Toro 73550, 73551, 73552, 73590, 74268 Service Manual

REPAIR MANUAL

For 3 Cylinder LiquidĆCooled Diesel Engines

FORM MS-1055-5/02  2002 BRIGGS & STRATTON DAIHATSU LLC PRINTED IN U.S.A.

1

BRIGGS & STRATTON DAIHATSU 3 CYLINDER

LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055)

Section 1

General Information

Section Contents

Page

ENGINE IDENTIFICATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IN THE INTEREST OF SAFETY 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE VIEWS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS AND DATA 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FASTENER SPECIFICATIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BRIGGS & STRATTON NUMERICAL NUMBER SYSTEM 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE SCHEDULE 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE IDENTIFICATION NUMBERS

The engine model and type number are located on the vale cover, Fig. 1. The serial number is stamped into the right
side of the cylinder block, behind the intake manifold, Fig. 2.

MODEL AND

TYPE NO.

SERIAL NO.

Fig. 1 – Engine Model And Type Number

Fig. 2 – Engine Serial Number

MAY 2002

1

GENERAL INFORMATION

1

IN THE INTEREST OF SAFETY

This safety alert symbol indicates that this
message involves personal safety. Signal

words danger, warning and caution indicate
hazard degree. Death, personal injury and/OR
property damage may occur unless instruc­tions are followed carefully.

WARNING: DO NOT

1. DO NOT run engine in an enclosed area. Exhaust
gases contain carbon monoxide, an odorless and
deadly poison.

2. DO NOT place hands or feet near moving or
rotating parts. Keep all guards in place.

3. DO NOT place hands or feet near electric cooling
fan (if equipped). Fan may start suddenly, de­pending on coolant temperature.

4. DO NOT store, spill, or use diesel fuel near an
open flame, or devices such as a stove, furnace,
or water heater which use a pilot light or devices
which can create a spark.

5. DO NOT refuel indoors where area is not well
ventilated. Outdoor refueling is preferred.

6. DO NOT fill fuel tank while engine is running. Allow
engine to cool for 2 minutes before refueling.
Store fuel in approved, correct color safety
containers.

7. DO NOT remove fuel tank cap while engine is
running.

8. DO NOT operate engine when smell of fuel is
present or other explosive conditions exist.

9. DO NOT operate engine if diesel fuel is spilled.
Move machine away from the spill and avoid
creating any ignition until the spill has been
wiped up.

10. DO NOT smoke when filling fuel tank.

11. DO NOT tamper with maximum speed set screw
or full load set screw of the injector pump which
may increase the governed engine speed.

12. DO NOT tamper with the engine speed selected
by the original equipment manufacturer.

13. DO NOT operate engine with a damaged muffler
or without muffler. Inspect periodically and
replace, if necessary. If engine is equipped with
muffler deflector(s), inspect periodically and
replace, if necessary, with correct deflector(s).

14. DO NOT operate engine with an accumulation of
grass, leaves, dirt or other combustible material in
the muffler area.

15. DO NOT use this engine on any forest covered,
brush covered, or grass covered unimproved land
unless a spark arrester is installed on the muffler.
The arrester must be maintained in effective
working order by the operator. In the State of
California the above is required by law (Section
4442 of the California Public Resources Code).
Other states may have similar laws. Federal laws
apply on federal lands.

16. DO NOT touch hot muffler(s) or cylinder(s)
because contact may cause burns.

17. DO NOT remove the radiator cap while the engine
is hot. To avoid scalding from hot coolant or steam
blowing out of the radiator, use extreme care when
removing the radiator cap. If possible, wait for
engine to cool. If not possible, wrap a thick rag
around cap while removing. To release pressure,
slowly turn cap counter clockwise to the first stop.
When all pressure has been released, press down
on cap and continue turning.

18. DO NOT start or run engine with air cleaner or air
cleaner cover removed.

WARNING: DO

1. ALWAYS DO disconnect the negative wire from
the battery terminal when servicing the engine or
equipment, TO PREVENT ACCIDENTAL
STARTING.

2. ALWAYS DO disconnect fuel shut off solenoid wire
from injection pump before checking compression,
TO PREVENT ACCIDENTAL STARTING.

3. DO wear eye protection when operating or
repairing equipment.

4. DO keep governor parts free of grass and other
debris which can affect engine speed.

5. DO examine muffler(s) periodically to be sure it is
functioning effectively. A worn or leaking
muffler(s) should be repaired or replaced as
necessary.

6. DO check fuel lines and fittings frequently for
cracks or leaks. Replace if necessary.

CAUTION:

DO use clean fresh diesel fuel with a minimum of 40
cetane.

DO NOT use kerosene. The injection pump requires
diesel fuel for lubrication. Damage to the injection
pump and/or engine may result if kerosene is used.

NOTE: Use Original Briggs & Stratton-Daihatsu

Service Replacement Parts when
servicing your engine. Authorized Briggs
& Stratton-Daihatsu Service Centers
carry a stock of such parts. The use of
Briggs & Stratton-Daihatsu parts
preserves the original design of your
engine. Imitation replacement parts may
not fit or function as original Briggs &
Stratton-Daihatsu parts and can expose
the operator to potential personal injury.
Contact any Authorized Briggs &
Stratton-Daihatsu Service Center for
Original Briggs & Stratton-Daihatsu
Replacement Parts.

