Mitsubishi S12A2 Service Manual
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Mitsubishi S12A2 Service Manual

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SERVICE MANUAL
199269-20170
September 2010
Pub. No. 99269-20170

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Summary of Contents for Mitsubishi S12A2

  • Page 1 SERVICE MANUAL 199269-20170 September 2010 Pub. No. 99269-20170...
  • Page 3 FOREWORD This service manual describes the maintenance and adjustment procedures, and specifi- cations for the Mitsubishi marine engine. To maintain the performance of the engine for many years and to ensure safe operation, it is important to use the engine correctly and conduct scheduled inspection and mainte- nance, and it may also be necessary to take appropriate measures which involve in disas- sembly, inspection, repair and assembly work of the engine and engine parts.

  • Page 4: How To Use This Manual

    HOW TO USE THIS MANUAL This service manual consists of several chapters, which will give you quick references to specifications, maintenance standards, adjustment and service procedures including practices to disassemble, inspect, repair and assemble the Mitsubishi marine engines. A short summary describing the contents of each chapter is given in the CHAPTER INDEX page, and there is also a detailed table of contents at the beginning of each chapter.
  • Page 5 FOREWORD Terms used in this manual Nominal value means the basic nominal size of a part to be measured. Standard value means the quantitative requirement for dimension of a part, clearance between parts and performance.The values are rounded off for the inspection job, and do not necessarily conform to the design values. Limit value means the limit value, which the measured value reaches, the part needs repair or replacement with a new one.
  • Page 6 FOREWORD Safety Cautions Fire and Explosion Precautions Pay Attention to Fuel, Oil and Exhaust Gas Keep Flames Away Leak Do not use flames near the engine (in the engine room).The flame is dan- If any fuel, oil or exhaust gas leakage is found, imme- gerous to ignite combustibles and diately take corrective measures to stop it.Such leak- cause a fire.Wipe off spilled fuel, oil...
  • Page 7 FOREWORD Stay Away From Rotating and Moving Parts Lockout and Tagout Install Protective Covers Over Rotating Be sure to lockout and tagout before starting inspec- Parts After Inspection and Maintenance tion and maintenance. Lockout and tagout are effec- Work tive methods of cutting off machines and equipment Check the covers over engine rotating from energy sources.
  • Page 8 FOREWORD Be Careful of Falling Be Careful of Exhaust Gas Poison- Lift Engine Carefully Be careful of Ventilation to Operate Engine Use slings or wire ropes strong enough to lift the load considering the If the engine is installed in an engine weight.To lift the engine, hitch enclosed area, and the exhaust gas is the proper slings to the lifting hangers...
  • Page 9 FOREWORD Be Careful of Burns Be Careful When Handling Fuel, Engine Oil or LLC Do Not Touch the Engine During or Immedi- Use Specified Fuel, Engine Oil and Long- ately After Operation Life Coolant (LLC) Only Do not touch any parts of the engine during or immediately after opera- Use the fuel, oil and LLC specified in this manual only, tion.You can get burned.Before start-...
  • Page 10 FOREWORD When Abnormality Occurs Battery Do Not Add Cooling Water Immediately Be Careful with Battery After a Sudden Stop Due to Overheating Never use flames or generate sparks near the battery.The bat- If the engine stops suddenly due to overheating, or tery gives off highly flammable you suddenly stop the engine by any reason, do not hydrogen gas and oxygen gas.Any...
  • Page 11 FOREWORD Other Cautions Never Break the Seals Do Not Tamper To ensure the proper engine operation, the fuel control If tampered, the warranty is totally void even in the link is provided with seals that protect the fuel injection warranty period.Tampering with the engine can not volume and rotation speed settings against tamper- only damage the engine but also may lead to personal ing.If the seal is tampered, no guarantee will be pro-...
  • Page 12 FOREWORD Use Care to Protect Engine From Water Warm-up the Engine Before Use Use care to protect engine from water such as rain After starting the engine, run the engine at a low idling entering through the air inlet or exhaust openings.Do speed for 5 to 10 minutes for warming-up.
  • Page 13 FOREWORD Cautions for Engine Transportation Observe Safety Rules at Work Site To road-transport the engine, consider the engine Observe the safety rules established at the workplace weight, width and height, and obey applicable laws when operating and maintaining the engine.Do not and regulations such as road traffic laws, vehicle road operate the engine if you are in bad health.

  • Page 14: Warning Labels

    FOREWORD Warning Labels Maintenance of Warning Labels Make sure all warning/caution labels are legible. Clean or replace the warning or caution label when the description or illustration is not clear to read. For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvent, gasoline or other chemicals to prevent the label from fading and peering.
  • Page 15 FOREWORD Points on Assembling Points on Disassembling and As- Wash all engine parts, except such parts as oil seals, O- sembling rings and rubber seats, in cleaning oil and dry them with This service manual contains the recommended practices to compressed air.

  • Page 17: External View

    GENERAL CONTENTS Chapter 1 GENERAL 1. External View 2. Outline of Systems 3. Contents of Plate and Label 4. Specifications Chapter 2 SERVICE DATA 1. Maintenance Service Data 2. Tightening Torque Table Chapter 3 SERVICE TOOLS 1. Special Tools Chapter 4 OVERHAUL INSTRUCTIONS 1.
  • Page 18 Chapter 8 FUEL SYSTEM 1. Fuel System - Remove and Inspect 2. Fuel System - Disassemble, Inspect and Assemble 3. Fuel System - Install Chapter 9 LUBRICATION SYSTEM 1. Lubrication System - Remove and Inspect 2. Lubrication System - Disassemble, Inspect and Assemble 3.

  • Page 19: Table Of Contents

    Chapter 1 GENERAL External View ......................1-3 Outline of Systems ....................1-15 Outline of Fuel System ......................1-15 Outline of Lubrication System....................1-15 Outline of Cooling System ...................... 1-16 Outline of Inlet and Exhaust System..................1-18 Contents of Plate and Label ................. 1-19 Name Plate ..........................
  • Page 21 Chapter 1 GENERAL Chapter 1 GENERAL 1. External View S12A2-PTA Thermostat Thermostat Front hanger Alternator Water pump Tension Pulley Damper Note: Configuration may differ depending on the customization and specifications. Engine Front View S12A2-PTA Exhaust gas outlet Rear hanger Direction of rotation...
  • Page 22 Chapter 1 GENERAL S12A2-PTA Turbocharger Fuel injection pump Cooling water outlet Governor oil filter Air cooler Stop lever Fuel filter Rear Front Governor Cooling water inlet Fuel feed pump Water drain cock Oil filler Starter Breather Oil level gauge Stop solenoid...
  • Page 23 Chapter 1 GENERAL S12A2-PTA2 Front hanger Thermostat Thermostat Tension Pulley Alternator Water pump Damper Note: Configuration may differ depending on the customization and specifications. Engine Front View S12A2-PTA2 Exhaust gas outlet Rear hanger Direction of rotation Direction of rotation Direction of rotation...
  • Page 24 Chapter 1 GENERAL S12A2-PTA2 Silencer Turbocharger Cooling Fuel injection pump water outlet Air cooler Stop lever Fuel filter Rear Front Actuator Cooling water inlet Fuel feed pump Water drain cock Oil filler Starter Breather Oil level gauge Fuel return port...
  • Page 25 Chapter 1 GENERAL S12A2-Y1PTA2 Front hanger Thermostat Thermostat Water pump side tension pulley Fan side tension pulley Alternator Water pump Damper Note: Configuration may differ depending on the customization and specifications. Engine Front View S12A2-Y1PTA2 Exhaust gas outlet Rear hanger...
  • Page 26 Chapter 1 GENERAL S12A2-Y1PTA2 Air cooler Fuel filter Cooling water outlet Fuel injection pump Stop lever Front Rear Actuator Cooling Fuel feed pump water inlet Water drain cock Oil filler Starter Breather Fuel return port Oil level gauge Stop solenoid...
  • Page 27 Chapter 1 GENERAL S12A2-PTK Thermostat Thermostat Front hanger Air cooler cooling water outlet Alternator Water pump Damper Tension Pulley Note: Configuration may differ depending on the customization and specifications. Engine Front View S12A2-PTK Exhaust gas outlet Rear hanger Air cooler cooling water inlet...
  • Page 28 Chapter 1 GENERAL S12A2-PTK Turbocharger Engine cooling Fuel injection pump water outlet Air cooler Stop lever Fuel filter Front Rear Actuator Engine cooling water inlet Fuel feed pump Water drain cock Oil filler Starter Breather Oil level gauge Fuel return port...
  • Page 29 Chapter 1 GENERAL S12A2-PTAW Thermostat Thermostat Front hanger Alternator Water pump Tension Pulley Damper Note: Configuration may differ depending on the customization and specifications. Engine Front View S12A2-PTAW Exhaust gas outlet Rear hanger Direction of rotation Direction of rotation Direction of rotation...
  • Page 30 Chapter 1 GENERAL S12A2-PTAW Engine cooling water outlet Air cooler Fuel filter Air cooler cooling water outlet Fuel injection pump Stop lever Front Rear Actuator Engine cooling Fuel feed pump water inlet Water drain cock Oil filler Starter Breather Oil level gauge...
  • Page 31 Chapter 1 GENERAL S12A2-Y2PTAW Thermostat Thermostat Alternator Air cooler water pump Water pump Tension Pulley Tension Pulley Damper Note: Configuration may differ depending on the customization and specifications. Engine Front View S12A2-PTAW Exhaust gas outlet Direction of rotation Direction of rotation...
  • Page 32 Chapter 1 GENERAL S12A2-Y2PTAW Fuel filter Fuel injection pump Air cooler Stop lever Rear Front Actuator Engine cooling Fuel feed pump water inlet Water drain cock Oil filler Starter Breather Oil level gauge Fuel return port Stop solenoid Note: Configuration may differ depending...

  • Page 33: Outline Of Systems

    Chapter 1 GENERAL 2. Outline of Systems 2.1 Outline of Fuel System Fuel injection nozzle Fuel leak-off pipe Fuel injection pump To right side of engine Fuel filter From right side of engine From fuel tank To fuel tank Outline of Fuel System 2.2 Outline of Lubrication System Woodward PSG type governor Turbocharger...

  • Page 34: Outline Of Cooling System

    Chapter 1 GENERAL TOHO SEISAKUSHO SG4017 type actuator spec Turbocharger Woodward PROACT type governor spec Camshaft Rocker shaft Piston Main gallery Piston cooling nozzle Oil cooler Timing gear Fuel Injection Pump Bypass oil filter Crankshaft Water pump Oil pump Oil filter Safety valve Oil strainer Outline of Lubrication System...
  • Page 35 Chapter 1 GENERAL PTK, PTAW spec External cooling type Air cooler(right) Oil cooler Thermostat Water jacket Engine cooling water outlet Air cooler cooling water outlet Air cooler Engine cooling water inlet cooling water outlet Water outlet pipe Water bypass pipe Engine cooling water inlet Water pump...

  • Page 36: Outline Of Inlet And Exhaust System

    Chapter 1 GENERAL MTK, MPTK spec with fresh water cooling system or seawater cooling system Water pump Oil cooler Air cooler(right) Air cooler cooling water inlet Thermostat Water jacket Heat exchanger Air cooler Water outlet pipe cooling water Expansion outlet tank Air cooler(left) Water bypass pipe...

  • Page 37: Contents Of Plate And Label

    Chapter 1 GENERAL 3. Contents of Plate and Label 3.1 Name Plate The name plate is attached on the lateral side of the engine, and shows the following information: Right Engine serial number Manufactured date 3 4 5 6 Total displacement Front Rear Engine output...

  • Page 38: Specifications

    Chapter 1 GENERAL 4. Specifications Engine model S12A2 Type Water cooled, four stroke cycle diesel, turbo charged No. of cylinders - Arrangement 12-V Combustion system Direct injection system Valve mechanism Overhead Cylinder bore × stroke 150 × 160 mm [5.905 × 6.299 in.] Total displacement 33.93 L [2070.534 cu.
  • Page 39 Chapter 1 GENERAL Equipment name Specification name V-belt 32620-00300 V-belt Crankshaft pulley 32620-10500 Ribbed belt 32620-01100 Standard (32621-00052) Flywheel (32621-00080) Single damper Damper Double damper (32625-54101) (45685-60600) (32625-04301) (45120-90300) Front pulley (32625-04801) (32625-05901) (45125-97300) (32620-00700) Screw adjust type (32561-76050) Screw adjust type (32561-64010) Screw adjust type (32561-79010)
  • Page 40 Chapter 1 GENERAL Equipment name Specification name Woodward make PSG type governor TOHO SEI- SAKUSHO Co., LTD. Governor SG4017 type actuator Woodward make PROACT type actua- RUN ON (04400-08801) RUN ON Stop solenoid (04400-28800) RUN OFF (04400-02000) TD13M-54VRC-40 TD13M-42B-40 TD13M-48F-40 TD10L-42F-34 TD10L-42F-43 TD10L-45VRC-28...
  • Page 41 Chapter 1 GENERAL Equipment name Specification name (04343-38000) (34468-21100) Alternator (04344-05001) (04343-35500) (34368-02400) 1-23...

  • Page 43: Table Of Contents

    Chapter 2 SERVICE DATA Maintenance Service Data ..................2-3 Maintenance Service Data of Engine General................2-3 Maintenance Service Data of Basic Engine................2-4 Maintenance Service Data of Fuel System................2-9 Maintenance Service Data of Lubrication System ..............2-13 Maintenance Service Data of Cooling System ............... 2-13 Maintenance Service Data of Electrical System ..............

  • Page 45: Maintenance Service Data

    Chapter 2 SERVICE DATA Chapter 2 SERVICE DATA 1. Maintenance Service Data 1.1 Maintenance Service Data of Engine General Item Nominal value Standard value Limit value Remarks 2.35 MPa 1.86 Mpa Cranking Compression pressure {24 kgf/cm {300 kgf/cm (120 to 200 min [419 psi] [4267 psi] 0.49 to 0.64 MPa...

