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Mitsubishi diesel engines Service Manual

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FOREWORD
This service manual describes the specifications as well as the maintenance and
adjustment procedures for Mitsubishi diesel engines. This manual also includes the
detailed information on basic and special tools as the need arises.
The Mitsubishi diesel engines can offer highly efficient and reliable performance for
many years to come, which, however, only can be achieved through the proper
handling and the periodical inspection/maintenance work exercised in according to
the procedures of disassembly, inspection/adjustment and reassembly described in this
manual.
Before attempting any work on your engine, thoroughly read this manual to
familiarize with the engine and the required procedures of the work.
All information contained in this manual is based on the engine produced at the time
of publication and is subject to change as the engine improved without notice.
Pub. No. 99619-12140

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Table of Contents

   Summary of Contents for Mitsubishi diesel engines

  • Page 1 Mitsubishi diesel engines. This manual also includes the detailed information on basic and special tools as the need arises. The Mitsubishi diesel engines can offer highly efficient and reliable performance for many years to come, which, however, only can be achieved through the proper...
  • Page 2: How To Use This Manual

    HOW TO USE THIS MANUAL This Service Manual describes the specifications of Mitsubishi diesel engines (land and standard applications) and relevant service standards, as well as the procedures for servicing the engines such as for disassembly, inspection, repair and reassembly. This manual is divided into Groups. Each Group covers a specific area of the engine.
  • Page 3 2. Terms Nominal value ······This is the nominal dimension of the part being measured. Standard value ······This is the dimension of the individual part being measured, the clearance between the parts in question, or the standard performance in question. Standard values have been arranged within the range appropriate for the inspection being carried out, and are not necessarily the design values.
  • Page 4: Table Of Contents

    GENERAL CONTENTS Group No. Group Name Page SAFETY CAUTIONS 0 - 1 GENERAL 1 - 1 SERVICE STANDARDS 1 -11 TOOLS LIST 1 -21 OVERHAUL TIMING 1 -25 REMOVAL PREPARATIONS 1 -29 ENGINE MAIN PARTS - DISASSEMBLY 2 - 1 ENGINE MAIN PARTS - INSPECTION AND Engine Main Parts 2 -17...
  • Page 6: Safety Cautions 0

    SAFETY CAUTIONS ····························0-5 Warning Risk of fire and explosion ···0-2 • œ Handle LLC with care ······························0-2 • œ Never use open fire • œ Lawful disposal of waste oil and ··········0-2 ···············································0-5 • œ Keep things tidy around the engine coolant •...
  • Page 7: Warning Risk Of Fire And Explosion

    SAFETY CAUTIONS Warning Risk of fire and explosion • œ Never use open fire • œ Pay attention to fuel and oil leakage When topping up or replacing fuel If leakage of fuel or oil is found, immediately take or engine oil, or cleaning parts in measures to stop it.
  • Page 8: Warning Risk Of Entanglement Into

    SAFETY CAUTIONS Warning Risk of entanglement into the machine • œ Keep guards on the rotating parts • œ Lockout/tagout Ensure that all guards are correctly Perform lockout/tagout before carrying out any installed over the rotating parts of inspection/service. the engine. Damaged or loose Lockout/tagout is an ideal way of disconnecting the guards should be repaired.
  • Page 9: Warning Risk Of Burn

    SAFETY CAUTIONS Warning Risk of burn Warning Exhaust gas is • œ Do not touch the engine while it is poisonous running or for a while after it is • œ Ensure good ventilation while the stopped engine is running Never touch any part of the engine If the engine is installed inside a while it is running or for a while after...
  • Page 10: Warning Beware Of Falling Engine

    SAFETY CAUTIONS Warning Beware of Caution Use correct falling engine engine oil and LLC • œ Exercise caution when lifting the • œ Only use the specified fuel, engine oil engine and coolant (LLC) The wire rope used to lift the engine Only use the fuel, engine oil and coolant (LLC) that should have...
  • Page 11: Caution Handling Of Battery