2

ENGINE VIEWS

1

GENERAL INFORMATION

Diesel

1. Thermostat

2. Oil filler cap

3. Electric starter

4. Oil pan

5. Alternator

1

5

2

3

13

6

12

4

11

7

6. Injector nozzle

7. Glow plug

8. Oil drains

9. Oil filter

10

10. Dipstick

11. Injector pump

9

12. Engine Date code
xxxxxxxx

13. Engine Model & Type number
xxxxxx xxxx-xx

8

Turbo-charged
Diesel

1. Thermostat

2. Oil filler cap

3. Turbocharger

4. Electric starter

5. Alternator

6. Oil pan

7. Injector nozzle

8. Glow plug

9. Oil drains

10. Oil cooler

(if equipped)

11. Oil filter

12. Dipstick

13. Injector pump

14. Engine Date code

xxxxxxxx

15. Engine Model & Type number
xxxxxx xxxx-xx

3

1

GENERAL INFORMATION

ENGINE SPECIFICATIONS

582447

Model 432447 522447

Type Diesel, 4-cycle, 3 cylinder, in-line, liquid cooled
Valve mechanism OHV, gear driven

Bore x stroke mm (in)

68 x 64

(2.680 x 2.520)

68 x 78

(2.680 x 3.070)
Piston displacement cc (cu in) 697 (42.5) 850 (52.0) 952 (58.1)
Firing order 1-2-3 (front, center, back)

Compression ratio 25.0:1 24.4:1

@58A447
@588447

72 x 78

(2.834 x 3.070)

24.0:1

@ 24.8:1

Compression pressure (normal)
Engine at operating temperature – (psi)
glow plugs removed

@

300 RPM Bar

33.0

(469)

32.0

(455)

34.0
(498)
@ 37
(526)

Compression pressure (minimum)
Engine at operating temperature – (psi)
glow plugs removed

@

300 RPM Bar

30.0

(425)

29.0

(412)

30.5
(433)
@ 27
(384)

Gross HP @ 3600 RPM 19.5 23.6

Gross Torque @ 2400 RPM 32.5 40.0

26.5

@ 28.0

44.1

@ 49.2

434.4 x 442.9
x 548.4

(17.1 x 17.44 x

21.59)

@ 434.4 x

447.5 x 559.0

Dimensions (L x W x H) mm (in)

441.8 x 440.4 x

523.9

(17.4 x 17.34 x

20.6)

434.4 x 442.9 x

548.4

(17.1 x 17.44 x

21.59)
(17.1 x 17.62 x

22.01)

Dry weight kg (lbs) 76 (168) 78 (172) 89 (196)

4

1

Cylinder

Valve

Val

g

I

23

Specifications

Valve timing
Exh

23

Valve cl

ld)

Pi

Crankshaft &

GENERAL INFORMATION

Cylinder
Head

ve

Cylinder
Block &
Camshaft

Connecting
Rod & Piston

Crankshaft &
Crankshaft
Bearing

Type Single piece casting
Material Cast Iron
Combustion Chamber Swirl Type

seat angle

Valve timin

earance (co

Intake

Exhaust

ntake

aust

Opens 10° BTDC
Closes 45° ABDC
Opens 45° BBDC
Closes 10° ATDC
Intake mm (in) 0.20 (.008 in)
Exhaust mm (in) 0.20 (.008 in)

45°
45°

5°

5°

Cylinder block Mono-block, three cylinder, cast iron

Camshaft Carbon steel

Connecting rod Carbon steel
Piston Pin Bearing Machined – Piston pin, slip fit

Crankpin

Bearing

Material aluminum alloy – replaceable insert

Piston Heat resistant aluminum alloy

ston ring

Compression ring Two, chrome plated

Oil ring One, combination type, chrome plated
Crankshaft One piece cast iron
Crankshaft main

bearing

Material Replaceable insert – aluminum alloy

°

°

5

1

Syst

GENERAL INFORMATION

LUBRICATING SYSTEM

Lubricating Method Pressure lube

Oil Pump

Oil Filter Type Full flow, paper

Oil Capacity 3.3 ltr (3.5 qt)

Oil Pump Relief Valve Opening Pressure 4.6 Bar (65 psi)

Lubrication Oil API SE/CD class or higher

Type Trochoid

Drive Gear drive

COOLING SYSTEM

Cooling Method Liquid cooled, forced circulation

Coolant Capacity (engine only) Approximately 1.8 ltr (1.9 qt)

Cooling System Pressure 1.0-0.75 Bar (15-11 psi)

Pressure Cap Capacity 0.9 Bar (13 psi)

Water Pump

Thermostat

Cooling Fan Drive V-belt

Type Centrifugal

Drive V-belt

Type Wax pellet with bypass

Specification 82° C (180° F)

FUEL SYSTEM

Fuel Requirements Diesel fuel (Cetane number 40 or higher)

Type Bosch VE (distributor type)

Injector Pump

Injector Nozzle

Idle Speed RPM See Table 3, Page 7

Injector Timing (Plunger stroke)
#1 Cyl. TDC

Nozzle Type Throttle type

Injector pressure Bar (psi) 140 (1,991)

See Tables 1 & 2, Page 6

ELECTRICAL SYSTEM

Battery

Charging

em

Glow Plug Voltage/Current V/A 11 Volts / 9.5 Amps

Starter Voltage/Kilowatt V/K

Voltage 12V (negative ground)

Capacity 24 AH (28 AH cold)

Alternator 28 Volt AC output – Minimum

Regulator/rectifier 14 Amp DC output with charge indicator circuit

Alternator {Optional} 40 Amp DC output – Internally regulated

Reduction gear type – 12 Volts / 1.0 kw
{12 Volts / 1.2 kw, optional}

6

1

TABLE 1

Injection Pump Timing

Engine Date Code Before 99010100

Model/Type No. Timing Specification

GENERAL INFORMATION

432447-0150-E2

522447-0105-E2

522447-0106-E2

522447-0107-E2

522447-0108-E2

522447-0109-E2

582447-0105-E2

582447-0125-E2

582447-0130-E2

582447-0131-E2

0.93 ± .03 mm (.0365” ± .001”)

