve seats with Tool.

Place a copper seat between contact surface of Tool and cylinder head.

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(4) Stake exhaust valve seat at five places with punch.

When staking valve seat, select different places than those staked before.

MEASURING CYLINDER HEAD-TO-VALVE DISTANCE

Measure distance from cylinder head surface to intake and exhaust valves. If specified distance is exceeded, replace valve(s) or valve seat(s). 

Specified distance:
Standard
Intake

0.275 - 0.675 mm

(0.0108 - 0.0266 in)

Exhaust

0.305 - 0.695 mm

(0.0120 - 0.0274 in)

Limit

Less than

1.25 mm (0.0492 in)

for intake and exhaust valves

CAMSHAFT AND CAMSHAFT BUSHING

CAMSHAFT BUSHING CLEARANCE

Measure inside diameter of camshaft bushing with an inside dial gauge and outside diameter of camshaft journal with a micrometer.

Clearance between camshaft and bushing (A-B):

Standard

Front

0.024 - 0.102 mm (0.0009 - 0.0040 in)

Center (SD 4-cylinder), Nos. 2 and 3 (SD33) 0.037 - 0.115 mm (0.0015 - 0.0045 in)

Rear

0.024 - 0.102 mm (0.0009 - 0.0040 in)

Limit

Less than 0.15 mm (0.0059 in)

Camshaft bushing undersize:

0.25 mm (0.0098 in), 0.50 mm (0.0197 in), 0.75 mm (0.0295 in)

REPLACING CAMSHAFT BUSHING

1. Remove rear plug.

2. Remove camshaft bushing with Tool.

Remove bushing from front side of engine.

Page 13

3. Install new bushing with Tool, following in the reverse order of re-moval.

  • a. Align cylinder block oil passage hole and bushing oil hole.
  • b. Install bushing with beveled end facing front.

4. Check camshaft bushing clearance.

5. Install new rear plug with a drift.

Apply liquid sealer.

CAMSHAFT ALIGNMENT

1. Check camshaft journal and cam surface for bend, wear or damage.

If fault is beyond limit, replace.

2. Check camshaft bend at center journal.

If bend is greater than specified limit, repair or replace camshaft.

Camshaft bend

(Total indicator reading): Standard 0 - 0.03 mm (0 - 0.0012 in) Limit

Less than 0.06 mm (0.0024 in)

3. Measure camshaft end play between locating plate and gear. If beyond the specified limit, replace camshaft locating plate.

Camshaft end play: Standard 0.08 - 0.28 mm (0.0031 - 0.0110 in) Limit

Less than 0.5 mm (0.020 in)

4. Measure camshaft cam height. If beyond the specified limit, replace camshaft.

Cam height limit: 36.8 mm (1.449 in)

CYLINDER BLOCK

Check cylinder block for cracks or flaws.

2. Check cylinder block warpage with cylinder liner removed. If beyond the limit, correct with a surface grinder.

Warpage of cylinder block surface (Without cylinder liner):

Longitudinal

Less than 0.10 mm (0.0039 in) Transverse direction

Less than 0.02 mm (0.0008 in)

Surface grinding limit: Height from upper face of cylinder block to crankshaft centerline should be greater than specified limit.

CYLINDER LINER

1. Check cylinder liner wear by means of bore diameter.

Cylinder liner bore wear limit: Less than 0.3 mm (0.012 in) Bore standard: SD22 and SD33 82.995 - 83.025 mm (3.2675 - 3.2687 in) SD23 and SD25 89.000 - 89.035 mm (3.5039 - 3.5053 in)

2. Measure cylinder liner bore for out-of-round and taper with a bore gauge. If beyond the limit, replace cylinder liner.

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INSPECTION AND REPAIR

Out-of-round (X--Y): Standard 0.02 mm (0.0008 in) Taper (A--B): Standard 0.02 mm (0.0008 in)

3. Check amount of projection of cylinder liner.

Cylinder liner projection: Standard 0.02 - 0.09 mm (0.0008 - 0.0035 in) Deviation of each cylinder Less than 0.05 mm (0.0020 in)

CYLINDER LINER REPLACEMENT

1. Remove cylinder liner with Tool.

2. Install cylinder liner with Tool or press stand.

3. Check amount of projection of cylinder liner.

PISTON, PISTON PIN AND PISTON RINGS

1. Check for damage, scratches and wear. Replace if such a fault is detected.

  • 2. Check piston outside diameter.
  • 5-ring piston

Measure piston outside diameter at 50.5 mm (1.988 in) from piston head. If beyond the limit, replace piston.

Piston wear limit:

Less than 0.15 mm (0.0059 in) Piston outside diameter: Standard 82.845 - 82.885 mm (3.2616 - 3.2632 in)

• 3-ring piston

Measure piston outside diameter at 70.0 mm (2.756 in) from piston head. If beyond the limit, replace piston.

Piston wear limit: Less than 0.15 mm (0.0059 in)

Piston outside diameter: Standard SD22 and SD33 3 rings 82.905 - 82.945 mm (3.4998 - 3.5014 in)

5 rings 82.845 - 82.885 mm (3.2616 - 3.2632 in) SD23 and SD25 88.895 - 88.935 mm (3.4998 - 3.5014 in)

3. Measure Piston ring to ring groove clearance. If beyond the limit, replace piston rings or piston.

Piston ring to groove clearance (side clearance): Limit

Unit: mm (in)

Ring
No. 		5 rings 3 rings
1 Less than
0.5 (0.020) 		Less than
0.5 (0.020)
2 Less than Less than
0.3 (0.012)
3 0.3 (0.012) Less than
0.15 (0.0059)
4
5 		Less than
0.15 (0.0059)

Page 15

4. Measure piston ring end gap by securely placing piston ring in cylinder liner at position where cylinder bore wear is least. If beyond the maximum limit, replace piston ring.

Maximum ring gap: 1.5 mm (0.059 in)

Bend Less than 0.05 mm (0.0020 in) Torsion Less than 0.05 mm (0.0020 in)

5. Measure piston pin to piston clearance. If beyond the limit, replace piston pin and piston.

Piston pin to piston clearance (A–B): Limit

Unit: mm (in)

5 rings & 3 rings

Less than 0.003 (0.0001)

CONNECTING ROD

If a connecting rod has any flaw on both slides of the thrust face and the large end, correct or replace it. Check connecting rod for bend or torsion using a connecting rod aligner. If bend or torsion exceeds the limit, correct or replace.

Bend and torsion [per 100 mm (3.94 in) length] : Standard

REPLACEMENT OF CONNECTING ROD SMALL END BUSHING

1. Drive in the small end bushing until it is flush with the end surface of the rod.

Be sure to align the oil holes.

2. After driving in the small end bushing, finish the bushing to the inside diameter specified by maintenance standard.

Small end bushing inside diameter Maintenance standard: 26.025 - 26.038 mm (1.0246 - 1.0251 in)

CRANKSHAFT

1. Check journal and crank pin for flaws or clogged oil passage. If necessary, replace crankshaft.

EM-14

2. Check journal and crank pin for out-of-round and taper with a micro-meter.

If beyond the specified value, replace or regrind crankshaft.

After regrinding crankshaft, use suitable undersize main bearing.

Out-of-round (X-Y): Less than 0.02 mm (0.0008 in) Taper (A-B): Less than 0.02 mm (0.0008 in)

When regrinding crankshaft, finish fillets as follows:

R Crank journal: 3.0 mm (0.118 in) Crank pin: 3.5 mm (0.138 in)

Do not attempt to cut counterweight of crankshaft.

3. Check crankshaft bend on center journal. If beyond the specified value, replace or repair.

Crankshaft bend (Total indicator reading): Standard 0 - 0.06 mm (0 - 0.0024 in)

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INSPECTION AND REPAIR

Limit Less than 0.2 mm (0.008 in)

BEARINGS MAIN BEARING OIL CLEARANCE

Thoroughly clean all bearings, journal and caps, and check for scratches, melt, scores or wear. Replace bearings, if any fault is detected. Set main bearings on cylinder block and install crankshaft.

3. Set plastigage at each journal.

4. Install main bearing caps with main bearings and tighten.

Do not turn crankshaft.

T : Main bearing cap bolt: 167 - 172 N⋅m (17.0 - 17.5 kg-m, 123 - 127 ft-lb)

5. Remove cap and measure main bearing oil clearance with plastigage. If clearance is not within specification, replace bearings.

Main bearing oil clearance: Standard 0.035 - 0.093 mm (0.0014 - 0.0037 in) Limit Less than 0.15 mm (0.0059 in)

CONNECTING ROD BEARING OIL CLEARANCE

Measure connecting rod bearing oil clearance in same manner as main bearing oil clearance.

If clearance is not within specification, replace bearings.

Do not turn connecting rod or crankshaft.

(T) : Connecting rod cap: SD22 and SD33 51-56 N·m (5.2 - 5.7 kg-m, 38 - 41 ft-lb) SD23 and SD25 67 - 71 N·m (6.8 - 7.2 kg-m, 49 - 52 ft-lb) Connecting rod bearing oil clearance: Standard 0.035 - 0.087 mm (0.0014 - 0.0034 in) Limit Less than 0.15 mm (0.0059 in)

EM-15

CRANKSHAFT PILOT BUSHING

CRANKSHAFT PILOT BUSHING REPLACEMENT

1. Pull out bushing with Tool.

2. Insert pilot bushing until distance between flange end and bushing is specified value.

Distance "A": Approx. 3.5 mm (0.138 in)

Page 17

a. Do not oil bushing.

b. Do not insert excessively.

