Mitsubishi Heavy Industries S4S Service Manual
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Mitsubishi Heavy Industries S4S Service Manual

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SERVICE MANUAL
July 2016
99616-101A0
Pub. No.
Printed in Japan

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Summary of Contents for Mitsubishi Heavy Industries S4S

  • Page 1 SERVICE MANUAL July 2016 99616-101A0 Pub. No. Printed in Japan...
  • Page 2      ...
  • Page 3 INTRODUCTION This service manual describes the specifications, maintenance and service procedures for Mitsubishi diesel engines. 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 regular inspection and maintenance, and also to take necessary measures which involves the disassembly, inspection, repair and reassembly of the engine and engine parts.
  • Page 5 INTRODUCTION How to use this manual This service manual consists of several Groups, which are arranged so as to allow you to make reference quickly to specifications, maintenance standards, adjustment procedures and service procedures including methods for disassembly, inspection, repair and reassembly of the Mitsubishi Diesel Engine (standard model for land use). A short summary describing the content of each Group is given in the General Contents page, and there is also a detailed table of contents at the beginning of each Group.
  • Page 6 INTRODUCTION Terms used in this manual Nominal means the rated (design) size or magnitude of a part to be measured. Standard means the quantitative requirement for dimension of a part, clearance between parts and performance. This is given in a form of tolerance.
  • Page 7 INTRODUCTION Safety Cautions Fire and explosion Keep flames away Care about fuel, oil and exhaust gas leakage Store fuel and engine oil in a well If any fuel, oil or exhaust gas leakage is found, immedi- ventilated designated area. ately take corrective measures to stop it. Make sure that the caps of fuel and Such leakages, if left uncorrected, can cause fuel or engine oil containers are tightly...
  • Page 8 INTRODUCTION Stay clear of all rotating and moving parts Install protective covers on rotating parts Lockout and tagout Make sure the protective covers for Be sure to lockout and tagout before starting inspection engine rotating parts are properly and maintenance. installed as intended.
  • Page 9 INTRODUCTION Be careful of burns Be careful of exhaust fume poi- soning Do not touch the engine during or immedi- ately after operation Operate engine in well-ventilated area Do not touch the engine during or If the engine is installed in an en- immediately after operation...
  • Page 10 INTRODUCTION Be careful of falling down Be careful of handling fuel, engine oil and LLC Lift engine correctly To lift the engine, always use a cor- Use only specified fuel, engine oil and long- rect wire rope capable of withstand- life coolant (LLC) ing the engine weight.
  • Page 11 INTRODUCTION Service battery When abnormality occurs Handle the battery correctly Stop overheated engine after cooling run • Never use flames or allow sparks Even if the engine comes to overheat, do not stop the to generate near the battery. The engine immediately.
  • Page 12 INTRODUCTION Other cautions Modification of engine prohibited Warming-up operation Unauthorized modification of the engine will void the After starting the engine, run the engine at low idling manufacturer’s warranty. speeds for 5 to 10 minutes for warming-up. Start the Modification of the engine may not only cause engine work after this operation is completed.
  • Page 13 INTRODUCTION Maintenance of air cleaner or pre-cleaner Avoidance of prolonged time of starter oper- The major cause of abnormal wear on engine parts is ation dust entering with intake air. Worn parts produce many Do not operate the starter for more than 10 seconds at problems such as an increase of oil consumption, de- a time even if the engine does not start.
  • Page 14 INTRODUCTION About warning labels Maintenance of warning labels Make sure all warning/caution labels are legible. Clean or replace the warning/caution labels when the description and/or illustration are not clear to read. For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvents, gasoline or other chemicals to prevent the letters from getting blurred or the adhesion from being weakened.

  • Page 15: Table Of Contents

    GENERAL CONTENTS Group Name Contents Group No. External view (in-line fuel injection pump and distributor-type fuel injection pump) System flow diagrams General Engine serial number location Main specifications Tips on disassembling and reassembling Maintenance service data Service data Tightening torque table Service tools Special tool Determining overhaul timing...

  • Page 17: General

    GENERAL 1. External view 4. Main specifications ....... 1-13 (in-line fuel injection pump and 4.1 S4S in-line distributor-type fuel injection pump) 1-2 fuel injection pump specification 1.1 S4S in-line (varies depending on the specification).. 1-13 fuel injection pump specification ....1-2 4.2 S4S distributor-type...

  • Page 18: External View (In-Line Fuel Injection Pump And Distributor-Type Fuel Injection Pump)

    GENERAL 1. External view (in-line fuel injection pump and distributor-type fuel injection pump) 1.1 S4S in-line fuel injection pump specification Governor Fuel filter Stop solenoid Air inlet Water pump (coolant inlet) Coolant drain plug Front Rear Fuei injection pump Oil level gauge...
  • Page 19 GENERAL 1.2 S4S-DT in-line fuel injection pump specification Stop solenoid Governor Fuel filter Water pump (coolant inlet) Coolant drain plug Front Rear Fuel leak Fuei injection pump Oil level gauge Fuel feed pump Crankshaft pulley Oil filter Oil drain plug...

  • Page 20: Fuel Injection Pump Specification

    GENERAL 1.3 S4S distributor-type fuel injection pump specification Fuel inlet Air inlet Water pump (coolant inlet) Fuel leak Magnetic valve (stop solenoid) Oil level gauge Rear Front Coolant drain plug Crankshaft pulley Flywheel Fuel injection pump Oil filter Oil drain plug...

  • Page 21: S4S-Dt Distributor-Type Fuel Injection Pump Specification

    GENERAL 1.4 S4S-DT distributor-type fuel injection pump specification Hanger Oil level gauge Fuel outlet Water pump (coolant inlet) Stop switch Front Rear Coolant drain cock Crankshaft pulley Fuel injection pump Flywheel Oil filter Oil drain plug Relief valve Engine left view...

  • Page 22: System Flow Diagrams

    GENERAL 2. System flow diagrams 2.1 Fuel system - flow diagram 2.1.1 S4S in-line fuel injection pump (swirl chamber) specification Fuel leak-off pipe Fuel filter Fuel injection nozzle Fuel return pipe Fuel injection pump Fuel inlet Fuel system - flow diagram 2.1.2...

  • Page 23: S4S Distributor-Type Fuel Injection Pump (Swirl Chamber) Specification

    GENERAL 2.1.3 S4S distributor-type fuel injection pump (swirl chamber) specification Fuel inlet Fuel filter Fuel leak-off pipe Fuel injection nozzle Fuel return pipe Fuel leak Fuel injection pump Fuel system - flow diagram 2.1.4 S4S-DT distributor-type fuel injection pump (direct injection) specification...

  • Page 24: Lubrication System - Flow Diagram

    GENERAL 2.2 Lubrication system - flow diagram 2.2.1 S4S in-line fuel injection pump specification Piston Pushrod Valve mechanism Crankshaft Tappet Relief valve Camshaft Main gallery Oil filter Idler gear Fuel injection pump Oil pump Oil pan Oil strainer Lubrication system - flow diagram 2.2.2...

  • Page 25: S4S Distributor-Type Fuel Injection Pump Specification

    GENERAL 2.2.3 S4S distributor-type fuel injection pump specification Valve mechanism Piston Pushrod Crankshaft Tappet Relief valve Camshaft Main gallery Idler gear Oil pump Oil filter Oil strainer Oil pan Lubrication system - flow diagram 2.2.4 S4S-DT distributor-type fuel injection pump specification...

  • Page 26: Cooling System - Flow Diagram

    Cylinder head Cooling outlet Thermostat Bypass pipe Water jacket Water pump Cooling inlet Cooling system - flow diagram 2.3.2 S4S-DT Cooling outlet Cylinder head Thermostat Water jacket Bypass pipe Water pump Cooling inlet Oil cooler Cooling system - flow diagram...

  • Page 27: Inlet And Exhaust System - Flow Diagram

    GENERAL 2.4 Inlet and exhaust system - flow diagram 2.4.1 Non-turbocharged engine Air breather pipe Blow-by gas (blow-by gas reduction) Inlet Exhaust Inlet Exhaust Inlet and exhaust system - flow diagram 2.4.2 Turbocharged engine Turbocharger Inlet Exhaust Exhaust Inlet Blow-by gas Air breather pipe Discharge Exhaust manifold...

  • Page 28: Engine Serial Number Location

    GENERAL 3. Engine serial number location The engine serial number is stamped on the right side of Engine crankcase. serial number Stamp location of engine serial number 1-12...

  • Page 29: Main Specifications

    GENERAL 4. Main specifications 4.1 S4S in-line fuel injection pump specification (varies depending on the specification) Table 1-1 Main specifications S4S in-line fuel injection pump specification (1 / 3) Engine model S4S-DT Type Water cooled, 4 cycle diesel engine No. of cylinders - arrangement...