  • Page 46: Maintenance Service Data Of Basic Engine

    Chapter 2 SERVICE DATA 1.2 Maintenance Service Data of Basic Engine Unit: mm [in.] Nominal Item Standard value Limit value Remarks value 32.055 to 32.080 32.100 Rocker bushing inside diameter ø32 [1.26] [1.2620 to 1.2630] [1.2638] Rockers 31.975 to 31.991 31.950 Rocker shaft outside diameter ø32 [1.26]...
  • Page 47 Chapter 2 SERVICE DATA Unit: mm [in.] Nominal Item Standard value Limit value Remarks value Distortion of bottom surface 0.03 [0.0012] or less 0.07 [0.0028] Cylinder 134.9 to 135.1 head Height (reference) [5.3110 to 5.3189] 150.000 to 150.040 150.140 Inside diameter ø150 [5.9] [5.9055 to 5.9071] [5.9110]...
  • Page 48 Chapter 2 SERVICE DATA Unit: mm [in.] Nominal Item Standard value Limit value Remarks value 58.020 to 58.040 58.070 Inside diameter of connecting rod bushing ø58 [2.28] [2.2842 to 2.2850] [2.2862] 0.05/100 [0.0020/3.94] Bend and twist or less 0.6 to 0.9 End play 1.0 [0.039] [0.024 to 0.035]...
  • Page 49 Chapter 2 SERVICE DATA Unit: mm [in.] Nominal Item Standard value Limit value Remarks value 103.900 to 103.920 103.860 Standard [4.0905 to 4.0913] [4.0890] 103.650 to 103.670 103.610 0.25 [0.0098] [4.0807 to 4.0815] [4.0791] Crankpin 103.400 to 103.420 103.360 outside 0.50 [0.0197] ø104 [4.1] [4.0709 to 4.0716]...
  • Page 50 Chapter 2 SERVICE DATA Unit: mm [in.] Nominal Item Standard value Limit value Remarks value 3.500 3.482 to 3.500 Standard 3.450 [0.1358] [0.1378] [0.1371 to 0.1378] 3.625 3.607 to 3.625 0.25 [0.0098] 3.575 [0.1407] [0.1427] [0.1420 to 0.1427] Main bear- Thickness at 3.750 3.732 to 3.750...

  • Page 51: Maintenance Service Data Of Fuel System

    Chapter 2 SERVICE DATA 1.3 Maintenance Service Data of Fuel System Unit: mm [in.] Limit Item Nominal value Standard value Remarks value P/N: 32561-54010("C" mark) 21.6 MPa 22.1- 22.6 MPa 32561-57090("E" mark) {220 kgf/cm²} {225 to 230 kgf/cm²} 32561-64010("A" mark) [3129 psi] [3200 to 3271 psi] 32561-76050("-"...
  • Page 52 Chapter 2 SERVICE DATA Unit: mm [in.] Limit Item Nominal value Standard value Remarks value 71.988 to 72.018 ø72 [2.83] [2.8342 to 2.8353] Case bearing inside diameter of counterbore 89.985 to 90.020 ø90 [3.54] [3.5427 to 3.5441] 71.987 to 72.000 Out- Small ø72 [2.83]...
  • Page 53 Chapter 2 SERVICE DATA Unit: mm [in.] Limit Item Nominal value Standard value Remarks value 46.989 to 47.014 ø47 [1.85] [1.8500 to 1.8509] Inside diameter of case bearing 79.988 to 80.018 ø80 [3.15] housing [3.1491 to 3.1503] 89.987 to 90.022 ø90 [3.54] [3.5428 to 3.5442] 46.989 to 47.014...
  • Page 54 Chapter 2 SERVICE DATA Unit: mm [in.] Limit Item Nominal value Standard value Remarks value 46.989 to 47.014 ø47 [1.85] [1.8500 to 1.8509] Inside diameter of case bearing 79.988 to 80.018 ø80 [3.15] housing [3.1491 to 3.1503] 99.987 to 100.022 ø100 [3.94] [3.9365 to 3.9379] 46.989 to 47.014...

  • Page 55: Maintenance Service Data Of Lubrication System

    Chapter 2 SERVICE DATA 1.4 Maintenance Service Data of Lubrication System Unit: mm [in.] Item Nominal value Standard value Limit value Remarks 0.100 to 0.200 0.400 Drive gear and driven gear backlash [0.0039 to 0.0079] [0.0157] Backlash between oil pump gear and 0.12 to 0.18 crankshaft gear [0.0047 to 0.0071]...

  • Page 56: Maintenance Service Data Of Cooling System

    Chapter 2 SERVICE DATA 1.5 Maintenance Service Data of Cooling System Unit: mm [in.] Nominal Limit Item Standard value Remarks value value Inside diameter of pulley 79.961 to 79.991 ø80 [3.15] bearing fit [3.1481 to 3.1492] Outside 79.987 to 80.000 ø80 [3.15] diameter [3.1491 to 3.1496]...
  • Page 57 Chapter 2 SERVICE DATA Unit: mm [in.] Nominal Limit Item Standard value Remarks value value ø62 61.988 to 62.018 [2.44] [2.4405 to 2.4416] Inside diameter of case bearing housing 71.988 to 72.018 ø72 [2.83] [2.8342 to 2.8353] Outside 71.987 to 72.000 ø72 [2.83] diameter [2.8341 to 2.8346]...
  • Page 58 Chapter 2 SERVICE DATA Unit: mm [in.] Nominal Limit Item Standard value Remarks value value ø110 109.987 to 110.022 [4.33] [4.3302 to 4.3316] Inside diameter of case bearing housing ø120 119.987 to 120.022 [4.72] [4.7239 to 4.7253] Outside ø120 119.985 to 120.000 diameter [4.72] [4.7238 to 4.7244]...

  • Page 59: Maintenance Service Data Of Electrical System

    Chapter 2 SERVICE DATA 1.6 Maintenance Service Data of Electrical System Unit: mm [in.] Item Nominal Limit Standard value Remarks value value 18.90 to 18.94 Front shaft outside diameter ø19 [0.75] [0.7441 to 0.7457] 19.000 to 19.033 Front bearing inside diameter ø19 [0.75] [0.7480 to 0.7493] 19.000 to 19.033...
  • Page 60 Chapter 2 SERVICE DATA Unit: mm [in.] Item Nominal Limit Standard value Remarks value value Outside diameter ø43 [1.69] 42 [1.65] Runout 0.06 [0.0024] Commutator [0.004] 0.7 to 0.9 Undercut depth [0.028 to 0.035] [0.008] (reference at At pull starting 0.066 [0.0026] Coil 20°C [68 ºF] )
  • Page 61 Chapter 2 SERVICE DATA Unit: mm [in.] Item Nominal Limit Standard value Remarks value value 24 A or more 1500 (when engine is hot) Rotating Output cur- 38 A or more Initial rent speed 2500 (when engine is exciting P/N: (at 27 V) hot) (min...

  • Page 62: Air Start System

    Chapter 2 SERVICE DATA 1.6.1 Belt tension Unit N {kgf} [lbf] Belt straight distance (mm) [in.] Number Item 300 [11.81] or more than 300 to 400 more than 400 to 500 more than 500 to 600 more than 600 of ribs below [11.81 to 15.75] [15.75 to 19.69]...

  • Page 63: Tightening Torque Table

    Chapter 2 SERVICE DATA 2. Tightening Torque Table 2.1 Tightening Torque Spec for Basic Engine Tightening torque Dia x Pitch Description Remarks (M-thread) N·m kgf·m lbf·ft Cylinder head bolt 20 × 2.5 Note (a) [Wet] Rocker cover 12 x 1.25 15 ±...

  • Page 64: Tightening Torque Spec For Fuel System

    Chapter 2 SERVICE DATA 2.2 Tightening Torque Spec for Fuel System Tightening torque Dia x Pitch Description Remarks (M-thread) N·m kgf·m lbf·ft Coupling shaft 12 x 1.75 88 ± 5 9 ± 0.5 65 ± 3.6 Bosch S3S pump with bolt P.C.D. 10 x 1.5 61.5 ±...

  • Page 65: Tightening Torque Spec For Electrical System

    Chapter 2 SERVICE DATA 2.6 Tightening Torque Spec for Electrical System Tightening torque Dia x Pitch Description Remarks (M-thread) N·m kgf·m lbf·ft Starter - Install 12 x 1.25 59 ± 5.9 6 ± 0.6 43 ± 4.3 Magnetic switch 6 x 1.0 4.5 ±...

  • Page 66: Tightening Torque For Standard Bolts

    Chapter 2 SERVICE DATA 2.8 Tightening Torque for Standard Bolts Thread size Width across Strength classification Threads Dia. x Pitch flats 10.9 (M-thread) (mm) [in.] N·m kgf·m lbf·ft N·m kgf·m lbf·ft 8 x 1.25 12 [0.47] 12.3 22.4 10 x 1.25 14 [0.55] 24.6 44.1...

  • Page 67: Tightening Torque For Standard Eyebolts

    Chapter 2 SERVICE DATA 2.9 Tightening Torque for Standard Eyebolts Strength classification Thread size Width across flats Dia. × Pitch (mm) [in.] (M-thread) N·m kgf·m lbf·ft 8 × 1.25 12 [0.47] 8 ± 1 0.8 ± 0.1 5.90 ± 0.73 10 ×...
  • Page 69 Chapter 3 SERVICE TOOLS Special Tools......................3-3...