    SAFETY CAUTIONS Caution Handling of Caution How to handle battery emergencies • œ Handle the battery with care • œ Engine overheat - Idle to cool down, then stop the engine • E Batteries emit hydrogen oxygen gases, both of which are In the event of engine overheat, do not stop the flammable.
  • Page 12: Caution Other Considerations

    SAFETY CAUTIONS Caution Other considerations • œ Never alter or modify the engine • œ Warming up the engine Altering or modifying the engine in any way will Before starting work, warm up the engine by nullify the warranty. running it at low idle for 5 to 10 minutes. A modified engine may not only break but also lead Warming up the engine will not only smoothen the to injury.
  • Page 13: Air Cleaner Maintenance Precautions

    SAFETY CAUTIONS • œ Air cleaner maintenance precautions • œ Use appropriate tools when carrying out service Wear of engine parts is accelerated largely by the dust contained in the intake air. Worn engine parts When carrying out any service, use appropriate tools will lead to various problems such as increased oil and in correct ways.
  • Page 14 GENERAL 1. Overview ····························································································· 1 - 2 ··················································································· 1 - 2 1.1 Outline Drawing ········································································ 1 - 4 1.2 Fuel System Schematic ··········································································· 1 - 4 1.3 Oil System Schematic ···································································· 1 - 5 1.4 Cooling System Schematic ··························································· 1 - 5 1.5 Inlet / Exhaust System Schematic ···········································································...
  • Page 15: Overview

    GENERAL 1. Overview 1.1 Outline Drawing S3L, S3L2 Oil filler Hanger Thermostat Exhaust manifold Alternator Starter Rear end Front end Flywheel V belt Oil pan Left-hand side Engine LH side view Fuel injection nozzle Fuel injection pump Water pump Stop solenoid Coolant drain plug Inlet cover Rear end...
  • Page 16 GENERAL S4L, S4L2 Hanger Oil filler Thermostat Exhaust manifold Alternator Starter Rear end Front end V belt Flywheel Oil pan Left-hand side Engine LH side view Fuel injection nozzle Fuel injection pump Water pump Stop solenoid Inlet cover Coolant drain plug Rear end Front end Flywheel housing...
  • Page 17: Fuel System Schematic

    GENERAL 1.2 Fuel System Schematic Fuel injection pipe Fuel leak-off pipe To fuel tank Fuel injection nozzle Fuel pump Fuel injection pump Fuel filter From fuel tank Fuel system schematic 1.3 Oil System Schematic Oil pressure switch Oil main gallery Oil filter Relief valve Oil pump...
  • Page 18: Cooling System Schematic

    GENERAL 1.4 Cooling System Schematic Water bypass valve Water pump Thermostat Radiator Cooling fan Cooling system schematic 1.5 Inlet / Exhaust System Schematic Exhaust gas Intake air Air breather pipe (positive crankcase Blow-by gas ventilation) Intake air (from air cleaner) Exhaust gas (to muffler) Inlet cover...
  • Page 19: Engine Serial Number

    GENERAL 1.6 Engine Serial Number Engine serial number The engine serial number is stamped on the top face of the fuel injection pump bracket on the right-hand side of the cylinder block. Engine serial number location 1.7 Engine Model and Application Codes The engine model code is embossed on the side of the fuel injection pump mount on the right-hand side of the cylinder block.
  • Page 20: Specifications

    GENERAL 2. Specifications Engine Type S3L2 S4L2 Type Water-cooled; 4-stroke cycle; Diesel powered No. of cylinders Combustion Swirl chamber type Valve mechanism Overhead valve type 78• ~ 78.5 78• ~ 92 78• ~ 78.5 78• ~ 92 Cylinder bore• ~ stroke mm (in.) (3.07•...
  • Page 21 Paper element Voltage - Polarity 12 V - ƒ ¦ ground, 24 V - ƒ ¦ ground Type M001T68281, M008T70471A, M008T81071A Manufacturer Mitsubishi Electric Corporation Pinion Pinion shift (reduction) engagement Starter Output V-kW 12 V-1.7, 12 V-2.0, 24 V-3.2 No. of units...
  • Page 22: Disassembly / Reassembly Notes