  • Page 30: Varies Depending On The Specification)

    GENERAL Table 1-1 Main specifications S4S in-line fuel injection pump specification (2 / 3) Engine model S4S-DT Forced circulation type Lubricating method (pressure feed by oil pump) Standard Class CF or CH-4, SAE30 equivalent (API service classification) Engine total: approx. 10 L [2.64 U.S.gal.]...
  • Page 31 GENERAL Table 1-1 Main specifications S4S in-line fuel injection pump specification (3 / 3) Engine model S4S-DT Voltage - polarity 12V - negative (-) ground Pinion meshing type Pinion shift Starter Output 12V - 2.2kW (varies depending on the specification)

  • Page 32: S4S Distributor-Type Fuel Injection Pump Specification (Varies Depending On The Specification)

    GENERAL 4.2 S4S distributor-type fuel injection pump specification (varies depending on the specification) Table 1-2 Main specifications S4S distributor-type fuel injection pump specification (1 / 3) Engine model S4S-DT Type Water cooled, 4 cycle diesel engine No. of cylinders - arrangement...
  • Page 33 GENERAL Table 1-2 Main specifications S4S distributor-type fuel injection pump specification (2 / 3) Engine model S4S-DT Forced circulation type Lubricating method (pressure feed by oil pump) Standard Class CF or CH-4, SAE30 equivalent (API service classification) Engine total: approx. 10 L [2.64 U.S.gal.]...
  • Page 34 GENERAL Table 1-2 Main specifications S4S distributor-type fuel injection pump specification (3 / 3) Engine model S4S-DT Voltage - polarity 12V - negative (-) ground Pinion meshing type Pinion shift Starter Output 12V - 2.2kW Ring gear and pinion ratio...

  • Page 35: Tips On Disassembling And Reassembling

    GENERAL 5. Tips on disassembling and reassem- bling This service manual specifies the recommended procedures to be followed when servicing Mitsubishi engines. The manual also specifies the special tools that are required for the work, and the basic safety precautions to follow when working.

  • Page 37: Service Data

    SERVICE DATA 1. Maintenance service data ....2-2 1.1 General ............ 2-2 1.2 Basic engine ..........2-3 1.3 Fuel system..........2-7 1.4 Lubrication system ........2-7 1.5 Cooling system ........2-7 1.6 Inlet and exhaust system ......2-8 1.7 Electrical system ........2-8 2.

  • Page 38: Maintenance Service Data

    SERVICE DATA 1. Maintenance service data 1.1 General Table 2-1 Maintenance service data table - General Unit: mm [in.] Inspection point Nominal Standard Limit Remark Maximum rotation speed (No-load) Be sure to check specifications (varies depending on the specification) Minimum rotation speed (No-load) 3.2 MPa 2.8 MPa Swirl chamber...

  • Page 39: Basic Engine

    SERVICE DATA 1.2 Basic engine Table 2-2 Maintenance service data table - Basic engine (1 / 4) Unit: mm [in.] Inspection point Nominal Standard Limit Remark ø 19 19.010 to 19.030 Rocker bushing inside diameter [0.75] [0.7484 to 0.7492] ø 19 18.980 to 19.000 Rocker Rocker shaft outside diameter...
  • Page 40 SERVICE DATA Table 2-2 Maintenance service data table - Basic engine (2 / 4) Unit: mm [in.] Inspection point Nominal Standard Limit Remark Repair limit: ø 94 94.000 to 94.035 94.200 [3.7087] Inside diameter Refinish cylinder to 0.25 [3.70] [3.7008 to 3.7022] Replace limit: [0.0098] or 0.50 [0.0197] 94.700 [3.7283]...
  • Page 41 SERVICE DATA Table 2-2 Maintenance service data table - Basic engine (3 / 4) Unit: mm [in.] Inspection point Nominal Standard Limit Remark 0.15 0.50 Flatness [0.0059] or less [0.0197] Flywheel 0.15 0.50 Runout [0.0059] or less [0.0197] 0.04 0.10 Runout Repair or replace.
  • Page 42 SERVICE DATA Table 2-2 Maintenance service data table - Basic engine (4 / 4) Unit: mm [in.] Inspection point Nominal Standard Limit Remark 77.850 [3.0650] ø 78 77.955 to 77.970 (Repair) Crank journal outside diameter [3.07] [3.0691 to 3.0697] 77.100 [3.0354] (Replace) ø...

  • Page 43: Fuel System

    SERVICE DATA 1.3 Fuel system Table 2-3 Maintenance service data table - Fuel system Unit: mm [in.] Inspection point Nominal Standard Limit Remark 11.77 MPa 11.77 to 12.75 MPa Make shim adjustment. Swirl chamber {120 kgf/cm²} {120 to 130 kgf/cm²} Pressure varies by 1 MPa Valve open- [1707 psi]...

  • Page 44: Inlet And Exhaust System

    SERVICE DATA 1.6 Inlet and exhaust system Table 2-6 Maintenance service data table - Inlet and exhaust system Unit: mm [in.] Inspection point Nominal Standard Limit Remark Distortion of exhaust manifold Repair by grinding or replace. [0.008] or less 1.7 Electrical system Table 2-7 Maintenance service data table - Electrical system Unit: mm [in.] Inspection point...

  • Page 45: Tightening Torque Table

    SERVICE DATA 2. Tightening torque table 2.1 Major bolt tightening torque 2.1.1 Basic engine Table 2-8 Tightening torque table - Basic engine Threads Torque Description Dia × Pitch Remark N·m kgf·m lbf·ft (mm) Cylinder head 12 × 1.75 118 ± 5 12 ±...

  • Page 46: Lubrication System

    SERVICE DATA 2.1.3 Lubrication system Table 2-10 Tightening torque table - Lubrication system Threads Torque Description Dia × Pitch Remark N·m kgf·m lbf·ft (mm) Oil pan 8 × 1.25 11.3 ± 1.5 1.15 ± 0.15 8.3 ± 1.1 14 × 1.5 39 ±...

  • Page 47: Standard Bolt And Nut Tightening Torque

    SERVICE DATA 2.2 Standard bolt and nut tightening torque 2.2.1 Metric automobile screw thread Table 2-14 Metric automobile screw thread Threads Width Strength classification Dia × Pitch across flats 10.9 (mm) (mm) [in.] N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft M6 ×...

  • Page 49: Service Tools

    SERVICE TOOLS 1. Special tool........3-2...
  • Page 50 SERVICE TOOLS 1. Special tool Table 3-1 Special tool list (1 / 3) Tool name Part No. Shape Engine compression pressure measuring Compression gauge 33391-02100 0 to 7 MPa {0 to 71.4 kgf/cm²} [0 to 1015.54 psi] Gauge adapter Engine compression pressure 30691-21100 (swirl chamber) measuring...
  • Page 51 SERVICE TOOLS Table 3-1 Special tool list (2 / 3) Tool name Part No. Shape Stem seal installer 32A91-10200 Stem seal installation Camshaft, thrust plate and Socket 34491-00300 rocker bracket installation Valve guide installer 32A91-00100 Valve guide installation Camshaft bushing Camshaft bushing installer set 30691-00010 removal/installation...
  • Page 52 SERVICE TOOLS Table 3-1 Special tool list (3 / 3) Tool name Part No. Shape Connecting rod bushing Connecting rod bushing puller 32A91-00500 removal/installation Oil seal sleeve installer Oil seal sleeve installation of 30691-13010 guide set crankshaft rear side Piston installer 34491-00200 Piston installation Oil pump bushing installer...

  • Page 53: Determination Of Overhaul

    DETERMINATION OF OVERHAUL 1. Determining overhaul timing ...4-2 2. Testing compression pressure ..4-3...

  • Page 54: Determining Overhaul Timing

    DETERMINATION OF OVERHAUL 1. Determining overhaul timing In most cases, the engine should be overhauled when the compression pressure of the engine becomes low. An increase in engine oil consumption and blow-by gas are also considered to evaluate the engine condition. Besides, such symptoms as a decrease in output, increase in fuel consumption, decrease in oil pressure, difficulty of engine starting and increase in noise are also considered for judging the overhaul timing, although those symptoms are often affected by other causes, and are not always effective to judge the overhaul timing.

  • Page 55: Testing Compression Pressure

    DETERMINATION OF OVERHAUL 2. Testing compression pressure (a) Be sure to measure the compression pressure for all the cylinders. It is not a good practice to measure the com- pression pressure for only one cylinder, and presume the compression for the remaining cylinder. (b) Also be sure to check engine speed when measuring the compression pressure, as compression pressure varies with engine speed.
  • Page 57 DISASSEMBLY OF BASIC ENGINE 1. Disassembling and inspecting cylinder head and valve mechanism ....5-2 1.1 Removing rocker shaft assembly..... 5-3 1.2 Disassembling rocker shaft assembly..5-3 1.3 Removing cylinder head bolt....5-3 1.4 Removing cylinder head assembly ..5-4 1.5 Removing valve and valve spring .... 5-4 1.6 Removing valve stem seal .......

  • Page 58: Disassembling And Inspecting Cylinder Head And Valve Mechanism

    DISASSEMBLY OF BASIC ENGINE 1. Disassembling and inspecting cylinder head and valve mechanism Replace Check threads for stripping. Check surface that makes contact with valve push rod for wear. Wear Check for wear.Check oil hole for clogging. Check surface that makes contact with valve cap for wear.

  • Page 59: Removing Rocker Shaft Assembly

    DISASSEMBLY OF BASIC ENGINE 1.1 Removing rocker shaft assembly Adjusting screw Always loosen shorter bolts first. Failing to do so may Rocker bracket bolt cause the damage to the rocker shaft bracket. (1) Loosen the rocker arm adjusting screws by rotating about one turn.

  • Page 60: Removing Cylinder Head Assembly

    DISASSEMBLY OF BASIC ENGINE 1.4 Removing cylinder head assembly Cylinder head When removing the cylinder head gasket, be careful not to damage the cylinder head or crankcase surface by tools such as a screwdriver. (1) Remove the cylinder head bolt. (2) Remove the cylinder head assembly by lifting it up.