COMBUSTION CHAMBER

Check combustion chamber for cracks and other damage. If necessary, replace.

COMBUSTION CHAMBER REPLACEMENT

Usually combustion chamber should not be removed.

1. Remove combustion chamber so that cylinder head cannot be damaged.

2. Install combustion chamber.

(1) Cool combustion chamber with dry ice for approximately 5 to 10 minutes.

WARNING:

Do not touch cooled combustion chamber with bare hand.

(2) Align combustion chamber knock pin with cylinder head notch, and drive in combustion chamber with a soft hammer.

3. Check amount of protrusion of combustion chamber.

FLYWHEEL

1. Check ring gear for wear or damage. If worn or damaged excessevely, replace.

Removal and installation of ring gear requires use of hydraulic press. Heat ring gear to 180 to 200°C (356 to 392°F), thus facilitating removal and installation.

Do not heat ring gear to more than 250°C (482°F).

2. If clutch contact surface of flywheel is worn, damaged or roughened beyond limit, replace.

3. Check flywheel runout before disassembling and after assembling. If beyond the limit, replace flywheel.

Runout (Total indicator reading): Less than 0.15 mm (0.0059 in)

GEAR TRAIN CAMSHAFT DRIVE GEAR

1. If gear tooth and key have scratches or are excessively worn, replace gear and key.

2. Check gear train backlash before disassembling and after assembling. If beyond the limit, replace gear.

Backlash: Standard 0.07 - 0.20 mm (0.0028 - 0.0079 in) Limit 0.30 mm (0.0118 in)

EM-16

INJECTION PUMP DRIVE GEAR

Check gear backlash before disassembling and after assembling. If beyond the limit, replace idler gear or injection pump drive gear.

Gear backlash: Standard 0.07 - 0.20 mm (0.0028 - 0.0079 in) Limit 0.30 mm (0.0118 in)

FRONT PLATE

Check front plate for warpage. If not within the limit, make flat or replace front plate.

Warpage limit: 0.2 mm (0.008 in)

Page 18

ENGINE ASSEMBLY

PRECAUTIONS

1. When installing sliding parts such as bearings, be sure to apply engine oil on the sliding surfaces.

2. Use new packing and oil seals.

3. Be sure to follow the specified order and tightening torque.

4 bearings (SD33) & 3 bearings (SD22)

4. Applying sealant

Use sealant to eliminate water and oil leaks.

Do not apply too much sealant. Parts requiring sealant are:

(1) Main bearing cap and cylinder block

(2) Cylinder block

After inserting rear bearing cap side seals, apply sealant to rear main bearing cap.

ASSEMBLING CYLINDER HEAD

1. Install glow plugs.

2. Install valve and valve spring.

(1) Install new valve stem seal with Tool.

(2) Install valve, valve spring, valve spring retainer and valve spring collet by using Tool.

a. Install valve spring (uneven pitch type) with its narrow pitch side (yellow or red painted) at cylinder head side.

  • b. When installing valve, apply engine oil on the valve stem and lip of valve stem oil seal.
  • c. Check whether the valve face is free of foreign matter.

ASSEMBLING PISTON AND CONNECTING ROD

Assemble pistons, piston pins and connecting rods of the designated cylinders.

  • a. Immerse piston in oil of 80°C (176°F), and push in piston pin. Install snap ring.
  • b. Install connecting rod and piston so that leaf type combustion chamber on piston head is opposite the matching marks on connecting rod and cap.

Page 19

SD22-3 bearing & SD33

No matching marks are stamped on service parts of connecting rod. Install so that connecting rod big end is offset with respect to piston, so that on No. 1, No. 3 and No. 5 cylinders this offset is rearward with respect to engine and on No. 2, No. 4 and No. 6 cylinders this offset is forward with respect to engine and so that leaf type combustion chamber on piston head is at right side of engine.

SD series 5-bearing engine

Install so that connecting rod big end is offset with respect to piston, and that this offset is forward on No. 1 and No. 3 cylinders with respect to engine and rearward on No. 2 and No. 4 cylinders.

Additionally, the leaf type combustion chamber on piston head must be at right side of engine.

Install piston ring so that mark stamped on ring faces upward.

ASSEMBLING ENGINE OVERALL

INSTALLING INTERNAL PARTS

First, mount cylinder block on work stand (refer to Engine Disassembly).

Then install following parts:

1. Install front plate, and measure front plate warpage.

2. Install valve lifter with engine oil coated.

3. Install camshaft assembly with engine oil applied to bushing.

4. Crankshaft

(1) Set upper main bearings at the proper position on cylinder block.

a. Install bearing so that side with oil groove is on cylinder block side and side without oil groove is on cap side.

b. Only apply engine oil to inside of bearing.

(2) Apply engine oil to crankshaft journal and pin and install crankshaft.(3) Install main bearing caps.

3 bearings (SD22) & 4 bearings (SD33)

a) Install main bearing cap so that embossed "F" mark is at front side of vehicle.

  • b) Apply engine oil to main bearing cap and cylinder block contact surfaces.
  • c) Install rear end oil seals to main bearing cap and cylinder block by hand so that they are protruded by 0.5 mm (0.020 in) from end surface.

Apply grease to contact surface of rear end oil seal and crankshaft.

Do not depress oil seal at middle portion.

Page 20

d) Install rear main bearing cap by aligning marks on cylinder block and cap.

  • e) Install new rear main bearing cap side seal with liquid sealant.
  • a. Face groove of side oil seal toward cap and block.
  • b. Make sure that side oil seal end protrudes by 0.5 mm (0.020 in) from cylinder block.

5 bearings (SD 4-cylinder)

a) Install main bearing cap so that "F" mark is at front side of vehicle.

  • b) Apply engine oil to main bearing cap and cylinder block contact surfaces.
  • c) Install oil seal assembly. Apply grease to contact surface of rear end oil seal and crankshaft.

(4) Install crankshaft thrust washer at the 4th journal from front.

Install thrust washer so that oil groove can face crankshaft.

(5) Tighten bearing cap bolts gradually in stages, starting from two to three separate stages, from center bearing and moving outward in sequence.

T : Main bearing cap bolt: 167 - 172 N⋅m (17.0 - 17.5 kg-m, 123 - 127 ft-lb)

(6) Measure crankshaft end play.

If not within specification, replace with proper thrust washer.

Crankshaft end play: Standard 0.06 - 0.14 mm (0.0024 - 0.0055 in) Limit Less than 0.4 mm (0.016 in) Thrust washer oversize: 0.2 mm (0.008 in) and 0.4 mm (0.016 in) oversize

EM-19

Install piston assembly with Tool. Install piston assembly by aligning matching mark on connecting rod big end.

Page 21

(2) Tighten connecting rod bearing cap nut.

T : Connecting rod bearing cap: SD22 and SD33 51 - 56 N·m (5.2 - 5.7 kg-m, 38 - 41 ft-lb) SD23 and SD25 67 - 71 N·m (6.8 - 7.2 kg-m, 49 - 52 ft-lb)

(3) Measure clearance between connecting rod big end and web of crankshaft.

If beyond the specified value, replace connecting rod.

Connecting rod thrust clearance: 0.1 - 0.2 mm (0.004 - 0.008 in)

  • 6. Install oil pump assembly.
  • 7. Measure piston top clearance.
  • (1) Set piston to T.D.C.

(2) Measure clearance between top of piston and cylinder block with dial gauge. Measure clearance at front and rear of each piston.

Piston top clearance: Standard --0.27 - +0.08 mm (--0.0106 - +0.0031 in) Limit --0.4 - +0.3 mm (--0.016 - +0.012 in)

8. Install crankshaft gear.

(1) Install crankshaft gear through key by aligning crank gear and camshaft gear matching marks.

(2) Measure gear backlash. Refer to Inspection and Repair.

9. Install oil jet so that it can face each gear.

10. Install rear engine plate (SD 4-cylinder)/flywheel housing (SD33)

EM-20

and flywheel and then bend lock plate (if equipped).

T: Flywheel bolt

3 bearings & 4 bearings 44 - 49 N·m (4.5 - 5.0 kg-m, 33 - 36 ft-lb) 5 bearings 88 - 98 N·m (9.0 - 10.0 kg-m, 65 - 72 ft-lb) Washer based bolt 127 - 147 N·m (13.0 - 15.0 kg-m, 94 - 108 ft-lb)

INSTALLING CYLINDER HEAD

1. Install new cylinder head gasket.

Securely install rubber rings into water and oil holes.

2. Install cylinder head by accommodating knock pin of cylinder block.

Be sure to install gasket with TOP mark facing upward if that mark is stamped.

3. Tighten cylinder head bolts in the sequence shown below. Install cylinder head.

Page 22

(1) Tighten main bolts to 59 - 78 N·m 6 - 8 ka-m. 43 - 58 ft-lb). (2) Tighten sub bolts to 20 - 29 N·m (2 - 3 kg-m, 14 - 22 ft-lb). (3) Tighten main bolts to 118 - 127 N·m (12 - 13 kg-m, 87 - 94 ft-lb). (4) Tighten sub bolts to 44 - 54 N-m (4.5 - 5.5 kg-m, 33 - 40 ft-lb).

