Table of Contents
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Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.
Ingersoll-Rand
Portable Power
P.O. Box 868 – 501 Sanford Ave
Mocksville, N.C. 27028
Revised (10-12)
Ingersoll-Rand Engine
Workshop Manual
Model Series
3IRH2N 3IRH8N
4IRH8N 4IRI8N
4IRI8T
1
P/N 22333660 (8/03)
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Table of Contents
Troubleshooting
Related Manuals for Ingersoll-Rand 3IRH8N
Summarization of Contents
Safety Precautions
2. Work – Wear (Garments)
Outlines safety precautions regarding appropriate clothing and personal protective equipment.
3. Tools
Provides guidelines for safe and correct use of tools, including lifting and handling.
4. Genuine Parts and Materials
Emphasizes the importance of using genuine Ingersoll-Rand parts for engine longevity.
5. Fastener Torque
Advises on following specified torque values and procedures for fasteners.
6. Electrical
Covers safety precautions related to electrical systems, including short circuits and battery handling.
7. Waste Management
Provides instructions for the safe and environmentally responsible disposal of waste materials.
8. Further Precautions
Details additional safety precautions for fueling, hot surfaces, and rotating parts.
Precautions for Service Work
1. Precautions for Safety
Reiterates the importance of reading and following all safety precautions.
2. Preparation for Service Work
Details necessary preparations for efficient and accurate service, including checking records.
3. Preparation before Disassembly
Lists required tools, materials, and preparation steps before commencing disassembly.
4. Precautions in Disassembly
Provides guidelines for inspecting, organizing, and cleaning parts during disassembly.
5. Precautions for Inspection and Measurement
Specifies precautions for inspecting and measuring parts to determine reusability.
6. Precautions for Reassembly
Covers correct assembly procedures, including part order, torque, and lubrication.
7. Precautions for Adjustment and Check
Details using measuring instruments for adjustment to specified service standards.
How to Read this Manual
1. Range of Operation Explanation
Describes the scope of procedures covered, from troubleshooting to adjustment operations.
2. How to Read the Explanations
Explains the use of exploded views, diagrams, and procedural steps for clarity.
3. Definition of Terms
Defines key terms and abbreviations used throughout the manual for precise understanding.
Abbreviations
Lists common abbreviations and their meanings for quick reference.
1. General
1.1 Engine Nomenclature
Explains the meaning of the alphanumeric designation used for engine models.
1.2 Specifications
Details engine specifications, including rating conditions and operational parameters.
1.3 Engine Model Specifications
1.3 3IRH2N
Presents detailed specifications for the 3IRH2N engine model, including dimensions and capacities.
1.3 3IRH8N
Presents detailed specifications for the 3IRH8N engine model, including dimensions and capacities.
1.3 4IRH8N
Presents detailed specifications for the 4IRH8N engine model, including dimensions and capacities.
1.3 4IRI8N
Presents detailed specifications for the 4IRI8N engine model, including dimensions and capacities.
1.3 4IRI8T
Presents detailed specifications for the 4IRI8T engine model, including dimensions and capacities.
1.3 Fuel Oil, Lubricating Oil and Cooling Water
1.3.1 Fuel Oil
Specifies selection criteria, handling, and storage for diesel fuel oil.
1.3.2 Lubricating Oil
Outlines engine oil selection, API classification, viscosity, and handling guidelines.
1.3.3 Cooling Water
Covers the use of clean water, antifreeze, mixing ratios, and replacement frequency for cooling systems.
1.6 Exhaust Gas Emission Regulation
1.6.1 The Emission Standard in USA
Presents EPA non-road diesel engine emission standards by engine power and model year.
1.6.2 Engine Identification
Shows examples of emission control labels for US EPA and both EPA and ARB.
1.6.3 Guarantee Conditions for the EPA Emission Standard
Specifies conditions related to engine installation and maintenance for EPA emission standards.
4. Perform Maintenance Without Fail
Emphasizes the necessity of performing maintenance as scheduled.