  • Page 61: Disassembling And Inspecting Flywheel

    DISASSEMBLY OF BASIC ENGINE 2. Disassembling and inspecting flywheel Replace Crack, knock hole defect Lip wear, damage or aging Crack, knock hole defect, gear damage Damaged threads Disassembling and inspecting flywheel Disassembling sequence 1 Flywheel 2 Flywheel housing 3 Oil seal 4 Gasket (Remove parts 2 and 3 as a unit)

  • Page 62: Removing Flywheel

    DISASSEMBLY OF BASIC ENGINE 2.1 Removing flywheel Be careful not to cut yourself with the ring gear when pulling out the flywheel. Be careful not to drop or hit the flywheel when remov- ing. (1) Remove one bolt from the flywheel. (2) Screw a guide bolt into the threaded hole of the bolt that Guide bolt has been removed.

  • Page 63: Disassembling And Inspecting Gear Case, Timing Gear And Camshaft

    DISASSEMBLY OF BASIC ENGINE 3. Disassembling and inspecting gear case, timing gear and camshaft Flaking, Wear, damage uneven contact, damage, Replace Clogging of oil key groove hole, wear defect, abnormal wear bushings Wear, damage Clogged oil hole Replace Replace Wear Replace Flaking, uneven contact,...

  • Page 64: Removing Crankshaft Pulley

    DISASSEMBLY OF BASIC ENGINE 3.1 Removing crankshaft pulley Prevent crankshaft from rotating The bar that stops the crankshaft from turning may come off. Pay due attention to safety. (1) Screw two guide bolts into the threaded holes at the rear end of the crankshaft.

  • Page 65: Measuring Timing Gear Backlash

    DISASSEMBLY OF BASIC ENGINE 3.4 Measuring timing gear backlash Measure the backlash of the timing gears by using one of the following two methods; measure the gear play with the dial gauge plunger applied to a tooth flank on the pitch circle at a right angle to the tooth axis, or measure the clearance between gears by inserting a feeler gauge between the gears at the tooth-to-tooth contacting area.

  • Page 66: Removing Oil Pan

    DISASSEMBLY OF BASIC ENGINE 3.7 Removing oil pan Oil pan Do not insert a chisel or screwdriver between the oil pan and crankcase to remove the oil pan, as it could Bolt deform the oil pan flange. (1) Turn the engine around. (2) Remove bolts from the oil pan.

  • Page 67: Removing Idler Gear

    DISASSEMBLY OF BASIC ENGINE 3.10 Removing idler gear (1) Remove the thrust plate bolt. (2) Remove the idler gear while turning the gear. Idler gear Removing idler gear 3.11 Removing camshaft Be careful not to damage the cams of camshaft and the bushings.

  • Page 68: Installing Camshaft Gear And Thrust Plate

    DISASSEMBLY OF BASIC ENGINE 3.13 Installing camshaft gear and thrust plate (1) Install the woodruff key and the thrust plate on the Press fit with hydraulic press crankshaft. Note: Be sure to install the thrust plate before installing the camshaft gear. Camshaft gear (2) Heat the camshaft gear with a gear heater to a Thrust plate...

  • Page 69: Disassembling And Inspecting Piston, Connecting Rod, Crankshaft And Crankcase

    DISASSEMBLY OF BASIC ENGINE 4. Disassembling and inspecting piston, connecting rod, crankshaft and crankcase Wear, damage Fatigue Surface scratches, cracks, damage, wear, carbon deposits Wear Cracks, clogged oil holes Wear Damaged threads Wear, clogged oil holes Serration for cracks, wear Scratches on inside and outside surfaces, seizing, Adhesion of water scale,...

  • Page 70: Removing Connecting Rod Cap

    DISASSEMBLY OF BASIC ENGINE 4.1 Removing connecting rod cap (1) Lay the engine by its side. (2) Mark the cylinder number on the connecting rod and connecting rod cap so that their combination is not changed when reassembling. (3) Remove the connecting rod caps. Note: Mark the cylinder No.

  • Page 71: Removing Piston Ring

    DISASSEMBLY OF BASIC ENGINE 4.4 Removing piston ring Remove the piston rings using piston ring pliers. Piston ring pliers P/N:31391-12900 Removing piston ring 4.5 Removing piston pin and piston (1) Using ring pliers, remove the snap ring. Snap ring pliers Removing piston pin (2) Using a wooden block and mallet, remove the piston pin, and separate the piston from the connecting rod.

  • Page 72: Removing Crankshaft

    DISASSEMBLY OF BASIC ENGINE 4.7 Removing crankshaft Be careful not to damage bearings when removing the crankshaft. (1) Slowly lift the crankshaft straight up. (2) Arrange the bearings in the order of disassembly so that their original positions are restored when reassembling. Note: (a) When raising the crankshaft, do not allow wire chain to come into contact with the crankshaft.
  • Page 73 INSPECTION AND REPAIR OF BASIC ENGINE 1. Inspecting and repairing cylinder head 3.11 Inspecting tappet........6-14 and valve mechanism .....6-2 3.11.1 Contact surface of camshaft....6-14 1.1 Measuring clearance between rocker 3.11.2 Contact surface of pushrod ..... 6-14 bushing and rocker shaft......6-2 3.12 Inspecting V-belt groove wear....

  • Page 74: Inspecting And Repairing Cylinder Head And Valve Mechanism

    INSPECTION AND REPAIR OF BASIC ENGINE 1. Inspecting and repairing cylinder head and valve mechanism 1.1 Measuring clearance between rocker bushing and rocker shaft Measuring direction Measure the rocker assembly inside diameter and the rocker Measuring shaft diameter. If the clearance exceeds the limit, replace direction either rocker assembly or rocker shaft with a new one.

  • Page 75: Replacing Valve Guide

    INSPECTION AND REPAIR OF BASIC ENGINE 1.3 Replacing valve guide Valve guide remover P/N:32A91-00300 Because valve guides must be inserted to the speci- fied amount, be sure to use a valve guide installer. (1) To remove valve guides, use a valve guide remover. Pulling out valve guide (2) To press-fit valve guides, use a valve guide installer.

  • Page 76: Inspecting Valve Face

    INSPECTION AND REPAIR OF BASIC ENGINE 1.4 Inspecting valve face Apply a thin coat of Shinmyoutan or equivalent lead-free coloring paste on the valve face, and strike the valve face against the valve seat using a valve lapper to check for contact condition.

  • Page 77: Refacing Valve Seat

    INSPECTION AND REPAIR OF BASIC ENGINE 1.6 Refacing valve seat (1) Use the valve seat cutter or valve seat grinder to reface the valve seat. After refacing, sand the valve seat lightly using 400 grit sandpaper, inserting it between the cutter and valve seat.

  • Page 78: Replacing Valve Seat

    INSPECTION AND REPAIR OF BASIC ENGINE 1.7 Replacing valve seat (1) To remove the valve seat, weld a stud to the valve seat as illustrated. Then, insert a rod into the valve guide Weld Shaft hole from the top of the cylinder head, and press out the valve seat with the rod.

  • Page 79: Lapping Valve And Valve Seat

    INSPECTION AND REPAIR OF BASIC ENGINE 1.8 Lapping valve and valve seat Always lap the valve against the valve seat after refacing the valve seat or after replacing the valve. (1) Apply a thin coat of lapping compound evenly to the valve face.

  • Page 80: Measuring Distortion Of The Bottom Surface Of The Cylinder Head

    INSPECTION AND REPAIR OF BASIC ENGINE 1.10 Measuring distortion of the bottom surface of the cylinder head Refacing of cylinder head should be kept to an abso- lute minimum. Excessive grinding of the cylinder head may result in defects such as defective combustion and stamping (contact between piston and valve).

  • Page 81: Removing Combustion Jet

    INSPECTION AND REPAIR OF BASIC ENGINE 1.12 Removing combustion jet Replace the combustion jet only when it has defect as crack. Round rod (1) Insert a round bar (approx; ø6 mm [0.24 in.]) into glow plug hole, and tap the combustion jet inner face perimeter lightly to pull out the combustion jet.

  • Page 82: Inspecting And Repairing Flywheel

    INSPECTION AND REPAIR OF BASIC ENGINE 2. Inspecting and repairing flywheel 2.1 Measuring flatness of flywheel Place the flywheel on a surface plate and move a dial gauge on the friction surface of the flywheel to measure the flatness. Grind the friction surface of the flywheel if the limit is exceeded.

  • Page 83: Inspecting And Repairing Timing Gear And Camshaft

    INSPECTION AND REPAIR OF BASIC ENGINE 3. Inspecting and repairing timing gear and camshaft 3.1 Measuring timing gear backlash Measure the backlash of the timing gears by using one of the following two methods; measure the gear play with the dial gauge plunger applied to a tooth flank on the pitch circle at a right angle to the tooth axis, or measure the clearance between gears by inserting a feeler gauge between...

  • Page 84: Measuring Camshaft Runout

    INSPECTION AND REPAIR OF BASIC ENGINE 3.4 Measuring camshaft runout Measure the camshaft runout using a dial gauge. If the limit is exceeded, correct the camshaft using a press, or replace the camshaft with a new one. Note: With a dial gauge set on the camshaft, rotate the camshaft one turn and read the gauge indication.

  • Page 85: Replacing Camshaft Bushing

    INSPECTION AND REPAIR OF BASIC ENGINE 3.7 Replacing camshaft bushing 3.7.1 Removing camshaft bushing Adapter Bushing Note: If the camshaft bushing is not installed, bore the +0.019 12.5S camshaft hole to ø57H6( and drive in the ▽ ▽ camshaft bushing when the clearance between camshaft journal and camshaft bushing exceeds the limit.

  • Page 86: Replacing Idler Shaft

    INSPECTION AND REPAIR OF BASIC ENGINE 3.9 Replacing idler shaft To remove the idler shaft, use the idler shaft puller. Idler shaft puller P/N:MH061077 Note: When installing the idler shaft into the crankcase, orient the idler shaft so that its oil hole faces the upper crankcase.