After installing engine in the vehicle, warm up engine and retighten cylinder head bolts.

4. Install push rod.

Turn push rod and make sure that it is within spherical area of valve

5. Install rocker shaft assembly.

a. Tighten in two or three stages outwardly from center bracket.

b. Fully loosen rocker arm screws.

1 : Rocker shaft bolt 20 - 25 N·m (2.0 - 2.5 kg-m 14 - 18 ft-lb)

INSTALLING FRONT PARTS

1. Install front cover with new gasket and new front oil seal

(i) : Front cover fixing bolt MG

4 - 6 N-m (0.4 - 0.6 kg-m. 2.9 - 4.3 ft-lb)

  • 10 13 N·m (1.0 - 1.3 kg-m) 7 - 9 ft-lb) (di-t) 0 - T 2. Install crank pulley.
  • (T) : Crank pulley 294 - 324 N.m (30 - 33 kg-m. 217 - 239 ft-lb)

  • Install oil pan with new gasket coated with liquid sealant. 4. Install water pump with new
  • gasket 5. Install thermostat housing with

new gasket

INSTALLING SIDE PARTS

1. Install oil pump spindle by aligning grooves of camshaft, oil pump, drive gear and oil pump drive shaft.

Face oil hole in support toward cylinder block side and install support with new O-ring (SD 4-cylinder)/ gasket (SD33)

  • 2. Connect oil cooler hose to cylinder head
  • 3. Install glow plug harness.

4. Align front cover and crank pulley mark for setting No. 1 piston at T.D.C.

  • 5. Install injection pump assembly. Refer to Section EF.
  • 6. Injection nozzle and tube.

(1) Install new washer and injection nozzle.

(2) Install spill tube.

  • (T) : Spill tube fixing nut 39 - 49 N.m (4 - 5 ka-m 29 - 36 ft-lb)
  • (3) Install injection tube.

T) : Injection tube flare nut

29 - 34 N·m (3.0 - 3.5 kg-m. 22 - 25 ft-lb)

7. Temporarily install oil cooler, oil filter bracket and oil pipe, and then gradually tighten them.

  • 8. Vacuum tube assembly.
  • 9. Install diesel pump controller.
Page 23

10. Connect diesel pump controller connecting rod to injection pump lever (if equipped).

After installation, make sure there is play in pump lever.

11. Adjust valve clearance.

Refer to Section MA. 12. Install rocker cover with new gasket.

T : Rocker cover bolt 10 - 13 N·m (1.0 - 1.3 kg-m, 7 - 9 ft-lb)

13. Dismount engine from work stand and remove engine attachment.

  • 14. Install rear and left side parts.
  • Breather assembly
  • Intake and Exhaust manifold
  • T : Intake and exhaust manifolds 15 18 N·m (1.5 1.8 kg-m, 11 13 ft-lb)
  • Alternator bracket
  • (T) : Bracket bolt 26 - 36 N⋅m (2.7 - 3.7 kg-m, 20 - 27 ft-lb)
  • Alternator assembly and fan belt

EM-22

  • Engine mountings
  • Starter motor
  • Clutch cover assembly
  • Refer to Section CL. • Transmission assembly
  • Refer to Section MT.
ENGINE TUNE-UP

After installing engine in vehicle, tune up engine.

Refer to Section MA.

  • Fill engine oil and coolant to the specified levels.
  • Bleed fuel system.
  • Adjust drive belt deflection.
  • Adjust injection timing.
  • Adjust idle speed.
  • Adjust valve clearance.
  • Retighten cylinder head bolt.

Page 24

0.35 (0.014)

Page 25
Valve spring
Painted 50.20 (1.976 yellow
Free length mm (in) Painted 50.35 (1.982 red
Pressure height
mm/N (mm/kg, in/lb) 		30.4/599.2
(30.4/61.1, 1.197/134.7
Assembled height
mm/N (mm/kg, in/lb) 		39/294
(39/30, 1.54/66)
Out of square mm (in) 1.3 (0.051)
Valve guide (SD23 and SD25)
Init.mm (BnU [areading] Unit: mm (in
Standard Service
Valve guide outside diameter 12.033 - 12.044
(0.4737 -
0.4742) 		26 - 36
(7.7 - 3
20 - 27
Valve guide inner diameter
(Finished size) 		8.00
(0.3150 		- 8.015
- 0.3156)
Cylinder head valve guide
hole diameter 		12.00 - 12.011
(0.4724 -
0.4729) 		11.1 - 1.4 J
18 - 10
Interference fit of valve guide e 0.022 - 0.044
(0.0009 - 0.0017)
Standard Max. tolerance
Stem to guide clearance
Intake 		0.015 - 0.045
(0.0006 -
0.0018) 		0.15 (0.0059)
Exhaust 0.04 - 0.07
(0.0016 -
0.0028) 		0.20 (0.0079)
Valve deflection limit 0.15 (0 0.0059)
Valve stem hole (Cylinder head) (SD22 and SD33)
Unit: mm (in)
Valve stem hole
diameter 		inner/JANT2U 8.000
(0.3150 		- 8.015
- 0.3156)
Trial mm statu Refer Standard Max. tolerance
Stem to stem ho
Intake 		e clearance and
netti ased
(ecoo.o) of 		0.015 - 0.045
(0.0006 -
0.0018) 		0.15 (0.0059)
Exhaust Less (hao
.05 (0.0020) 		0.04 - 0.07
(0.0016 -
0.0028) 		0.20 (0.0079)
Valve deflection limit 0.15 ( 0.0059)
Page 26

Unit mm (in)

Valve seat

268 D1- - EM733 (0100)0) a 9.0
10:01
SD22 and SD33 SD23 and SD25 2) (95594-5)
Standard Ser vice Standard Serv ice
Intake
Outer diameter "D1" 		39.035 - 39.045
(1.5368 - 1.5372) 		Šatvica No.4 41.035 - 41.045
(1.6155 - 1.6159) 		60.01
00.01
Cameharit (ourit
disinitian
Front
Inner diameter "D2" 32.9 - 33.1
(1.295 - 1.303) 		Billin Billing Ring gep- 34.9 - 35.1
(1.374 - 1.382) 		43 Cantar
Diameter of seat "D3" 36.95 - 37.05
(1.4547 - 1.4587) 		190.050 - 90.070 -
1 10.65 - 90.070 - 		- No. 1 38.95 - 39.05
(1.5335 - 1.5374) 		46
(467)
viineFi
Valve seat face angle
" $\phi'' 		89° - 90° - 89° - 90° 015
01301 | 19707 4
19 		Caminant bend
Exhaust
Outer diameter "D1" 		35.035 - 35.045
(1.3793 - 1.3797) 		35.235 - 35.245
(1.3872 - 1.3876) 		35.435 - 35.445
(1.3951 - 1.3955) 		37.035 - 37.045
(1.4581 - 1.4585) 		37.235 - 37.245
(1.4659 -
1.4663) 		37.435 - 37.44
(1.4738 -
1.4742)
Inner diameter "D2" 0 08
(3800 0 		28.4 - 28.6
(1.118 - 1.126) 		28.4 - 28.6
(1.118 - 1.126) 		28.4 - 28.6
(1.118 - 1.126) 		5 0.15 30.4 - 30.6
(1.197 - 1.205)
Diameter of seat "D3" 30.95 - 31.05
(1.2185 - 1.2224) 		30.95 - 31.05
(1.2185 - 1.2224) 		30.95 - 31.05
(1.2185 - 1.2224) 		0.0059 - 32.950 - 33.050
(1.2972 - 1.3012 		)
Cylinder head valve 34.995 - 35.01
(1.3778 - 1.3783) 		35.195 - 35.21
(1.3856 - 1.3862) 		35.395 - 35.41
(1.3935 - 1.3941) 		36.995 - 37.010
(1.4565 - 1.4571) 		-
Valve seat face angle 89° - 90° (8-A) regist Piston pin 89° - 90° Line : him itsi
Page 27
CAMSHAFT AND CAMSHAFT BUSHING
- 1 Init mm (in)
Standard Limit
Camshaft journal to
bushing clearance
Front 0.024 - 0.102
(0.0009 - 0.0040)
Center 0.037 - 0.115
(0.0015 - 0.0045) 		0.15 (0.0059)
Rear 0.024 - 0.102
(0.0009 - 0.0040)
Camshaft journal
diameter
Front 45.434 - 45.447
(1.7887 - 1.7892) 		-
Center 43.897 - 43.910
(1.7282 - 1.7287)
Rear 41.218 - 41.231
(1.6228 - 1.6233) 		-
Camshaft bend (Total
ndicator reading) 		Less than 0.03
(0.0012) 		0.06 (0.0024)
Camshaft end play 0.08 - 0.28
(0.0031 - 0.0110) 		0.50 (0.0197)
CYLINDER BLOCK AND CYLINDER LINER