  • Page 71: Special Tools

    Chapter 3 SERVICE TOOLS Chapter 3 SERVICE TOOLS 1. Special Tools Maintenance Tool name Part No. Illustration Usage item Basic engine Rocker bushing puller 32591-02600 Rocker Bushing - Replace Bushing inside/outside diam : ø32× 36 mm [1.26 × 1.42 in.] Idler bushing puller 32591-02500 Idler Bushing - Replace...
  • Page 72 Chapter 3 SERVICE TOOLS Maintenance Tool name Part No. Illustration Usage item Basic engine Nozzle remover 36291-00900 Fuel injection nozzle - remove M18×1.5 mm Valve spring 33591-04500 Valve spring - install/remove pusher Valve guide remover 36291-04200 Valve guide - remove Applicable valve guide inside/outside diam: ø10 X 18 mm [0.39 X 0.71 in.]...
  • Page 73 Chapter 3 SERVICE TOOLS Maintenance Tool name Part No. Illustration Usage item Basic engine Projection 37598-09201 Depth of counterbore in crankcase - plate measure L230 × W50 × T15 mm [L9.06 × W1.97 × T0.59 in.] Connecting rod 32591-18010 Connecting Rod Bushing -Install and bushing installer Remove Valve lapper...
  • Page 74 Chapter 3 SERVICE TOOLS Maintenance Tool name Part No. Illustration Usage item Basic engine Valve seat puller 32591-04200 Valve seat - remove Piston installer 37191-07100 Piston- Install Applicable piston diam: ø89 to 178 mm [3.50 to 7.01 in.] Crankcase 32591-04050 Depth of counterbore in crankcase - grinder Reface...
  • Page 75 Chapter 3 SERVICE TOOLS Maintenance Tool name Part No. Illustration Usage item Cooling Oil seal 32591-03100 Water pump, fan drive oil seal - Press- system installer Unit seal 37191-06300 Water pump unit seal - Install installer Water pump wrench 32691-01200 Water pump Oil drain pipe removal/installation Bearing installer...
  • Page 76 Chapter 3 SERVICE TOOLS Maintenance Tool name Part No. Illustration Usage item Inspection and Belt gauge 32591-09100 Belt tension - measure measurement...
  • Page 77 Chapter 4 OVERHAUL INSTRUCTIONS Determining Overhaul Timing ................4-3 Compression Pressure - Measure................4-4...
  • Page 79 Chapter 4 OVERHAUL INSTRUCTIONS Chapter 4 OVERHAUL INSTRUCTIONS 1. Determining Overhaul Timing In most cases, the engine should be overhauled when the compression pressure of the engine decrease. An increase in engine oil consumption and blow-by gas should be considered when evaluating the engine condition. Such symptoms as the output decrease, fuel consumption increase, oil pressure decrease, engine starting difficulty and noise increase should be considered to evaluate overhaul timing, although these symptoms are often affected by various causes, and are not always effective to consider overhaul timing.
  • Page 80 Chapter 4 OVERHAUL INSTRUCTIONS 2. Compression Pressure - Measure Compression gauge P/N:33A91-01700 (a) Be sure to measure the compression pressure of Gauge adapter all cylinders. It is not a clever way to measure P/N:36291-02200 the compression pressure of only two or three cylinders, and assume the compression pres- sure of all other cylinders.
  • Page 81 Chapter 5 DISASSEMBLY OF BASIC ENGINE Cylinder Heads and Valve Mechanisms - Disassemble and Inspect ....5-3 Fuel Pipe - Remove ........................5-4 Nozzle Assembly - Remove...................... 5-4 Valve Clearance - Inspect......................5-4 Fuel Injection Timing - Inspect....................5-5 Rocker Shaft Assembly - Remove.................... 5-5 Clearance Between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect...
  • Page 83 Chapter 5 DISASSEMBLY OF BASIC ENGINE Chapter 5 DISASSEMBLY OF BASIC ENGINE 1. Cylinder Heads and Valve Mechanisms - Disassemble and Inspect Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the efficient work.
  • Page 84 Chapter 5 DISASSEMBLY OF BASIC ENGINE 1.1 Fuel Pipe - Remove (1) Remove the clamp, and remove the fuel injection pipe. Eye bolt Fuel injection pipe (2) Remove the eyebolt of fuel injection nozzle, and Sealing Clamp remove the fuel leak-off pipe. washers While doing so, remove the sealing washers and keep them together to avoid the risk of losing.
  • Page 85 Chapter 5 DISASSEMBLY OF BASIC ENGINE 1.4 Fuel Injection Timing - Inspect Inspect the fuel injection timing, and know the current con- 88 ± 5 N·m 88 ± 5 N·m 88 ± 5 N·m dition. {9 ± 0.5 kgf·m} {9 ± 0.5 kgf·m} {9 ±...
  • Page 86 Chapter 5 DISASSEMBLY OF BASIC ENGINE 1.7 Valve Bridge - Remove Remove the valve bridge and bridge cap. Screw Note: Be careful not to drop the bridge cap into the cylinder head. Bridge cap Valve Bridge - Remove 1.8 Cylinder Head Assembly - Remove When removing the cylinder head gasket, be careful Eye nut P/N:08014-00003...
  • Page 87 Chapter 5 DISASSEMBLY OF BASIC ENGINE 1.10 Valve and Valve Spring - Remove Using a valve spring pusher, compress the valve spring evenly and remove the valve cotters. Valve spring pusher Note: If valves are reusable, mark each valve seat and the P/N : 33591-04500 mating valve to identify their original positions.
  • Page 88 Chapter 5 DISASSEMBLY OF BASIC ENGINE 2. Rear Mechanism - Disassemble and Inspect Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the efficient work. Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with any job.
  • Page 89 Chapter 5 DISASSEMBLY OF BASIC ENGINE 2.1 Flywheel Face and Radial Runout - Measure Measure the face and radial runouts of the flywheel, and know the current condition. For the measurement procedure, refer to "Flywheel Face Face runout measuring plane and Radial Runout - Measure"...
  • Page 90 Chapter 5 DISASSEMBLY OF BASIC ENGINE 2.4 Timing Gear Backlash - Measure Measure the timing gear backlash, and know the current condition. For the measurement procedure, refer to "Timing Gear Backlash - Measure" of "ASSEMBLY OF BASIC Camshaft gear Camshaft gear Camshaft gear ENGINE."...
  • Page 91 Chapter 5 DISASSEMBLY OF BASIC ENGINE 2.7 Idler Gear - Remove The camshaft gear mounting nuts are left-hand Socket P/N : 32591-02800 threaded. Be sure to turn them clockwise to loosen them. If the idler gear is removed first, the nut that fixes the cam- shaft gear cannot be loosened because the camshaft gear Camshaft gear Camshaft gear...
  • Page 92 Chapter 5 DISASSEMBLY OF BASIC ENGINE 2.10 Camshaft Gear - Remove (1) Remove the nut (left-hand thread). (2) Remove the camshaft gear with the puller using the threads in the gear. Threaded holes (M10 × 1.25 mm) Camshaft gear Puller Camshaft Gear - Remove 2.11 Camshaft - Remove Thrust plate...
  • Page 93 Chapter 5 DISASSEMBLY OF BASIC ENGINE 2.13 Rear Plate - Remove Remove the rear plate from the crankcase. Dowel pin Rear Plate - Remove 5-13...
  • Page 94 Chapter 5 DISASSEMBLY OF BASIC ENGINE 3. Front Mechanism - Disassemble and Inspect Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the efficient work. Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with any job.
  • Page 95 Chapter 5 DISASSEMBLY OF BASIC ENGINE 3.1 Fan, Fan Bracket Assembly and Belt - Remove (With fan spec) Remove the fan, fan bracket assembly and belt. 3.2 Damper Face and Radial Runout - Measure Measure the face and radial runout of the damper, and know the current condition.
  • Page 96 Chapter 5 DISASSEMBLY OF BASIC ENGINE 3.4 Front Cover - Remove Pointer When removing the oil seal (slinger portion), be careful not to damage the crankshaft.If the crankshaft has a flaw, oil will leak from its flaw even if new oil seal is Bolt installed.
  • Page 97 Chapter 5 DISASSEMBLY OF BASIC ENGINE 4. Cylinder Liner, Piston and Connecting Rod - Disassemble and Inspect Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the efficient work. Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with any job.
  • Page 98 Chapter 5 DISASSEMBLY OF BASIC ENGINE 4.1 Piston Protrusion - Measure Measure the piston protrusion, and know the current condi- tion. For the measurement procedure, refer to "Piston Protrusion Piston protrusion - Measure" of "ASSEMBLY OF BASIC ENGINE." Piston Protrusion - Measure 4.2 Connecting Rod End Play - Measure Measure the connecting rod end play, and know the current condition.
  • Page 99 Chapter 5 DISASSEMBLY OF BASIC ENGINE 4.5 Piston - Remove When holding the connecting rod with your hand to prevent it from swinging, be very careful, as you may suffer hand injuries from accidental movement of the connecting rod. (a) When pulling-out the piston, be careful not to drop the upper connecting rod bearing. (b) When removing piston, be careful not to damage cylinder liner by connecting rod runout.
  • Page 100 Chapter 5 DISASSEMBLY OF BASIC ENGINE 4.5.2 Removing the Piston With Pushing-up the Con- Eyebolt necting Rod Big End P/N:45815-32301 (M10 × 1.5 mm) (1) Remove the connecting rod cap and rotate the crank- shaft to bring the piston to the top dead center position. (2) Install the eye bolt to the threaded hole on the piston top, and support the piston to prevent it from falling down.
  • Page 101 Chapter 5 DISASSEMBLY OF BASIC ENGINE 4.7 Piston Pin and Piston - Remove (1) Remove the snap ring with ring pliers. (2) Place a piece of wood to piston pin end and lightly tap Snap ring with hammer to remove the piston pin, and separate the piston from connecting rod.
  • Page 102 Chapter 5 DISASSEMBLY OF BASIC ENGINE 5. Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the efficient work. Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with any job.
  • Page 103 Chapter 5 DISASSEMBLY OF BASIC ENGINE 5.1 Crankcase - Turn Over (Upend) Using a turnover machine, turn over the crankcase.When Weight of crankshaft and the turnover machine is not available, hitch slings to the crankcase: 1370 kg crankcase using wood pieces and cloth pads, and raise the [3020 lb] crankcase with a hoist or crane.
  • Page 104 Chapter 5 DISASSEMBLY OF BASIC ENGINE 5.5 Crankshaft - Remove (a) Before removing the crankshaft, remove the front side upper thrust plate first, and be careful not to drop it into crankcase. (b) When placing the crankshaft onto a pallet or other stands, be careful not to damage the crankshaft.
  • Page 105 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE Cylinder Head and Valve Mechanism - Inspect and Repair......... 6-3 Bushing Inside Diameter and Shaft Outside Diameter of Rocker - Measure......6-3 Rocker Bushing - Replace ......................6-3 Valve Stem Outside Diameter and Valve Guide Inside Diameter - Measure ......6-4 Valve Guide - Replace......................
  • Page 106 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE Crankcase and Crankshaft - Inspect and Repair ..........6-23 Crankcase Top Surface Distortion - Measure................. 6-23 Inside Diameter of Main Bearing Housing Bore - Measure ............ 6-23 Cylinder Liner Fitting Bore in Crankcase - Inspect ..............6-24 Counterbore in Crankcase - Repair ..................
  • Page 107 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE Chapter 6 I N SPECTI O N AND REPAI R OF BASI C ENGI N E 1. Cylinder Head and Valve Mechanism - Inspect and Repair 1.1 Bushing Inside Diameter and Shaft Outside Diameter of Rocker - Measure Measure the inside diameter of the rocker bushing and the outside diameter of the rocker shaft.If the measurement Measuring...
  • Page 108 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.3 Valve Stem Outside Diameter and Valve Guide Inside Diameter - Measure Measure the outside diameter of valve stem and the inside Measurement diameter of valve guide at the top and bottom sliding ends in direction right-angle directions as shown, as the sliding surface tends to wear at the top and bottom ends.If the measurement...
  • Page 109 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.5 Valve Face - Inspect Inspect the valve face after the valve guide is inspected or Seat width replaced.Lap the valve and valve seat whenever valve is refaced or replaced. Valve margin Valve sinkage Valve Face - Inspect 1.5.1 Valve Margin - Inspect...
  • Page 110 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.7 Valve Seat - Reface If any damage or inclusions are found, grind the sheet face. (1) Reface the valve seat with valve seat cutter or valve Socket seat grinder.After refacing, insert sand paper of approx (width across flats 400 grit between cutter and valve, and grind valve seat 32 mm [1.26 in.])
  • Page 111 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.8.3 Valve Seat - Install (1) Before installing the valve seat, measure the inside diameter of valve seat counterbore in cylinder head and the outside diameter of valve seat to make sure that the interference is within the range of standard value.If the value exceeds the standard, use the oversize valve seat.If the inside diameter of valve seat counterbore in...
  • Page 112 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.9 Valve and Valve Seat - Lap Lap the valve and valve seat whenever valve seat is refaced or valve is replaced, or the contact surfaces fail to keep a pressure in the pressure test after assembling. (1) Apply a thin coat of lapping compound evenly to the valve face.
  • Page 113 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.11 Squareness and Free Length of Valve Spring - Measure Measure the squareness and free length of valve spring.The free length or squareness exceeds the specified limit, Spring squareness replace a valve spring with a new one. Nominal Standard value Limit value...
  • Page 114 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.15 Distortion of Cylinder Head Bottom Surface - Measure Refacing depth of cylinder head is to be mini- mum.Excessive grinding of the cylinder head may result in defects such as contact between piston and valve.
  • Page 115 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 2. Rear Mechanism - Inspect and Repair 2.1 Idler Bushing Inside Diameter and Idler Shaft Outside Diameter - Measure Measure the idler bushing inside diameter and the idler shaft outside diameter.If the value exceeds the limit, replace the Measurement direction idler gear assembly or the idler shaft with a new one.
  • Page 116 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 2.4 Camshaft Runout - Measure Measure the runout of camshaft at TIR.If the value exceeds the limit, correct the camshaft using a press, or replace the V-block camshaft with a new one. Note: With a dial gauge set on the camshaft, rotate the cam- shaft one turn and read the gauge indication.
  • Page 117 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 2.7 Camshaft Bushing - Replace Before tightening the set bolt, be sure to check that the set bolt is in alignment with the set bolt hole in the Engine camshaft bushing. front Make sure that the oil hole in the camshaft bushing is in alignment with the oil hole from the oil gallery.