5. Maintenance Period and Quality Guarantee Period for Exhaust Emission Related Parts
Outlines maintenance and quality guarantee periods for parts related to exhaust emissions.
2. Inspection and Adjustment
2.1 Periodic Maintenance Schedule
Presents a table outlining periodic inspection and maintenance intervals based on hours or months.
2.2 Periodic Inspection and Maintenance Procedure
Details procedures for daily checks, including visual inspection, refueling, and fluid level checks.
2.2.1 Check before Daily Operation
Outlines daily inspection points before starting the engine for safe operation.
b. Replenishing Oil Pan with Engine Oil
Instructs on how to check and replenish engine oil, with important notices on overfilling.
4. Cooling Water Inspection
Details daily inspection procedures for cooling water levels in the sub-tank and radiator.
5. Checking Accelerator Operation
Describes how to check and adjust the accelerator for smooth operation.
6. Checking Alarm Operation
Emphasizes checking alarm functions for engine oil and cooling water warnings.
2.2.2 Inspection after Initial 50 Hours Operation
Specifies inspection items after the initial 50 hours of operation and subsequently every 250 hours.
a. Drain Engine Oil
Provides steps for draining engine oil and preparing for filter replacement.
b. Replacing Oil Filter
Details the procedure for removing and installing a new engine oil filter, including tightening torque.
c. Filling Oil and Inspection
Instructs on filling new engine oil to the correct level and checking for leaks.
2. Checking and Adjusting Radiator Fan V-belt
Explains how to check and adjust V-belt tension and visually inspect the belt for wear.
2.2.3 Inspection Every 50 Hours
Outlines inspection tasks to be performed every 50 hours of operation, including fuel tank draining and oil/water separator draining.
3. Bleeding the Fuel System
Details the procedure for bleeding air from the fuel system to ensure proper pump function.
4. Battery Inspection
Covers battery inspection, focusing on electrical safety and proper ventilation.
1. Electrolyte Level
Describes how to check and maintain the battery's electrolyte level for optimal performance.
2. Battery Charge
Explains how to check battery charge using a tester or hydrometer.
b. Measurement with Hydrometer
Details how to measure specific gravity and correct it based on temperature.
c. Specific Gravity and Remaining Battery Charge
Provides a table correlating specific gravity readings with remaining battery charge.
d. Terminals
Instructs on cleaning corroded or soiled battery terminals.
e. Mounting Bracket
Covers inspection and tightening of the battery mounting bracket.
f. Battery Appearance
Advises on replacing the battery if it is cracked or deformed.
2.2.4 Inspection Every 250 Hours or 3 Months
Specifies inspection and replacement tasks for every 250 hours or 3 months, whichever comes first.
1. Oil and Filter Replacement
Details oil and filter replacement procedures for the second and subsequent intervals.
2. Inspection and Cleaning of Radiator Fin
Explains how to inspect and clean radiator fins to maintain cooling performance.
3. Adjustment of Governor Lever and Accelerator Device
Covers the procedure for checking and adjusting the governor lever and accelerator linkage.
4. Air Cleaner Element Cleaning
Provides instructions for cleaning the air cleaner element to maintain engine performance.
5. Fan Belt Tension Inspection and Adjustment
Details how to inspect and adjust the fan belt tension, referring to previous section.
2.2.5 Inspection Every 500 Hours or 6 Months
Outlines inspection and replacement tasks to be performed every 500 hours or 6 months.
1. Air Cleaner Element Replacement
Instructs on replacing the air cleaner element, including considerations for dual-element systems.
2. Fuel Filter Replacement
Details the procedure for replacing the fuel filter at specified intervals.
3. Cleaning Oil/Water Separator
Explains how to periodically wash the oil/water separator element and inside cup.
3. Cleaning Oil/Water Separator
Provides detailed steps for cleaning the oil/water separator element and cup.
2.2.6 Inspection Every 1,000 Hours or One Year
Specifies inspection and maintenance tasks for every 1,000 hours or one year.
1. Replacing Cooling Water
Details the procedure for replacing the cooling water to prevent rust and scale buildup.