    GENERAL 3. Disassembly / Reassembly Notes This Service Manual specifies various procedures recommended by Mitsubishi Heavy Industries, Ltd. for servicing Mitsubishi diesel engines. These procedures include, wherever appropriate, required special tools and related safety precautions. The instructions provided in this manual, however, cannot fully guarantee safety as potential risks beyond ordinary imagination are hidden everywhere.
  • Page 23 GENERAL Tighten hardware to the specified torque, if provided in the manual. Be sure to use a torque wrench. Gaskets, packing and O-rings should be replaced with new parts unless specified otherwise. 1 - 10...
  • Page 24: Service Standards

    SERVICE STANDARDS 1. Service Standards Table····································································· 1 -12 2. Tightening Torques Table···································································· 1 -16 ··········································································· 1 -16 2.1 Major Bolts and Nuts ······································································· 1 -17 2.2 Standard Bolts and Nuts ··············································································· 1 -17 2.3 Standard Eyebolts ··········································································· 1 -18 2.4 Standard Union Nuts ························································································...
  • Page 25: Service Standards Table

    SERVICE STANDARDS 1. Service Standards Table Unit: mm (in.) Nominal Item Standard value Limit Remarks value Max. speed 2700 (based on the rated speed) Min. speed 1000• } 25 min 2.6 MPa Both oil and coolant 2.9 MPa (30 kgf/cm Compression pressure (27 kgf/cm temperatures at 20 to...
  • Page 26 SERVICE STANDARDS Unit: mm (in.) Nominal Item Standard value Limit Remarks value Free length 47 (1.85) 46 (1.81) ƒ Æ =2.0° • ¢ = 0.5 ƒ ¢ =0.2 (0.0197) Squareness (0.0079) across the Lf=47 entire length (1.8518) 39.0 (1.536)/ 30.1 (1.185)/ Installed length / load 131 to 145 279 to 309...
  • Page 27 SERVICE STANDARDS Unit: mm (in.) Nominal Item Standard value Limit Remarks value ƒ Ó 52 51.985 to 52.000 Crank journal diameter (STD) • \ (2.0482 to 2.0488) (2.0488) ƒ Ó 48 47.950 to 47.964 Crank pin diameter • \ (1.8892 to 1.8897) (1.8912) Crankshaft bend 0.025 (0.0010)
  • Page 28 SERVICE STANDARDS Unit: mm (in.) Nominal Item Standard value Limit Remarks value Paper-element type air Replace every Clean every 100 hours cleaner 500 hours Inlet / exhaust manifold 0.15 (0.006) Grind or • \ mounting face distortion or less replace 0.5 to 2.0 Adjust with Pinion gap...
  • Page 29: Tightening Torques Table

    SERVICE STANDARDS 2. Tightening Torques Table 2.1 Major Bolts and Nuts Thread Tightening torque diameter Fittings Remarks • ~ pitch N¥ m kgf¥ m lbf¥ ft (mm) Engine proper Cylinder head bolt M10• ~ 1.75 83.4 to 93.2 8.5 to 9.5 61.5 to 68.7 Rocker cover bolt M8•...
  • Page 30: Standard Bolts And Nuts

    SERVICE STANDARDS 2.2 Standard Bolts and Nuts Thread diameter N¥ m kgf¥ m lbf¥ ft N¥ m kgf¥ m lbf¥ ft • ~ pitch (mm) 2.94 to 4.90 0.3 to 0.5 2.2 to 3.6 7.85 to 9.80 0.8 to 1.0 5.8 to 7.2 M6•...
  • Page 31: Standard Union Nuts