Unit: mm (in)

and the second se the second s
- 20 (0. .79)
S
O
O 		Front 268
10.55)
SEM251
Standard Wear limit
Surface flatness
(Without cylinder liner) 		Less than 0.10
(0.0039)
(Shaft direction)
Less than 0.02
(0.0008)
(Right angle
direction) 		0.3 (0.012)
Cylinder bore
(With cylinder liner)
Inner diameter
SD22 and SD33 		82.985 - 83.020
(3.2671 - 3.2685)
SD23 and SD25 89.000 - 89.030
(3.5039 - 3.5051) 		0.3 (0.012)
Out-of-round (X-Y) Less than 0.02
(0.0008)
Taper (A-B) Less than 0.02
(0.0008)
Projection "S" 0.02 - 0.09
(0.0008 - 0.0035)
Division of each
cylinder "S" 		Less than 0.05
(0.0020)
Piston to cylinder liner
clearance
SD22 and SD33 		0.04 - 0.11 (0.0 016 - 0.0043)
SD23 and SD25 0.09 - 0.115 (0.0 0035 - 0.0045)
Interference fit cylinder
liner to block
SD22 and33 		0.01 - 0.03 (0.0 004 - 0.0012)
SD23 and SD25 0.02 - 0.09 (0.00 008 - 0.0035)

EM671
Cam height ''A'' 37.28 - 37.32
(1.4677 - 1.4693)
Cam height limit 36.8 (1.449)
Page 28

Unit: mm (in)

D SEM427 Standard Service Cylinder liner inner diameter "D" SD22 and SD33 82.995 - 83.025 (3.2675 - 3.2687) 83.03 - 83.05 (3.2689 - 3.2697) SD23 and SD25 89.000 - 89.035 (3.5039 - 3.5053) 89.050 - 89.070 (3.5059 - 3.5067)

PISTON, PISTON RING AND PISTON PIN

Piston

Star ndard Limit
5 rings 3 rings 5 rings 3 rings
Side clearance
No. 1 		0.06
(0.0024 		0.06 - 0.10
(0.0024 - 0.0039) 		0.5 (0.020)
No. 2 0.04
(0.0016 		- 0.08
- 0.0031) 		0.3 (0.012)
No. 3 0.04 -
0.08
(0.0016 -
0.0031) 		0.02 -
0.06
(0.0008 -
0.0024) 		02 -
.06 0.3
008 - (0.012)
024)
No. 4 0.02 -
0.06 		0.15
(0.0059) 		_
No. 5 (0.0008 -
0.0024) 		0.15
(0.0059) 		-
Ring gap
No. 1 		0.30
(0.0118 		- 0.45
- 0.0177)
No. 2 0.20
(0.0079 		- 0.35
- 0.0138) 		1.5 (0.059)
No. 3 0.20 -
0.35
(0.0079 -
0.0138) 		0.15 -
0.30
(0.0059 -
0.0118)
No. 4 & No. 5 0.15 -
0.30
(0.0059 -
0.0118) 		-
Piston pin

Unit: mm (in)

Ont: him (iii)
SD22 and SD33 SD23 and SD25
Piston pin outer
diameter 		25.993 - 26.000
(1.0233 - 1.0236)
Interference fit of
piston pin to piston 		0 - 0.003
(0 - 0.0001) 		-0.007 - 0.010
(0.0003 - 0.0004)
Piston pin to connecting rod clearance 0.025 - 0.045
(0.0010 - 0.0018)
Page 29
CONNECTING ROD
CRANKSHAFT

Taper

Unit: mm (in)
Center distance
SD22, SD25 and SD33 		170.0 (6.69)
SD23 174.2 (6.86)
Connecting rod bend or torsion
[Per 100 mm (3.94 in) length]
Standard 		0 - 0.05 (0 - 0.0020)
Limit 0.05 (0.0020)
Piston pin bore diameter 26.025 - 26.038
(1.0246 - 1.0251)
Big end play
Standard 		0.1 - 0.2 (0.004 - 0.008)
Limit 0.2 (0.008)

Journal diameter "A" 70.907 - 70.920
(2.7916 - 2.7921)
Pin diameter ''B'' 52.913 - 52.926
(2.0832 - 2.0837)
'S''
SD22, SD25 and SD33 		50.00 (1.9685)
SD23 46.00 (1.8110)

EM715

Taper of journal and pin
"A-B"
Standard 0.01 (0.0004)
Limit 0.02 (0.0008)
Out-of-round of journal and pin ''X-Y'' L
Standard 0.01 (0.0004)
Limit 0.02 (0.0008)
Crankshaft bend
Standard 		0 - 0.03 (0 - 0.0012)
Limit 0.10 (0.0039)
Crankshaft end play
Standard 		0.06 - 0.14 (0.0024 - 0.0055)
Limit 0.40 (0.0157)
Page 30

Unit: mm (in)

BEARING
Bearing clearance
Standard Limit
Main bearing clearance
3 or 4 bearings 		0.035 - 0.093
(0.0014 - 0.0037) 		0.15 (0.0059)
5 bearings 0.035 - 0.087
(0.0014 - 0.0034)
Connecting rod bearing clearance 0.035 - 0.081
(0.0014 - 0.0032) 		0.15 (0.0059)
Main bearing undersize

Crank journal diameter 07 - 70.920 (2.7916 - 2.7921)

otaridard 10:001 10:020 (2:/010 2:/021)
Undersize
0.25 (0.0098) 		70.657 - 70.670 (2.7818 - 2.7823)
0.50 (0.0197) 70.407 - 70.420 (2.7719 - 2.7724)
0.75 (0.0295) 70.157 - 70.170 (2.7621 - 2.7626)
1.00 (0.0394) 69.907 - 69.920 (2.7522 - 2.7528)
Connecting rod bearing undersize
Crank pin diameter
Standard 52.913 - 52.926 (2.0832 - 2.0837)
Undersize
0.25 (0.0098) 		52.663 - 52.676 (2.0733 - 2.0739)
0.50 (0.0197) 52.413 - 52.426 (2.0635 - 2.0640)
0.75 (0.0295) 52.163 - 52.176 (2.0537 - 2.0542)
1.00 (0.0394) 51.913 - 51.926 (2.0438 - 2.0443)
MISCELLANEOUS COMPONENTS

Unit: mm (ii

0.07 - 0.20
(0.0028 - 0.0079)
Less than
0.15 (0.0059)
TIGHTENING TORQUE

Engine outer parts

- 1 H - 1 H N·m kg-m ft-lb
Water outlet bolt 10 - 13 1.0 - 1.3 7 - 9
Water pump bolt M8 10 - 13 1.0 - 1.3 7 - 9
M10 20 - 25 2.0 - 2.5 14 - 18
Manifold bolt and r nut 15 - 18 1.5 - 1.8 11 - 13
Injection pump nut
(In-line) 		20 - 25 2.0 - 2.5 14 - 18
Injection pump (VE E type)
nut 		20 - 25 2.0 - 2.5 14 - 18
bolt 16 - 22 1.6 - 2.2 12 - 16
Injection pump
(C.A.VD.P.A.) 		15 - 20 1.5 - 2.0 11 - 14
Injection nozzle to * 1 59 - 69 6.0 - 7.0 43 - 51
cylinder head *2 69 - 78 7.0 - 8.0 51 - 58
Oil cooler bolt 10 - 13 1.0 - 1.3 7 - 9
Oil cooler pipe nut 10 - 13 1.0 - 1.3 7 - 9
Timing gear cover b olt 10 - 13 1.0 - 1.3 7 - 9
Injection pump time er nut 59 - 69 6 - 7 43 - 51
Injection pump driv
gear nut (VE type) 		/e 59 - 69 6.0 - 7.0 43 - 51
Injection pump driv
gear (C.A.VD.P.A. 		re
) 		15 - 20 1.5 - 2.0 11 - 14
Feed pump gear
(C.A.VD.P.A.) 		15 - 20 1.5 - 2.0 11 - 14
Injection tube flare nut 29 - 34 3.0 - 3.5 22 - 25
Spill tube with cap i nut 39 - 49 4 - 5 29 - 36
Oil filter bracket bo lt 26 - 36 2.7 - 3.7 20 - 27
Alternator bracket b polt 26 - 36 2.7 - 3.7 20 - 27
Alternator to adjust
bar bolt 		ing 11 - 14 1.1 - 1.4 8 - 10
Diesel pump control
bolt 		ller 10 - 13 1.0 - 1.3 7 - 9
Diesel pump control
bracket bolt 		ler 45 - 61 4.6 - 6.2 33 - 45
Thermostat housing 10 - 13 1.0 - 1.3 7 - 9

*1: Part No. of injection nozzle

16600-90060, 16600-36W00, 16600-T9000 *2: Part No. of injection nozzle

16600-37502, 16600-90012, 16600-90019, 16600-J5571, 16600-T3401, 16600-T3470, 16600-T6200, 16600-T6201, 16600-Y8400, 16600-Y8401.