  • Page 87: Inspecting V-Belt Groove Wear

    INSPECTION AND REPAIR OF BASIC ENGINE 3.12 Inspecting V-belt groove wear Check the V-belt groove of the pulley for wear. Attach a new V-belt around the pulley, apply high tension and measure the sinkage of V-belt. If the wear appears excessive, and the belt top surface sinks 1.6 mm [0.06 in.] 1.6mm [0.06 in.] or more down from the top edge of groove, or more...

  • Page 88: Inspecting And Repairing Piston, Connecting Rod, Crankshaft And Crankcase

    INSPECTION AND REPAIR OF BASIC ENGINE 4. Inspecting and repairing piston, connecting rod, crankshaft and crankcase 4.1 Measuring crankcase top surface distor- tion Refacing of cylinder head should be kept to an abso- lute minimum. Excessive grinding of the cylinder head may result in defects such as defective combustion and stamping (contact between piston and valve).

  • Page 89: Measuring Cylinder Inside Diameter

    INSPECTION AND REPAIR OF BASIC ENGINE 4.2 Measuring cylinder inside diameter (1) Measure the inside diameter of the cylinder at three Measuring levels, i.e., upper (with much stepped wear), middle, directions and lower levels, in both directions parallel to and perpendicular to the crankshaft direction.

  • Page 90: Measuring Piston Outside Diameter

    INSPECTION AND REPAIR OF BASIC ENGINE 4.3 Measuring piston outside diameter (1) Measure the piston outside diameter of the piston skirt Direction at right angles to piston pin at right angles to the piston pin. If it is less than the limit, replace the piston with a new piston.

  • Page 91: Measuring Clearance Between Piston Ring Groove And Piston Ring

    INSPECTION AND REPAIR OF BASIC ENGINE 4.5 Measuring clearance between piston ring groove and piston ring Remove carbon deposits from pistons and check the entire circumference of the piston. (1) Remove deposits such as carbon from each ring groove. (2) Check each ring groove for wear or damage. If it is worn or damaged, replace the piston with a new one.

  • Page 92: Measuring Piston Protrusion

    INSPECTION AND REPAIR OF BASIC ENGINE 4.7 Measuring piston protrusion Piston protrusion must always meet the standard, as the amount of protrusion not only influences on the engine performance, but also it is important to prevent valve interference. Measure the protrusion of each piston following the instructions below.

  • Page 93: Measuring Clearance Between Connecting Rod Bearing And Crankpin

    INSPECTION AND REPAIR OF BASIC ENGINE 4.8 Measuring clearance between connecting 54 ± 5 N·m rod bearing and crankpin Measuring Measuring {5.5 ± 0.5 kgf·m} directions points [40 to 3.6 lbf·ft] When grinding crankpins, be sure to grind all the pins to the same size.

  • Page 94: Replacing Connecting Rod Bushing

    INSPECTION AND REPAIR OF BASIC ENGINE 4.10 Replacing connecting rod bushing Use a connecting rod bushing installer to replace the Connecting rod bushing installer connecting rod bushing. P/N:32A91-00500 Match marks side (1) With the bushing joints oriented as shown in the illustration, align the oil hole of bushing with the oil hole of connecting rod, and press-fit the connecting rod bushing into the connecting rod.

  • Page 95: Inspecting Connecting Rod Bearing

    INSPECTION AND REPAIR OF BASIC ENGINE 4.12 Inspecting connecting rod bearing Inspect the connecting rod bearings. If any defect is found, replace it with a new one. Scratches Flaking Fusion Inspecting connecting rod bearing 4.13 Measuring connecting rod end play (1) Install the connecting rods onto the respective crankpins and tighten the connecting rod cap bolts to the specified torque.

  • Page 96: Measuring Crankshaft Journal Outside Diameter

    INSPECTION AND REPAIR OF BASIC ENGINE 4.15 Measuring crankshaft journal outside diam- eter Measure the crankshaft journal diameter using micrometer. Check the crankshaft journal for roundness, cylindricality and the clearance with the bearing. If the measurement value is below the repair limit, grind the Measuring Measuring direction...

  • Page 97: Grinding Crankshaft

    INSPECTION AND REPAIR OF BASIC ENGINE 4.17 Grinding crankshaft R3 mm R3 mm [0.12 in.] [0.12 in.] (a) When grinding crank journals, be sure to grind all the journals to the same size. (b) Finish the fillet radius to the specified dimension. Grind the crankshaft journal (or pin) in the diameter that fit R3 mm the inside diameter of the next undersize main (or...

  • Page 98: Measuring Crankshaft End Play

    INSPECTION AND REPAIR OF BASIC ENGINE 4.18 Measuring crankshaft end play (1) Measure the crankshaft end play (clearance between the +0.039 +0.015 [1.22 in.] crank arm at the thrust force receiving journal and the 0.00 bearing cap with thrust plate attached). If the limit is exceeded, replace the thrust plate with a new one.

  • Page 99: Replacing Crankshaft Gear

    INSPECTION AND REPAIR OF BASIC ENGINE 4.20 Replacing crankshaft gear 4.20.1 Removing crankshaft gear Using a gear puller, remove the gear from the crankshaft. Crankshaft gear Note: Do not strike the gear with a hammer. Puller P/N:MH061326 Removing crankshaft gear 4.20.2 Installing crankshaft gear (1) Install the key on the crankshaft.

  • Page 100: Installing Oil Seal Sleeve

    INSPECTION AND REPAIR OF BASIC ENGINE 4.22 Installing oil seal sleeve Oil seal sleeve installer set Be careful not to dent or wound the oil seal sleeve cir- P/N:30691-13010 cumference. Guide When installing the oil seal sleeve, apply the oil to the P/N:30691-13100 inside of the oil seal sleeve, and drive it into the crankshaft by using oil seal sleeve installer set.

  • Page 101: Inspecting Main Bearing Surface

    INSPECTION AND REPAIR OF BASIC ENGINE 4.24 Inspecting main bearing surface Check the inside surface of each main bearing shell for abnormal contact, scratches, corrosion and peeling from Scratch on the inner and outer circumference, foreign material. Also check the outside surface of each corrosion, and detachment bearing shell which comes into contact with the crankcase or main bearing cap for abnormal seating.
  • Page 103 REASSEMBLY OF BASIC ENGINE 1. Reassembling piston, connecting rod, 4. Reassembling cylinder head and crankshaft and crankcase ....7-2 valve mechanism ......7-15 1.1 Installing main bearing ......7-2 4.1 Cleaning cylinder head bottom surface.. 7-15 1.2 Installing thrust plate ........ 7-2 4.2 Installing valve stem seal .......

  • Page 104: Reassembling Piston, Connecting Rod, Crankshaft And Crankcase

    REASSEMBLY OF BASIC ENGINE 1. Reassembling piston, connecting rod, crankshaft and crankcase 1.1 Installing main bearing Main bearing upper Do not apply oil to the bearing outer surface, as the oil may cause the bearing seizure. (1) Press the upper main bearing into position by aligning its lug to the lug groove on the crankcase.

  • Page 105: Installing Main Bearing Caps

    REASSEMBLY OF BASIC ENGINE 1.5 Installing main bearing caps Apply ThreeBond 1212 to corner of cap The foremost and rearmost caps should be installed so that they are flush with the crankcase surface. Install the main bearing caps from the front side in the order of the numbers marked on them.

  • Page 106: Measuring Crankshaft End Play

    REASSEMBLY OF BASIC ENGINE 1.8 Measuring crankshaft end play Attach a dial gauge to the end of the crankshaft to measure the end play. If the end play deviates from the standard value, loosen the main bearing cap bolts and retighten. Make sure that the crankshaft turns freely.

  • Page 107: Installing Piston Ring

    REASSEMBLY OF BASIC ENGINE 1.10 Installing piston ring Piston ring plier Top mark No.1 P/N:31391-12900 A marking is stamped near the end gap to indicate the compression ring top face of piston ring. Install all piston rings with this mark facing upward. No.2 compression If the rings are installed upside down, it could cause...

  • Page 108: Installing Connecting Rod Bolt And Connecting Rod Bearing

    REASSEMBLY OF BASIC ENGINE 1.12 Installing connecting rod bolt and connect- ing rod bearing Lug groove (1) Press fit the connecting rod bolts into the connecting rod. Note: When press fitting the bolt, make sure that the bolt fully contacts its seating position without any interference with the shoulder of mounting surface.

  • Page 109: Installing Connecting Rod Cap

    REASSEMBLY OF BASIC ENGINE 1.14 Installing connecting rod cap (1) Install the connecting rod cap with its match mark facing on the same side as the match mark on the connecting rod. (2) Tighten the connecting rod cap nuts evenly and progressively to the specified torque.

  • Page 110: Reassembling Timing Gear And Camshaft

    REASSEMBLY OF BASIC ENGINE 2. Reassembling timing gear and camshaft 2.1 Installing oil pump Set a new O-ring to the oil pump case, and install the oil pump to the crankcase. Oil pump O-ring Installing oil pump 2.2 Installing front plate (1) Clean the mounting surface of the gasket.

  • Page 111: Installing Camshaft Gear And Thrust Plate

    REASSEMBLY OF BASIC ENGINE 2.3 Installing camshaft gear and thrust plate Press fit with hydraulic press Be careful not to damage the cam of the camshaft and the bushing. Camshaft gear Warm the camshaft gear and insert the thrust plate without fail when installing the gear.