0.93 ± .03 mm (.0365” ± .001”)

0.93 ± .03 mm (.0365” ± .001”)

0.93 ± .03 mm (.0365” ± .001”)

0.93 ± .03 mm (.0365” ± .001”)

0.93 ± .03 mm (.0365” ± .001”)

0.93 ± .03 mm (.0365” ± .001”)

0.81 ± .03 mm (.032” ± .001”)

0.93 ± .03 mm (.0365” ± .001”)

0.81 ± .03 mm (.032” ± .001”)

TABLE 2

Injection Pump Timing

Engine Date Code After 98123100

Model Series Timing Specification

432447 – All

522447 – All

582447 – All

58A447 – All

588447

0.90 ± .03 mm (.035” ± .001”)

0.90 ± .03 mm (.035” ± .001”)

0.81 ± .03 mm (.032” ± .001”)

0.90 ± .03 mm (.035” ± .001”)

7

1

22100 87802

9U1

22100-8780

8U1

22100-87809

8U2

INJECTOR PUMP IDENTIFICATION

IDENTIFICATION CODE

NAME
PLATE

IDENTIFICATION
CODE

7 : 700 cc
8 : 850 cc
9 : 950 cc

DESTINATION
U : USA
J : Japan
X : Except for
USA

SERIAL
NUMBER

TABLE 3

Engine Speed Specification Chart

Pump Mfg. Part No. ID Code Model & Type No. Idle Speed (rpm) Top No Load (rpm)

22100-87801 7U1 432447-0105-E2

22100-8713 7U2 432447-0205-E2

582447-0105-E2

582447-0205-E2
582447-0130-E2

22100-87802 9U1

582447-0230-E2
582447-0219-E2

582447-0222–E2
582447-0221-E2
582447-0225-E2
582447-0232-E2
582447-0125-E2

22100-87806 9U2

582447-0131-E2

582447-0231-E2

7

522447-0105-E2
522447-0108-E2
522447-0106-E2

522447-0109-E2
22100-87810 8U3 522447-0107-E2
22100-87815 8U4 522447-0107-E2
22100-87817 8U5 522447–0107–E2
22100-87811 9U4 58A447–0205–E2
22100-87818 9U5 588447–0205–E2

588447–0216–E2
588447–0230–E2
588447–0225–E2

1200±50 3850±50
1200±50 3850±50

1200±50 3850±50

1200±50 3300±50

1600±50 3600±50

1750±50 3600±50
1050±50 3850±50
1200±50 3400±50
1850±50 3420±50

1700±50 3600±50

1200±50 3850±50
1600±50 3350±50
1850±50 3420±50
1850±50 3420±50
1525±50 2775±50
1540±50 2790±50
1540±50 2790±50
1200±50 3850±50
1200±50 3850±50
1800±50 3600±50
1600±50 3600±50
1050±50 3850±50

8

1

GENERAL INFORMATION

Description Wrench/Socket Size Torque

Alternator Adjust. Bracket 12 mm 19.0 Nm (170 in. lbs.)

Alternator – 14 Amp (to bracket) 12 mm 19.0 Nm (170 in. lbs.)

Alternator – 40 Amp (to bracket) 12 mm 61.0 Nm (45 ft. lbs.)

Alternator Bracket (to block) 12 mm 19.0 Nm (170 in. lbs.)

Camshaft Gear 17 mm 41.0 Nm (30 ft. lbs.)

Camshaft Retainer 10 mm 8.0 Nm (70 in. lbs.)

Conn. Rod Nuts 12 mm 36.0 Nm (320 in. lbs.)

Crankshaft Pulley 19 mm 88.0 Nm (65 ft. lbs.)

Cyl. Head Bolts (8 mm dia.) 12 mm 34.0 Nm (25 ft. lbs.)

Cyl. Head Bolts (9 mm dia.) 13 mm 43.0 Nm (32 ft. lbs.)

Cyl. Head Bolts (10 mm dia.) 14 mm 68.0 Nm (50 ft. lbs.)

Exhaust Manifold 12 mm 19.0 Nm (170 in. lbs.)

Fan Pulley 10 mm 7.0 Nm (60 in. lbs.)

Flywheel 14 mm 47.0 Nm (35 ft. lbs.)

Fuel Delivery Lines 17 mm 25.0 Nm (220 in. lbs.)

Fuel Return Line 17 mm 27.0 Nm (20 ft. lbs.)

Glow Plug 12 mm Deep 17.0 Nm (150 in. lbs.)

Idler Gear 12 mm 25.0 Nm (220 in. lbs.)

Injector Pump (mounting) 12 mm 19.0 Nm (170 in. lbs.)

Injector Pump Drive Gear 19 mm 61.0 Nm (45 ft. lbs.)

Injector Pump Bracket 12 mm 19.0 Nm (170 in. lbs.)

Injector Nozzle 21 mm Deep 61.0 Nm (45 ft. lbs.)

Injector Pump Distributor Bolt 14 mm 17.0 Nm (150 in. lbs.)

Intake Manifold 10 mm 8.0 Nm (70 in. lbs.)

Main Bearing Screws 14 mm 58.0 Nm (43 ft. lbs.)

Oil Drain Plug 14 mm 25.0 Nm (220 in. lbs.)