Page 31
Engine internal parts
N∙m kg-m ft-lb
Main bearing cap b olt 167 - 172 17.0 - 17.5 123 - 127
Crank pulley nut 294 - 324 30 - 33 217 - 239
Flywheel bolt
3 bearings & 4 b 		pearings 44 - 49 4.5 - 5.0 33 - 36
5 bearings 88 - 98 9.0 - 10.0 65 - 72
Bolt w/washer 127 - 147 13 - 15 94 - 108
Front cover bolt M6 4 - 6 0.4 - 0.6 2.9 - 4.3
M8 10 - 13 1.0 - 1.3 7 - 9
Front end plate bol t 10 - 13 1.0 - 1.3 7 - 9
Camshaft gear bolt 44 - 49 4.5 - 5.0 33 - 36
Oil pump bolt 13 - 19 1.3 - 1.9 9 - 14
Oil pan bolt 7 - 10 0.7 - 1.0 5.1 - 7.2
Cylinder head bolt Sub 44 - 54 4.5 - 5.5 33 - 40
Main 118 - 127 12 - 13 87 - 94
Rocker arm shaft b olt 20 - 25 2.0 - 2.5 14 - 18
Rocker arm lock nu ıt 20 - 25 2.0 - 2.5 14 - 18
Camshaft thrust pla
bolt 		ite 4 - 6 0.4 - 0.6 2.9 - 4.3
Connecting rod big
end nut
SD22 and SI 033 51 - 56 5.2 - 5.7 38 - 41
SD23 and SI 025 67 - 71 6.8 - 7.2 49 - 52
Rocker cover bolt 10 - 13 1,0 - 1.3 7 - 9
Oil jet (for piston) 29 - 39 3 - 4 22 - 29
Page 32
Engine application
Tool number Tool name SD22 SD23 SD25 SD33
ST05300000 Engine attachment Х Х Х
  1. (1) KV11101800
  2. (2) KV10106500
Engine
attachment
Engine stand
shaft 		- - Х
ST0501S000
(1) ST05011000
(2) ST05012000 		Engine stand
Base
2 		X Х Х Х
KV111021S0
① ST16660000
② KV11101300 		Crankshaft main bearing
Cap puller
Adapter 		Х _ Х
KV10107900 Valve lip seal puller х х х х
Page 33
Engine application
Tool number Tool name SD22 SD23 SD25 SD33
KV101092S0
① KV10109210
② KV10109220 		Valve spring compressor
Compressor
Adapter 		Х Х Х Х
ST1101S000 Valve guide reamer х _ - х
KV101039S0
(1) ST11081000
(2) ST11032000
(3) ST11033000 		Valve guide reamer set
Reamer [12.2 mm (0.480 in) dia.]
[8.0 mm (0.315 in) dia.]
Valve guide drift
(1) (2) (3) (4)
(3) (4)
(3) (4)
(4)
(4)
(4)
(4)
(4)
(4)
(4) 		Х х -
KV111011S0
① KV11101120
② KV11101130 		Valve seat remover
Adapter (Exhaust)
Adapter (Intake) 		Х To Х
KV111012S0
(1) KV11101220
(2) KV11101230
(3) KV11101240 		Valve seat insert tool
Adapter (Intake)
Adapter (Exhaust)
Adapter (Exhaust) 		x - _ X
Page 34
Tool number Tool name Engine application
SD22 SD23 SD25 SD33
KV111023S0 Cylinder liner tool х x x x
∟KV11102320 Cylinder liner tool adapter - X x -
KV11102500 Cylinder liner tool adapter Х _ х
ST16610001 Pilot bushing puller х Х х _
ST16690000 Pilot bushing puller _ _ _ х
KV11101000 Valve oil seal drift х х х Х
EM03470000 Piston ring compressor х х Х Х
KV11100300 Nozzle holder socket х х х х
Page 35
Teal anathar Tool name Engine application
Tool number Tool name SD22 SD23 SD25 SD33
ST16650000
(1) ST16650010
(2) ST16650020
(3) ST16650030
(4) ST16650040 		Cam bush replacer
Bar
Adapter (Front)
Adapter (Center)
Adapter (Rear) 		Х Х Х х
ST19530000 Injection pump timer puller Х х х х
ST19320000 Oil filter wrench Х х Х X
KV11100400 Socket wrench X х x X
Page 36

GENERAL INFORMATION

GI

CONTENTS
SPECIFICATIONS . GI-2
Table of model and corresponding
engine . GI-2
ENGINE SERIAL NUMBER LOCATION . . GI-3

TIGHTENING TORQUE OF STANDARD BOLT ......GI-4

SECTIONI

There are a tew different kinds of SD22 engines with respect to the number of piston rings and main bearings. When you are not sure of the number of piston rings and main bearings. When you are not sure of the number of piston rings or main bearings of a particular SD22 anging, refer to the table below.

Page 37
SPECIFICATIONS
SPECIFICATIONS
Engine model SD 22 SD23 SD25 SD33
Cylinder arrangeme ent - 742 In-line
Number of cylinde rs 4 6
Valve arrangement 14-14-15 0. H.V. ALC: NO n due more a
Bore x Stroke mm (in) 83 x 100 (3 3.27 × 3.94) 89 x 92 (3.50 x 3.62) 89 x 100 (3.50 x 3.94) 83 x 100 (3.27 x 3.94)
Displacement cm 3 (cu in) 2,164 ( 132.05) 2,289 (139.67) 2,488 (151.82) 3,246 (198.07)
Firing order MAGNOS ST AND 1-4-2-6-3-5
Number of piston Compression 3 riquiale as 2 6.16 nti üntredi e ection3 to be
rings 2.201TADIS
Number of main bearings 3 esponding 6 STANDARD BOL ble of model and con
Compression ratio le occur 20 20.8 20.5 20.7 21.4 *1 21.4 *1 20.8
Cetane number of diesel fuel More than 45 ER LOCA INE SERIAL NUMB

*1: Only for 720 model

TABLE OF MODEL AND CORRESPONDING ENGINE
Model Engine Injection pump type Remarks
430 SD22 DIESEL KIKI-BOSCH in-line *2
160 SD33 & T DIESEL KIKI-BOSCH in-line
CARLION 35 DIESEL KIKI-BOSCH in-line
H40 SD25 DIESEL KIKI-BOSCH VE And the second
0005 DIESEL KIKI-BOSCH in-line Only for Hong Kong
W40 SD25 DIESEL KIKI-BOSCH VE Y-NOTICE-
140 SD22 DIESEL KIKI-BOSCH in-line *2
SD22 C.A.VD.P.A. Only for Taiwan
unstaan ing prone engine. ar-the engine. DIESEL KIKI-BOSCH in-line wartner Hilly the tan-last may be per
F22 SD25 DIESEL KIKI-BOSCH VE Only for Europe and Australia
SD23 DIESEL KIKI-BOSCH in-line performance of privice. Be sure to
SD22 DIESEL KIKI-BOSCH VE *2
E23 SD23 DIESEL KIKI-BOSCH VE ensi dar brois and parts svailable
ACCURCINGING Y SD22 DIESEL KIKI-BOSCH in-line *2
MARCENERY w the service an DIESEL KIKI-BOSCH in-line and the standard strong with the
700 SD23 DIESEL KIKI-BOSCH VE Only for Europe and Australia
720 DIESEL KIKI-BOSCH in-line
1.9 SD25 DIESEL KIKI-BOSCH VE Only for Europe and Australia

*2: There are a few different kinds of SD22 engines with respect to the number of piston rings and main bearings. When you are not sure of the number of piston rings or main bearings of a particular SD22 engine, refer to the table below.

Page 38
DENGINE SERIAL NUMBER LOCATION
Number of
Piston rings 5 rings ion dou'l 3 rings SD22-743434 ~ (only for Hong Kong)
5 rin
430 S 0.0-0.0 SD22 619766 SD22-754092 ~ (for other countries)
Main bearings 3 bearings 3022-018700 5 bearings
0.8 8 Piston rings 11-8 0.1 5 rings
140
.at, s 		Main bearings -16 - 22 8,5 3 bearings
81-5 Piston rings 16-22 5 rings SD22-557447 ~ 3 rings
23 Main bearings 26 - 36 24.1 3 bearings
ME Piston rings VSTEM 5 rings 301.1942 Automatica and 3 rings
720 Main bearing act Bt/Phy. 3 bearings SD22-703539 ~ 5 bearings
ENGINE SERIAL NUMBER LOCATION

The engine number is stamped on the right side of the cylinder block.

SDXX XXXXX Serial No. Engine model

Page 39
TIGHTENING TORQUE OF STANDARD BOLT
TIGHTENING TORQUE OF STANDARD BOLT
Grade Grade Nominal size Diameter
M SCOB mm Her 		Pitch mm 025 Tightening torque
Kongi
Tunut B 		FIGHTHIN N∙m kg-m ft-lb
M6 082 ~ 35-5503 6.0 1.0 3 - 4 0.3 - 0.4 2.2 - 2.9
M8 golfaild đ 80 1.25 8 - 11 0.8 - 1.1 5.8 - 8.0
37 x 18 5.0
6 		1.0 8 - 11 0.8 - 1.1 5.8 - 8.0
4T M10 132 (900) 10.0 1.5 16 - 22 1.6 - 2.2 12 - 16
587447~ 8022 10.0 1.25 16 - 22 1.6 - 2.2 12 - 16
M12 Loni 12.0 1.75 26 - 36 2.7 - 3.7 20 - 27
- tinitz 12.0 1.25 30 - 40 3.1 - 4.1 22 - 30
i feral mu'n beer M14 - esacos $022 14.0 1.5 46 - 62 4.7 - 6.3 34 - 46
and Contract M6 6.0 1.0 6 - 7 0.6 - 0.7 4.3 - 5.1
presentation of the MR 8.0 1.25 14 - 18 1.4 - 1.8 10 - 13
ten a that HOITAG TAN 01.0300.04 1.0 14 - 18 1.4 - 1.8 10 - 13
71 M10 SAM 5751 10.0 1.5 25 - 35 2.6 - 3.6 19 - 26
1.14.50 WITO 10.0 1.25 26 - 36 2.7 - 3.7 20 - 27
420 M12 12.0 1.75 45 - 61 4.6 - 6.2 33 - 45
180 60110.1 12.0 1.25 50 - 68 5.1 - 6.9 37 - 50
M14 14.0 1.5 76 - 103 7.7 - 10.5 56 - 76
Held. M6 6.0 1.0 8 - 11 0.8 - 1.1 5.8 - 8.0
M8 e dinata a Reference 8.0 1.25 19 - 25 1.9 - 2.5 14 - 18
1945 5625 3 1.0 20 - 27 2.0 - 2.8 14 - 20
9т M10 ALC: N 10.0 1.5 36 - 50 3.7 - 5.1 27 - 37
Sec. U. AVAR 5.033 1.25 39 - 51 4.0 - 5.2 29 - 38
M12 1 Vaglox 12.0 1.75 65 - 88 6.6 - 9.0 48 - 65
WILZ S.L 12.0 1.25 72 - 97 7.3 - 9.9 53 - 72
M14 14.0 1.5 109 - 147 11.1 - 15.0 80 - 108

1. Special parts are excluded.

2. This standard is applicable to bolts having the following marks embossed on the bolt head.

Grade Mark 4T ....................................