  • Page 118 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 3. Front Mechanism - Inspect and Repair 3.1 Damper - Inspect Visually Check the damper for cracks around outer periphery, swell- ing in end plate, silicone oil leakage, and discoloration and separation of coating due to overheating.If any defect is found, replace the damper with a new one.
  • Page 119 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4. Piston and Connecting Rod - Inspect and Repair 4.1 Piston - Inspect Visually Check the combustion surface, piston pin bore, ring groove, sliding surface and bottom surface of piston. If any defect are found, replace the piston with a new one.
  • Page 120 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.5 Piston Pin Bore Inside Diameter - Measure Measure the piston pin bore inside diameter.If the value exceeds the limit, replace the piston with a new one. Nominal Item Standard value Limit value value Measurement Piston pin bore...
  • Page 121 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.9 Connecting Rod Bushing Inside Diameter - Measure Measure the inside diameter of the connecting rod bushing. If the value exceed the limit, replace the connecting rod Measurement direction bushing with a new one. Measurement point Nominal...
  • Page 122 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.10.2 Connecting Rod Bushing - Remove (1) Apply engine oil to inner surface of connecting rod bushing. (2) Attach the collar A to the mandrel and insert the assem- Mandrel Mark on collar A bly into the connecting rod bushing while aligning the (red stamp mark) match mark (red scribed line) on the collar A with that...
  • Page 123 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.10.3 Connecting Rod Bushing - Press-In (a) Make sure that the match marks (red lines) on col- Connecting rod bushing oil hole lars A and B are align. (b) Make sure that the oil hole of connecting rod Collar A bushing is in alignment with match mark (red ø4 match mark...
  • Page 124 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE (4) Measure the inside diameter of the connecting rod Bushing inner surface bushing. roughness Inside diameter of 1.6S Ra0.4μm If the value is out of the standard, ream the inside diam- connecting rod bushing eter to the standard.
  • Page 125 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.13 Side Face Width of Connecting Rod Big End - Measure (1) Inspect the side face of connecting rod big end visu- ally.If there is any defect such as wear or flaw, replace the connecting rod with a new one.
  • Page 126 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.16 Connecting Rod Bearing Thickness - Measure Measure the thickness of connecting rod at its center. If the value exceeds the limit, replace both upper and lower connecting rod bearing shells with new ones as a set.When Measurement at the center the crankshaft is re-ground due to wear of crank pin, use the...
  • Page 127 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5. Crankcase and Crankshaft - Inspect and Repair 5.1 Crankcase Top Surface Distortion - Measure Refacing depth of crankcase is to be minimum. Excessive grinding of the crankcase may result in defects such as defective combustion and stamping between piston and valve.
  • Page 128 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.3 Cylinder Liner Fitting Bore in Crankcase - Inspect (1) Inspect the counterbore in crankcase. Check for cracks Fitting bore of cylinder liner Counterbore in crankcase in edges, uneven contact between counterbore and bot- in crankcase tom face of cylinder liner flange.If any defect is found, reface the counterbore in crankcase.
  • Page 129 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.5.1 Crankpin and Crank Journal - Grind When using the undersize bearing, grind to the standard value corresponding to undersize bearing to be used.Do not change the fillet radius and bearing journal width when grinding.If a remarkable decrease in hardness is found, Measurement quench the crankshaft again and inspect it with the magnetic...
  • Page 130 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.6 Width of Crankpin and Rearmost Crank Main Journal - Measure (1) Inspect the ends of crankshaft for harmful flaw and Rearmost crank wear. Crankpin width journal width (2) Measure the crankpin and rearmost crank main journal width.
  • Page 131 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.7 Crankshaft Runout - Measure Support the crankshaft at front and rear main journals with V-blocks, and measure the crankshaft runout at the center V-block main journal with dial gauge.If the runout deviates slightly from the standard, correct the crankshaft by grinding.If the value exceeds the standard considerably, straighten the crankshaft with pressing machine.
  • Page 132 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.8 Crankshaft Gear - Inspect If there is any defect on the crankshaft gear teeth, such as flaking, wear, or local contact, replace the crankshaft gear with a new one. 5.9 Crankshaft Gear - Replace Use protective gloves when you touch hot parts.
  • Page 133 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.10 Oil Seal Slinger - Inspect If any defect such as dent, damage, wear and backlash that Rear Front could lead to oil leakage are found on the rear oil seal Timing slinger, replace the rear oil seal slinger with a new one.
  • Page 134 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.12 Main Bearing - Inspect Inspect the sliding surface, back surface and end surface of main bearing. If any defect such as local contact, sliding scratches, corrosion and foreign material inclusion is found, replace the main bearing with a new one.
  • Page 135 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.15 Thickness of Thrust Plate - Measure Measure the thickness of thrust plate. If the value exceeds the limit, replace the thrust plate with a new one.When the crankshaft is re-ground due to wear, use the oversize thrust plate.
  • Page 137 Chapter 7 ASSEMBLY OF BASIC ENGINE Crankshaft and Main Bearing - Install ..............7-3 Crankcase - Turn Over (Upend) ....................7-3 Piston Cooling Nozzle - Install ....................7-3 Upper Main Bearing - Install ..................... 7-4 Crankshaft - Install........................7-5 Upper thrust plates - Install....................... 7-5 Lower Main Bearing Shell and Lower Thrust Plate - Install ............
  • Page 138 Chapter 7 ASSEMBLY OF BASIC ENGINE Cylinder Head and Valve Mechanism - Assemble ..........7-27 Cylinder Head - Assemble ...................... 7-27 Valve Sinkage - Measure......................7-28 Tappet - Install ........................7-28 Liquid Gasket - Apply......................7-28 Cylinder Head Gasket - Install ....................7-29 Cylinder Head Assembly - Install....................
  • Page 139 Chapter 7 ASSEMBLY OF BASIC ENGINE Chapter 7 ASSEMBLY OF BASIC ENGINE 1. Crankshaft and Main Bearing - Install 1.1 Crankcase - Turn Over (Upend) Using a turnover machine, turn over the crankcase.When the turnover machine is not available, hitch slings to the Crankcase crankcase using wood pieces and cloth pads, and raise the weight:1010 kg [2227 lb]...
  • Page 140 Chapter 7 ASSEMBLY OF BASIC ENGINE 1.3 Upper Main Bearing - Install (a) Do not apply engine oil to the back face of the main bearing shell and main bearing fitting bore in the crank- case when installing the main bearing.Install the main bearing only after cleaning off foreign material, oil and grease from these surface using cleaning solvent.
  • Page 141 Chapter 7 ASSEMBLY OF BASIC ENGINE 1.4 Crankshaft - Install (1) Make sure that the sliding surfaces of the upper main Apply engine oil to bearing shells installed in the crankcase are evenly the crank journal coated with clean engine oil. after cleaning.
  • Page 142 Chapter 7 ASSEMBLY OF BASIC ENGINE 1.7 Main Bearing Cap - Install Be sure to observe the specified tightening sequence when tightening the main bearing cap bolts and side bolts. (1) Make sure that the main bearings and thrust plates installed to main bearing caps are evenly coated with clean engine oil.
  • Page 143 Chapter 7 ASSEMBLY OF BASIC ENGINE 1.8 Crankshaft End Play - Measure (1) Verify the smooth rotation of the crankshaft. (2) Apply a dial gauge probe to the rear end face of crank- shaft. (3) Using a bar, move the crankshaft fully to the front and rear to read the each measurement.
  • Page 144 (3) Measure the depth of counterbore in crankcase. Item Part No. Standard value 32608-00200 12.00 to 12.05 mm (S12A2-1) [0.4724 to 0.4744 in.] Depth of counterbore in crankcase 32608-00300 15.00 to 15.05 mm (S12A2-2) [0.5906 to 0.5925 in.] (4) Measure the thickness of cylinder liner flange.
  • Page 145 Chapter 7 ASSEMBLY OF BASIC ENGINE (5) Calculate the cylinder liner flange protrusion by sub- tracting the depth of counterbore in crankcase from the Crankcase Shim thickness of the cylinder liner flange. Cylinder liner If the value exceeds the limit, insert a shim under the cylinder liner flange.Select a shim which makes the cylinder liner flange protrusion the largest within the tolerance of the standard.
  • Page 146 Chapter 7 ASSEMBLY OF BASIC ENGINE 2.3 Cylinder Liner - Install Apply engine oil to the O-ring sliding surfaces to prevent O-rings from twisting. Do not apply engine oil to the O-ring grooves on cylinder liner. (1) Install the O-rings to the cylinder liner. (2) Insert the shim to the cylinder which needs the adjust- ment of cylinder liner flange protrusion.
  • Page 147 Chapter 7 ASSEMBLY OF BASIC ENGINE 2.5 Cylinder Liner Inside Diameter - Measure Measure the inside diameter of the cylinder liner at three levels, i.e., upper (position of No.1 compression ring when Cylinder liner piston is at the top dead center), liner middle position, and O-ring installed position, in both parallel and perpendicular directions to the piston pin direction.
  • Page 148 Chapter 7 ASSEMBLY OF BASIC ENGINE 2.7 Piston Ring - Install Ring expander P/N:37191-03200 Every piston ring has a top mark near the end Up mark gap.Install piston rings with the marks facing upward. Be careful not to install piston rings upside down. If No.1 compression ring piston rings are assembled incorrectly, it results in...
  • Page 149 Chapter 7 ASSEMBLY OF BASIC ENGINE 2.9 Piston Installation - Prepare (1) Turn the crankshaft to a position where the connecting rod big end does not hit the crankpin on the piston installing. Position so that connecting Crankpin rod big-end does not hit crankpin Position of Crankpin - Adjust (2) Clean the cylinder liner inner surface and the crankpin,...
  • Page 150 Chapter 7 ASSEMBLY OF BASIC ENGINE 2.11 Piston - Install Eyebolt P/N:45815-32201 When installing the piston, install the eye bolt to the (M8 × 1.25 mm) Eyebolt threaded hole on the piston top, and lift the piston with P/N:45815-32301 (M10 × 1.5 mm) chain block.When the installation work is done by hand, be sure to take preventive measures so that pis- ton does not falling down, and be very careful not to...
  • Page 151 Chapter 7 ASSEMBLY OF BASIC ENGINE (5) Install piston into cylinder liner by tapping the piston head with soft-head hammer. Note: Make sure that the piston is not caught in the cylinder liner, or the connecting rod big end does not hit the crank pin.
  • Page 152 Chapter 7 ASSEMBLY OF BASIC ENGINE 2.12 Connecting Rod Cap - Install Lower connecting rod Connecting rod bolt bearing (a) Make sure that the matching numbers on the con- Lug groove necting rod and the connecting rod cap are on the Threaded same side and in alignment.
  • Page 153 Chapter 7 ASSEMBLY OF BASIC ENGINE 2.13 Connecting Rod End Play - Measure Measure the end play of the connecting rod. Connecting rod If the value exceeds the limit, find the causal parts, and replace them with new ones. Item Standard value Limit value 0.6 to 0.9 mm...
  • Page 154 Chapter 7 ASSEMBLY OF BASIC ENGINE 3. Front Mechanism - Assemble 3.1 Front Cover - Install (1) Apply sealant (ThreeBond 1211) to the packing mount- ing surface of the crankcase, and install the packing. (2) Apply sealant (ThreeBond 1211) to the packing for front cover mounting surface, and install the front cover.
  • Page 155 Chapter 7 ASSEMBLY OF BASIC ENGINE 3.3 Crankshaft Pulley, Damper and Front Pulley - Install (1) Install the guide bolt to damper mounting thread on the crankshaft. 539 ± 27 N·m (2) Put the crankshaft pulley, belt and damper to the guide {55 ±...
  • Page 156 Chapter 7 ASSEMBLY OF BASIC ENGINE 4. Rear Mechanism - Assemble 4.1 Rear Plate - Install (1) Make sure that plugs that block the oil gallery of the Plug crankcase are installed (3 places). (2) Apply sealant (ThreeBond 1211) to the packing mount- ing surface of the crankcase, and install the packing.
  • Page 157 Chapter 7 ASSEMBLY OF BASIC ENGINE 4.3 Camshaft - Install Sling Sling Sling Install the camshaft through the posh rod hole in the Crankcase by supporting it with a lifting sling.Be care- ful not to bump the camshaft to avoid the damage to cam lobe and bushing.
  • Page 158 Chapter 7 ASSEMBLY OF BASIC ENGINE 4.6 Governor Drive and Fuel Injection Pump Accessory Drive - Install 4.6.1 Fuel Injection Pump Accessory Drive - Install Accessory drive (1) Install the O-ring to the mounting surface of the fuel injection pump accessory drive case.Apply a thin coat of ThreeBond 1212 to the flange.
  • Page 159 Chapter 7 ASSEMBLY OF BASIC ENGINE 4.8 Idler Gear - Install (1) Turn the crankshaft to move the No. 1 cylinder to the Camshaft gear top dead center. (2) Apply engine oil to the idler shaft. (3) Install the idler gear, aligning it with the match marks. (4) Install the thrust plate to the idler shaft.
  • Page 160 Chapter 7 ASSEMBLY OF BASIC ENGINE 4.10 Timing Gear Backlash - Measure Measure the backlash of timing gears using either method: measure the gear backlash with a dial gauge applying its probe to a tooth flank on the pitch circle at a right angle to the tooth axis, or measure the clearance between gears by Camshaft gear Camshaft gear...
  • Page 161 Chapter 7 ASSEMBLY OF BASIC ENGINE 4.12 Rear Oil Seal - Install Use the rear seal installer assembly to install the rear oil Insert bolt seal. (1) Apply clean engine oil evenly to the oil seal lip. Guide flange Note: Pay attention to the installing side of oil seal, and be Insert Swing washer careful not to damage the oil seal.