  • Page 112: Installing Oil Pump Gear

    REASSEMBLY OF BASIC ENGINE 2.6 Installing oil pump gear (1) Install the oil pump gear to the oil pump shaft. (2) Tighten the jam nut to the specified torque. Oil pump gear 33 ± 5 N·m {3.4 ± 0.5 kgf·m} [24.6 ±...

  • Page 113: Installing Front Oil Seal

    REASSEMBLY OF BASIC ENGINE 2.9 Installing front oil seal Using an installer, install new oil seal in the timing gear case. Make sure the oil seal is flush with the gear case. Installer Installing front oil seal 2.10 Installing timing gear case (1) Aligning with the dowel pins, install the gasket to the Gasket crankcase.

  • Page 114: Installing Oil Pan

    REASSEMBLY OF BASIC ENGINE 2.12 Installing oil pan (1) Clean the mount surfaces of the crankcase, timing gear case, and oil pan. (2) Squeeze ThreeBond 1207C (32A91-05100: liquid gasket) in a 4 mm [0.16 in.] diameter bead all around the oil pan flange periphery, and spread it. (3) Install the oil pan to the crankcase within five minutes of applying the liquid gasket.

  • Page 115: Installing Cover

    REASSEMBLY OF BASIC ENGINE 2.13 Installing cover Tighten the cover mounting bolts evenly. Cover Installing cover 2.14 Installing crankshaft pulley The bar that prevnets crankshaft rotation The bar could come off. Be very careful. (1) Screw two guide bolts into the threaded holes at the rear end of the crankshaft.

  • Page 116: Reassembling Flywheel

    REASSEMBLY OF BASIC ENGINE 3. Reassembling flywheel 3.1 Installing oil seal Apply a small quantity of grease to the new oil seal, and Flywheel housing install the oil seal to the rear plate. Apply grease Be careful of the oil seal installation direction. Note: Use an oil seal with a sleeve if the oil seal contacting surface of the crankshaft is worn.

  • Page 117: Reassembling Cylinder Head And Valve Mechanism

    REASSEMBLY OF BASIC ENGINE 4. Reassembling cylinder head and valve mechanism 4.1 Cleaning cylinder head bottom surface Do not use the liquid gasket to the cylinder head. Taking care not to damage the cylinder head bottom surface, remove residue of old gasket. Note: First, roughly scrape off residue of old gasket using a scraper.

  • Page 118: Installing Cylinder Head Gasket

    REASSEMBLY OF BASIC ENGINE 4.4 Installing cylinder head gasket Do not use the liquid gasket to the cylinder head. (1) Make sure that there is no dirt or dents on the top surfaces of the crankcase and pistons. (2) Place new gasket on the crankcase by aligning it with dowel pins on the crankcase.

  • Page 119: Inserting Pushrod

    REASSEMBLY OF BASIC ENGINE 4.7 Inserting pushrod (1) Insert each pushrod into its hole in the cylinder head. (2) Make sure that the ball end of each pushrod is placed Pushrod correctly on the tappet cup. Tappet Inserting pushrod 4.8 Reassembling rocker shaft assembly (1) Apply engine oil to the rocker shaft.

  • Page 120: Determining Top Dead Center Of No.1 Cylinder Compression Stroke

    REASSEMBLY OF BASIC ENGINE 4.10 Determining top dead center of No.1 cylin- der compression stroke (1) Determine the No.1 cylinder top dead center position, and at this position, ensure that the notch mark "0" stamped on the crankshaft pulley is aligned with the pointer.

  • Page 121: Installing Rocker Cover

    REASSEMBLY OF BASIC ENGINE 4.12 Installing rocker cover (1) Make sure that the gasket is firmly installed into the rocker cover. (2) Tighten the rocker cover mounting nuts to the specified 11.5 ± 1.5 N·m torque. {1.15 ± 0.15 kgf·m} [8.5 ±...
  • Page 123 FUEL SYSTEM 1. Removing fuel system.....8-2 3. Installing fuel system ....8-16 1.1 Removing fuel filter and fuel pipe..... 8-2 3.1 Installing fuel injection pump ....8-16 1.2 Removing fuel injection pipe, 3.2 Checking fuel injection timing fuel leak-off pipe and fuel injection nozzle 8-3 (in-line fuel injection pump type) ....

  • Page 124: Removing Fuel System

    FUEL SYSTEM 1. Removing fuel system Cover the openings on the injection pipe, nozzle inlet connector and injection pipe to prevent dust from entering the fuel system. 1.1 Removing fuel filter and fuel pipe Filter for in-line -type Filter for distributor-type fuel injection pump fuel injection pump Removing fuel filter and fuel pipe...

  • Page 125: Removing Fuel Injection Pipe, Fuel Leak-Off Pipe And Fuel Injection Nozzle

    FUEL SYSTEM 1.2 Removing fuel injection pipe, fuel leak-off pipe and fuel injection nozzle 1.2.1 Removing fuel injection pipe, fuel leak-off pipe and fuel injection nozzle (in-line type fuel injection pump) Swirl chamber specification Direct injection specification Replace Replace Removing fuel injection pipe, fuel leak-off pipe and fuel injection nozzle (in-line type fuel injection pump) Removing sequence 1 Fuel return pipe...

  • Page 126: Removing Fuel Injection Pipe, Fuel Leak-Off Pipe And Fuel Injection Nozzle (Distributor-Type Fuel Injection Pump)

    FUEL SYSTEM 1.2.2 Removing fuel injection pipe, fuel leak-off pipe and fuel injection nozzle (distributor-type fuel injection pump) Swirl chamber specification Direct injection specification Replace Replace Removing fuel injection pipe, fuel leak-off pipe and fuel injection nozzle (distributor-type fuel injection pump) Removing sequence 1 Fuel return pipe 5 No.

  • Page 127: Removing Fuel Injection Pump

    FUEL SYSTEM 1.3 Removing fuel injection pump In-line-type fuel injection pump Distributor-type fuel injection pump Replace Crankcase Removing fuel injection pump Removing sequence 1 Bracket 2 Fuel injection pump flange 3 Bracket...

  • Page 128: Disassembling, Inspecting And Reassembling Fuel System

    FUEL SYSTEM 2. Disassembling, inspecting and reassembling fuel system 2.1 Disassembling and inspecting fuel filter (in-line type fuel injection pump) Crack and damaged threads Clogged, cracks. Replace: Every 500 hrs. Disassembling and inspecting fuel filter (in-line type fuel injection pump) Disassembling sequence 1 Filter element 2 Filter bracket...

  • Page 129: Disassembling And Inspecting Fuel Filter

    FUEL SYSTEM 2.2 Disassembling and inspecting fuel filter Crack and damaged threads Replace Clogged, cracks. Replace: Every 500 hrs. Replace Disassembling and inspecting fuel filter Disassembling sequence 1 Level sensor 2 Filter element 3 Body...

  • Page 130: Changing Fuel Filter

    FUEL SYSTEM 2.3 Changing fuel filter When handling fuel, make sure no open flames are nearby. Wipe off any spilled fuel. Spilled fuel becomes fire hazard. (1) Clean the outside of the fuel filter and the area around Body (2) Disconnect the fuel filter level sensor from its connector.

  • Page 131: Disassembling And Inspecting Fuel Injection Nozzle (Swirl Chamber Type)

    FUEL SYSTEM 2.4 Disassembling and inspecting fuel injection nozzle (swirl chamber type) Replace Wear Settling, breakage Wear, damage Carbon deposit, nozzle hole clogging Disassembling and inspecting fuel injection nozzle (swirl chamber type) Disassembling sequence 1 Nozzle retaining nut 4 Pressure pin 7 Nozzle holder 2 Nozzle tip assembly 5 Pressure spring...

  • Page 132: Disassembling And Inspecting Fuel Injection Nozzle (Direct Injection Type)

    FUEL SYSTEM 2.5 Disassembling and inspecting fuel injection nozzle (direct injection type) Wear Fatigue, breakage Wear, damage Carbon deposit, clogged spay holes Disassembling and inspecting fuel injection nozzle (direct injection type) Disassembling sequence 1 Nozzle retaining nut 4 Straight pin 7 Shim 2 Nozzle tip assembly 5 Pressure pin...

  • Page 133: Inspecting And Adjusting Fuel Injection Valve Opening Pressure

    FUEL SYSTEM 2.6 Inspecting and adjusting fuel injection valve opening pressure Nozzle tester Never touch the injection nozzle tip during nozzle injection test. (1) Mount the nozzle on the nozzle tester. (2) Push down the handle at a speed of once a second and read the pressure when injection starts.

  • Page 134: Cleaning And Inspecting Nozzle Tip

    FUEL SYSTEM 2.8 Cleaning and inspecting nozzle tip (1) Clean the needle valve and body of the nozzle tip in a clean wash oil. (2) After cleaning, assemble the needle valve and the body Nozzle tip end in a clean gas oil. Note: The needle valve and body are precision parts.

  • Page 135: Reassembling Fuel Injection Nozzle (Swirl Chamber Type)

    FUEL SYSTEM 2.9 Reassembling fuel injection nozzle (swirl chamber type) 36.7 ± 2.5 N·m {3.75 ± 0.25 kgf·m} [27.1 ± 1.8 lbf·ft] 58.9 ± 5.9 N·m {6 ± 0.6 kgf·m} [43.4 ± 4.3 lbf·ft] Reassembling fuel injection nozzle (swirl chamber type) 8-13...

  • Page 136: Reassembling Fuel Injection Nozzle (Direct Injection Type)

    FUEL SYSTEM 2.10 Reassembling fuel injection nozzle (direct injection type) 29.4 ± 5 N·m {3 ± 0.5 kgf·m} [21.7 ± 3.6 lbf·ft] Reassembling fuel injection nozzle (direct injection type) 8-14...