    SERVICE STANDARDS 2.4 Standard Union Nuts Nominal Cap nut size N¥ m kgf¥ m lbf¥ ft diameter 28.8 M14• ~ 1.5 M16• ~ 1.5 36.1 M20• ~ 1.5 57.5 72.3 M22• ~ 1.5 M27• ~ 1.5 115.8 M30• ~ 1.5 144.6 M30•...
  • Page 32: Sealants List

    SERVICE STANDARDS 3. Sealants List Mating Sealing item Sealant Applied location component Stop solenoid ThreeBond 1212 Governor case Water drain joint Threaded part ThreeBond 1102 Block Threaded portion Oil pressure switch Torque spring set ThreeBond 1212 Governor case Cylinder block Sealing cap Cylinder head Holes in the cylinder...
  • Page 33 SERVICE STANDARDS 1 - 20...
  • Page 34: Tools List

    TOOLS LIST 1. General Tools ····················································································· 1 -22 2. Special Tools······················································································· 1 -23...
  • Page 35 TOOLS LIST 1. General Tools Description Part number Remarks • \ Tool set MM413-900 Consists of items ‡ @ to ‡ D ‡ @ Spanner MK96008010 Width across flats [8• ~ 10 mm (0.31• ~ 0.39 in.)] ‡ A Spanner MK96012014 Width across flats [12•...
  • Page 36: Special Tools

    TOOLS LIST 2. Special Tools Description Part number Shape Application Piston Pin 31A91-00100 Piston pin Setting Tool removal / installation Camshaft Bushing ST332340 Punching / press-fitting of Installer front camshaft bushing Compression Gauge ST332270 Compression measuring Adapter Oil Pressure Switch MD998054 Oil pressure switch Socket Wrench...
  • Page 37 TOOLS LIST 1 - 24...
  • Page 38: Overhaul Timing

    OVERHAUL TIMING 1. Identifying the Timing for Overhaul······················································ 1-26 2. Measuring the Compression Pressure ················································ 1-27...
  • Page 39 OVERHAUL TIMING 1. Identifying the Timing for Overhaul Generally, when the compression pressure has dropped below the specified value, overhaul of the engine needs to be considered. Other parameters should also be considered in making the decision as to whether or not to overhaul the engine, such as engine oil consumption and blow-by gas volume.
  • Page 40 OVERHAUL TIMING 2. Measuring the Compression Pressure Move the control lever to STOP position. Remove the glow plugs from all cylinders. Install the special tool Compression Gauge Compression gauge Adapter and a compression gauge onto the cylinder being measured. Compression gauge adapter Special tool Part number...
  • Page 41 OVERHAUL TIMING 1 - 28...
  • Page 42: Draining The Engine Oil

    REMOVAL PREPARATIONS 1. Preparations ························································································ 1-30 ································································· 1-30 1.1 Removing the Electric Wiring ············································································· 1-30 1.2 Draining the Coolant ········································································· 1-30 1.3 Draining the Engine Oil...
  • Page 43 REMOVAL PREPARATIONS 1. Preparations 1.1 Removing the Electric Wiring Starter Remove the wiring harnesses from the following equipment. Before removal, attach mating tags etc. onto the terminals to aid reassembly. • E Starter • E Switches Starter wiring Retaining bolt Removing the electric wiring 1.2 Draining the Coolant Loosen the coolant drain plug on the right-hand...
  • Page 44 ENGINE MAIN PARTS - DISASSEMBLY 1. Cylinder Head, Valve Mechanism························································ 2 - 2 ······················································· 2 - 3 1.1 Removing the rocker shaft assembly ················································· 2 - 3 1.2 Disassembling the rocker shaft assembly ··························································· 2 - 3 1.3 Removing the cylinder head bolts ·····················································...
  • Page 45: Cylinder Head, Valve Mechanism