  • Page 162 Chapter 7 ASSEMBLY OF BASIC ENGINE 4.15 Pickup - Install (Electronic governor spec) Timing gear case (1) Turn the crankshaft to move the ring gear teeth top to the center line of pickup installing hole. (2) Insert the pickup into the hole slowly and carefully by hand.
  • Page 163 Chapter 7 ASSEMBLY OF BASIC ENGINE 5. Cylinder Head and Valve Mechanism - Assemble 5.1 Cylinder Head - Assemble Valve stem Guide and seal installer (a) Be careful when inserting the valve through stem P/N:32591-10300 seal, as the edge of stem can cause damage to Stem seal the stem seal lip.
  • Page 164 Chapter 7 ASSEMBLY OF BASIC ENGINE 5.2 Valve Sinkage - Measure Measure the valve sinkage. Seat width If the value exceeds the limit, replace the valve or valve seat with a new one.Lap the valve and valve seat whenever valve or valve seat is refaced or replaced.
  • Page 165 Chapter 7 ASSEMBLY OF BASIC ENGINE 5.5 Cylinder Head Gasket - Install (1) Wipe off oil, grease and other contamination from the cylinder head bottom surface and crankcase top sur- Dowel pin Dowel pin Dowel pin face. (2) Install the cylinder head gasket coated with liquid gas- ket onto crankcase with dowel pin and hole in align- ment.
  • Page 166 Cylinder Head Bolt - Tighten Angle Tightening position Snug torque method 118±5.9 N·m Cylinder head bolt {12±0.6 kgf·m} 75±3° (short) [87±4 lbf·ft] S12A2-1 196±9.8 N·m Cylinder head bolt {20±1.0 kgf·m} 60±3° (long) [145±7 lbf·ft] 118±5.9 N·m Cylinder head bolt {12±0.6 kgf·m} 110±3°...
  • Page 167 Chapter 7 ASSEMBLY OF BASIC ENGINE 5.8 Bridges and Bridge Caps - Install (1) Apply engine oil to the bridge guide. Bridge cap (2) Install the bridge on bridge guide. Place the screw-fit- ted end of bridge to exhaust manifold side. (3) Apply engine oil to the bridge contact area of bridge Application of cap, and install the bridge cap.Be careful not to drop the...
  • Page 168 Chapter 7 ASSEMBLY OF BASIC ENGINE 5.11 Rocker shaft assembly - Assemble (1) Insert the rocker shaft bracket to the rocker shaft Rocker shaft bracket bracket.Match the chipped parts of the rocker shaft and the head bolt hole of rocker shaft bracket. Notch Rocker shaft Rocker Shaft - Assemble...
  • Page 169 Chapter 7 ASSEMBLY OF BASIC ENGINE 5.13 Valve Clearance - Check and Adjust Adjust the valve clearance when the engine is cold. Note:(a) The inlet valves are on the left side and exhaust valves are on the right when the cylinder head is viewed from camshaft side.
  • Page 170 Chapter 7 ASSEMBLY OF BASIC ENGINE 5.14.2 Fuel Injection Timing - Check (1) Turn the crankshaft in normal direction, and stop the turning when the No. 1 cylinder is positioned at approx 10° before the specified fuel injection timing. Also, make sure that the line stamped on the fuel injec- tion pump coupling is positioned before and close to the pointer.
  • Page 171 Chapter 7 ASSEMBLY OF BASIC ENGINE 5.15 Valve Timing - Inspect The specified valve timing is automatically made, when gears are assembled by aligning match marks and valve clearance is adjusted to the specified value.To make sure, check the valve timing as follows: 5.15.1 Valve timing at normal valve clearance (no Top dead center thickness gauge insertion)
  • Page 172 Chapter 7 ASSEMBLY OF BASIC ENGINE 5.16 Fuel Injection Nozzle Assembly - Install (1) Apply a thin coat of grease to the gasket and install it to fuel injection nozzle. Fuel leak off pipe Eye bolt (2) Insert the fuel injection nozzle to the cylinder head, and Fuel injection pipe temporarily tighten the nozzle gland.
  • Page 173 Chapter 8 FUEL SYSTEM Fuel System - Remove and Inspect ............... 8-3 Fuel Injection Pipe - Remove and Inspect ................8-3 Fuel Leak-off Pipe and Fuel Pipe - Remove and Inspect ............8-4 Fuel Filter and Fuel Pipe - Remove and Inspect ..............8-6 Stop Solenoid - Remove and Inspect ..................
  • Page 175 Chapter 8 FUEL SYSTEM Chapter 8 FUEL SYSTEM 1. Fuel System - Remove and Inspect 1.1 Fuel Injection Pipe - Remove and Inspect Standard spec PTA2 spec Leak, crack, contact Replace Replace Double pipe spec Replace Replace Leak, crack, contact Replace Fuel Injection Pipe - Remove and Inspect Removing Sequence...
  • Page 176 Chapter 8 FUEL SYSTEM 1.2 Fuel Leak-off Pipe and Fuel Pipe - Remove and Inspect Return to fuel tank Replace Replace Replace Replace With fuel filter (wire element) spec Replace Fuel Leak-off Pipe and Fuel Pipe - Remove and Inspect Removing Sequence 1 Left leak-off pipe 8 Fuel pipe...
  • Page 177 Chapter 8 FUEL SYSTEM Return to fuel injection pump Replace Replace With fuel filter (wire element) spec Replace Fuel Leak-off Pipe and Fuel Pipe - Remove and Inspect Removing Sequence 1 Fuel pipe 5 Leak-off pipe 2 Fuel pipe 6 Left leak-off pipe 3 Fuel pipe 7 Right leak-off pipe 4 Fuel filter (wire mesh element)
  • Page 178 Chapter 8 FUEL SYSTEM 1.3 Fuel Filter and Fuel Pipe - Remove and Inspect Change over type fuel filter spec Standard fuel filter spec Standard fuel filter spec Change over type fuel filter spec Fuel Filter and Fuel Pipe - Remove and Inspect Removing Sequence 1 Left fuel pipe 4 Right fuel pipe...
  • Page 179 Chapter 8 FUEL SYSTEM 1.4 Stop Solenoid - Remove and Inspect Stop solenoid RUN ON spec Looseness, bend Rotation Stop Solenoid - Remove and Inspect Removing Sequence 1 Link 5 Lever 9 Snap ring 2 Bolt, Spacer, Rubber cushion 6 Spring pin 10 Ball bearing 3 Stop solenoid 7 Lever...
  • Page 180 Chapter 8 FUEL SYSTEM Stop solenoid RUN OFF type Looseness, bend Rotation Stop Solenoid - Remove and Inspect Removing Sequence 1 Link 5 Lever 9 Snap ring 2 Bolt 6 Spring pin 10 Ball bearing 3 Stop solenoid 7 Lever 11 Bracket 4 Spring pin 8 Shaft...
  • Page 181 Chapter 8 FUEL SYSTEM 1.5 Fuel Control Link - Remove and Inspect Woodward PSG type governor spec TOHO SEISAKUSHO SG4017 type actuator spec a. PSG spec Looseness, bend Rotation a. PSG spec Contact face wear, bend Flaw, wear, bend Rotation Looseness, bend b.
  • Page 182 Chapter 8 FUEL SYSTEM Woodward PROACT type actuator spec Looseness, bend Looseness, bend Rotation Rotation Looseness, bend Looseness, bend Contact face wear, bend Rotation Flaw, wear, bend Rotation Looseness, bend Fuel Control Link - Remove and Inspect Removing Sequence 1 Right link 6 Left link 10 Left lever 2 Right link...
  • Page 183 Chapter 8 FUEL SYSTEM TOHO SEISAKUSHO SG4017 type actuator PTA2 spec Looseness, bend Looseness, bend Rotation Rotation Looseness, bend Looseness, bend Contact face wear, bend Rotation Flaw, wear, bend Rotation Looseness, bend Fuel Control Link - Remove and Inspect Removing Sequence 1 Right link 6 Left link 10 Left lever...
  • Page 184 Chapter 8 FUEL SYSTEM 1.6 Fuel Injection Pump - Remove and Inspect With back stay spec PTA,PTA2,PTK spec PTA,PTK,MTK,MPTA, MPTK spec Drive case Fuel Injection Pump - Remove and Inspect Removing Sequence 1 Right stay 9 Right injection pump bracket 2 Right coupling cover 10 Left stay 3 Right cover stay...
  • Page 185 Chapter 8 FUEL SYSTEM Tamper proof attachment spec Y2PTAW Crankcase Y2PTAW Y2PTAW Fuel Injection Pump - Remove and Inspect Removing Sequence 1 Right stay 10 Right stay 2 Right coupling cover 11 Left coupling cover 3 Pump mounting bolt 12 Pump mounting bolt 4 Pump mounting bolt 13 Pump mounting bolt 5 Right fuel injection pump (Approx 43 kg [95 lb])
  • Page 186 Chapter 8 FUEL SYSTEM 2. Fuel System - Disassemble, Inspect and Assemble 2.1 Fuel Filter (Wire Element) - Disassemble, Inspect and Assemble Replace Replace Replace Cracks, flaw 20 N·m Replace {2.0 kgf·m} [14.7 lbf·ft] Replace Fuel Filter (Wire Element) - Disassemble, Inspect and Assemble Disassembling Sequence 1 Plug, packing 6 Element...
  • Page 187 Chapter 8 FUEL SYSTEM 2.2 Fuel Filter (Paper Element) - Disassemble, Inspect and Assemble Standard fuel filter spec Air vent plug 9 ± 1 N·m {0.9 ± 0.1 kgf·m} [6.6 ±0.7 lbf·ft] Filter wrench Use the filter wrench to remove the fuel filter.
  • Page 188 Chapter 8 FUEL SYSTEM Changeover spec Replace Air vent plug 9 ± 1 N·m {0.9 ± 0.1 kgf·m} [6.6 ±0.7 lbf·ft] Filter wrench Crack, flaw Use the filter wrench to remove the fuel filter cartridge. (Use only when removing) Replace Dent Fuel Filter (Paper Element) - Disassemble, Inspect and Assemble Disassembling Sequence...
  • Page 189 Chapter 8 FUEL SYSTEM 2.2.1 Fuel Filter Cartridge - Install (a) Make sure that there is no flame around the area before handling fuel. (b) Wipe any spilled fuel to prevent a fire. (c) Do not use the fuel filter cartridge that has a dent on the case. If the case has a dented, it can cause damage to the fuel filter cartridge, leading to fuel leaks during operation, and results in a fire.
  • Page 190 Chapter 8 FUEL SYSTEM 2.3 Fuel Injection Nozzle - Disassemble and Inspect Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the efficient work. Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with any job.
  • Page 191 Chapter 8 FUEL SYSTEM Screw adjust type Replace Replace Deformation, deterioration, flaw Carbon deposit, nozzle hole clogging, needle valve sticking Fuel Injection Nozzle - Disassemble and Inspect Disassembling Sequence 1 Inlet connector, gasket 4 Nozzle spring 7 Nozzle tip 2 Connector, gasket 5 Push rod 8 Nozzle holder 3 Adjusting screw...
  • Page 192 Chapter 8 FUEL SYSTEM 2.4 Fuel Injection Nozzle - Inspect and Adjust 2.4.1 Fuel Injection Start Pressure - Inspect and Nozzle tester Adjust P/N:04239-00050 Never touch fuel spray during fuel injection nozzle test. (Screw adjust type) (1) Install the fuel injection nozzle to the nozzle tester. (2) Push down the handle at a speed of one stroke a second and measure the pressure when injection starts.
  • Page 193 Chapter 8 FUEL SYSTEM 2.4.2 Fuel Injection Nozzle Spray - Inspect When adjusting the nozzle opening pressure with the nozzle tester, inspect for nozzle orifice clogging, fuel spray pattern Good Faulty spray and dripping. If spray condition is faulty, clean or replace the nozzle tip.
  • Page 194 Chapter 8 FUEL SYSTEM 2.4.5 Spacer - Inspect High pressure (Shim adjust type) seal face Inspect the spacer visually. If its needle valve contact sur- face or high pressure seal surface wears remarkably, replace the spacer with a new one. Note: When the nozzle tip is replaced, replace the spacer and nozzle spring with new ones.
  • Page 195 Chapter 8 FUEL SYSTEM 2.5 Fuel Injection Nozzle - Assemble Shim adjust type Do not hit with a hammer when installing into cylinder head. 44 ± 5 N·m {4.5 ± 0.5 kgf·m} [32.5 ± 3.69 lbf·ft] Application of engine oil to gasket top and bottom faces 68.5 ±...
  • Page 196 Chapter 8 FUEL SYSTEM Screw adjust type Do not hit with a hammer, etc. when installing into cylinder head. 44 ± 5 N·m {4.5 ± 0.5 kgf·m} [32.5 ± 3.69 lbf·ft] 74 ± 5 N·m {7.5 ± 0.5 kgf·m} [54.5 ± 3.69 lbf·ft] Application of engine oil to gasket top and bottom faces 68.5 ±...
  • Page 197 Chapter 8 FUEL SYSTEM 2.6 Fuel Injection Pump Accessory Drive - Disassemble and Inspect Fuel injection pump S7S spec Fuel injection pump S3S spec Deformation, lip surface wear Rotation Wear, flaw Wear, flaw Fuel injection pump S7S spec Wear, flaw Rotation Peeling, wear Fuel Injection Pump Accessory Drive - Disassemble and Inspect...
  • Page 198 Chapter 8 FUEL SYSTEM 2.7 Outside Diameter and Inside Diameter of Accessory Drive Bearing Fit - Inspect (1) Turn the bearing and if the turning is not smooth, replace the bearing with a new one. (2) Inspect the fit of drive shaft and bearing. If significant wear is found, replace them with new ones.
  • Page 199 Chapter 8 FUEL SYSTEM 2.8 Fuel Injection Pump Accessory Drive - Assemble Fuel injection pump S7S spec Application of engine oil 294 ± 15 N·m {30 ± 1.5 kgf·m} Application of [216.8 ± 11.06 lbf·ft] engine oil to lip portion Fuel injection pump S3S spec Application of engine oil 294 ±...
  • Page 200 Chapter 8 FUEL SYSTEM 2.9 Governor Drive - Disassemble and Inspect Oil pressure governor spec Replace S3S spec S7S spec Wear of tooth Settling Rotation S7S spec S3S spec Rotation Rotation Replace Wear of tooth Wear of tooth Rotation Rotation Governor Drive - Disassemble and Inspect Disassembling Sequence 1 Drive case cover, packing, oil seal...
  • Page 201 Chapter 8 FUEL SYSTEM 2.10 Outside Diameter and Inside Diameter of Bearing Fit Rotate the bearing and if the rotation is not smooth, replace the bearing with a new one. Inspect the fit of drive shaft, idler shaft and bearing. If significant wear is found, replace them with new ones. Inspect the fit of drive case and bearing.
  • Page 202 Chapter 8 FUEL SYSTEM Nominal Item Standard value value ø47 mm 46.989 to 47.014 mm [1.85 in.] [1.8500 to 1.8509 in.] ø80 mm 79.988 to 80.018 mm Inside diameter of case bearing housing [3.15 in.] [3.1491 to 3.1502 in.] ø100 mm 99.987 to 100.022 mm [3.94 in.] [3.9365 to 3.9379 in.]...
  • Page 203 Chapter 8 FUEL SYSTEM 2.11 Governor Drive - Assemble Backlash 0.12 to 0.18 mm Apply engine oil [0.0047 to 0.0071 in.] Apply engine oil to the lip Backlash 0.12 to 0.18 mm Fuel injection pump [0.0047 to 0.0071 in.] S7S spec Apply engine oil Apply engine oil Fuel injection pump...
  • Page 204 Chapter 8 FUEL SYSTEM 2.11.2 Rubber - Install Insert the drive gear to the drive shaft, then assemble the pin and rubber. Rubber - Install 2.11.3 Drive gear and Case - Assemble Insert the drive shaft assembly to the drive case. Drive shaft - Install 8-32...
  • Page 205 Chapter 8 FUEL SYSTEM 3. Fuel System - Install Install the parts in the reverse order of the disassemble sequence. (Refer to the illustration for disassembling.) Clean and dry well the fuel passage. 3.1 Fuel Injection Pump - Install With back stay spec 58 ±...
  • Page 206 Chapter 8 FUEL SYSTEM 58 ± 5.8 N·m Tamper proof attachment spec 58 ± 5.8 N·m 33 ± 3.3 N·m {5.9 ± 0.59 kgf·m} {5.9 ± 0.59 kgf·m} {3.4 ± 0.34 kgf·m} [42.8 ± 4.28 lbf·ft] 108 ± 11 N·m [42.8 ±...
  • Page 207 Chapter 8 FUEL SYSTEM 3.1.1 Checking before installing fuel injection pump (1) When installing the right bank fuel injection pump, rotate the crankshaft so that No. 1 piston is at the top dead center of compression stroke, and when installing the left bank fuel injection pump, rotate the crankshaft so that No.
  • Page 208 Chapter 8 FUEL SYSTEM 3.1.2 Fuel Injection Pump - Install (a) Wash the bolt, bushing and washer before using. Foreign material on the contact surface of drive coupling and laminated plates can cause the slipping or damage of coupling. (b) After the tightening of couplings check the laminated plates for distortion. If the plates are distorted loosen and retighten the bolts.