  • Page 137: Inspecting And Cleaning Gauze Filter Of Distribute Type Fuel Injection Pump (Bosch)

    FUEL SYSTEM 2.11 Inspecting and cleaning gauze filter of distribute type fuel injection pump (Bosch) Keep flames away when handling a diesel fuel. Wipe off any spilled fuel thoroughly. Spilled fuel could cause a fire. Cover the openings on the fuel injection pump to prevent dust from entering the fuel system. When output shortage and/or hunting of the engine occured, the gauze filter may be dirty.

  • Page 138: Installing Fuel System

    FUEL SYSTEM 3. Installing fuel system 3.1 Installing fuel injection pump In-line-type fuel injection pump Distributor-type fuel injection pump Replace Replace Crankcase Installing fuel injection pump 8-16...

  • Page 139: Checking Fuel Injection Timing (In-Line Fuel Injection Pump Type)

    FUEL SYSTEM 3.2 Checking fuel injection timing (in-line fuel injection pump type) The fuel injection timing varies with the output, speed and other engine specifications. Be sure to check the engine's specification sheet. 3.2.1 Determining top dead center of No.1 cylin- der compression stroke (1) Attach a socket and rachet handle to the nut of crankshaft pulley, and rotate the crankshaft in the...

  • Page 140: Inspecting Fuel Injection Timing (Distributor-Type Fuel Injection Pump)

    FUEL SYSTEM 3.3 Inspecting fuel injection timing (distributor-type fuel injection pump) 3.3.1 Inspecting fuel injection timing When the fuel injection pump is replaced, confirm the fuel injection timing after the replacement. To confirm it, bring No. 1 cylinder piston to the top dead center on compression stroke.
  • Page 141 FUEL SYSTEM (4) Put a mark B on the flange plate where aligned with the mark A of the fuel injection pump. Alignment mark of fuel injection pump Flange plate Fuel injection When removing the flange plate from the fuel injection pump Front plate pump assembly, be sure to put a mark on the flange...
  • Page 142 FUEL SYSTEM (9) Replace the gasket installed between flange plate and the fuel injection pump with a new one. Install the flange plate and the fuel injection pump gear to the fuel injection pump. (10) Align the mark A of the fuel injection pump with the mark B which was marked above procedure (4) and tighten the nut.

  • Page 143: Installing Fuel Injection Pipe, Fuel Leak-Off Pipe And Fuel Injection Nozzle8-21

    FUEL SYSTEM 3.4 Installing fuel injection pipe, fuel leak-off pipe and fuel injection nozzle 3.4.1 Installing fuel injection pipe, fuel leak-off pipe and fuel injection nozzle (in-line type fuel injection pump) Swirl chamber specification Direct injection specification Replace 22.6 ± 2 N·m {2.3 ±...

  • Page 144: Installing Fuel Injection Pipe, Fuel Leak-Off Pipe And Fuel Injection Nozzle (Distributor-Type Fuel Injection Pump)

    FUEL SYSTEM 3.4.2 Installing fuel injection pipe, fuel leak-off pipe and fuel injection nozzle (distributor-type fuel injection pump) Swirl chamber specification Direct injection specification Replace 22 ± 1 N·m 22.6 ± 2 N·m {2.2 ± 0.2 kgf·m} {2.3 ± 0.2 kgf·m} 58.9 ±...

  • Page 145: Installing Fuel Filter And Fuel Pipe

    FUEL SYSTEM 3.5 Installing fuel filter and fuel pipe Filter for in-line -type Filter for distributor-type fuel injection pump fuel injection pump Installing fuel filter and fuel pipe 8-23...
  • Page 147 LUBRICATION SYSTEM 1. Removing lubrication system ..9-2 1.1 Removing oil filter and relief valve ... 9-2 1.2 Removing oil cooler ......... 9-3 1.3 Removing oil pump, oil pan and oil strainer9-4 2. Disassembling, inspecting and reassembling lubrication system ..9-5 2.1 Disassembling and inspecting oil pump... 9-5 2.2 Inspecting oil pump ........

  • Page 148: Removing Lubrication System

    LUBRICATION SYSTEM 1. Removing lubrication system 1.1 Removing oil filter and relief valve Replace Replace Removing oil filter and relief valve Removing sequence 1 Oil filter 2 Relief valve...

  • Page 149: Removing Oil Cooler

    LUBRICATION SYSTEM 1.2 Removing oil cooler Replace Replace Removing oil cooler Removing sequence 1 Oil cooler assembly 2 Oil cooler gasket...

  • Page 150: Removing Oil Pump, Oil Pan And Oil Strainer9-4

    LUBRICATION SYSTEM 1.3 Removing oil pump, oil pan and oil strainer Replace Removing oil pump, oil pan and oil strainer Removing sequence 1 Oil pump 2 Oil pan 3 Oil strainer 4 Safety valve (for the engine with oil cooler)

  • Page 151: Disassembling, Inspecting And Reassembling Lubrication System

    LUBRICATION SYSTEM 2. Disassembling, inspecting and reassembling lubrication system 2.1 Disassembling and inspecting oil pump Replace Disassembling oil pump Disassembling sequence 1 O-ring 2 Shaft assembly 3 Outer rotor 4 Pump case...

  • Page 152: Inspecting Oil Pump

    LUBRICATION SYSTEM 2.2 Inspecting oil pump 2.2.1 Measuring clearance between outer rotor and inner rotor Measure the clearance between the outer rotor and the inner rotor. If measured value exceeds the limit, replace the oil Thick feeler gauge pump with new one. Item Standard Limit...

  • Page 153: Measuring Clearance Between Main Shaft And Pump Case

    LUBRICATION SYSTEM 2.2.4 Measuring clearance between main shaft and pump case Measuring Measure the diameter of the shaft and the inside diameter of Measuring directions directions the bore in the case for the shaft to find the clearance between the two. If the clearance exceeds the limit, replace Measuring the oil pump assembly.

  • Page 154: Reassembling Oil Pump

    LUBRICATION SYSTEM 2.3 Reassembling oil pump Flush Flush Reassembling oil pump...

  • Page 155: Disassembling And Inspecting Oil Cooler

    LUBRICATION SYSTEM 2.4 Disassembling and inspecting oil cooler Clogging, crack Replace Replace Crack, deformation Disassembling and inspecting oil cooler Disassembling sequence 1 Oil cooler case 2 Oil cooler element...

  • Page 156: Inspecting Oil Filter

    LUBRICATION SYSTEM 2.5 Inspecting oil filter Apply engine oil to the gasket when installing Clogged, cracks. Replace: Every 250 hrs. Inspecting oil filter 9-10...

  • Page 157: Inspecting Relief Valve

    LUBRICATION SYSTEM 2.6 Inspecting relief valve (1) Check the relief valve and its seat for contact. Check the spring for fatigue and damage. If faulty, replace the relief valve with new one. (2) Measure the relief valve opening pressure. If the pressure does not fall within the standard range, replace the relief valve with new one.

  • Page 158: Installing Lubrication System

    LUBRICATION SYSTEM 3. Installing lubrication system 3.1 Installing oil pump, oil pan and oil strainer 69 ± 5 N·m {7 ± 0.5 kgf·m} [50.6 ± 3.6 lbf·ft] Replace 11.3 ± 1.5 N·m {1.15 ± 0.15 kgf·m} [8.3 ± 1.1 lbf·ft] 39 ±...

  • Page 159: Installing Oil Cooler

    LUBRICATION SYSTEM 3.2 Installing oil cooler Replace Replace Installing oil cooler 9-13...

  • Page 160: Installing Oil Filter And Relief Valve

    LUBRICATION SYSTEM 3.3 Installing oil filter and relief valve Replace Replace 49 ± 5 N·m {5 ± 0.5 kgf·m} [36.1 ± 3.6 lbf·ft] Installing oil filter and relief valve 9-14...
  • Page 161 COOLING SYSTEM 1. Removing cooling system .....10-2 1.1 Removing cooling fan, fan pulley and V-belt............10-2 1.2 Removing thermostat......10-3 1.3 Removing water pump ......10-4 2. Disassembling, inspecting and reassembling cooling system ..10-5 2.1 Disassembling and inspecting thermostat10-5 2.2 Inspecting thermostat......10-6 2.3 Disassembling water pump....

  • Page 162: Removing Cooling System

    COOLING SYSTEM 1. Removing cooling system 1.1 Removing cooling fan, fan pulley and V-belt Removing cooling fan, fan pulley and V-belt Removing sequence 1 Plate 3 V-belt 2 Cooling fan 4 Water pump pulley 10-2...

  • Page 163: Removing Thermostat

    COOLING SYSTEM 1.2 Removing thermostat Replace Crack, deterioration, damage Crack, water leakage, damage Removing thermostat Removing sequence 1 Hose 2 Thermostat assembly 3 Gasket 10-3...

  • Page 164: Removing Water Pump

    COOLING SYSTEM 1.3 Removing water pump Replace Crack, deformation, damage Removing water pump Removing sequence 1 Water pump assembly 2 Gasket 10-4...

  • Page 165: Disassembling, Inspecting And Reassembling Cooling System

    COOLING SYSTEM 2. Disassembling, inspecting and reassembling cooling system 2.1 Disassembling and inspecting thermostat Replace Replace Disassembling thermostat Disassembling sequence 1 Thermostat cover 2 Gasket 3 Thermostat 4 Thermostat case 10-5...