Oil Pan 10 mm 8.0 Nm (70 in. lbs.)

Oil Pressure Relief Valve 19 mm 34.0 Nm (25 ft. lbs.)

Oil Pump Gear 12 mm 19.0 Nm (170 in. lbs.)

Oil Pump Pickup 10 mm 8.0 Nm (70 in. lbs.)

Rear Seal Support 10 mm 6.0 Nm (50 in. lbs.)

Rocker Arm Assy. 12 mm Deep 19.0 Nm (170 in. lbs.)

Rocker Arm Adjustment 10 mm 11.0 Nm (95 in. lbs.)

Starter 14 mm 40.0 Nm (30 ft. lbs.)

Starter Bracket 14 mm 34.0 Nm (25 ft. lbs.)

Starter Solenoid Phillips 9.0 Nm (80 in. lbs.)

Starter Motor Thru Bolts 10 mm 9.0 Nm (80 in. lbs.)

Timing Gear Case 10 mm 8.0 Nm (70 in. lbs.)

Timing Gear Cover
(3 different lengths)

Valve Cover 10 mm 6.0 Nm (50 in. lbs.)

Water Pump 12 mm 19.0 Nm (170 in. lbs.)

10 mm 8.0 Nm (70 in. lbs.)

9

1

GENERAL INFORMATION

BRIGGS & STRATTON DAIHATSU NUMERICAL NUMBER SYSTEM

All Briggs & Stratton Daihatsu engines have a unique numerical designation system. Each engine is identified by a
Model, Type and Code/Serial number. Example: Model Type Code/Serial

432447 0125 01 020521145

This chart explains the numerical model designation system. It is possible to determine most of the important mechani­cal features of the engine by merely knowing the model number. Here is how it works.

CUBIC INCH

DISPLACEMENT

ă6
ă8
ă9
10
11
12
13
16
17
18
19
22
23
24
25
26
28
29
30
32
35
38
40
42
43
44
46
52
58

FIRST DIGIT

AFTER DISPLACEMENT

BASIC

DESIGN SERIES

0 - Gas-Mechanical
1 - Natural Gas-Mechanical
2 - Diesel-Mechanical
3 - Gas-Electronic
4 - Natural Gas-Electronic
5 - Diesel-Electronic
6
7
8 - Diesel - Turbo
9
A - Diesel Turbo

B to Z

SECOND DIGIT

AFTER DISPLACEMENT

CRANKSHAFT,

CARBURETOR,

GOVERNOR

0 - Horizontal Shaft

Diesel Electronic or
Mechanical Governor

1 - Horizontal Shaft

VacuĆJet Carburetor
Pneumatic Governor

2 - Horizontal Shaft

PulsaĆJet Carburetor
Pneumatic or Mechanical
Governor

3 - Horizontal Shaft

FloĆJet Carburetor
Pneumatic Governor

4 - Horizontal Shaft

FloĆJet Carburetor
Electronic or
Mechanical Governor

5 - Vertical Shaft

VacuĆJet Carburetor
Pneumatic or Mechanical

Governor
6 - Vertical Shaft
7 - Vertical Shaft

FloĆJet Carburetor

Pneumatic or Mechanical

Governor
8 - Vertical Shaft

FloĆJet Carburetor

Mechanical Governor
9 - Vertical Shaft

PulsaĆJet Carburetor

Pneumatic or Mechanical

Governor

THIRD DIGIT

AFTER DISPLACEMENT

PTO BEARING,

REDUCTION GEAR,

AUXILIARY DRIVE,

LUBRICATION TYPE OF STARTER

0 - Plain Bearing/DU

NonĆFlange Mount

1 - Plain Bearing

Flange Mounting

2 - Sleeve Bearing

Flange Mounting
Splash Lube

3 - Ball Bearing

Flange Mounting
Splash Lube

4 - Flange Mounting

Pressure Lubrication on
Horizontal Shaft

5 - Plain Bearing

Gear Reduction
(6 to 1) CW Rotation
Flange Mounting

6 - Plain Bearing

Gear Reduction
(6 to 1) CCW Rotation

7 - Plain Bearing

Pressure Lubrication on
Vertical Shaft

8 - Plain Bearing

Auxiliary Drive (PTO)
Perpendicular to Crankshaft

9 - Plain Bearing

Auxiliary Drive
Parallel to Crankshaft

FOURTH DIGIT

AFTER DISPLACEMENT

0 - Without Starter
1 - Rope Starter
2 - Rewind Starter
3 - Electric Starter Only

120 Volt Gear Drive

4 - Electric Starter/Generator

12 Volt Belt Drive

5 - Electric Starter Only

12 Volt Gear Drive
6 - Alternator Only
7 - Electric Starter

12 Volt Gear Drive

With Alternator
8 - Vertical Pull Starter or

Side Pull Starter

The type number identifies certain unique features such as the crankshaft or governor spring used on an engine.
The code/serial number identifies the assembly date of the engine and serial number. In some instances it is neces-

sary to know the code/serial number as well as the model and type number when performing adjustments, repairs or
ordering replacement parts for an engine. Here is how it works.

Example: 990521150

A. The first two digits, 02, indicate the calendar

year, 2002.

B. The second two digits, 05, indicate the calen-

dar month, May.

10

C. The third two digits, 21, indicate the calendar

month day.

D. The last three digits, 145, indicate the serial

number.

1

Lubrication

system

GENERAL INFORMATION

MAINTENANCE SCHEDULE

More frequent service is required when operating in adverse conditions (note 4 below).