    ENGINE MAIN PARTS - DISASSEMBLY 1. Cylinder Head, Valve Mechanism Spring fatigue Clogged oil hole End face wear, damage Damaged threads Bend Wear Worn rocker shaft, Clogged oil hole Spring fatigue, damage Valve guide wear, damage Bottom face distortion Cracks, Damage, Coolant leakage, Oil leakage, Scale formation, Wear, Gasket, Carbon deposit...
  • Page 48: Removing The Rocker Shaft Assembly

    ENGINE MAIN PARTS - DISASSEMBLY 1.1 Removing the rocker shaft assembly Loosen the rocker stay bolts. Remove the rocker shaft assembly together with the rocker stay bolts. Remove the valve caps. Keep the rocker shaft assembly with the rocker stay bolts. Removing the rocker shaft assembly 1.2 Disassembling rocker...
  • Page 49: Removing The Cylinder Head Assembly

    ENGINE MAIN PARTS - DISASSEMBLY 1.4 Removing the cylinder head assembly Remove the cylinder head assembly by lifting it straight up. Note: If the bonding of the cylinder head gasket prevents the head assembly from being separated from the cylinder block, tap the cylinder head side face on a relatively thick portion with a plastic hammer.
  • Page 50: Flywheel, Timing Gear, Camshaft

    ENGINE MAIN PARTS - DISASSEMBLY 2. Flywheel, Timing Gear, Camshaft Flywheel end of engine Replace: Gasket Oil seal wear, damage, deterioration Cracks, Damage Frictional surface streak, stepped wear, cracks; Ring gear damage, abnormal wear Disassembly of flywheel <Disassembly sequence> ‡ @ Flywheel ‡...
  • Page 51 ENGINE MAIN PARTS - DISASSEMBLY Timing gear end of engine Wear on tappet contact face with cam Replace: Gasket Cam lobe wear, damage Ball bearing wear, noise Wear, damage of each gear Replace: Gasket Speedometer driven gear damage Cam lobe wear, Bent shaft Cracks, Damage, Distortion Crankshaft pulley groove wear, damage Disassembly of timing gear and camshaft...
  • Page 52: Removing The Flywheel

    ENGINE MAIN PARTS - DISASSEMBLY 2.1 Removing the flywheel Have an assistant lock the flywheel pulley using a wrench or other similar tool to prevent the flywheel from rotating. Remove one of the flywheel retaining bolts. The person who locks the crankshaft pulley Locking the flywheel with a wrench etc.
  • Page 53: Removing The Rear Plate

    ENGINE MAIN PARTS - DISASSEMBLY 2.3 Removing the rear plate The rear plate has been located into position with knock pins. Therefore, the plate needs to be removed by pulling it straight towards you. Removing the rear plate 2.4 Removing the oil seal case Remove the oil seal case retaining bolts.
  • Page 54: Removing The Timing Gear Case

    ENGINE MAIN PARTS - DISASSEMBLY 2.7 Removing the timing gear case Remove the timing gear case retaining bolts. Then, remove the timing gear case. The front plate is bolted in place separately from the timing gear case. Do not attempt to tap away the front plate together with the timing gear case.
  • Page 55: Removing The Idler Gear

    ENGINE MAIN PARTS - DISASSEMBLY 2.9 Removing the idler gear Remove the idler gear by sliding it out along the helical teeth. Removing the idler gear 2.10 Removing the camshaft Remove the thrust plate retaining bolts. Gently pull out the camshaft, taking care not to damage it.
  • Page 56: Removing The Oil Pump

    ENGINE MAIN PARTS - DISASSEMBLY 2.13 Removing the oil pump Remove the oil pump retaining bolts. Then, remove the oil pump from the cylinder block. Removing the oil pump 2.14 Removing the front plate Remove the four front plate retaining bolts. Then, gently tap the plate with a plastic hammer to remove the gasket.
  • Page 57: Cylinder Block, Crankshaft, Pistons, Oil Pan