  • Page 166: Inspecting Thermostat

    COOLING SYSTEM 2.2 Inspecting thermostat [0.35] Be careful of burns or a fire when measuring tempera- ture, as it involves a high-temperature and open flame. 76.5 ± 1.5°C 90°C [170 ± 3.5°F] [194°F] To test the thermostat operation, immerse the thermostat in a Temperature container filled with water.

  • Page 167: Disassembling Water Pump

    COOLING SYSTEM 2.3 Disassembling water pump Crack, water leakage, deformation Replace Crack, water leakage, damage, impeller and shaft rotation Disassembling water pump Disassembling sequence 1 Water pump cover 2 Gasket 3 Water pump 2.4 Inspecting water pump Check to make sure that the impeller and shaft of water pump rotate smoothly without noise and irregularities.

  • Page 168: Installing Cooling System

    COOLING SYSTEM 3. Installing cooling system 3.1 Installing water pump Water pump and Crack, deformation, water pump cover fixing bolts (×3) damage 9.8 ± 1 N·m {1 ± 0.1 kgf·m} Replace [7.2 ± 0.7 lbf·ft] 32.4 ± 2 N·m {3.3 ± 0.2 kgf·m} Water pump and [23.9 ±...

  • Page 169: Installing Thermostat

    COOLING SYSTEM 3.2 Installing thermostat Replace 18.1 ± 1.5 N·m {1.85 ± 0.15 kgf·m} [13.4 ± 1.1 lbf·ft] Crack, deterioration, damage Crack, water leakage, damage Installing thermostat 10-9...

  • Page 170: Installing Cooling Fan, Fan Pulley And V-Belt

    COOLING SYSTEM 3.3 Installing cooling fan, fan pulley and V-belt Installing cooling fan, fan pulley and V-belt Inspect and adjust the V-belt within 200 hours opera- tion. Depending on the operating condition, inspecting and adjusting interval may shorten. 10-10...
  • Page 171 INLET AND EXHAUST SYSTEMS 1. Removing turbocharger, inlet and exhaust systems .....11-2 1.1 Removing turbocharger ......11-2 1.2 Removing inlet manifold......11-3 1.3 Removing exhaust manifold....11-4 2. Disassembling, inspecting and reassembling inlet and exhaust systems .....11-5 2.1 Measuring exhaust manifold distortion .. 11-5 3.

  • Page 172: Removing Turbocharger, Inlet And Exhaust Systems

    INLET AND EXHAUST SYSTEMS 1. Removing turbocharger, inlet and exhaust systems 1.1 Removing turbocharger Replace Replace Replace Replace Removing turbocharger Removing sequence 1 Oil pipe 3 Air hose 5 Turbocharger 2 Oil pipe 4 Air pipe 11-2...

  • Page 173: Removing Inlet Manifold

    INLET AND EXHAUST SYSTEMS 1.2 Removing inlet manifold Replace Replace Removing inlet manifold Removing sequence 1 Air inlet elbow 2 Inlet manifold 11-3...

  • Page 174: Removing Exhaust Manifold

    INLET AND EXHAUST SYSTEMS 1.3 Removing exhaust manifold Replace Removing exhaust manifold Removing sequence 1 Exhaust manifold 11-4...

  • Page 175: Disassembling, Inspecting And Reassembling Inlet And Exhaust Systems

    INLET AND EXHAUST SYSTEMS 2. Disassembling, inspecting and reassembling inlet and exhaust systems 2.1 Measuring exhaust manifold distortion (1) Check the flange for crack. (2) Check the flange surface for distortion. If the distortion Straight edge exceeds the standard, retouch the surface. Item Standard 0.2 mm...

  • Page 176: Installing Turbocharger, Inlet And Exhaust Systems

    INLET AND EXHAUST SYSTEMS 3. Installing turbocharger, inlet and exhaust systems 3.1 Installing exhaust manifold Replace 30.4 ± 2.9 N·m {3.1 ± 0.3 kgf·m} [22.4 ± 2.1 lbf·ft] (bolt only) 18.5 ± 3.5 N·m {1.9 ± 0.3 kgf·m} [13.6 ± 2.5 lbf·ft] (with spacer) Installing exhaust manifold 11-6...

  • Page 177: Installing Inlet Manifold

    INLET AND EXHAUST SYSTEMS 3.2 Installing inlet manifold Replace Replace Installing inlet manifold 11-7...

  • Page 178: Installing Turbocharger

    INLET AND EXHAUST SYSTEMS 3.3 Installing turbocharger Replace 4 ± 1 N·m {0.4 ± 0.1 kgf·m} [3 ± 0.7 lbf·ft] 16.2 ± 2.4 N·m {1.6 ± 0.2 kgf·m} [11.9 ± 1.7 lbf·ft] Replace Replace Replace Installing turbocharger 11-8...
  • Page 179 ELECTRICAL SYSTEM 1. Removing electrical system ..12-2 2.6 Inspecting and repairing alternator..12-20 1.1 Removing starter........12-2 2.6.1 Inspecting rectifier ......... 12-20 1.2 Inspection before removing alternator ... 12-3 2.6.2 Inspecting rotor assembly...... 12-20 1.2.1 Inspecting alternator operation....12-3 2.6.3 Inspecting stator ........12-21 1.2.2 Handling precaution .........12-3 2.6.4 Inspecting brushes for wear ....

  • Page 180: Removing Electrical System

    ELECTRICAL SYSTEM 1. Removing electrical system 1.1 Removing starter Removing starter Removing sequence 1 Harness 2 Nut 3 Starter 12-2...

  • Page 181: Inspection Before Removing Alternator

    ELECTRICAL SYSTEM 1.2 Inspection before removing alternator 1.2.1 Inspecting alternator operation Locate the cause of faulty charging from malfunctions described below. Do not remove the alternator for inspection and repair unless inspection cannot be performed with the alternator installed on the engine. Adjusted value of voltage regulator is high.

  • Page 182: Removing Alternator (12V-50A)

    ELECTRICAL SYSTEM 1.3 Removing alternator (12V-50A) Removing alternator (12V-50A) Removing sequence 1 Alternator 2 Adjusting plate 3 bracket 12-4...

  • Page 183: Removing Alternator (12V-75A, Option)

    ELECTRICAL SYSTEM 1.4 Removing alternator (12V-75A, option) Removing alternator (12V-75A, option) Removing sequence 1 Alternator 2 Adjusting plate 3 bracket 12-5...

  • Page 184: Removing Glow Plug

    ELECTRICAL SYSTEM 1.5 Removing glow plug Swirl chamber specification Direct injection specification Removing glow plug Removing sequence 1 Nut 2 Connection plate 3 Glow plug 12-6...

  • Page 185: Disassembling, Inspecting And Reassembling Electrical System

    ELECTRICAL SYSTEM 2. Disassembling, inspecting and reassembling electrical system 2.1 Inspection before disassembling starter 2.1.1 Inspecting magnetic switch Perform the inspection as described below. If faulty, replace the magnetic switch with a new one. Switch Do not apply current continuously for longer than 10 seconds.

  • Page 186: No Load Test

    ELECTRICAL SYSTEM 2.1.2 No load test Switch Use as thick a wire as possible and firmly tighten each Ammeter terminal. When detecting the rotation at the tip of the pinion, be careful, as the pinion pops out during operation. Battery (1) Connect the starter to the circuit as shown in the Volt meter illustration.

  • Page 187: Disassembling And Inspecting Starter

    ELECTRICAL SYSTEM 2.2 Disassembling and inspecting starter Surface clearness of commutator, Check for waer seizure, wear worn or damaged or damage. gear, and disconnection. Check for rotation Check for Replace rotation Check for slippage or seisure. Check gear for worn or damaged teeth.

  • Page 188: Removing Pinion Set

    ELECTRICAL SYSTEM 2.2.1 Removing pinion set The starter generates heat if it is left with current being applied. Remove the pinion within 10 seconds. (1) Connect the starter to the circuit as shown in the Battery illustration. (2) Turn the switches SW1 and SW2 ON to move the Disconnect lead wire with pinion out and then turn the SW2 OFF to stop the terminal, which connected...

  • Page 189: Removing Magnetic Switch

    ELECTRICAL SYSTEM 2.2.2 Removing magnetic switch Disconnect the leads, and remove the magnetic switch. Magnetic switch 2.2.3 Removing rear bracket Remove the through bolts and screws of the brush holder, and then remove the rear bracket. 2.2.4 Removing armature and yoke Rear bracket (1) Remove the armature and the yoke.

  • Page 190: Inspecting And Repairing Starter

    ELECTRICAL SYSTEM 2.3 Inspecting and repairing starter 2.3.1 Inspecting brushes for wear Measure the length of the brushes. If the measured value is Brush less than the limit, replace both the brush holder assembly and the brush assembly with new ones. Item Standard Limit...

  • Page 191: Measuring Commutator Outside Diameter12-13

    ELECTRICAL SYSTEM 2.3.5 Measuring commutator outside diameter Measure the commutator outside diameter. If the measured value is less than the limit, replace the armature with a new one. Item Nominal Limit 32 mm 31.4 mm Commutator outside diameter [1.26 in.] [1.236 in.] Measuring commutator outside diameter 2.3.6...

  • Page 192: Inspecting Field Coil

    ELECTRICAL SYSTEM (3) Check that there is continuity between segments in various combinations. If poor or no continuity is observed, replace the armature with a new one. Inspecting continuity between segment 2.3.8 Inspecting field coil (1) Check that there is no continuity between the end of the coil (brush) and the yoke.

  • Page 193: Inspecting Magnetic Switch

    ELECTRICAL SYSTEM 2.3.13 Inspecting magnetic switch Terminal B Inspect the magnetic switch for following items. Replace the magnetic switch if it is defective. (1) Open circuit of coil Check the continuity between terminal S and terminal M, also check the continuity between terminal S and Terminal S ground, If continuity is not exist, the coil is open circuit.