System Maintenance Operation Daily

Lubrication
system

Cooling
system

Engine

Electrical
system

Check oil level

Check for oil leaks

Change oil

Change oil filter

Check coolant

Change coolant

Check fan belt

Service air cleaner

Check cylinder head bolt torque

Check valve clearance

Check battery electrolyte

D

D

D

Every

50

hours

D1 D2 D5

D1 D2

D1 D2, 4 D3, 4

Every

100

hours

D

Every

200

hours

D

Every

600

hours

D

D

Every

800

hours

Yearly

D

Fuel
system

1 Perform first maintenance operation after 50 hours.
2 Then perform maintenance operation at this interval.
3 Replace after ever 600 hours of operation.
4 Service more often when operating under heavy load or in high temperatures.
5 Perform maintenance annually if operated less than 100 hours.
6 Follow manufacturer’s maintenance schedule if non-B&SD approved part is used.

Change fuel filter element

D6

11

2

BRIGGS & STRATTON DAIHATSU 3 CYLINDER

LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055)

Section 2

Cylinder Head and Valves

Section Contents

Page

REMOVE CYLINDER HEAD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISASSEMBLE CYLINDER HEAD 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSPECT AND REPAIR

Cylinder Head 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Guides 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISASSEMBLE ROCKER ARM SHAFT 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ASSEMBLE ROCKER ARM SHAFT 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ASSEMBLE CYLINDER HEAD 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALL CYLINDER HEAD 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUST VALVES 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overhead Valve Train

1MAY 2002

2

CYLINDER HEAD AND VALVES

REMOVE CYLINDER HEAD

ALWAYS disconnect fuel shut off solenoid wire

from injection pump before checking compres­sion, to prevent accidental starting.

Drain cooling system and disconnect radiator hoses.

1. Remove the following parts from engine,
Fig. 1-Fig. 5:

a. Alternator adjusting bracket screw
b. V-belt
c. Fan (if equipped)

Fig. 2:
d. Water pump

e. Exhaust manifold
NOTE: Remove exhaust system before removing

exhaust manifold.

A

B

C

Fig. 1 – Remove V-belt And Fan

D

Fig. 3:
f. Valve cover

Discard rubber seal.

NOTE: Clean areas around fuel lines and injec-

tors to prevent dirt entry.

Fig. 4:
g. Fuel delivery lines

h. Fuel return line
i. Glow plug wiring
j. Breather tube and intake manifold

Fig. 2 – Remove Water Pump And Exhaust Manifold

F

Fig. 3 – Remove Valve Cover

I

H

G

J

E

Fig. 4 – Remove Fuel Lines

2

2

CYLINDER HEAD AND VALVES

Fig. 5:
k. Fuel injector nozzles

l. Glow plugs

2. Set No. 1 piston at TDC, Fig. 6:

a. Rotate crankshaft pulley until timing mark on

pulley is aligned with reference point on timing
cover.

b. If intake and exhaust valves have clearance,

No. 1 piston is at TDC – compression stroke.

c. If intake and exhaust valves do not have

clearance, turn crankshaft pulley one
complete revolution. Valves will then have
clearance.

L

K

Fig. 5 – Remove Glow Plugs And Injectors

REFERENCE

POINT

TIMING

MARK

3. Remove rocker arm assembly and push rods,
Fig. 7.

a. Remove valve stem caps.
NOTE: Mark push rods so that they may be

reassembled in their original position.

4. Remove cylinder head assembly, Fig. 8.

a. Loosen cylinder head bolts in the order shown.
NOTE: Current style head bolts are 9 mm diame-

ter. Early style head bolts are 8 mm
diameter. Torque specifications are differ­ent.

Fig. 6 – Set Cylinder No. 1 At TDC

VALV E

STEM

CAP

Fig. 7 – Remove Rocker Arm Assembly And Push Rods

2

6

10

13

11

7

3

9

5

1

4

8

12

14

Fig. 8 – Loosen Cylinder Head Bolts

3

CYLINDER HEAD AND VALVES

2

3

4

5

6

9

10

DISASSEMBLE CYLINDER HEAD

1. Cylinder Head Assembly

8

1

2. Cylinder Head Gasket

3. Valve Stem Cap

4. Valve Spring Retainer Locks

5. Valve Spring Retainer

6. Valve Spring

11

7

2

7. Valve

8. Valve Spring Seat

9. Valve Stem Seal

10. Valve Guide

11. Combustion Chamber

Fig. 9 – Cylinder Head Components

Remove valves, Fig. 10.

1. Use valve spring compressor, Tool #19417, to
compress valve springs. Remove the following
parts, Fig. 9:

a. Valve spring retainer locks – 4
b. Valve spring retainer – 5
c. Valve spring – 6
d. IN and EX valve – 7
e. Valve spring seats – 8

2. Remove and discard valve stem seals, Fig. 11.

Fig. 10 – Remove Valves

Fig. 11 – Remove Valve Stem Seal

4

2

CYLINDER HEAD AND VALVES

INSPECT AND REPAIR

1. Check cylinder head mounting surfaces, Fig. 12
and Fig. 13.

Be sure all gasket material is removed from surfaces
before checking. Use a gasket scraper if necessary.

a. Inspect cylinder head for cracks or damage.
b. Use a straight edge and check cylinder head

lower surface for distortion.

Fig. 13:
c. Check intake and exhaust manifold mounting

surfaces.

If mounting surfaces are distorted more than 0.1 mm
(0.004 in.), the cylinder head must be replaced.

It is not recommended that cylinder head
mounting surfaces be resurfaced.

NOTE: Intake manifold and exhaust manifold

may be checked in the same manner. Use
same specifications as cylinder head.