  • Page 209 Chapter 8 FUEL SYSTEM 3.2 Fuel Control Link - Install 3.2.1 Control shaft - Install If the bearings at both ends of control shaft are not properly installed, or if the bearings do not rotate smoothly, it could result in a hunting or other malfunctions. Control shaft Bearing cover Stop lever...
  • Page 210 Chapter 8 FUEL SYSTEM 3.2.3 Fuel Control Link - Install and Adjust Woodward PGS governor spec Control lever Adjustable length control link B-1 Fuel Adjustable length Fixed length injection pump control link B-2 (208.5 ± 1.0 mm [11.97 ± 0.0394 in.]) control rink A-2 Control rack 95.5 mm...
  • Page 211 Chapter 8 FUEL SYSTEM Woodward PSG governor spec Toho Seisakusho SG4017 actuator spec Control shaft Control lever Fuel injection pump Fixed length (304 ± 1.0 mm [11.97 ± 0.0394 in.])control rink A-1 Control rack Distance between the end face of fuel injection pump Distance between the end face of fuel injection pump Distance between the end face of fuel injection pump and the center of hole at control rack end: 78 mm [3.07 in.]...
  • Page 212 Chapter 8 FUEL SYSTEM (5) Adjust the variable-length control link B-2 to 158±1.5 mm [6.2±0.06 in.], and install it in between the control lever and the governor lever. Fine adjust so that the distance between fuel injection pump end face and the center of hole at the end of rack becomes 67.5 mm [2.66 in.] with 2mm [0.079 in.] play when the governor output shaft is at zero (no injection).
  • Page 213 Chapter 8 FUEL SYSTEM 3.2.4 Fuel Control Link - Install and Adjust Woodward ProAct actuator spec Distance from the end of Distance from the end of Distance from the end of fuel injection pump fuel injection pump fuel injection pump to the holecenter of rack end to the holecenter of rack end to the holecenter of rack end...
  • Page 214 Chapter 8 FUEL SYSTEM Woodward ProAct actuator spec Toho Seisakusho SG4017 actuator PTA2 spec Distance from the end of fuel injection pump to the hole center at rack end Rack "0": 67.5 mm [2.60 in.] Play: approx. 2 mm [0.12 in.] Control lever Control link lever Control shaft...
  • Page 215 Chapter 8 FUEL SYSTEM (5) Install the variable-length control link B-1 for the left bank C between the control lever and the governor lever. Fine adjust so that the distance between fuel injection pump end face and the center of hole at the end of rack becomes 67.5 mm [2.66 in.] with 2mm [0.079 in.] play when the angle scale of actuator output shaft is at zero (no injection).
  • Page 216 Chapter 8 FUEL SYSTEM 3.3 Stop Solenoid - Install 3.3.1 Stop solenoid RUN-ON type: Turned ON during operation, when turned OFF, the solenoid is deactivated to stop the engine. RUN-OFF type: Turned OFF during operation, when turned ON, the solenoid is activated to stop the engine. 3.3.2 Stop solenoid (RUN ON type) - Adjust RUN ON stop system spec Stop solenoid OFF:...
  • Page 217 Chapter 8 FUEL SYSTEM 3.3.3 Stop solenoid (RUN OFF type) - Adjust Stop solenoid RUN OFF stop system spec ON: 99 ± 0.5 mm [2.697 ± 0.020 in.] Play: approx. 3 mm [0.12 in.] Clearance: 0 mm (contact) Follower Stop lever Adjustable length control link Engine running condition...
  • Page 219 Chapter 9 LUBRICATION SYSTEM Lubrication System - Remove and Inspect ............9-3 Oil Pipe - Remove........................9-3 Oil Pipe for Fan Drive - Remove....................9-4 Oil Cooler and Oil Filter - Remove and Inspect ................ 9-5 Breather - Remove and Inspect....................9-8 Oil Level Gauge and Oil Filler - Remove and Inspect...............
  • Page 221 Chapter 9 LUBRICATION SYSTEM Chapter 9 LUBRICATION SYSTEM 1. Lubrication System - Remove and Inspect 1.1 Oil Pipe - Remove Distributor Crankcase Crankcase Electronic governor spec Drive case Drive case Right side injection pump Replace: Gasket O-ring Electronic governor spec Oil Pipe - Remove Removing Sequence 1 Right drain pipe...
  • Page 222 Chapter 9 LUBRICATION SYSTEM 1.2 Oil Pipe for Fan Drive - Remove Crankcase Crankcase Crankcase Fan drive bracket Front cover Fan drive bracket Top positioning bypass filter spec Ribbed belt spec Crankcase Fan drive bracket Front cover Replace: sealing washer Oil Pipe for Fan Drive - Remove Removing Sequence 1 Flexible pipe...
  • Page 223 Chapter 9 LUBRICATION SYSTEM 1.3 Oil Cooler and Oil Filter - Remove and Inspect Land use standard spec Front cover Crankcase Replace: Gasket, O-ring Continuous generator Oil Cooler and Oil Filter - Remove and Inspect Removing Sequence 1 Oil filter 4 Oil cooler 7 Oil pipe 2 Oil pipe...
  • Page 224 Chapter 9 LUBRICATION SYSTEM MPTA, MPTK spec Front cover Front cover MTK spec Crankcase Replace: Gasket, O-ring Oil Cooler and Oil Filter - Remove and Inspect Removing Sequence 1 Oil filter 4 Oil cooler 7 Oil pipe 2 Oil pipe 5 Stay 8 Bypass oil filter assembly 3 Oil pipe...
  • Page 225 Chapter 9 LUBRICATION SYSTEM Bypass oil filter downward spec MTK, MPTA, MPTK, spec PTA2,Y2PTAW spec Crankcase PTA2 spec Replace: Gasket, O-ring MPTA, MPTK, C2MPTK spec Oil Cooler and Oil Filter - Remove and Inspect Removing Sequence 1 Oil filter 4 Oil cooler 7 Oil pipe 2 Oil pipe 5 Stay...
  • Page 226 Chapter 9 LUBRICATION SYSTEM 1.4 Breather - Remove and Inspect MPTA spec MPTK spec Marine standard spec Upward spec Downward spec Replace: Gasket O-ring Breather - Remove and Inspect Removing Sequence 1 Oil drain pipe 3 Stay 5 Breather assembly 2 Breather pipe 4 Rubber hose...
  • Page 227 Chapter 9 LUBRICATION SYSTEM 1.5 Oil Level Gauge and Oil Filler - Remove and Inspect Land use standard spec PTA, PTA2, PTAW spec Standard type oil pan spec MPTA, MPTK spec (MEE) PTA, Marine standard spec Deep type oil pan spec Replace: packing MPTA(SKL), MPTK spec(VOLVO) Oil Level Gauge and Oil Filler - Remove and Inspect...
  • Page 228 Chapter 9 LUBRICATION SYSTEM 1.6 Oil Filter for Governor - Remove and Inspect Oil pressure governor spec Drive case Crankcase Replace: sealing washer *Woodward PSG type governor Oil Filter for Governor - Remove and Inspect Removing Sequence 1 Oil pipe 3 Oil pipe 5 Oil filter assembly for governor 2 Oil pipe...
  • Page 229 Chapter 9 LUBRICATION SYSTEM 1.7 Oil Pan, Oil Strainer and Oil Pump - Remove and Inspect Land Deep Deep Replace: Gasket, O-ring Oil Pan, Oil Strainer and Oil Pump - Remove and Inspect Removing Sequence 1 Oil pan 3 Strainer support 5 Oil strainer (Standard type: approx.
  • Page 230 Chapter 9 LUBRICATION SYSTEM Marine spec MPTK, MPTA spec MTK, MPT spec Replace: Gasket, O-ring Oil Pan, Oil Strainer and Oil Pump - Remove and Inspect Removing Sequence 1 Oil pan (Deep type: approx. 83 kg [183 3 Strainer support 5 Oil strainer lb.]) 4 Oil pump assembly...
  • Page 231 Chapter 9 LUBRICATION SYSTEM 2. Lubrication System - Disassemble, Inspect and Assemble 2.1 Oil strainer - Disassemble and Inspect Replace Replace Replace Replace Clogged strainer hole: Wash with diesel fuel Oil strainer - Disassemble and Inspect Disassembling Sequence 1 Oil strainer 2 Oil pipe 9-13...
  • Page 232 Chapter 9 LUBRICATION SYSTEM 2.2 Oil Pump and Safety Valve - Disassemble and Inspect Flaw, crack Flaw, wear Replace Settling, breakage, wear Flaw, crack Contact, peeling, wear Contact, peeling, wear Flaw, wear Oil Pump and Safety Valve - Disassemble and Inspect Disassembling Sequence 1 Safety valve assembly 5 Washer, nut...
  • Page 233 Chapter 9 LUBRICATION SYSTEM 2.3 Oil Pump and Safety Valve - Inspect 2.3.1 Drive Gear and Driven Gear Backlash - Mea- sure Measure the backlash between drive gear and driven gear.If the value exceeds the limit, replace the gears with new ones. Item Standard value Limit value...
  • Page 234 Chapter 9 LUBRICATION SYSTEM 2.3.5 Oil Pump Bushing - Replace Oil pump (1) Use the oil pump bushing puller to replace oil pump bushing puller bushings. P/N:32691-02700 Bushing inside diameter (2) Replace the oil pump bushing in a timely manner. If the +0.025 ø34 bushing is too stubborn to remove, replace the bushing...
  • Page 235 Chapter 9 LUBRICATION SYSTEM 2.4 Oil Pump and Safety Valve - Assemble 294 ± 15 N·m {30 ± 1.5 kgf·m} [217 ± 11 lbf·ft] Oil Pump and Safety Valve - Assemble 9-17...
  • Page 236 Chapter 9 LUBRICATION SYSTEM 2.5 Oil Cooler, Oil Filter, and Relief Valve - Disassemble and Inspect Replace Replace Fatigue, breakage, wear Replace Clogging, rupture, crack Replace Crack, deformation Without With oil filter alarm oil filter alarm Replace Replace Changeover-type No changeover Replace Replace Replace...
  • Page 237 Chapter 9 LUBRICATION SYSTEM 2.6 Oil Filter - Inspect When replacing the oil filter, sample the oil (500 ml [0.13 U.S. gal]) and check for metal and other particles. If metal or other particles are found, cut and unfold the element, and inspect the color and shape of metal particles trapped in ele- ment to identify the cause.
  • Page 238 Chapter 9 LUBRICATION SYSTEM 2.10 Bypass Valve - Inspect Inspect the bypass valve opening pressure. If limit is exceeded, replace it with a new one. Item Standard value 0.44 ± 0.05 MPa Bypass valve opening pressure {4.49 ± 0.51 kgf/cm [64 ±...
  • Page 239 Chapter 9 LUBRICATION SYSTEM 2.14 Bypass Oil Filter - Disassemble and Inspect Replace: every 250 hours Remove with oil filter wrench Replace Replace Replace Replace: Replace: every 250 hours every 250 hours MTK, MPTA, MPTK spec PTA2,Y2PTAW spec Bypass Oil Filter - Disassemble and Inspect Disassembling Sequence 1 Bypass filter bracket 2 Cartridge element...
  • Page 240 Chapter 9 LUBRICATION SYSTEM 2.15 Governor Oil Filter - Disassemble and Inspect Governor Oil Filter - Disassemble and Inspect Disassembling Sequence 1 Element 2 Bracket 9-22...
  • Page 241 Chapter 9 LUBRICATION SYSTEM 3. Lubrication System - Install Install the parts in the reverse order of the disassemble sequence.(Refer to the illustration for disassembling.) Thoroughly clean and dry the oil passage. 3.1 Oil pump, Oil strainer and Oil pan - Install 3.1.1 Backlash When Installing Oil Pump - Adjust After installing the oil pump to crankcase, measure the backlash of crankshaft gear and oil pump gear.
  • Page 243 Chapter 10 COOLING SYSTEM Cooling System - Remove and Inspect ............... 10-3 Tension Pulley - Remove and Inspect (Water pump side) ............. 10-3 Tension Pulley - Remove and Inspect (Fan side)..............10-4 Thermostat Case and Water Pipe - Remove and Inspect ............10-5 Water Pipe - Remove and Inspect..................
  • Page 245 Chapter 10 COOLING SYSTEM Chapter 10 COOLING SYSTEM 1. Cooling System - Remove and Inspect 1.1 Tension Pulley - Remove and Inspect (Water pump side) PTAW spec Crack, wear PTA2 spec Crack, wear Tension Pulley - Remove and Inspect (Water pump side) Removing Sequence 1 Tension bolt 7 Belt...
  • Page 246 Chapter 10 COOLING SYSTEM 1.2 Tension Pulley - Remove and Inspect (Fan side) PTA2 spec Crack, wear Tension Pulley - Remove and Inspect (Fan side) Removing Sequence 1 Tension bolt 3 Belt 2 Mounting bolt 4 Tension pulley assembly 10-4...
  • Page 247 Chapter 10 COOLING SYSTEM 1.3 Thermostat Case and Water Pipe - Remove and Inspect Replace Replace MPTA, MTK spec PTA,PTA2,PTK, MPTK spec PTAW spec PTA,PTAW spec MPTA,MPTK spec Replace Replace MTK spec MPTA, PTA,PTA2,PTK, MPTK spec PTAW spec Thermostat Case and Water Pipe - Remove and Inspect Removing Sequence 1 Coupling 3 Water outlet pipe...
  • Page 248 Chapter 10 COOLING SYSTEM 1.4 Water Pipe - Remove and Inspect PTA,PTA2 spec Replace Replace cooler cooler PTA spec PTA2 spec PTA spec Replace Air cooler Air cooler PTA2 spec Replace Replace Replace Replace Replace Replace Air cooler Replace Air cooler Air cooler Air cooler PTA spec...
  • Page 249 Chapter 10 COOLING SYSTEM PTK spec Replace Air cooler Cooling water inlet Replace Air cooler Replace Replace Air cooler Air cooler Replace Water Pipe - Remove and Inspect Removing Sequence 1 Coupling 6 Bypass pipe 2 Water pipe 7 Coupling 3 Coupling 8 Water pipe 4 Bypass pipe...
  • Page 250 Chapter 10 COOLING SYSTEM MPTA,C2MPTK spec Replace Air cooler MPTA spec C2MPTK spec cooler Air cooler Replace Replace Replace Replace Replace Replace cooler Water Pipe - Remove and Inspect Removing Sequence 1 Water outlet pipe 7 Coupling 13 Coupling 2 Coupling 8 Bypass pipe 14 Coupling 3 Water pipe...
  • Page 251 Chapter 10 COOLING SYSTEM MPTK spec Replace Air cooler Cooling water inlet Replace Air cooler Replace Replace Replace Air cooler Cooling water outlet Air cooler Replace Water Pipe - Remove and Inspect Removing Sequence 1 Coupling 7 Bypass pipe 2 Water pipe 8 Coupling 3 Water pipe 9 Water outlet pipe...
  • Page 252 Chapter 10 COOLING SYSTEM PTAW spec Air cooler Replace Motor pump Air cooler Replace Replace Air cooler Air cooler Replace Water Pipe - Remove and Inspect Removing Sequence 1 Coupling 7 Rubber hose 2 Water pipe 8 Water pipe 3 Water pipe 9 Coupling 4 Coupling 10 Water pipe...
  • Page 253 Chapter 10 COOLING SYSTEM 1.5 Heat Exchanger and Water Pipe - Remove and Inspect MPTK spec 2 Replace Replace Replace Replace Water pump Heat Exchanger and Water Pipe - Remove and Inspect Removing Sequence 1 Strap coupling 6 Strap coupling 2 Water pipe 7 Water pipe 3 Water pipe...
  • Page 254 Chapter 10 COOLING SYSTEM 1.6 Sea Water Pump and Water Pipe - Remove and Inspect MTK,MPTK spec Replace Heat exchanger Replace Replace Replace MPTK spec Replace Replace Replace Air cooler Replace Replace Replace Replace MTK spec Replace Replace Replace Replace Sea Water Pump and Water Pipe - Remove and Inspect Removing Sequence 1 Sea water pipe...
  • Page 255 Chapter 10 COOLING SYSTEM 1.7 Expansion Tank and Water Pipe - Remove and Inspect MTK spec Replace Replace Water pump Replace Replace Expansion Tank and Water Pipe - Remove and Inspect Removing Sequence 1 Strap coupling 5 Bypass pipe 2 Water pipe 6 Coupling 3 Water pipe 7 Bypass pipe...
  • Page 256 Chapter 10 COOLING SYSTEM 1.8 Water pump and Water Pipe - Remove and Inspect PTAW spec Replace Replace Replace Replace PTA,PTA2,PTAW,PTK, MTK,MPTA,MPTK spec Replace MTK,MPTK spec Replace PTA2 spec Water pump and Water Pipe - Remove and Inspect Removing Sequence 1 Water pipe 5 Stay 9 Oil pipe...
  • Page 257 Chapter 10 COOLING SYSTEM 2. Cooling System - Disassemble, Inspect and Assemble 2.1 Tension Pulley - Disassemble and Inspect (Water pump side) Crack, flaw, deflection of shaft, oil hole clogging Belt groove wear Rotation Tension Pulley - Disassemble and Inspect (Water pump side) Disassembling Sequence 1 Bolt 4 Ball bearing...
  • Page 258 Chapter 10 COOLING SYSTEM 2.1.2 Tension pulley - Assemble (1) Apply engine oil to the fitting faces of bearing and ten- ø78 [3.07] sion pulley. Special jig (2) Fabricate a special press-fitting jig. Fit the bearing in ø38 the tension pulley using the jig and a hand-press. [2.13] [1.5] Bearing...