GI-4

Page 40

HETEY3. DAG HUNDLEDGIN. CHEAH

MAINTENANCE

MA

CONTENTS
BASIC MECHANICAL SYSTEM . MA- 2 COOLING AND LUBRICATION 러렌
Retightening cylinder head bolts, SYSTEM MA-11
manifold nuts and venturi nuts . MA- 2 Changing engine coolant MA-11 A. A.1
Adjusting intake and exhaust valve Checking cooling system hoses and off.
clearance . MA- 2 connections for leaks MA-11
Checking and adjusting drive belt MA- 3 Changing engine oil and oil filter MA-11
Checking engine compression pressure . MA- 4 Checking engine oil for leaks MA-12
INJECTION AND FUEL SYSTEM MA- 5 Checking and changing injection pump 7.144
Checking and adjusting injection - oil (Lubrication type only) MA-12
timing , MA- 5 Lubricating injection pump governor
Idle and maximum speed adjustment MA- 5 diaphragm MA-13
Injection nozzle . MA- 8 ELECTRICAL SYSTEM MA-13 1.01
Cleaning and replacing air cleaner L Checking glow plugs MA-13 20
filter . MA- 8 SERVICE DATA AND
Checking fuel filter, draining water SPECIFICATIONS MA-14 2
and replacing filter . MA- 9 Inspection and adjustment MA-14 Q
Checking fuel lines (Hoses, piping, Tightening torque MA-14 12
connectors, etc.) . MA- 10 TROUBLE DIAGNOSES AND 0 _0
Checking rubber hoses (Water, air vacuur n n Situe CORRECTIONS MA-15
and oil hoses, etc.) MA- 10 SPECIAL SERVICE TOOLS MA-29

VENTURI, NUTS

Leafu uf this area may capita rough or the second s

NAME OF T

1. .

Most almonitor with a pryong barand built presses in writers the manabuilt state.

Then tighten fully wangely

159.AM

Page 41
BASIC MECHANICAL SYSTEM
RETIGHTENING CYLINDER HEAD BOLTS, MANIFOLD NUTS AND VENTURI NUTS
CYLINDER HEAD BOLTS

1. Run engine until coolant temperature indicator points to the middle of gauge, then stop engine.

2. Remove valve rocker cover.

3. Tighten cylinder head bolts according to the order shown in the figure, starting with the center and moving toward the ends.

T : Cylinder head bolts

Main bolts (○): 118 - 127 N-m (12 - 13 kg-m, 87 - 94 ft-lb) Sub bolts (□): 44 - 54 N·m (4.5 - 5.5 kg-m, 33 - 40 ft-lb)

When tightening main bolts (near the rocker shaft side), be sure to use Tool.

4. Install valve rocker cover.

MANIFOLD AND EXHAUST TUBE

WARNING: Do not check the exhaust system

until it has cooled off. Otherwise, you may burn yourself.

(T) : Intake & Exhaust manifold nuts 15 - 18 N⋅m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

For the exhaust tube nuts' tightening torque specifications, refer to Section EF of the applicable Service Manual.

VENTURI NUTS

Leaks at this area may cause rough idle, surging, deceleration, popping or whistle.

(T) : Venturi nuts 3 - 4 N⋅m

(0.3 - 0.4 kg-m, 2.2 - 2.9 ft-lb)

ADJUSTING INTAKE AND EXHAUST VALVE CLEARANCE

  • a. Adjustment should be made while engine is hot.
  • b. Adjustment cannot be made while engine is in operation.

To adjust, proceed as follows:

1. Remove valve rocker cover.

2. Set No. 1 piston to Top Dead Center on compression stroke.

3. Adjust clearances of (1), (2), (3) and (5) valves.

Adjust clearances of valves (1), (2), (4), (6), (8) and (10).

Page 42

(1) Using feeler gauge, measure clearance between rocker arm and valve head.

Feeler gauge should move with a very slight drag.

(2) If clearance is not the specified value, loosen rocker arm nut and turn rocker arm screw to provide proper clearance.

(3) Hold rocker arm screw and tighten rocker arm nut.

(4) Recheck clearance,

Bring No. 4 piston (SD 4-cylinder) or No. 6 piston (SD33) to Top Dead Center on compression stroke. Adjust clearances of (4), (6), (7) and (8) valves.

Adjust clearances of valves (3), (5), (7), (9), (1) and (12).

5. Install valve rocker cover.

1. Visually inspect for cracks or damage.

The belts should not touch the bottom of the pulley groove.

2. Check belt tension by pushing.

The belts should deflect by the specified amount.

  • Drive belt deflection:
  • 8 12 mm
  • (0.31 0.47 in)
  • Applied pressing force: 98 N (10 kg, 22 lb)

3. Adjust belt tension as follows:

FAN BELT

1. Loosen upper and lower alternator securing bolts until alternator can be moved slightly.

2. Move alternator with a prying bar until belt tension is within the specified range.

Then tighten bolts securely.

AIR CONDITIONER COMPRESSOR BELT

1. Loosen idler pulley lock nut.

2. Turn idler pulley adjusting bolt in either direction until air conditioner compressor belts' tension is within the specified range.

3. Tighten idler pulley lock nut.

POWER STEERING PUMP BELT

1. Loosen pump fixing bolt and adjusting bar bolt.

2. Move pump until fan belt tension is within the specified range.

Then tighten pump fixing bolt and adjusting bar bolt.

Page 43
BASIC MECHANICAL SYSTEM
CHECKING ENGINE COMPRESSION PRESSURE

  • 1. Warm up engine.
  • 2. Remove following parts:
  • Injection tube on nozzle side
  • Spill tube assembly.

When removing spill tube, hold nut and nozzle to prevent it from breaking.

Nozzle assemblies

Nozzle gaskets

3. Fit compression gauge adapter to cylinder head. Make sure bleeder of gauge is closed.

T : Compression gauge adpater

76 - 78 N-m (7.7 - 8.0 kg-m, 56 - 58 ft-lb)

  • 4. Set no fuel injected condition.In-line type
  • In-line type
  • (1) For model equipped with injection pump controller
  • a. Disconnect harness connector between injection pump control unit (D.P.C.) and injection pump controller.

b. Confirm that injection pump control lever stays in the stop position.

(2) For model not equipped with injection pump controller Set control lever of injection pump at zero injection.

VE and C.A.V.-D.P.A. type Disconnect or remove fuel cut solenoid wire.

5. Depress accelerator pedal fully and crank engine, then read gauge indication.

Engine compression measurement should be made as quickly as possible.

Compression pressure:

Unit: kPa (bar, kg/cm2, psi)/200 rpm

Standard 2,942
(29.4, 30, 427)
Minimum 2,452
(24.5, 25, 356)
Differential limit
between cylinders 		294
(2.9, 3, 43)

6. Remove compression gauge adapter and push bleeder. Make sure that bleeder is closed before attempting to check another cylinder.

If cylinder compression in one or more cylinders is low, pour a small quantity of engine oil into cylinders through the nozzle holes and retest compression.

  • If adding oil helps the compression pressure, chances are that piston rings are worn or damaged.
  • If pressure stays low, valve may be sticking or seating improperly.
  • If cylinder compression in any two adjacent cylinders is low, and if adding oil does not help the compression, there is leakage past the gasketed surface. Oil and water in combustion chambers can result from this problem.
  • 7. Install following parts:
  • Nozzle gaskets
Page 44

When installing injection nozzle, observe the following cautions.

  • Always use new injection nozzle gaskets ( (A) and (B) ).
  • When installing the small nozzle gasket (B), the installation direction is as shown in figure at right.

  • Nozzle assemblies
  • Spill tube assembly
  • Injection tube
  • Bleed air from fuel system. Refer to BLEEDING FUEL SYSTEM in sec-
INJECTION AND FUEL SYSTEM
CHECKING AND ADJUSTING INJECTION TIMING
CHECKING

Check alignment marks on pump and engine front plate. Align these if necessary or check initial injection timing.

Refer to section EF for adjusting initial timing.