2. Washing Turbocharger Blower
Explains the procedure for washing the turbocharger blower to address sluggish engine speed or poor exhaust color.
3. Inspection and Adjustment: Injection Pressure and Spray Pattern of Fuel Injection Valve
Covers the inspection and adjustment of fuel injection pressure and spray pattern.
b. Spray Pattern Inspection
Details how to inspect the spray pattern and seat oil-tightness of the fuel injection valve.
c. Nozzle Valve Sliding Test
Describes the procedure for testing the nozzle valve's sliding action for proper function.
d. Nozzle Punch Mark
Illustrates the meaning of nozzle punch marks for identification.
4. Valve Clearance
Explains how to measure and adjust valve clearance for both 2-valve and 4-valve cylinder heads.
a. Valve Clearance Measurement
Details the steps for measuring valve clearance, including setting the engine to TDC.
b. Valve Clearance Inspection and Adjustment
Provides instructions for loosening adjusting bolts and checking valve inclination or damage.
b. Valve Clearance Inspection and Adjustment
Details measuring valve clearance and adjusting screws, with specific notes for 4-valve heads.
4. Adjusting Other Cylinders
Explains the procedure for adjusting valve clearance on other cylinders after the initial setup.
2.2.7 Inspection Every 2000 Hours or 2 Years
Specifies inspection and maintenance tasks for every 2000 hours or 2 years.
1. Cleaning of Cooling Water System, Inspection of Parts and Maintenance
Covers cleaning and maintenance of cooling system parts to ensure efficient cooling.
2. Inspection and Replacement of Fuel Pipe and Cooling Water Pipe
Details regular checks and replacement of fuel and cooling water pipes to prevent leaks.
3. Lapping the Intake and Exhaust Valves
Explains the necessity of lapping valves for proper contact with seats.
4. Fuel Injection Timing Inspection and Adjustment
Covers the inspection and adjustment of fuel injection timing for optimal engine performance.
a. Positioning of the Piston
Describes how to position the piston at TDC for fuel injection timing adjustments.
b. Adjustment of Fuel Injection Angle (Positioning of Fuel Pump)
Details the procedure for adjusting the fuel injection pump angle based on recorded values.
c. Tighten the Installation Nut of a Pump Drive Gear
Specifies the tightening torque for the fuel pump drive gear installation nut.
2.4 Sensor Inspection
2.4.1 Oil Pressure Switch
Explains how to test the oil pressure switch for continuity.
2.4.2 Thermo Switch
Describes how to test the thermo switch for proper operation at specified temperatures.
2.5 Water Leak Check in Cooling Water System
Outlines the procedure for checking the cooling water system for leaks using a pressure tester.
3. Troubleshooting
3.1 Preparation before Troubleshooting
Outlines essential steps for preparing to troubleshoot, including gathering information and understanding the symptoms.
3.2 Quick Reference Table for Troubleshooting
Summarizes common trouble symptoms, their causes, and corrective actions in a quick reference table.
3.3 Troubleshooting by Measuring Compression Pressure
Details the process of measuring compression pressure to diagnose engine issues like starting failure.
4. Disassembly, Inspection and Reassembly of Engines
4.1 Complete Disassembly and Reassembly
Covers the overall process of engine disassembly and reassembly, including preparation and precautions.
4.1.1 Introduction
Prepares the user for engine inspection and service by outlining necessary steps and safety warnings.
4.1.2 Special Service Tools
Lists and illustrates special tools required for specific engine disassembly and assembly tasks.
4.1.2 Special Service Tools
Lists and illustrates specialized tools for stem seal insertion, filter wrench, and camshaft bushing.
4.1.2 Special Service Tools
Lists and illustrates specialized tools for piston insertion and piston ring replacement.
10. Measuring Instruments
Lists and describes various measuring instruments used for engine inspection and measurement.
10. Measuring Instruments
Lists and describes measuring instruments such as torque wrenches, cap testers, and digital thermometers.