CHECK COMBUSTION CHAMBER

Engine Model 522000: combustion chambers are
not replaceable.

Engine Models 432000 and 582000 with date code
after 990111007: combustion chambers are not
replaceable.

NOTE: Only Engine Models 432000 and 582000

with date code before 981225006 have
replaceable combustion chambers.

1. Check combustion chamber, Fig. 14.

a. Use a straight edge and feeler gauge.

If combustion chamber protrudes more than 0.05 mm
(.002 in.) above surface of cylinder head, it must be
replaced.

2. Remove combustion chamber, Fig. 15.

Insert a 10 mm brass rod through injector nozzle hole
and drive out combustion chamber.

NOTE: Do not damage threads in injector hole.

STRAIGHT

EDGE

Fig. 12 – Check Cylinder Head For Distortion

Fig. 13 – Check Cylinder Head For Distortion

COMBUSTION

CHAMBER

COMBUSTION

CHAMBER

Fig. 14 – Check Combustion Chamber

BRASS ROD

COMBUSTION

CHAMBER

Fig. 15 – Remove Combustion Chamber

5

2

CYLINDER HEAD AND VALVES

3. Install combustion chamber, Fig. 16.

Align locating projection on combustion chamber with
groove in cylinder head. Use a soft hammer and drive
in new combustion chamber until it bottoms.

CHECK AND REPAIR VALVE GUIDES

1. Check valve guide bushings for wear using reject
gauge, Tool #19382, Fig. 17.

COMBUSTION

CHAMBER

Fig. 16 – Install Combustion Chamber

Remove if damaged or if reject gauge enters valve
guide.

2. Remove valve guide bushing if required, Fig. 18.

a. Use bushing driver, Tool #19367, and press

out valve guide bushing from combustion
chamber side.

b. Check valve guide bushing OD. Then see

specifications below.

Std. Bushing OD: – 11.05 mm (.435 in.)
Replacement Bushing OD: – 11.08 mm (.4362 in.)

c. If bushing OD measurement indicates that a

replacement bushing has already been
installed, the cylinder head must be replaced.

REJECT

GAGE

Fig. 17 – Check Valve Guide Bushing

PRESSING OUT

GUIDE

Fig. 18 – Remove Valve Guide Bushing

6

2

3. Using bushing driver, Tool #19416, press in new
valve guide bushing until tool bottoms on cylinder
head, Fig. 19.

CYLINDER HEAD AND VALVES

Fig. 19 – Installing Valve Guide Bushing

VALVES AND SEATS

1. Valve faces may be resurfaced to 45°. See Fig. 20
for dimensions for valves. Lap valves and seats
with valve lapping Tool, #19258 and valve lapping
compound, Tool #94150.

2. Valve seats may be reconditioned using valve seat
cutter, Tool #19446.

NOTE: Check valve guide bushings first. If valve

guides are worn, they must be replaced
before refacing valve seats

If valve seat is wider than dimension shown in Fig. 21,
a narrowing cutter should be used to ensure that
contact area of valve seat is centered on face of valve,
Fig. 20.

a. Use a 60° cutter to narrow seat from bottom

and a 30° cutter to narrow seat from top,
Fig. 21.

NOTE: If valve seat is loose or cracked, replace

cylinder head.

3. Measure valve stem diameter at specified
distance from end of valve, as shown in Fig. 22.

Replace IN if less than 5.927 mm (0.2333 in.).

Replace EX if less than 5.923 mm (0.2332 in.).

0.8 mm TO 1.2 mm
(1/16” TO 3/64”)

0.8 mm TO 1.2 mm
(1/16” TO 3/64”)

VALVE SEAT DIMENSIONS

Fig. 21 – Valve Seat Dimensions

SEATING AREA CENTERED

ON VALVE FACE

Fig. 20 – Valve Dimensions

45°

60° CUTTER

30° CUTTER

35 mm
(1.38”)

1.0 mm
(.040”)

MINIMUM

Fig. 22 – Measure Valve Stem Diameter

7

2

CYLINDER HEAD AND VALVES

4. Inspect valve stem cap for wear, Fig. 23.

Replace if cap is worn recessed.

5. Check valve springs for squareness and free
length, Fig. 24.

Replace if out of square more than 1.0 mm
(.040 in.).

Replace if free length is less than 30.7 mm
(1.209 in.).

Fig. 23 – Check Valve Stem Cap

Fig. 24 – Check Valve Springs

DISASSEMBLE ROCKER ARM SHAFT

1. Remove snap rings from ends of rocker arm shaft. Remove set screw from center rocker arm support. Disassemble
rocker arm assembly. Note position of all components, Fig. 25.

SET

SCREW

ROCKER

ARM

SHAFT

(1)

SPRING

(2)

ROCKER

ARM SUPPORT

(3)

SPACER

(3)

ROCKER

ARM

(6)

SNAP
RING

(2)

Fig. 25 – Rocker Arm Components

8

2

2. Check rocker arms and shaft, Fig. 26.

a. Check rocker arm-bearing surface.

Replace if greater than 10.03 mm (0.395 in.).

b. Check rocker arm shaft

Replace if less than 9.96 mm (0.392 in.).

c. Check rocker arm studs for stripped threads

and replace if required.

CYLINDER HEAD AND VALVES

Fig. 26 – Checking Rocker Arm And Shaft

ASSEMBLE ROCKER ARM SHAFT

1. Oil all components before assembling. Small grooves in rocker shaft next to oil holes must face down. Assemble
rocker arm components, noting order of assembly as shown in Fig. 27. Note position of three thrust washers.
Install set screw in center rocker arm shaft support.