    ENGINE MAIN PARTS - DISASSEMBLY 3. Cylinder Block, Crankshaft, Pistons, Oil Pan Piston ring wear, damage, Ring gap clearance Piston wear, seizure, Connecting rod bend, streak, twist, Ring groove wear Big end thrust clearance Cylinder damage, stepped wear Top face distortion Dirty or clogged oil and water galleries Crank journal/pin damage,...
  • Page 58: Removing The Oil Pan

    ENGINE MAIN PARTS - DISASSEMBLY 3.1 Removing the oil pan Turn the engine upside down. Remove the oil pan by tapping it on the bottom corners with a plastic hammer. Do not insert a chisel or a screwdriver between the oil pan and the cylinder block to remove the oil pan.
  • Page 59: Removing The Pistons

    ENGINE MAIN PARTS - DISASSEMBLY 3.4 Removing the pistons Rotate the crankshaft to place the piston being removed at the top dead center. Using a wooden piece such as the stem of a hammer, push the piston and connecting rod assembly on the mating face with the connecting rod cap to remove the assembly from the cylinder block.
  • Page 60 ENGINE MAIN PARTS - DISASSEMBLY 3.8 Separating piston from connecting rod Remove the piston pin using the special tool Piston Pin Setting Tool. Special tool Part number Piston Pin Setting Tool 31A91-00100 Piston Pin Setting Tool (2) Insert the tool’s push rod into the piston pin hole. Using a press against the push rod, extract the Push rod piston pin.
  • Page 61 ENGINE MAIN PARTS - DISASSEMBLY 2 - 16...
  • Page 62 ENGINE MAIN PARTS - INSPECTION AND CORRECTION 1. Cylinder Head, Valve Mechanism······················································· 2 -18 ··································· 2 -18 1.1 Measuring the cylinder head bottom face distortion ····················· 2 -18 1.2 Measuring the rocker arm bore and the rocker shaft diameter ························ 2 -18 1.3 Measuring the valve spring for squareness and free length ···························································...
  • Page 63: Cylinder Head, Valve Mechanism

    ENGINE MAIN PARTS - INSPECTION AND CORRECTION 1. Cylinder Head, Valve Mechanism 1.1 Measuring the cylinder head bottom face distortion Using a straight edge across the bottom face of the cylinder head and a thickness gauge, measure for any distortion. If the measured distortion exceeds the limit, correct with a surface grinder.
  • Page 64: Measuring The Push Rod For Bend

    ENGINE MAIN PARTS - INSPECTION AND CORRECTION 1.4 Measuring the push rod for bend If the measured value exceeds the limit, replace the push rod. Unit: mm (in.) Limit Push rod Push rod bend 0.3 (0.012) Note: Use a dial gauge to measure the push rod for bend.
  • Page 65: Replacing The Valve Guide

    ENGINE MAIN PARTS - INSPECTION AND CORRECTION 1.7 Replacing the valve guide Using a punching tool, remove the valve guide Valve guide from the bottom to the top of the cylinder head. Using a press, insert a new valve guide from the Cylinder head top of the cylinder head so that the valve guide protrusion above the cylinder head face is to the...
  • Page 66: Correcting The Valve Face

    ENGINE MAIN PARTS - INSPECTION AND CORRECTION If the measured valve head sinkage exceeds the limit, correct the valve seat or replace the cylinder head assembly. Unit: mm (in.) Standard Limit value 0.25 to 0.75 Valve head sinkage (0.0098• } 0.0295) (0.0600) 1.9 Correcting the valve face If the valve face is excessively worn, correct with...
  • Page 67: Lapping The Valve Face Against The Valve Seat

    ENGINE MAIN PARTS - INSPECTION AND CORRECTION 1.11 Lapping the valve face against the valve seat If the valve seat is corrected or the valve is Valve lapper replaced, be sure to lap the valve face against the valve seat in the following manner. Lapping compound Apply a light coating of lapping compound...
  • Page 68: Flywheel, Timing Gear, Camshaft