IDLE AND MAXIMUM SPEED ADJUSTMENT

IN-LINE TYPE

CAUTION:

  • a. Do not remove sealing wires unless absolutely necessary.
  • b. Maximum speed adjusting screw is retained by sealing wire and need not be adjusted under normal circumstances. However if it should become necessary, adjust it with the screw. After adjustment, always wind up with sealing wire

Throttle control wire adjustment

  • Turn idle control knob fully counterclockwise
  • Push idle control knob in.

2. Make sure that free play is 1 mm (0.04 in) at venturi's throttle lever

3. If not within the specified range, adjust with wire adjusting nut.

4. After adjusting free play properly, tighten lock nut.

Idle adjustment f deruis lug tentenite

  • Turn idle control knob fully counterclockwise.
  • Push idle control knob in.

2. Run engine until coolant temperature indicator points to the middle of gauge.

3. Attach tachometer's pick-up to No.1 fuel injection tube.

In order to obtain a more accurate reading of engine speed, remove the clamps on No. 1 injection tube.

4. Loosen lock nut, then adjust engine to the specified idle speed with idle speed screw.

I dle speed:

  • 550 650 rpm
    • (without power steering/
    • Air conditioner)
  • 650 750 rpm
  • (with power steering/
    • Air conditioner)

5. After adjusting idle speed, tighten lock nut.

Page 45
INJECTION AND FUEL SYSTEM
Maximum speed adjustment

Maximum speed adjusting screw is retained by sealing wire and need not be adjusted under normal circumstances. However, if it should become necessary to adjust it, the following procedures should be followed:

1. Start engine and warm it up until coolant temperature indicator points to middle of gauge.

2. Connect tachometer's pick-up to No. 1 fuel injection tube.

To obtain accurate reading of engine rpm, loosen clamp that secures No. 1 fuel injection tubes.

3. To obtain maximum speed, turn the adjusting screw either direction while fully depressing accelerator pedal.

Maximum engine speed (Under no load): 4,200 - 4,400 rpm

4. After adjustment, tighten lock nut securely.

5. Wind up with a sealing wire.

Dash pot
Adjusting

After idle adjustment, dash pot adjustment must be performed.

1. Warm up engine.

2. Attach a diesel tacho tester's pickup to No. 1 injection tube.

In order to obtain a more accurate reading of engine speed, remove the clamp on No. 1 injection tube.

3. Loosen dash pot lock nut.

4. Maintain engine speed at 1,280 to 1,350 rpm. Operate and adjust dash pot so that control lever tip contacts dash pot tip.

343.1 300708

VE-TYPE

CAUTION:

a. Do not remove sealing wires unless absolutely necessary.

b. Disturbing full-load adjusting screw adjustment will change fuel flow characteristics, resulting in an improperly adjusted engine. Readjustment of fuel injection pump should be done using a pump tester.

c. If maximum speed adjusting screw is turned in direction that increases control lever angle, engine damage may result.

Throttle control wire adjustment

1. Turn idle control knob fully counterclockwise.

2. Make sure that clearance between idle control lever pin and fuel injection pump control lever is within the specified range.

Clearance: 1 - 2 mm (0.04 - 0.08 in)

3. If not within the specified range, adjust with idle control wire adjusting nut.

4. After adjusting clearance, tighten lock nut.

Idle adjustment

1. Turn idle control knob fully counterclockwise.

2. Start engine and warm it up until coolant temperature indicator points to middle of gauge.

3. Attach tachometer's pick-up to No. 1 fuel injection tube.

In order to take accurate reading of engine rpm, remove clamps that secures No. 1 fuel injection tube.

Page 46
INJECTION AND FUEL SYSTEM

4. Adjust engine to specified idle speed with idle speed adjusting screw.

Idle speed: 550 - 650 rpm (without power steering/ Air conditioner) 650 - 750 rpm (with power steering/ Air conditioner)

5. After adjusting idle speed properly, tighten lock nut.

Maximum speed adjustment

Maximum speed adjusting screw is retained by sealing wire and need not be adjusted under normal circumstances. However, if it should become necessary to adjust it, the following procedure should be followed:

1. Start engine and warm it up until coolant temperature indicator points to middle of gauge.

2. Connect tachometer's pick-up to No. 1 fuel injection tube.

To obtain accurate reading of engine rpm, remove clamps that secures No. 1 fuel injection tube.

3. Depress accelerator pedal fully under no load and, at this point, read the tachometer indication.

4. If indication is lower than specified maximum engine speed, turn maximum speed adjusting screw counterclockwise 1 or 2 rotations. Then depress accelerator pedal to floor under no load and, at this point, read indication.

5. If indication is still lower than specified speed, repeat step 4 above until specified engine speed is reached. 6. After adjustment, tighten lock nut securely.

7. Wind up with a sealing wire.

C.A.V.-D.P.A. TYPE
CAUTION:

  • a. Do not remove sealing wires unless absolutely necessary.
  • Always adjust the engine's maximum speed so that it can not overrun. Overrunning can damage engine.
Throttle control wire adjustment

1. Turn idle control knob fully counterclockwise.

2. Make sure that free play is 1 mm (0.04 in) at pump control lever.

If not within the specified range, adjust with wire adjusting nuts. After adjusting free play properly,

tighten lock nut.

Idle adjustment

1. Run engine until coolant temperature indicator points to middle of gauge.

2. Disengage accelerator wire at injection pump throttle lever.

3. Adjust engine to the specified idle speed with idle adjusting screw.

Idle speed: 650 rpm

If engine speed does not drop to specified idle speed by means of idle adjusting screw, adjust anti-stall screw. Refer to Anti-stall Adjustment.

4. After adjusting idle speed properly, tighten lock nut.

5. Engage accelerator wire at injection pump throttle lever.

Ensure that engine does not stall when accelerator pedal is abruptly released from fully depressed position. If it stalls, make "an anti-stall adjustment".

Maximum speed adjustment

1. Disengage accelerator wire at the injection pump throttle lever.

2. Run engine under no load, and move throttle lever to fully open position. Adjust engine to specified max. rpm (under no load).

Max. engine speed (No load): 4,250 - 4,300 rpm

Page 47

3. After adjustment, tighten lock nut securely.

4. Slide a sealing sleeve over max. speed adjusting screw, and wind up with a wire.

5. Engage accelerator wire at injection pump throttle lever.

Seal up at the following three places. (1) Max. speed adjusting screw

(Nissan) (2) Control cover mounting bolt (Pump manufacturer)

(3) Cover plate mounting bolt on pump housing side (Pump manufacturer)

If injection pump is renewed, have new pump adjusted for max. engine speed and sealed up by distributor.

Anti-stall adjustment

If any of the following conditions is noted, make an anti-stall adjustment.

  • Engine stalls when accelerator pedal is abruptly released from full throttle position.
  • Engine does not drop to idle speed with idle adjusting screw.
Adjustment of condition (a)

1. Disengage accelerator wire at

injection pump throttle lever. 2. Turn anti-stall screw in until engine speed starts to increase. From that position, turn screw out one-half rotation.

3. After adjusting idle speed and engaging accelerator wire, ensure that engine does not stall.

If lock nut is left loose during adjustment, fuel may leak.

Tighten lock nut whenever fuel leakage occurs.

Adjustment of condition (b)

Turn anti-stall screw out, then adjust engine to specified idle speed in same manner as adjustment of condition (a).

INJECTION NOZZLE

Check valve for nozzle tester should be closed to prevent damage to gauge.

Check initial injection pressure by pumping tester handle one time per second.

  • Initial injection pressure: DIESEL KIKI 9,807 - 10,297 kPa (98.1 - 103.0 bar, 100 - 105 kg/cm2, 1,422 - 1,493 psi) C.A.V.-D.P.A. 12,259 - 13,239 kPa (122.6 - 132.4 bar, 125 - 135 kg/cm2, 1,778 - 1,920 psi)
    • New nozzle initial injection pressure: DIESEL KIKI 10,297 - 11,082 kPa (103.0 - 110.8 bar, 105 - 113 kg/cm2, 1,493 - 1,607 psi) C.A.V.-D.P.A. 13,141 - 13,730 kPa (131.4 - 137.3 bar, 134 - 140 kg/cm2, 1,905 - 1,991 psi)

The new nozzle requires that the initial injection pressure always be checked.

b. Check spray pattern by pumping tester handle 4 to 6 times per second or more.

If injection starting pressure or spray pattern is not normal, adjust injection nozzle. For details, refer to INJECTION NOZZLE ASSEMBLY in EF section.

CLEANING AND REPLACING AIR CLEANER FILTER

a. Replace viscous type filter element at the specified maintenance intervals. It does not have to be cleaned between replacement periods.

Page 48

b. Clean dry type filter element at the specified maintenance intervals. If necessary, replace it.

2. Replace or clean air cleaner element.

3. Loosen center bolt and remove bolt, filter body, element, lower cover, etc.

4. Clean component parts.

5. Install new element and assemble fuel filter.

Refer to Bleeding Fuel System in EF section.

Page 49
C.A.V.-D.P.A. type

1. Check for contamination, leaks or cracks.

Clean, repair or replace if necessary.

2. Drain fuel in filter.

3. Loosen center bolt and remove stud, filter bowl, element assembly, etc.

4. Clean component parts.

5. Install new element and assemble fuel filter.

Always replace seal rings and O-ring.

6. Bleed fuel system.

Refer to Bleeding Fuel System in EF section.