10. Measuring Instruments
Lists and describes measuring instruments like speedometers, circuit testers, and compression gauge kits.
4.1.3 Complete Disassembly
Details the step-by-step procedure for completely disassembling the engine, noting remarks for each step.
4.1.3 Complete Disassembly
Continues the disassembly procedure, covering cooling water system, cylinder head, and crankshaft pulley removal.
4.1.3 Complete Disassembly
Continues the disassembly procedure, covering lubricating oil pump, flywheel, and gear case removal.
4.1.3 Complete Disassembly
Continues the disassembly procedure, covering main bearing caps, crankshaft, and connecting rod removal.
4.1.4 Precautions before and during Reassembly
Provides crucial precautions for cleaning components and replacing parts during reassembly.
4.1.5 Adjusting Operation
Instructs to perform adjusting operations after completing the engine reassembly.
4.2 Cylinder Head: Disassembly, Inspection and Reassembly
4.2.1 Components (2-Valve Cylinder Head)
Illustrates and lists the components of the 2-valve cylinder head assembly.
4.2.2 Disassembly Procedure
Provides a step-by-step guide for disassembling the cylinder head assembly, referencing numbered illustrations.
4.2.3 Reassembly Procedure
States that reassembly is performed in the reverse order of disassembly.
4.2.4 Servicing Points
Highlights specific points and precautions during the disassembly and reassembly of the cylinder head components.
4.2.4 Servicing Points
Covers servicing points for the thermostat, fuel filter, oil filter, and bonnet assembly.
4.2.4 Servicing Points
Details servicing points for push rods, cylinder head bolts, and fuel injection valves.
4.2.4 Servicing Points
Explains the procedure for removing and installing intake/exhaust valves, including stem seals and valve springs.
4.2.5 Parts Inspection and Measurement
Provides detailed procedures for inspecting and measuring cylinder head components like combustion surface and valve sink.
14. Valve Guide
Covers inspection of valve guides for damage and wear, and provides service part codes.
Valve Stem Clearance
Lists standard and limit values for valve stem clearance for different engine models.
15. Intake/Exhaust Valve
Details cleaning and checking of intake/exhaust valves, including seat contact and head thickness.
16. Valve Spring
Instructs on inspecting valve springs for damage and corrosion.
17. Valve Rocker Arm
Covers inspection of valve rocker arms for contact surface, defects, and wear.
18. Rocker Arm Shaft
Details inspection of the rocker arm shaft for seizure and wear.
19. Push Rod
Covers inspection of the push rod for surface contact and bend limit.
20. Valve Clearance Adjusting Screw
Instructs on inspecting the surface of the valve clearance adjusting screw.
21. Rocker Arm Spring
Covers inspection of rocker arm springs for defects and corrosion.
4.3 Gear Train and Camshaft
4.3.1 Components
Illustrates and lists the components of the gear train and camshaft assembly.
4.3.2 Disassembly Procedure
Provides a step-by-step guide for disassembling the gear train and camshaft assembly.
4.3.3 Reassembly Procedure
States that reassembly is performed in the reverse order of disassembly.
4.3.4 Servicing Points
Highlights specific points and precautions during the disassembly and reassembly of the crankshaft pulley and gear case cover.
4.3.4 Servicing Points
Covers servicing points for the fuel injection pump drive gear, flywheel, and camshaft side gap measurement.
4.3.4 Servicing Points
Details servicing points for camshaft gear extraction and gear case installation.
4.3.5 Parts Inspection and Measurement
Provides procedures for inspecting and measuring camshaft components, including shaft bend and cam height.
4.3.5 Parts Inspection and Measurement
Details inspection and measurement of idle gear and PTO drive gear for wear and damage.
4.3.6 Oil Seal Replacement
Explains how to replace oil seals, emphasizing proper lubrication and tool usage.
4.3.7 Camshaft Bushing Replacement
Details how to replace camshaft bushings using special service tools.
4.4 Cylinder Block
4.4.1 Components
Illustrates and lists the components of the cylinder block assembly.