SET

SCREW

ROCKER

ARM

SHAFT

OIL

GROOVES

DOWN

(1)

SPRING

(2)

ROCKER

ARM SUPPORT

(3)

THRUST
WASHER

(3)

ROCKER

ARM

(6)

SNAP

RING

(2)

Fig. 27 – Rocker Arm Components

9

CYLINDER HEAD AND VALVES

2

ASSEMBLE CYLINDER HEAD

12

3

4

5

6

9

10

8

1. Cylinder Head

2. Cylinder Head Gasket

3. Valve Stem Cap

4. Valve Spring Retainer Locks

5. Valve Spring Retainer

11

6. Valve Spring

7. Valve

8. Valve Spring Seat

9. Valve Stem Seal

13

10. Valve Guide

11. Push Rod

1

12. Rocker Arm Assembly

13. Rocker Arm Stud

NOTE: When replacing rocker arm studs,

torque to 20.0 Nm (180 in. lbs.).

7

Fig. 28 – Cylinder Head Components

1. Install new valve stem seals, Fig. 29. Oil inner
surface and lip of seal before installing. Press seal
on to valve guide bushing until it bottoms.

2

VALVE STEM

SEAL

(CUTAWAY VIEW)

10

Fig. 29 – Install Valve Stem Seals

2

2. Install valve spring seats, Fig. 30.

NOTE: Lightly coat valve stems with Valve Guide

Lubricant #93963 before installing valves.

3. Install valves.

4. Install valve springs with valve spring compressor,
Tool #19417, Fig. 31.

NOTE: After installing valve spring retainer locks,

tap valve spring retainer lightly with a soft
hammer to ensure locks are seated.

CYLINDER HEAD AND VALVES

VALV E

SPRING

SEATS

Fig. 30 – Install Valve Spring Seats And Valves

INSTALL CYLINDER HEAD

1. Place cylinder head gasket over alignment dowels
on cylinder block, Fig. 32.

NOTE: Make sure coolant, oil passages and head

bolt holes are aligned.

2. Install cylinder head assembly, Fig. 33. Lubricate
threads of cylinder head bolts with engine oil.
Torque head bolts in 14.0 Nm (10 ft. lbs.) incre­ments in sequence shown.

NOTE: Current style head bolts are 9 mm

diameter. Early style head bolts are 8 mm

diameter.
a. Torque 9 mm head bolts to 43.0 Nm (32 ft. lbs.).
b. Torque 8 mm head bolts to 34.0 Nm (25 ft. lbs.).
NOTE: Engine Models 58A447 588447 have 10

mm diameter head bolts. Torque head

bolts to 68 Nm (60 ft. lbs.).

Fig. 31 – Install Valve Springs

ALIGNMENT

DOWEL

LOCATIONS

Fig. 32 – Install Cylinder Head Gasket

12

8

4

2

6

10

14

5

9

13

Fig. 33 – Install Cylinder Head Assembly

11

3

1

7

11

2

CYLINDER HEAD AND VALVES

3. Lubricate push rods with engine oil then install with
recessed end up, Fig. 34.

4. Install valve stem caps on valve stems. Install
rocker arm assembly, Fig. 35. Install washers and
torque nuts to 19.0 Nm (170 in. lbs.).

NOTE: Make sure rocker adjustment studs are

seated in recessed end of push rods.

Fig. 34 – Install Push Rods

RECESSED

END UP

5. Install intake manifold with new gasket, Fig. 36.

a. Torque screws to 8.0 Nm (70 in. lbs.).

6. Install Injectors, fuel lines and glow plugs, Fig. 37.

a. Torque injectors to 61.0 Nm (45 ft. lbs.).
b. Torque fuel return line to 27.0 Nm (20 ft. lbs.).
c. Torque fuel delivery lines to 25.0 Nm (220 in.

lbs.).

d. Torque glow plugs to 17.0 Nm (150 in. lbs.).

Fig. 35 – Install Rocker Arm Assembly

Fig. 36 – Install Intake Manifold

12

Fig. 37 – Install Glow Plugs And Injectors

2

7. Install exhaust manifold with new gasket, Fig. 38.

a. Torque screws to 19.0 Nm (170 in. lbs.).

GENERAL ASSEMBLY

1. Install water pump with new gasket, Fig. 39.

a. Torque screws and nuts to 19.0 Nm (170 in.

lbs.).

CYLINDER HEAD AND VALVES

Fig. 38 – Install Exhaust Manifold

2. Install water pump pulley, Fig. 40.

3. Install fan (if equipped).

a. Torque screws to 7.0 Nm (60 in. lbs.).

4. Install V-belt, Fig. 41.

5. Install alternator bolts A and B .

Belt deflection limit is 10–12 mm/10 kg
(3/8–1/2 in/22 lbs.).

a. Torque bolt A to 19.0 Nm (170 in. lbs.).

b. Torque bolt B to 61.0 Nm (45 ft. lbs.).

Fig. 39 – Install Water Pump

Fig. 40 – Install Water Pump Pulley And Fan

BELT

HANDLE

A

3/8 – 1/2 Inch
(10 – 12 mm)

BELT MOVEMENT

Fig. 41 – Adjusting V-belt

B

13

CYLINDER HEAD AND VALVES

No. 1 piston at TDC, of

Rotate Crankshaft 360

2

ADJUST VALVES

1. Before adjusting valves, make sure that No. 1
cylinder is at TDC – compression stroke, Fig. 42.

a. Adjust valves and check, Fig. 43.