  • Page 259 Chapter 10 COOLING SYSTEM (7) Fit the snap ring in the groove on the inner periphery of the tension pulley. Snap ring Snap Ring - Install (8) Install the thrust plate with bolt. Thrust plate Thrust plate - Install (9) Tighten the bolt. Note: After assembly, confirm that the tension pulley rotates Bolt smoothly.
  • Page 260 Chapter 10 COOLING SYSTEM 2.2 Tension Pulley - Disassemble and Inspect (Water pump side for Air cooler) PTAW spec Belt groove wear Crack, flaw, deflection of shaft, oil hole clogging Rotation Tension Pulley - Disassemble and Inspect (Water pump side for Aircooler) Disassembling Sequence 1 Bolt 4 Snap ring...
  • Page 261 Chapter 10 COOLING SYSTEM 2.2.2 Tension pulley - Assemble (1) Apply engine oil to the fitting faces of bearing and ten- sion pulley. ø 52 [2.05] Special jig (2) Fabricate a special press-fitting jig. Fit the bearing in ø 20 the tension pulley using the jig and a hand-press.
  • Page 262 Chapter 10 COOLING SYSTEM (7) Fit the snap ring in the groove on the inner periphery of the tension pulley. Snap ring Snap Ring - Install (8) Install the outside spacer. Spacer Outer Spacer - Install (9) Install the thrust plate with bolt. Thrust plate Thrust plate - Install (10)Tighten the bolt.
  • Page 263 Chapter 10 COOLING SYSTEM 2.3 Tension Pulley - Disassemble and Inspect (Water pump side PTA2 spec) PTA2 spec Lip surface wear, flaw, deterioration Belt groove wear Replace Crack, flaw, deflection of shaft, oil hole clogging Rotation Tension Pulley - Disassemble and Inspect (Water pump side PTA2 spec) Disassembling Sequence 1 Bearing cover 4 Plain washer...
  • Page 264 Chapter 10 COOLING SYSTEM 2.3.2 Tension pulley - Assemble Apply grease (1) Before pressing-fit the tension pulley, apply grease to Ball bearing both ball of ball bearing and ball-cage. (2) Apply grease to the inside tension pulley, and press-fit the lower ball bearing. (3) Install the plain washer, and press-fit the upper ball bearing.
  • Page 265 Chapter 10 COOLING SYSTEM 2.4 Tension Pulley - Disassemble and Inspect (Fan side PTA2 spec) PTA2 spec Lip surface wear, flaw, deterioration Belt groove wear Replace Crack, flaw, deflection of shaft, oil hole clogging Rotation Tension Pulley - Disassemble and Inspect (Fan side PTA2 spec) Disassembling Sequence 1 Bearing cover 5 Tension spacer...
  • Page 266 Chapter 10 COOLING SYSTEM 2.4.2 Tension pulley - Assemble Apply grease Ball bearing (1) Before pressing-fit the tension pulley, apply grease to both ball of ball bearing and ball-cage. (2) Apply grease to the inside tension pulley, and press-fit the lower ball bearing. (3) Install the plain washer, and press-fit the upper ball bearing.
  • Page 267 Chapter 10 COOLING SYSTEM 2.5 Thermostat - Disassemble and Inspect MTK spec MPTA, PTA,PTA2,PTK, MPTK spec PTAW spec 30 ± 3.0 N·m {3.0 ± 0.3 kgf·m} [22.1 ± 2.2 lbf·ft] Replace Replace Thermostat - Disassemble and Inspect Disassembling Sequence 1 Thermostat cover 3 Thermostat 2 Packing 4 Thermostat case...
  • Page 268 Chapter 10 COOLING SYSTEM 2.6 Thermostat - Inspect Stir the water with a stick. Be very careful with hot water and flames. Or, you may get burned or cause a fire. (1) Immerse the thermostat in a container filled with water. (2) Heat the water while measuring water temperature.
  • Page 269 Chapter 10 COOLING SYSTEM 2.7 Heat Exchanger - Disassemble and Inspect MTK spec Cleaning: every 2000 hours or within 24 months Replace: every 500 hours Replace or within 12 months Replace Replace Heat Exchanger - Disassemble and Inspect Disassembling Sequence 1 U-bolt 3 Zinc 2 Cover...
  • Page 270 Chapter 10 COOLING SYSTEM 2.8 Water pump - Disassemble and Inspect Replace Corrosion, crack, flaw Corrosion, flaw Replace Corrosion, crack, damage Replace Rotation Replace V-belt groove wear, damage Water pump - Disassemble and Inspect Disassembling Sequence 1 Nut and lock washer 6 Spacer 11 Ball bearing 2 Water pump pulley, key...
  • Page 271 Chapter 10 COOLING SYSTEM 2.8.1 Water pump Mounted on Engine - Inspect With fingers, touch the drain pipe located at bottom center of the water pump case.If water is oozing out, the unit seal is defective, and if oil is oozing out, the oil seal is defective. Water pump Mounted on Engine - Inspect 2.8.2 Water pump Pulley - Remove Install the pulley puller to the holes on the water pump pul-...
  • Page 272 Chapter 10 COOLING SYSTEM 2.9 Water pump - Inspect Measure the bearing fit diameters of water pump bearing housing and shaft, and the inside and outside diameters of bearing.If any of the measurements is out of the standard, replace the part with a new one. Item Nominal value Standard value...
  • Page 273 Chapter 10 COOLING SYSTEM 2.10 Water pump - Assemble 12.3 ± 2.5 N·m Replace {1.3 ± 0.3 kgf·m} [9.07 ± 1.84 lbf·ft] 196 ± 29.6 N·m {20 ± 3.0 kgf·m} [144.6 ± 21.83 lbf·ft] 260 ± 12 N·m {26 ± 1.2 kgf·m} [191.8 ±...
  • Page 274 Chapter 10 COOLING SYSTEM 2.10.1 Oil Seal - Install (1) Using installer, press-fit the oil seal, making sure that Oil seal installer Apply engine oil oil seal surface is flush with the water pump case face. P/N:32591-03200 to oil seal lip (2) Apply engine oil to the oil seal lip.
  • Page 275 Chapter 10 COOLING SYSTEM 2.11 Water pump for Air cooler Cooling - Disassemble and Inspect PTAW spec Corrosion, flaw Replace Replace Corrosion, crack, flaw Rotation Rotation Wear, flaw Water pump for Air cooler Cooling - Disassemble and Inspect Disassembling Sequence 1 Water pump pulley 5 Snap ring 9 Ball bearing...
  • Page 276 Chapter 10 COOLING SYSTEM 2.11.1 Water pump for Air cooler Cooling Mounted on Engine - Inspect Touch the drain port at the bottom center of water pump case with a finger.If water or oil is oozing out, the unit seal is defective.
  • Page 277 Chapter 10 COOLING SYSTEM 2.11.4 Water pump for Air cooler Cooling - Inspect Measure the bearing fit diameters of water pump bearing housing and shaft, and the inside and outside diameters of bearing.If any of the measurements is out of the standard, replace the part with a new one. Item Nominal value Standard value...
  • Page 278 Chapter 10 COOLING SYSTEM 2.12 Water pump for Air cooler Cooling - Assemble Replace Application of grease Make it flush 0.5 to 1.1 mm [0.020 to 0.043 in.] Fill with 31 grams grease. Application of Loctite 22.5 ± 2.25 N·m Application of sealant {2.29 ±...
  • Page 279 Chapter 10 COOLING SYSTEM 2.12.1 Unit Seal - Install (1) Apply sealant (ThreeBond 1102) to the circumference of the unit seal. (2) Press-in the unit seal into water pump case with unit seal installer. Unit seal Note: Replace the unit seal with a new one whenever it is re- Apply sealant moved from water pump case.
  • Page 280 Chapter 10 COOLING SYSTEM 2.13 Sea Water Pump - Disassemble and Inspect MTK,MPTK spec Lip face wear, deterioration Rotation Spline wear Rotation Replace Wear, deterioration Settling, crack, flaw Replace Wear, flaw Sea Water Pump - Disassemble and Inspect Disassembling Sequence 1 Cover 6 Bushing, unit seal 11 Shaft, key...
  • Page 281 Chapter 10 COOLING SYSTEM 2.13.1 Outside Diameter and Inside Diameter of Bearing Fit - Inspect Turn the bearing and if turning is not smooth, replace the bearing with a new one.Inspect the fit of bearing case and bearing. If heavy wear is found, replace them with new ones.Inspect the fit of shaft and bearing. If heavy wear is found, replace them with new ones.
  • Page 282 Chapter 10 COOLING SYSTEM 2.14 Sea Water Pump - Assemble MTK spec 7.5 ± 0.5 N·m Apply grease to rolling surface {0.75 ± 0.05 kgf·m} [5.53 ± 0.37 lbf·ft] 196 ± 10 N·m {20 ± 1 kgf·m} [144.6 ± 7.38 lbf·ft] 15 ±...
  • Page 283 Chapter 10 COOLING SYSTEM 2.14.1 Oil Seal - Install (1) Press-fit the oil seal to the holder with the installer. Note: Always replace the oil seal with a new one. Installer (2) Apply grease to the oil seal groove and lips. Oil seal Apply grease Oil Seal - Install...
  • Page 284 Chapter 10 COOLING SYSTEM 2.14.5 Shaft and Bearing - Install (1) Press-fit the ball bearing to the water pump shaft with the installer. Shaft Installer (2) Press-fit the ball bearing and water pump shaft to the holder with the installer. Holder Bearing Shaft and Bearing - Install...
  • Page 285 Chapter 10 COOLING SYSTEM 2.14.9 Impeller - Install (1) Tap-in the impeller to shaft. Blade tip Note: Place the impeller to bend its impellers in following di- Impeller rection to the Water pump rotation. Rotation direction Impeller - Install (2) Install the impeller cover. Impeller cover Impeller cover - Install 2.14.10Cover - Install...
  • Page 286 Chapter 10 COOLING SYSTEM 2.15 Fan Drive Assembly - Disassemble and Inspect Rotation Belt groove wear Crack, flaw PTA2 spec PTA2 spec Replace Rotation Wear Replace Fan Drive Assembly - Disassemble and Inspect Disassembling Sequence 1 Fan spacer 5 Oil seal 9 Ball bearing 2 Cap nut 6 Snap ring...
  • Page 287 Chapter 10 COOLING SYSTEM 2.16 Fan Drive - Inspect Inspect the fit between the fan drive shaft and fan drive case bearing, and if unusual wear is found, replace with new one. Item Nominal value Standard value ø100 [3.94] 99.987 to 100.022 mm [3.9365 to 3.9379 in.] Inside diameter of case bearing housing ø110 [4.33] 109.987 to 110.022 mm [4.3302 to 4.3316 in.]...
  • Page 288 Chapter 10 COOLING SYSTEM 2.17 Oil Seal Sleeve - Inspect If any defects such as dents, scars, wear and looseness that can lead to oil leakage are found, replace the oil seal sleeve with a new one. 2.18 Oil Seal Sleeve - Replace Use protective gloves when you touch hot parts.Han- dling with bear hands could result in burns.
  • Page 289 Chapter 10 COOLING SYSTEM 2.19 Fan Drive - Assemble Apply engine oil to the oil seal lip. Flush with the case face. 178 ± 8.9 N·m 108 ± 10.8 N·m {18 ± 0.9 kgf·m} 108 ± 10.8 N·m {11 ± 1 .1 kgf·m} [131.3 ±...
  • Page 290 Chapter 10 COOLING SYSTEM 2.19.1 Inner ball bearing - Insert (1) Apply engine oil to the rolling surface of the ball bear- ing. (2) Press-in the bearing to drive shaft with bearing installer. Bearing installer P/N: 32691-04200 Application of engine oil Inner ball bearing - Insert 2.19.2 Outer ball bearing - Insert (1) Apply engine oil to the rolling surface of the ball bear-...
  • Page 291 Chapter 10 COOLING SYSTEM 2.19.4 Fan - Assemble 108 ± 10.8 N·m Fan pulley Installation the fan at the final step of assembling work. {11 ± 1 .1 kgf·m} (1) Install the key to the fan end of fan drive shaft. (2) Install the fan pulley to the key of fan drive shaft.
  • Page 292 Chapter 10 COOLING SYSTEM 3. Cooling System - Install Install the parts in the reverse order of the disassemble sequence.(Refer to the illustration for disassembling.) Clean and dry well the cooling water passage. 3.1 Water Pipe (Air cooler) - Install Apply silicone sealant to the both sides of packings between air cooler in/out connectors and water pipes.
  • Page 293 Chapter 11 INLET AND EXHAUST SYSTEMS Inlet and Exhaust Systems - Remove and Inspect ..........11-3 Air Duct and Air cooler - Remove and Inspect................ 11-3 Pre-cleaner and Paper Type Air Cleaner - Remove and Inspect ........... 11-6 Exhaust Pipe - Remove and Inspect ..................11-9 Exhaust Manifold - Remove and Inspect ................
  • Page 295 Chapter 11 INLET AND EXHAUST SYSTEMS Chapter 11 INLET AND EXHAUST SYSTEMS 1. Inlet and Exhaust Systems - Remove and Inspect 1.1 Air Duct and Air cooler - Remove and Inspect PTA,PTK,MPTA spec Crack, flaw, deformation Crack, flaw, deformation Crack, flaw, Replace deformation Replace...
  • Page 296 Chapter 11 INLET AND EXHAUST SYSTEMS PTA2 spec Crack, flaw, deformation Crack, flaw, deformation Replace Replace Replace Replace Turbocharger Turbocharger Turbocharger Turbocharger Turbocharger Turbocharger Replace Replace Replace Air Duct and Air cooler - Remove and Inspect Removing Sequence 1 Connector 3 Air cooler (approx.
  • Page 297 Chapter 11 INLET AND EXHAUST SYSTEMS MTK,MPTK spec Crack, flaw, deformation Turbocharger Replace Turbocharger Replace Crack, flaw, deformation Replace Replace Replace Replace Crack, flaw, Replace deformation Crack, flaw, deformation Replace Crack, flaw, deformation Replace Crack, flaw, deformation Air Duct and Air cooler - Remove and Inspect Removing Sequence 1 Coupling 4 Oil pipe...
  • Page 298 Chapter 11 INLET AND EXHAUST SYSTEMS 1.2 Pre-cleaner and Paper Type Air Cleaner - Remove and Inspect With pre-cleaner MTK,MPTA,MPTK spec Crack, flaw, deformation Replace Replace Replace Replace Crack, flaw, deformation With pre-cleaner PTA,PTA2,PTK spec Pre-cleaner - Remove and Inspect Removing Sequence 1 Silencer assembly 4 Inlet pipe...
  • Page 299 Chapter 11 INLET AND EXHAUST SYSTEMS With air cleaner PTA spec 1 Crack, flaw Crack, flaw, deformation Replace Crack, flaw Replace Crack, flaw, deformation Crack, flaw, deformation Air cleaner - Remove and Inspect Removing Sequence 1 Air cleaner (approx. 23 kg [51 lb.]) 4 Rubber hose 7 Air pipe 2 Elbow hose...
  • Page 300 Chapter 11 INLET AND EXHAUST SYSTEMS With air cleaner PTA spec 2 Crack, flaw Crack, flaw Crack, flaw Crack, flaw, deformation Replace Crack, flaw Replace Crack, flaw, deformation Crack, flaw, deformation Air cleaner - Remove and Inspect Removing Sequence 1 Air cleaner (approx. 23 kg [51 lb.]) 4 Air pipe 7 Air pipe 2 Rubber hose...
  • Page 301 Chapter 11 INLET AND EXHAUST SYSTEMS 1.3 Exhaust Pipe - Remove and Inspect With flexible pipe spec Crack, flaw, deformation Crack, flaw, deformation Crack, flaw, deformation Replace Crack, flaw, deformation Replace Replace Exhaust Pipe - Remove and Inspect Removing Sequence 1 Flexible pipe 4 Ring 7 Exhaust pipe (approx.
  • Page 302 Chapter 11 INLET AND EXHAUST SYSTEMS 1.4 Exhaust Manifold - Remove and Inspect Crack, flaw, deformation Replace: Gasket Exhaust Manifold - Remove and Inspect Removing Sequence 1 Coupling 3 Exhaust manifold 2 Flexible joint 11-10...
  • Page 303 Chapter 11 INLET AND EXHAUST SYSTEMS 2. Inlet and Exhaust Systems - Disassemble, Inspect and Assemble 2.1 Air cooler - Disassemble, Inspect and Assemble PTA,PTK,PTAW,MPTA spec Replace Replace Replace Replace The gap between the element and plate must be sealed with KE45-W (Shin-Etsu Chemical Co.) or equivalent silicon sealant.
  • Page 304 Chapter 11 INLET AND EXHAUST SYSTEMS PTA2 spec The gap between the element and plate must be sealed with KE45-W (Shin-Etsu Chemical Co.) or equivalent silicon sealant. Replace Replace Replace Replace The gap between the element and plate must be sealed with KE45-W (Shin-Etsu Chemical Co.) or equivalent silicon sealant.