  • Page 194: Reassembling Starter

    ELECTRICAL SYSTEM 2.4 Reassembling starter N·m +0.2 kgf·m} +1.5 lbf·ft] Pinion shaft gear Armature rear side bearing (Apply small amount Pinion of grease, be sure not to allow entering grease into commutator.) Oil seal Pinion shaft bearing Armature shaft gear Reduction gear Magnetic switch lever thrust part Reassembling starter...

  • Page 195: Disassembling And Inspecting Alternator12-17

    ELECTRICAL SYSTEM 2.5 Disassembling and inspecting alternator Dirt, damage and seizure of Rotation slip ring, and coil resistance Crack, damage Crack, damage Rotation Short circuit and open circuit Deformation and damage Sliding state and wear of brushes Broken wire and ground of coil Disassembling and inspecting alternator Disassembling sequence 1 Nut...

  • Page 196: Separating Front Bracket From Stator

    ELECTRICAL SYSTEM 2.5.1 Separating front bracket from stator Rear bracket Do not disassemble the alternator unless the repair is necessary. Do not insert the screwdrivers too deep, as it can dam- age the stator. (1) Remove the through bolts. (2) With two flat-head screwdrivers inserted between the front bracket and stator, pry them apart.

  • Page 197: Removing Stator

    ELECTRICAL SYSTEM 2.5.5 Removing stator Unsoldering must be finished as quickly as possible. Extended heating will damage the diodes. Cut off the joint of the stator and remove the stator from the rectifier. Stator core Rectifier Soldering Removing stator 2.5.6 Removing regulator assembly Remove the screws of the regulator assembly and then Screws...

  • Page 198: Inspecting And Repairing Alternator

    ELECTRICAL SYSTEM 2.6 Inspecting and repairing alternator 2.6.1 Inspecting rectifier Trio-diodes Heat sink (-) Check that diodes in a rectifier function properly. To check, measure both negative (-) and positive (+) resistance alternately twice. If both infinite negative and infinite positive resistances are observed, the diode is open- circuited.

  • Page 199: Inspecting Stator

    ELECTRICAL SYSTEM 2.6.3 Inspecting stator (1) Checking continuity between lead wires. Check that there is continuity between a pair of lead wires. Also check that there is no continuity between a pair of lead wires and other pair of lead wires. If defective, replace the stator.

  • Page 200: Replacing Brushes

    ELECTRICAL SYSTEM 2.6.5 Replacing brushes (1) To remove the brush and the spring, unsolder the brush Soldering lead. Replacing brushes (2) To install a new brush, push the brush into the brush holder as shown in the illustration, and then solder the Brush lead to the brush.

  • Page 201: Reassembling Alternator

    ELECTRICAL SYSTEM 2.7 Reassembling alternator Reassembling alternator 2.7.1 Installing rectifier assembly and regulator assembly Regulator Install the rectifier assembly and regulator assembly on the assembly rear bracket. Regulator assembly Removing rectifier assembly and regulator assembly 12-23...

  • Page 202: Installing Stator

    ELECTRICAL SYSTEM 2.7.2 Installing stator Soldering must be finished as quickly as possible. Extended heating will damage the diodes. Install the stator and solder the leads of the stator to the rectifier. Stator core Rectifier Soldering Installing stator 2.7.3 Installing front bearing Drive the front bearing into the front bracket and secure the Front Screw Front bearing...

  • Page 203: Assembling Stator And Front Bracket

    ELECTRICAL SYSTEM 2.7.6 Assembling stator and front bracket (1) When installing the rotor into the rear bracket, lift the Rear bracket brushes with a piece of wire inserted through the small hole in the bracket. After installation, remove the wire. Brush Wire Securing brushes...

  • Page 204: Heating Test Of Glow Plug

    ELECTRICAL SYSTEM 2.8 Heating test of glow plug Connect the wiring to the terminal, and ground the body. If the glow plug heats red, it is normal. Rated voltage - Item Temperature Armature current 800°C [1472°F] 10.5 ± 0.1 V - 9.7 ± 1.0 A Swirl (When applying the (When applying...

  • Page 205: Inspecting Magnetic Valve (Stop Solenoid, Distributor-Type)

    ELECTRICAL SYSTEM 2.10 Inspecting magnetic valve (stop solenoid, distributor-type) 2.10.1 Continuity test of magnetic valve (stop solenoid) Inspect the continuity between the terminal and body as shown in the illustration. If there is no continuity or if the resistance is lower than the standard value, replace the magnetic valve assembly with new one.

  • Page 206: Installing Stop Solenoid (Run-On Type, For In-Line Pump Type)

    ELECTRICAL SYSTEM 2.12 Installing stop solenoid (RUN-ON type, for in-line pump type) (1) Install the solenoid bracket to the flywheel housing. Install the stop solenoid to the solenoid bracket. L joint Stop (2) With placing the stop lever of the fuel injection pump solenoid on the operating position (fully pulled), install the L joint, the rod and the nut, and connect the stop lever and...

  • Page 207: Installing Electrical System

    ELECTRICAL SYSTEM 3. Installing electrical system 3.1 Installing glow plug Swirl chamber specification Direct injection specification 1.3 ± 0.3 N·m 1.3 ± 0.3 N·m {0.13 ± 0.03 kgf·m} {0.13 ± 0.03 kgf·m} [0.96 ± 0.22 lbf·ft] [0.96 ± 0.22 lbf·ft] 17.2 ±...

  • Page 208: Installing Alternator (12V-50A)

    ELECTRICAL SYSTEM 3.2 Installing alternator (12V-50A) Installing alternator (12V-50A) 12-30...

  • Page 209: Installing Alternator (12V-75A, Option)

    ELECTRICAL SYSTEM 3.3 Installing alternator (12V-75A, option) Installing alternator (12V-75A, option) 12-31...

  • Page 210: Installing Starter

    ELECTRICAL SYSTEM 3.4 Installing starter Terminal B N·m +0.2 kgf·n} +1.5 lbf·ft] Installing starter 12-32...
  • Page 211 ADJUSTMENT AND OPERATION 1. Adjusting engine......13-2 1.1 Inspecting and adjusting valve clearance13-2 1.1.1 Inspecting valve clearance .......13-2 1.1.2 Adjusting valve clearance ......13-2 1.2 Draining fuel system ......13-3 1.2.1 Draining fuel filter ........13-3 1.3 Bleeding fuel system......13-4 1.3.1 Bleeding fuel filter (in-line fuel injection pump) ......13-4 1.3.2 Bleeding fuel injection pump (in-line fuel injection pump) ......13-4...

  • Page 212: Adjusting Engine

    ADJUSTMENT AND OPERATION 1. Adjusting engine 1.1 Inspecting and adjusting valve clearance Inspect and adjust the valve clearance when the engine is Firing order cold. (cylinder No.): 1-3-4-2 Turning angle: Item Standard 180° Inlet Valve clearance 0.25 mm [0.0098 in.] (when engine is cold) Exhaust 1.1.1...

  • Page 213: Draining Fuel System

    ADJUSTMENT AND OPERATION 1.2 Draining fuel system (a) When draining the fuel filter, fuel flows out together with the water. Wipe off spilled fuel thoroughly. Spilled fuel cause a fire. (b) Tighten the drain plug securely after draining water otherwise fuel may leak, and it will lead to a fire.

  • Page 214: Bleeding Fuel System

    ADJUSTMENT AND OPERATION 1.3 Bleeding fuel system Completely wipe off any spilled fuel from the air vent plug with a cloth, and be sure to tighten the air vent plug after air bleeding. Failure to do so could cause a fire.

  • Page 215: (Distributor-Type Fuel Injection Pump)

    ADJUSTMENT AND OPERATION 1.3.3 Bleeding fuel filter (distributor-type fuel injection pump) (1) Loosen the air vent plug of the fuel filter with a wrench. (2) Repeatedly press the priming pump with the cloth applied to the air vent plug. (3) When fuel with air bubbles no longer comes out, tighten the air vent plug securely.

  • Page 216: Inspecting V-Belt And Adjusting V-Belt Tension

    ADJUSTMENT AND OPERATION 1.4 Inspecting V-belt and adjusting V-belt tension (a) If defects such as cuts or surface separations are found during inspection, replace the V-belt. (b) Keep oil and grease away from the V-belt, since they may cause the V-belt to slip and shorten the service life. (c) Excessive V-belt tension can cause rapid wear of the alternator bearing and shorten the service life of the V- belt.

  • Page 217: Break-In Operation

    ADJUSTMENT AND OPERATION 2. Break-in operation 2.3 Break-in operation time After the engine is overhauled, couple the engine to the dynamometer, and run the engine for break-in operation and The relationship between the load in break-in operation and inspection. the operation time is as shown below. 2.1 Starting up Break-in operation time (1) Before starting the engine, check the levels of coolant,...

  • Page 218: Performance Test (Jis Standard)

    ADJUSTMENT AND OPERATION 3. Performance test (JIS standard) The following describes the procedures specified in "Earth moving machinery - Engines - Part 1: Test code of net power (JIS D0006-1)" and "Earth moving machinery - Engines - Part 2: Standard format of specifications and testing methods of diesel engines (JIS D0006-2)."...

  • Page 219: Calculation Of Corrected Power

    ADJUSTMENT AND OPERATION 3.4.2 Calculation of corrected power Multiply the measured brake power or torque by the calculated diesel engine correction factor to obtain a corrected value. If the applicable range of the correction formula is exceeded, indicate the corrected values and record the test conditions on the test record.

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