Valve Clearance (cold) IN and EX 0.20 mm (0.008 in.)

b. Torque adjusting screws and jam nuts to 11.0

Nm (95 in. lbs.).

REFERENCE

POINT

Fig. 42 – Set Cylinder No. 1 at TDC

TIMING

MARK

With No. 1 piston at TDC of compression stroke, check
and adjust valve clearances for cylinders shown in
chart at right.

Rotate crankshaft one complete turn (360°)"clockwise
to check and adjust remaining valves.

2. Install valve cover with new rubber seal, Fig. 44.

a. Torque cover nuts to 7.0 Nm (50 in. lbs.).
NOTE: Make sure rubber seal is in groove in

valve cover.

Fig. 43 – Adjust Valve Clearances

Piston Position Cylinder 1 2 3

IN

EX

IN

EX

l l

l l

l

No. 1 piston at TDC, of
compression stroke

Rotate Crankshaft 360°
clockwise

l

14

Fig. 44 – Install Valve Cover

3

BRIGGS & STRATTON DAIHATSU 3 CYLINDER

LIQUID-COOLED DIESEL ENGINE REPAIR MANUAL (MS-1055)

Section 3

Timing Gears and Gear Case

Section Contents

Page

REMOVE TIMING GEAR COVER AND GEARS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING GEARS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVE GEAR CASE 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACE TIMING GEAR COVER OIL SEAL 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ASSEMBLE TIMING GEAR CASE AND GEARS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1MAY 2002

3

TIMING GEARS AND GEAR CASE

REMOVING TIMING GEAR COVER
AND GEARS

Make sure that #1 cylinder is at TDC, compression
stroke. See Section 2, Fig. 6.

Remove V-belt and fan (if equipped). Drain oil from
engine.

NOTE: Clean areas around fuel lines and injec-

tors to prevent dirt entry.

1. Remove the following parts, Fig. 1.
a. Glow plug wiring.
b. Glow plugs.
c. Injector pump bracket.
d. Remove fuel delivery lines.

2. Remove the following parts, Fig. 2.
a. Remove oil pan and discard gasket.
b. Remove oil pick-up tube and strainer. Discard

gasket.

A

B

Fig. 1 – Remove Fuel Delivery Lines

OIL PICK-UP

TUBE

D

C

3. Remove bell housing adapter screw if equipped.
and install flywheel holder, Tool #19418.

4. LEAVE TOOL INSTALLED.
a. Remove crankshaft pulley using Tool

# 19420, Fig. 3.

5. Remove timing gear cover, Fig. 4.
a. Discard timing gear cover gasket.

Fig. 2 – Removing Oil Pan

FLYWHEEL

HOLDER

Fig. 3 – Removing Crankshaft Pulley

Fig. 4 – Removing Timing Gear Cover

2

3

6. Remove oil pump drive gear, Fig. 5.
a. Check oil pump drive gear for damaged teeth.

CHECKING GEARS

Inspect gear teeth for wear or damage.
CHECK GEARS IN SEQUENCE SHOWN.

1. Check gear backlash between idler gear and
crankshaft gear using dial indicator as shown in
Fig. 6.
a. Set tip of indicator on gear tooth, then rock

idler gear back and forth noting indicator
reading.

NOTE: Crankshaft must not turn while checking.

TIMING GEARS AND GEAR CASE

OIL
PUMP
GEAR

Fig. 5 – Removing Oil Pump Gear

IDLER
GEAR

CRANKSHAFT

GEAR

2. If backlash exceeds 0.2 mm (.008”) check idler
gear bearing and shaft for wear, Fig. 7.

Reject Dimension: Idler Gear ID –

34.17 mm (1.345”)

Idler Gear Shaft OD –

33.91 mm (1.335”)
a. If idler gear bearing and shaft are within

specification, replace with new idler gear and
recheck.

b. If backlash exceeds 0.2 mm (.008”) with NEW

idler gear, crankshaft gear is worn.

NOTE: If crankshaft gear is worn the crankshaft

must be replaced.

3. Hold idler gear as shown and check gear backlash
between camshaft timing gear and idler gear using
dial indicator, Fig. 8.

Camshaft timing gear backlash must not exceed

0.2 mm (.008”).

NOTE: Idler gear must not turn while checking.

Fig. 6 – Checking Idler Gear Backlash

IDLER

IDLER

GEAR

GEAR

SHAFT

Fig. 7 – Checking Idler Gear And Shaft

CAMSHAFT

TIMING

GEAR

IDLER
GEAR

Fig. 8 – Checking Camshaft Timing Gear Backlash

3

3

TIMING GEARS AND GEAR CASE

4. Hold idler gear as shown and check gear backlash
between injector pump timing gear and idler gear
using dial indicator, Fig. 9.

Injector pump timing gear backlash must not exceed

0.2 mm (.008”).
NOTE: Idler gear must not turn while checking.

If gears are worn it is recommended that they be
replaced as a set.

REMOVE GEAR CASE

1. Remove injector pump timing gear with a three jaw
puller, Fig. 10.
a. Remove 2 nuts and injector pump. Discard

O-ring.

Fig. 9 – Checking Injector Pump

Timing Gear Backlash

O-RING

2. Remove parts in sequence shown, Fig. 11.
a. Remove 3 screws and camshaft retainer.
b. Remove remaining 5 screws.

3. Remove timing gear case and discard gasket,
Fig. 12.
a. Remove oil pump rotor from cylinder block.

Fig. 10 – Removing Injector Pump

B

B

Fig. 11 – Removing Timing Gear Case

ROTOR

A

Fig. 12 – Remove Timing Gear Case

4