DRAINING WATER

  • a. Drain water from fuel filter in accordance with maintenance schedule. Also do this when warning light comes on (for VE-type.)
  • b. Bleed air from fuel system.
  • c. Be sure to place a container beneath fuel filter.

In-line type 11 1111 0/41303H3

1. Loosen drain cock and drain water.

After draining all fuel from fuel filter, tighten drain cock. Bleed fuel system

Refer to Bleeding Fuel System in EF section.

VE-type

Set a container under fuel filter. Remove fuel detector sensor and drain water.

Pumping priming pump will quicken water drain.

3. Install fuel detector sensor to filter.

4. Bleed fuel system.

Refer to Bleeding Fuel System in EF section.

C.A.V.-D.P.A. type

1. Remove drain plug and drain water.

2. Install drain plug to filter.

3. Bleed fuel system.

Refer to Bleeding Fuel System in EF section.

CHECKING FUEL LINES (Hoses, piping, connectors, etc.)

1. Check fuel line for leaks, particularly around fuel pipe and fuel hose connections with engine running.

2. Tighten loose connections and replace any damaged or deformed parts.

CHECKING RUBBER HOSES (Water, air vacuum and oil hoses, etc.)

1. Check injection pump governor vacuum hose and air hose, water hose and oil hose for damage, cracks or deterioration,

Tighten loose connections and replace any parts with cracks or deterioration.

Page 50
COOLING AND LUBRICATION SYSTEM
CHANGING ENGINE COOLANT
WARNING.

To avoid the danger of being scalded never attempt to change the coolant when the engine is hot.

When changing engine coolant or heater equipped models, set heater "TEMP" control lever at full "HOT" position.

1. Open drain cock at bottom of radiator, and remove radiator cap.

Remove cylinder block drain plug.

  • 3 Drain coolant completely. Then flush cooling system.
  • 4. Close drain cock and plug.

5 Fill radiator with coolant up to filler opening, observing instructions attached to anti-freeze container for mixing ratio of anti-freeze to water.

  • 6. Run engine for a few minutes. If necessary, add coolant.
  • 7. Fill reservoir tank with coolant up to "MAX" level.

8. Install radiator cap.

Check drain cock and plug for any sign of leakage.

CHECKING COOLING SYSTEM HOSES AND CONNECTIONS FOR LEAKS

Check hoses and fittings for loose connections or deterioration.

Retighten or replace if necessary.

CHECKING BADIATOB CAP

Using cap tester, check the radiator cap relief pressure.

If the pressure gauge drops rapidly and excessively replace the radiator cap.

CHECKING COOLING SYSTEM FOR LEAKS

Attach pressure tester and pump tester, and apply specified pressure. Check for drop in pressure.

If pressure drops, check for leaks from hoses, radiator, or water pump. If no external leaks are found, check heater core, block and head.

CHANGING ENGINE OIL AND OIL FILTER

1. Warm up engine.

filler cap, and allow oil to drain, with a clean rag,

  • A milky oil indicates the presence of cooling water. Isolate the cause and take corrective measures.
  • An oil with extremely low viscosity indicates the presence of fuel.

. Clean and install oil pan drain nlug with washer.

T : Oil pan drain plug 49 - 59 N-m (5 - 6 kg-m, 36 - 43 ft-lb)

Remove oil filter.

Cartridge type

(1) Using Tool, remove oil filter.

2. Remove oil pan drain plug and oil (2) Wipe oil filter mounting surface

Page 51
COOLING AND LUBRICATION SYSTEM

(3) Smear a little engine oil on rubber SD33 CHECKING AND CHANGING lip of new oil filter.

(4) Install new oil filter. Hand-tighten ONLY, DO NOT use a wrench to tighten the filter.

Center shaft type

(1) Remove center shaft.

  • (2) Take out filter element.
  • (3) Install new element

Always use new gaskets.

(4) Tighten center shaft.

T : Oil filter center shaft SD 4-cylinder 25 - 29 N·m (2.5 - 3.0 ko-m. 18 - 22 ft-lb)

20 - 25 N·m (2.0 - 2.5 kg-m. 14 - 18 ft-lb)

5. Refill engine with new engine oil. referring to Recommended Lubricants in Owner's Manual loaded on vehicle

  • a. Start engine. Check area around drain plug and oil filter for any sign of oil leakage. If any leakage is evident, these parts have not been properly installed.
  • b. Run engine until water temperature indicator points to the middle of gauge. Then stop engine and check oil level with dipstick. If necessary, add engine oil.
  • When checking oil level, park the car on a level surface.

CHECKING ENGINE OIL FOR LEAKS

Check cylinder head, front engine cover, oil pan, oil pump, oil filter gasket, etc. or other parts for sign of leaks past their gasketed surfaces. If necessary, replace gaskets or faulty parts. After maintenance has been done, check replaced parts to see if any leaks occur.

INJECTION PUMP OIL (Lubrication type only)

3. Check for leaks.

Page 52

DIAPHRAGM

LUBRICATING INJECTION 2. Lubricate governor diaphragm. PUMP GOVERNOR Fill with three to four droplets of diaphragm oil.

1. Drain fuel from governor chamber.

ELECTRICAL SYSTEM

CHECKING GLOW PLUGS

Remove glow plugs from cylinder

Check continuity in glow plugs. If there is no continuity, replace it.

Page 53

TIGHTENING TORQUE

INSPECTION AND ADJUSTMENT
BASIC MECHANICAL SYSTEM
Valve clearance (Hot) mm (in)
Intake 		0.35 (0.014)
Exhaust 0.35 (0.014)
Fan belt deflection
mm/N (kg), (in/lb) 		8 - 12/98 (10),
(0.31 - 0.47/22)
Compression pressure
kPa (bar, kg/cm 2 , psi)/rpm
Standard 		2,942 (29.4, 30, 427)/200
Minimum and all liter hami-in 2,452 (24.5, 25, 356)/200
Compression differential limit between cylinders 294 (2.9, 3, 43)/200
INJECTION SYSTEM
Injection timing B.T.D.C.
DIESEL KIKI-Bosch in-line 		/rpm
a type 		18°/600
(Only for 720 model
with SD23 or SD25)
20°/600 (For the others)
VE type 8°/600
C.A.VD.P.A. type 14.5°/600
Idling
In-line & VE type 		rpm 550 - 650 (without power steering/air conditioner)
1. Selection allowed in the 650 - 750 (with power steering/air conditioner)
C,A,V,-D,P,A, type 650
Max. engine speed under
no load
In-line type 		rpm 4,200 - 4,400
VE type 4,450 - 4,750
(Except for Europe)
4,500 - 4,700
(For Europe)
C.A.VD.P.A. type 4,250 - 4,300
Dash pot
Touch speed 		rpm 1,280 - 1,350
N·m kg-m ft-lb
Cylinder head bolt
1st turn: Main bolt 		59 - 78 6.0 - 8.0 43 - 58
2nd turn: Sub bolt 20 - 29 2.0 - 3.0 14 - 22
3rd turn: Main bolt 118 - 127 12 - 13 87 - 94
4th turn: Sub bolt 44 - 54 4.5 - 5.5 33 - 40
Rocker shaft bra
bolt 		cket 20 - 25 2.0 - 2.5 14 - 18
Manifold nut
Intake & exhau 		ist 15 - 18 1.5 - 1.8 11 - 13
Injection nozzle *1 59 - 69 6.0 - 7.0 43 - 51
(to cylinder head 1) *2 69 - 78 7.0 - 8.0 51 - 58
Injection pump s
nut
DIESEL KIKI
in-line type 		ecuring
Bosch 		20 - 25 2.0 - 2.5 14 - 18
VE-turna nut 20 - 25 2.0 - 2.5 14 - 18
v E-type bolt 16 - 22 1.6 - 2.2 12 - 16
C.A.VD.P.A. type 15 - 20 1.5 - 2.0 11 - 14
Oil filter center
shaft 		SD 4-
cylin-
der 		25 - 29 2.5 - 3.0 18 - 22
(Full-flow type) SD33 20 - 25 2.0 - 2.5 14 - 18
Venturi securing nut 3 - 4 0.3 - 0.4 2.2 - 2.9
e anna in sacar mg the second se
Oil pan drain plu ) 49 - 59 5.0 - 6.0 36 - 43

Part No. of injection nozzle 16600-90060, 16600-36W00, 16600-T9000 Part No. of injection nozzle

16600-37502, 16600-90012, 16600-90019, 16600-35571, 16600-T3401, 16600-T3470, 16600-T6200, 16600-T6201, 16600-Y8400, 16600-Y8401

COOLING SYSTEM
enter a tour, agrette , p.
Radiator cap relief pressure 88 (0.88, 0.9, 13)
Cooling system leakage testing pressure 157 (1.57, 1.6, 23)
Page 54
TROUBLE DIAGNOSES AND CORRECTIONS

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SPECIAL SERVICE TOOLS

the second se
Tool number Tool name
ED19600000 Compression gauge set
ST19320000 Oil filter wrench
KV11100300 Nozzle holder socket A
KV11100400 Socket
DURT AND CA MSHAFT
EM-11
EM-12
EM-12
EM-12 		HOD EM-17
ASSEMBLING ENGINE OVERALL EM-16
SERVICE DAYA AND
SPECIFICATIONS EM-23
INSPECTION AND ADJUSTMENT EM-23
Page 69

MODEL 160 SERIES (Equipped with SD33 engine)

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