4.4.2 Disassembly Procedure
Provides a step-by-step guide for disassembling the cylinder block assembly.
4.4.3 Reassembly Procedure
States that reassembly is performed in the reverse order of disassembly.
4.4.4 Servicing Points
Highlights servicing points for the oil pan and piston/connecting rod assembly, including rod bolt torque.
4.4.4 Servicing Points
Details servicing points for the mounting flange and journal bearing caps, including side gap measurement.
4.4.4 Servicing Points
Covers servicing points for main bearing caps, including tightening torque and bearing metal identification.
Point 5: Crankshaft
Details the procedure for removing the crankshaft, emphasizing safety and careful handling.
Point 6: Piston Pin and Rings
Explains the removal and installation of piston pins and rings, including piston orientation.
Point 7: Oil Seal
Instructs on replacing oil seals with new ones and applying lubricant during assembly.
4.4.5 Parts Inspection and Measurement
Provides detailed procedures for inspecting and measuring cylinder block components like cylinder bores and roundness.
c. If the limit is exceeded or any surface defect is found, repair by boring and honing.
Details procedures for repairing cylinder bores by boring and honing, including using oversized parts.
26. Crankshaft
Covers inspection of the crankshaft for seizure, wear, bend, and measurements of crankpin and journal.
26. Crankshaft
Lists standard and limit dimensions for crankpin and journal outside diameters, metal thickness, and oil clearance.
26. Crankshaft
Provides standard and limit dimensions for crankshaft journal outside diameters, metal thickness, and oil clearance.
27. Thrust Metal Inspection
Details inspection of thrust metals for damage, wear, side gap, and thickness.
28. Piston
Covers inspection of pistons for outside diameter, pin hole measurement, and clearance.
c. Piston Ring, Ring Groove and End Clearance Measurement
Explains how to measure piston ring groove width, ring width, side clearance, and end clearance.
Piston Ring Dimension
Lists standard and limit dimensions for piston ring groove width, ring width, side clearance, and end clearance for different models.
29. Connecting Rod
Details inspection of connecting rods for appearance, twist, parallelism, and small end measurements.
d. Rod Big End Measurement
Explains how to measure the rod big end, including crankpin and bushing dimensions.
30. Tappet
Covers inspection of tappets for contact surface and outside diameter measurement.
4.4.6 Cylinder Bore Correction
Details procedures for correcting cylinder bores using honing, including required tools and fluids.
4.4.7 Piston Pin Bushing Replacement
Explains how to replace piston pin bushings using special service tools.
4.4.8 Oil Seal Replacement
Details the procedure for replacing oil seals, including lubrication and tool usage.
5. Lubrication System
5.1 Lubrication System Diagram
Illustrates the flow of lubricating oil through the engine's system, including key components.
5.2 Trochoid Pump Components
Illustrates the components of the trochoid oil pump for different engine models.
5.3 Disassembly(Reverse the Procedure Below for Assembly)
Details the step-by-step procedure for disassembling the trochoid oil pump.
5.4 Servicing Points
Highlights specific points and precautions during the disassembly and reassembly of the trochoid oil pump.
5.5 Parts Inspection and Measurement
Provides procedures for inspecting and measuring trochoid pump components, including clearances.
5.5.1 Trochoid Pump Inspection and Measurement
Details the measurement of outer rotor clearances and inner rotor clearances for the trochoid pump.
5.5.1 Trochoid Pump Inspection and Measurement
Covers the measurement of rotor shaft clearance for the trochoid pump.
6. Cooling System
6.1 Cooling Water System
Illustrates the engine's cooling water system, showing the flow path and main components.
6.2 Cooling Water Pump Components
Illustrates the components of the cooling water pump assembly.
6.3 Disassembly (Reverse the Procedure Below for Assembly)
Details the step-by-step procedure for disassembling the cooling water pump and thermostat.
6.4 Servicing Points
Highlights specific points and precautions during the disassembly and reassembly of the cooling water pump and thermostat.