    ENGINE MAIN PARTS - INSPECTION AND CORRECTION 2. Flywheel, Timing Gear, Camshaft 2.1 Measuring the flywheel flatness Place the flywheel on a surface plate. Run a dial gauge over the frictional surface of the flywheel to measure the flatness. If the measured value exceeds the limit, grind the frictional surface.
  • Page 69: Measuring The Clearance Between The Idler Gear And The Idler Shaft

    ENGINE MAIN PARTS - INSPECTION AND CORRECTION 2.4 Measuring the clearance between the Measuring idler gear and the idler shaft direction Measure the inner diameter of the idler gear. Measure the idler shaft diameter. If the difference between the two exceeds the limit, Measuring location replace the idler gear or the idler shaft.
  • Page 70: Extracting The Camshaft Bushing

    ENGINE MAIN PARTS - INSPECTION AND CORRECTION 2.7 Extracting the camshaft bushing Camshaft Cylinder block Remove the camshaft bushing using the special bushing front face tool Camshaft Bushing Installer in the following manner. Special tool Part number Camshaft Bushing Installer ST332340 Camshaft bushing installer...
  • Page 71: Inspecting The Cam-to-tappet Contact

    ENGINE MAIN PARTS - INSPECTION AND CORRECTION 2.11 Inspecting the cam-to-tappet contact Inspect the tappet contact face with the cam. If abnormally worn, replace the tappet. Good Cam-to-tappet contact 2.12 Measuring the clearance between the Measuring Measuring direction direction tappet and the tappet guide Measure the tappet diameter.
  • Page 72: Cylinder Block, Crankshaft, Pistons, Oil Pan

    ENGINE MAIN PARTS - INSPECTION AND CORRECTION 3. Cylinder Block, Crankshaft, Pistons, Oil Pan 3.1 Measuring the piston diameter Measure squarely Using a micrometer, measure the piston diameter with piston pin across the piston skirt and squarely with the piston pin, as illustrated. Measuring location If the measured value is less than the limit, replace with a new part.
  • Page 73: Measuring The Clearance Between The Piston Pin And The Pin Boss

    ENGINE MAIN PARTS - INSPECTION AND CORRECTION 3.4 Measuring the clearance between the piston pin and the pin boss Measure the piston pin diameter. Measure the bore size of the piston pin boss. If the difference between them exceeds the limit, replace with Measuring Measuring new parts.
  • Page 74: Measuring The Connecting Rod End Play

    ENGINE MAIN PARTS - INSPECTION AND CORRECTION 3.6 Measuring the connecting rod end play Thickness gauge Tightening torque Install the connecting rod and the rod cap onto 32.4 to 37.3 N m (3.3 to 3.8 kgf m) the mating crank pin. Tighten the cap nuts to the [23.9 to 27.5 lbf ft] specified torque.
  • Page 75 ENGINE MAIN PARTS - INSPECTION AND CORRECTION (a) If any of the crank pins need grinding, grind all crank pins on the same crankshaft to the same dimension. (b) Finish the fillets to a radius of 2 mm (0.08 R2.5 mm in.).
  • Page 76: Measuring The Crankshaft For Bend

    ENGINE MAIN PARTS - INSPECTION AND CORRECTION R2 mm R2 mm (0.08 in.) (0.08 in.) (a) If any of the crank journals need grinding, grind all crank journals on the same crankshaft to the same dimension. (b) Finish the fillets to a radius of 2.5 mm (0.098 in.).
  • Page 77: Measuring The Cylinder Bore