  • Page 305 Chapter 11 INLET AND EXHAUST SYSTEMS MTK,MPTK spec Replace Replace Air cooler - Disassemble, Inspect and Assemble Disassembling Sequence 1 Air duct 2 Air cooler assembly 3 Center duct (One piece approx. 74 kg [163 lb]) 11-13...
  • Page 306 Chapter 11 INLET AND EXHAUST SYSTEMS 2.1.1 Air cooler - Inspect The air cooler differs in material and structure depend- ing on the application (fresh water or seawater). Pay attention to the difference when handling the air cooler. 2.1.2 Air cooler - Clean Blow compressed air (at a pressure of 0.29 to 0.49 MPa {3 Intake side to 5 kgf/cm...
  • Page 307 Chapter 11 INLET AND EXHAUST SYSTEMS 2.1.3 Air cooler - Inspect for Leakage Immerse the air cooler in water. In this condition, blow compressed air (at a pressure of 0.39 MPa {4 kgf/cm } [57 psi]) to the coolant passage to check for air leakage. Air leakage PTA, PTA2, PTAW, PTK, MPTA spec Air cooler - Check for Leakage...
  • Page 308 Chapter 11 INLET AND EXHAUST SYSTEMS 3. Inlet and Exhaust Systems - Install Install the parts in the reverse order of the disassemble sequence.(Refer to the illustration for disassembling.) Thoroughly clean and dry the inlet and exhaust passages. 3.1 Exhaust Manifold - Install 3.1.1 Cautions during installation of exhaust manifold (1) Make sure that the centers of exhaust manifold and cou- pling are aligned when installing.The misalignment of...
  • Page 309 Chapter 12 AIR START SYSTEM Air Start System - Remove and Inspect............... 12-3 Magnetic Valve - Remove and Inspect ................... 12-3 Air Pipe, Starter Valve and Distributor Valve - Inspect ............12-4 Air Starter - Remove and Inspect ................... 12-5 Air Start System - Disassemble, Inspect and Assemble........
  • Page 311 Chapter 12 AIR START SYSTEM Chapter 12 AIR START SYSTEM 1. Air Start System - Remove and Inspect 1.1 Magnetic Valve - Remove and Inspect Air direct starting spec Clean internal element with light oil: every 500 hours Abnormality of seat surface, broken line Magnetic Valve - Remove and Inspect Removing Sequence...
  • Page 312 Chapter 12 AIR START SYSTEM 1.2 Air Pipe, Starter Valve and Distributor Valve - Inspect Air direct starting spec Replace: Gasket O-ring Air Pipe, Starter Valve and Distributor Valve - Inspect Removing Sequence 1 No.1 thru 6 pilot air pipes 3 Distributer valve 2 Main air pipe 4 Starter valve...
  • Page 313 Chapter 12 AIR START SYSTEM 1.3 Air Starter - Remove and Inspect Air starter motor starting spec Air Starter - Remove and Inspect Removing Sequence 1 Clamp 4 Bracket 2 Air motor (approx. 60 kg [132 lb]) 5 Bracket 3 Auto-muffler 12-5...
  • Page 314 Chapter 12 AIR START SYSTEM 2. Air Start System - Disassemble, Inspect and Assemble 2.1 Starter Valve - Disassemble and Inspect Air direct starting spec Replace Replace Replace Settling, crack Seat face defect, wear Starter Valve - Disassemble and Inspect Disassembling Sequence 1 Retaining screw 5 Packing...
  • Page 315 Chapter 12 AIR START SYSTEM 2.2 Starter Valve - Inspect 2.2.1 Clearance Between Starter Valve and Starter Valve Guide - Measure (1) Measure the starter valve outside diameter and starter valve guide inside diameter, and calculate the clear- ance. (2) If the value exceeds the limit, replace the starter valve or starter valve guide with a new one.
  • Page 316 Chapter 12 AIR START SYSTEM 2.3 Starter Valve - Assemble Air direct starting spec 147 ± 7.35 N·m {15 ± 0.75 kgf·m} [108.4 ± 5.42 lbf·ft] 19 ± 0.95 N·m {1.94 ± 0.09 kgf·m} ± 0.7 lbf·ft] Application of engine oil Valve lift to valve sliding portion.
  • Page 317 Chapter 12 AIR START SYSTEM 2.4 Distributer Valve - Disassemble and Inspect Air direct starting spec Replace Replace Settling Crack, wear Crack, wear Replace Distributer Valve - Disassemble and Inspect Disassembling Sequence 1 Case cover 6 Bushing 2 Packing 7 Distributer case 3 Distributer valve, lock pin 8 Distributer spacer 4 Snap ring...
  • Page 318 Chapter 12 AIR START SYSTEM 2.5 Distributer Valve - Inspect 2.5.1 Distributer Valve Height - Measure Measure the distributer valve height. If the value exceeds the limit, replace the valve with a new one. Nominal Item Standard value Limit value value Distributer valve 22 mm...
  • Page 319 Chapter 12 AIR START SYSTEM 2.6 Distributer Valve - Assemble Air direct starting spec Application of oil Match mark Rotation direction No.1 cylinder top Fitting (No.6) 3° 9° 120° 120° Overlap 6° 120° 3° 9° 3° No.1 exhaust valve open 9°...
  • Page 321 Chapter 13 ADJUSTMENT AND OPERATION Engine - Adjust ...................... 13-3 Valve Bridge and Adjusting Screw - Check ................13-3 Valve Clearance - Check ......................13-3 Fuel Injection Timing - Check ....................13-3 Fuel System - Bleed Air ......................13-3 Belt and Belt Tension - Inspect and Adjust................13-6 Break-in Operation ....................
  • Page 323 Chapter 13 ADJUSTMENT AND OPERATION Chapter 13 ADJUSTMENT AND OPERATION 1. Engine - Adjust 1.1 Valve Bridge and Adjusting Screw - Check Check the adjustment of valve bridge and adjusting screw.If it is not adjusted, adjust it to the standard value. For the adjusting procedure, refer to "Valve Bridge and Adjusting Screw - Adjust"...
  • Page 324 Chapter 13 ADJUSTMENT AND OPERATION 1.4.2 Fuel Filter (Standard Spec) - Bleed Air Air vent plug Priming pump 8 to 10 N·m {0.8 to 1.0 kgf·m} If the air vent plugs, threads of bracket or sealing [5.9 to 7.4 lbf·ft] washers are damaged, replace them with new ones.
  • Page 325 Chapter 13 ADJUSTMENT AND OPERATION 1.4.5 Priming Pump Cap - Lock 90 ± 10° Gently tighten the priming cap by hand until Priming pump If the priming pump cap is not locked sufficiently, the the tightening force suddenly screw in cap wears due to engine vibration, which can increases.
  • Page 326 Chapter 13 ADJUSTMENT AND OPERATION 1.5 Belt and Belt Tension - Inspect and Adjust If any defects such as cuts or surface separations are found during inspection, replace the belt with a new one. Keep the belt free from oil and grease.Oil or grease causes the belt to slip and shorten the service life. Excessive belt tension can cause rapid wear of alternator bearing and shorten the service life of belt.
  • Page 327 Chapter 13 ADJUSTMENT AND OPERATION 1.5.3 Belt tension (water pump) - Adjust V-belt drive (1) Remove the belt cover. Lock nut 10 to 15 mm 10 to 15 mm 10 to 15 mm [0.39 to 0.59 in.] [0.39 to 0.59 in.] [0.39 to 0.59 in.] (2) Loosen all the fixing bolts of tension bracket.
  • Page 328 Chapter 13 ADJUSTMENT AND OPERATION 1.5.5 Belt Tension (Alternator) - Adjust V-belt drive Alternator pulley (1) Remove the belt cover. 10 to 15 mm 10 to 15 mm 10 to 15 mm [0.39 to 0.59 in.] [0.39 to 0.59 in.] [0.39 to 0.59 in.] Fixing bolt (2) Loosen all the fixing bolts of alternator.
  • Page 329 Chapter 13 ADJUSTMENT AND OPERATION Ribbed belt tension (N) table Belt straight distance (mm) [in.] Number Item 300 [11.81] or more than 300 to 400 more than 400 to 500 more than 500 to 600 more than 600 of ribs below [11.81 to 15.75] [15.75 to 19.69]...
  • Page 330 Chapter 13 ADJUSTMENT AND OPERATION 2. Break-in Operation 2.1 Preparation Before Engine Starting Check the levels of fuel, engine oil, and coolant, and also bleed air from fuel system and cooling system. Inspect the link between governor output lever and the fuel injection pump rack.Check that the fuel control rack is at the no- injection position when the engine is stopped.
  • Page 331 Chapter 13 ADJUSTMENT AND OPERATION 2.3.2 Inspection while the engine is running During the break-in operation, pay attention to followings and make sure that there is no abnormality. Oil pressure and oil temperature Exhaust temperature Coolant temperature and level Differences between right and left banks Leakage of oil, water, fuel and gas;...
  • Page 332 Chapter 13 ADJUSTMENT AND OPERATION 3. Engine-Test and Adjustment (a) Engine test, adjustment and seal shall be performed at the certified maintenance shop only. When the seal of engine is to be done at a service shop other than the certified shops, ask a certified shop for the presence of qualified person for the test, adjustment and seal.
  • Page 333 Chapter 13 ADJUSTMENT AND OPERATION 3.6 Seal After all performance tests and adjustments are completed, stop the engine, and seal the specified part between governor actua- tor and fuel injection pump rack. 3.6.1 Tamper Proof - Remove Tamper proof nut is composed of double structure, and can- not be removed by rotating.
  • Page 335 Engine inspection record sheet (SA series) No. 1 Cylinder liner bore inside diameter - measure No. 2 Cylinder liner flange protrusion - measure No. 3 Valve guide inside diameter and Vale stem diameter - measure No. 4 Cylinder head valve sinkage, seat width, and valve margin - measure No.
  • Page 336 No.1 INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Item Unit mm[in.] Cylinder liner bore inside diameter - measure Measuring location Standard Item to be Standard Limit Nominal measured Cylinder liner 150.000 to 150.040 150.140 [5.91] [5.9055 to 5.9071] [5.9110] inside diameter Location...
  • Page 337 No.2 INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Item Unit mm[in.] Cylinder liner bore flange protrusion - measure Measuring location Standard Item to be measured Standard 0.10 to 0.19 Cylinder liner flange protrusion [0.0039 to 0.0075] Measured value Item Cylinder liner bore flange protrusion Average value...
  • Page 338 No.3(1/2) INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Valve guide inside diameter and Valve stem diameter - Item Unit mm[in.] measure (1/2) Standard Measuring location Nominal Standard Limit Item to be measured Valve guide inside diameter 10.000 to 10.015 10.060 (same for inlet and exhaust) [0.39]...
  • Page 339 No.3(2/2) INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Valve guide inside diameter and Valve stem diameter - Item Unit mm[in.] measure (2/2) Standard Measuring location Nominal Standard Limit Item to be measured Valve guide inside diameter 10.000 to 10.015 10.060 (same for inlet and exhaust) [0.39]...
  • Page 340 No.4(1/2) INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Cylinder head valve sinkage, seat width, and valve margin - Item Unit mm[in.] measure(1/2) Measuring location Standard Item to be measured Standard Limit 30° Valve seat angle -0.1 to 0.1 Valve sinkage [-0.039 to 0.039] [0.020]...
  • Page 341 No.4(2/2) INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Cylinder head valve sinkage, seat width, and valve margin - Item Unit mm[in.] measure(2/2) Measuring location Standard Item to be measured Standard Limit 30° Valve seat angle -0.1 to 0.1 Valve sinkage [-0.039 to 0.039] [0.020]...
  • Page 342 No.5 INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Item Unit mm[in.] Cylinder head bottom face distortion - measure Measuring location Standard Item to be Standard Limit measured Distortion of 0.70 0.03 [0.0012] cylinder head or less [0.0276] bottom surface Measured value Item Cylinder head bottom face distortion...
  • Page 343 No. 6(1/2) INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Connecting rod bushing inside diameter and connecting rod Item Unit mm[in.] big-end bore diameter - measure (1/2) Measuring location Standard Item to be measured Standard Limit Nominal Connecting rod bushing 58.020 to 58.040 58.070 inside diameter...
  • Page 344 No. 6(2/2) INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Connecting rod bushing inside diameter and connecting rod Item Unit mm[in.] big-end bore diameter - measure (2/2) Measuring location Standard Item to be measured Standard Limit Nominal Connecting rod bushing 58.020 to 58.040 58.070 inside diameter...
  • Page 345 No. 7(1/2 INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Rocker bushing inside diameter and rocker shaft outside Item Unit mm[in.] diameter - measure(1/2) Measuring location Standard Nominal Standard Limit Item to be measured Rocker bushing 32.055 to 32.080 32.100 [1.26] [1.2620 to 1.2630]...
  • Page 346 No. 7(2/2 INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Rocker bushing inside diameter and rocker shaft outside Item Unit mm[in.] diameter - measure(2/2) Measuring location Standard Nominal Standard Limit Item to be measured Rocker bushing 32.055 to 32.080 32.100 [1.26] [1.2620 to 1.2630]...
  • Page 347 No. 8(1/2) INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Piston pin bore inside diameter and piston pin outside Item Unit mm[in.] diameter - measure(1/2) Measuring location Standard Nominal Standard Limit Item to be measured Piston pin bore 58.040 58.002 to 58.012 [2.2835 to 2.2839] inside diameter...
  • Page 348 No. 8(2/2) INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Piston pin bore inside diameter and piston pin outside Item Unit mm[in.] diameter - measure(2/2) Measuring location Standard Nominal Standard Limit Item to be measured Piston pin bore 58.040 58.002 to 58.012 [2.2835 to 2.2839] inside diameter...
  • Page 349 No. 9 INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Item Unit mm[in.] Valve clearance - measure Measuring location Standard Item to be measured Standard Valve Inlet 0.4 [0.016] clearance (A) Exhaust 0.5 [0.020] Measured value Valve clearance Valve clearance Inlet Exhaust Inlet...
  • Page 350 No. 10 INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Item Unit Fuel injection nozzle injection pressure - measure MPa{kgf/cm }[psi] Measuring location Standard Nominal Standard Item to be measured 21.6 22.1 to 22.6 Valve opening {220} {225 to 230} pressure [3133] [3205 to 3278]...
  • Page 351 No. 11 INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Camshaft bushing inside diameter and camshaft journal Item Unit mm[in.] outside diameter (right side) - measure Measuring location Standard Item to be measured Nominal Standard Limit 64.000 to 64.030 64.090 No.1 [2.52]...
  • Page 352 No. 12 INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Camshaft bushing inside diameter and camshaft journal Item Unit mm[in.] outside diameter (left side) - measure Measuring location Standard Item to be measured Nominal Standard Limit 64.000 to 64.030 64.090 No.1 [2.52]...
  • Page 353 No.13 INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Item Unit mm[in.] Crankshaft end play - measure Measuring location Standard Item to be measured Standard Limit 0.200 0.395 0.500 Crankshaft end play [0.0079 to 0.0156] [0.0197] Measured value Before disassembly After reassembly Approved by Checked by...

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