7. Fuel Injection Pump/Governor
7.1 Introduction
Introduces the MP fuel injection pump, its importance, and precision requirements.
7.2 Fuel Injection Pump
Provides an overview of the fuel injection pump and its associated system.
7.2.1 Fuel System Diagram
Illustrates the engine's fuel system, showing the flow path from the tank to the injection pump.
7.2.2 External View and Components
Illustrates the external view and components of the fuel injection pump assembly.
7.2.3 Disassembly Procedure
Provides a step-by-step guide for disassembling the fuel injection pump from the engine body.
7.2.4 Assembly Procedure
States that assembly is performed in the reverse order of disassembly.
7.2.5 Servicing Points
Highlights specific points and precautions during the disassembly and reassembly of the fuel injection pump.
7.2.5 Servicing Points
Details servicing points for installing the fuel injection pump, including the fuel pump spacer.
8. Turbocharger: Disassembly, Inspection and Reassembly
8.1 Structure and Functions
Explains the basic structure and functions of the turbocharger, including main specifications.
8.1.1 Main Specifications
Lists key specifications for different turbocharger models, such as applicable engines and maximum speeds.
8.1.2 Construction
Illustrates the construction of the turbocharger, showing numbered components.
8.1.3 Structural and Functional Outline
Describes the structure and function of individual turbocharger parts, including turbine, compressor, and waste gate.
8.1.4 Components
Provides a detailed list and illustration of all turbocharger components.
8.2 Service Standards and Tightening Torque
Lists service standards and tightening torques for turbocharger components.
8.2.1 Service Standards
Provides detailed dimensional standards and wear limits for various turbocharger parts.
8.2.1 Service Standards
Lists dimensional standards and wear limits for RHB31/RHB51 turbocharger types.
8.2.2 Tightening Torque
Specifies tightening torques for various bolts and nuts used in the RHF5 and RHB31/RHB51 turbocharger types.
8.3 Periodic Inspection Procedure
Outlines periodic inspection intervals for turbochargers based on application and operating conditions.
8.3.1 Periodic Inspection Intervals
Presents a table of recommended inspection intervals for turbochargers in different applications.
8.3.2 Inspection Procedure
Details procedures for inspecting rotor rotation and rotor play in the turbocharger.
8.3.3 Waste Gate Valve Adjustment Procedure
Explains the procedure for adjusting the waste gate valve opening pressure and lift.
8.3.3 Waste Gate Valve Adjustment Procedure
Details the method for checking waste gate valve opening pressure and lift, including required equipment and precautions.
8.4 Disassembly Procedure
Lists special tools required for turbocharger disassembly and reassembly.
8.4.1 Preparation for Disassembly
Details the preparation steps and special tools needed for turbocharger disassembly.
8.4.2 Inspection before Disassembly
Covers inspection of turbocharger parts before disassembly, including rotor play and smooth rotation.
8.4.3 Disassembly
Details the step-by-step procedures for disassembling the turbocharger, starting with the compressor housing.
8.4.3 Disassembly
Continues the disassembly procedure, covering floating bearing and seal ring removal.
8.5 Washing and Inspection Procedure
Provides procedures for washing and inspecting turbocharger components.
8.5.1 Washing
Details the inspection points before washing and the step-by-step washing procedure for various turbocharger parts.
8.5.2 Inspection Procedure
Covers inspection of compressor housing, turbine housing, compressor impeller, and turbine shaft.
8.5.2 Inspection Procedure
Details inspection of thrust bushing, oil thrower, thrust bearing, and floating bearing.
8.5.2 Inspection Procedure
Covers inspection of bearing housing, seal plate, and seal rings for defects and wear.
8.6 Reassembly Procedure
Provides instructions for reassembling the turbocharger, including preparation and installation of bearings and shafts.
8.6.1 Preparation for Reassembly
Lists parts that must be replaced with new ones during turbocharger reassembly.
8.6.2 Reassembly
Details the installation procedures for floating bearings and the turbine shaft.
8.6.2 Reassembly
Covers the installation procedures for the thrust bearing and seal plate, including tightening torques.
8.6.2 Reassembly
Details the installation procedures for the compressor impeller, turbine housing, and compressor housing.
75. Rotor Play Measurement
Instructs to perform rotor play measurement after reassembly and provides service standards.
8.7 Handling after Disassembly and Reassembly
Provides instructions for handling the turbocharger after installation, emphasizing foreign matter prevention.
8.7.1 Instructions for Turbocharger Installation
Details installation instructions for the turbocharger's lubrication, intake, and exhaust systems.
8.8 Troubleshooting
Provides troubleshooting guidance for common turbocharger faults, such as excessive exhaust smoke.
8.8.1 Excessively Exhaust Smoke
Addresses causes and corrective actions for excessive exhaust smoke, including intake air volume issues.
8.8.3 Sudden Oil Decrease
Addresses sudden oil decrease issues, linking them to bearing wear or seal damage.
8.8.4 Decrease in Output
Addresses causes for decreased turbocharger output, such as air leaks or clogged elements.
8.8.5 Poor (Slow) Response (Starting) of Turbocharger
Addresses causes for poor turbocharger response, like carbon deposits or incomplete combustion.
8.8.6 Abnormal Sound or Vibration
Addresses abnormal sound generation and vibration issues related to the turbocharger.
9. Service Standards
9.1 Engine Tuning
Provides service standards for engine tuning parameters like valve clearance, belt tension, and fuel injection.
9.2 Engine Body
Lists service standards for engine body components, focusing on the cylinder head.
9.2.1 Cylinder Head
Provides service standards for cylinder head distortion, valve sink, and valve seat angles.
2. Intake/Exhaust Valve and Guide
Lists service standards for intake/exhaust valve and guide dimensions, including clearance.
81. Valve Spring
Provides service standards for valve spring free length and inclination.
82. Rocker Arm and Shaft
Lists service standards for rocker arm and shaft dimensions, including hole diameter and clearance.
83. Push Rod
Provides service standards for push rod bend.
9.2.2 Gear Train and Camshaft
Lists service standards for the camshaft, including side gap, bending, cam height, and shaft dimensions.
2. Idle Gear Shaft and Bushing
Provides service standards for the idle gear shaft and bushing, including shaft diameter and clearance.
3. Backlash of Each Gear
Lists service standards for the backlash of various gears in the gear train.
9.2.3 Cylinder Block
Provides service standards for the cylinder block, including bore diameter and roundness.
2. Crankshaft
Lists service standards for the crankshaft, including pin and journal dimensions and clearances.
3. Thrust Bearing
Provides service standards for the crankshaft side gap of the thrust bearing.
4. Piston and Ring
Lists service standards for piston outside diameter, piston pin dimensions, and clearances.
Piston Ring
Lists standard and limit dimensions for piston ring groove width, ring width, side clearance, and end clearance.
5. Connecting Rod
Provides service standards for connecting rod thrust clearance and small end dimensions.
84. Tappet
Lists service standards for tappet hole and stem dimensions, and clearance.
9.3 Lubricating Oil System (Trochoid Pump)
Lists service standards for the lubricating oil system, specifically the trochoid pump.
9.3.1 Outside Clearance of Outer Rotor
Provides standard and limit values for the outside clearance of the trochoid pump's outer rotor.
9.3.2 Side Clearance of Outer Rotor
Provides standard and limit values for the side clearance of the trochoid pump's outer rotor.
9.3.3 Inside Clearance of Inner Rotor
Provides standard and limit values for the inside clearance of the trochoid pump's inner rotor.
9.3.4 Rotor Shaft Clearance
Provides standard and limit values for the rotor shaft clearance in the trochoid pump.
10. Tightening Torque for Bolts and Nuts
10.1 Tightening Torques for Main Bolts and Nuts
Details tightening torques for critical bolts like cylinder head, connecting rod, and flywheel bolts.
10.2 Tightening Torques for Standard Bolts and Nuts
Lists tightening torques for standard bolts and nuts, including hexagon bolts and PT plugs.
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