    ENGINE MAIN PARTS - INSPECTION AND CORRECTION 3.12 Measuring the cylinder bore Measuring direction Using a cylinder gauge, measure the cylinder bore and cylindricality. If any of the cylinders exceeds the limit, bore all cylinders of the same engine and replace the pistons and the piston rings with oversize parts.
  • Page 78 ENGINE MAIN PARTS - REASSEMBLY 1. Cylinder Block, Crankshaft, Pistons, Oil Pan······································ 2 -34 ·································································· 2 -34 1.1 Installing the main bearings ········································································ 2 -34 1.2 Installing the crankshaft ····························································· 2 -34 1.3 Installing the main bearing caps ········································································ 2 -35 1.4 Inserting the side seals ·········································...
  • Page 79: Cylinder Block, Crankshaft, Pistons, Oil Pan

    ENGINE MAIN PARTS - REASSEMBLY Cylinder Block, Crankshaft, Pistons, Oil Pan To reassembly, follow the disassembly sequence in reverse. 1.1 Installing the main bearings Install the main bearings (upper and lower) onto the cylinder block and the main bearing cap, ensuring that the lugs engage with the lug grooves.
  • Page 80: Inserting The Side Seals

    ENGINE MAIN PARTS - REASSEMBLY Tighten the main bearing cap bolts progressively in diagonal sequence and tighten to the specified torque at the final step. Tightening torque: 49.0 to 53.9 N m (5.0 to 5.5 kgf m) [36.2 to 39.8 lbf ft] Tightening the main bearing cap bolts Ensure that the crankshaft rotates smoothly, without any binding.
  • Page 81: Assembling The Piston Onto The Connecting Rod

    ENGINE MAIN PARTS - REASSEMBLY 1.5 Assembling piston onto connecting rod Install the special tool Piston Pin Setting Tool onto a hydraulic press. Special tool Part number Piston Pin Setting Tool 31A91-00100 Place the connecting rod on the tool. Coat the connecting rod small end with engine oil.
  • Page 82: Installing The Piston Rings

    ENGINE MAIN PARTS - REASSEMBLY 1.6 Installing the piston rings Using the special tool Piston Ring Pliers, install Top face mark No. 1 compression the No. 1 ring, No. 2 ring, and oil ring onto the ring piston. No. 2 compression Special tool Part number ring...
  • Page 83: Installing The Connecting Rod Caps

    ENGINE MAIN PARTS - REASSEMBLY 1.8 Installing the connecting rod caps While pressing the top of piston down to keep the connecting rod large end attached to the crank pin, rotate the crankshaft 180°. Install the connecting rod bearing (lower) onto the connecting rod cap, ensuring that the lug engages with the lug groove.
  • Page 84 ENGINE MAIN PARTS - REASSEMBLY Note: (a) Apply sealant in a bead of 4 mm (0.1575 in.) R17 (4 front and rear locations in total) Apply sealant as lined and in the illustrated pattern. (b) Cutting the end of the sealant tube at the 9.5 mm (0.37 in.) illustrated location will provide a 4 mm...
  • Page 85: Flywheel, Timing Gear, Camshaft

    ENGINE MAIN PARTS - REASSEMBLY Flywheel, Timing Gear, Camshaft To reassembly, follows the disassembly sequence in reverse. 2.1 Installing the front plate Completely scrape off any remaining gasket from the cylinder block and the front plate. Install the front plate onto the cylinder block. Tighten the four retaining bolts.
  • Page 86: Installing The Camshaft

    ENGINE MAIN PARTS - REASSEMBLY 2.5 Installing the camshaft Apply engine oil to the journals and cams. Insert the camshaft (complete with the camshaft gear) into the cylinder block. Take care not to damage the journals or cams when inserting the camshaft into the cylinder Apply engine oil block.
  • Page 87: Tightening The Crankshaft Pulley Nut

    ENGINE MAIN PARTS - REASSEMBLY 2.8 Tightening the crankshaft pulley nut Tightening torque: Use the studs and the bar described in Section 147 to 196 N m “2.3” to lock the crankshaft. (15.0 to 20.0 kgf m) [108.5 to 144.7 lbf ft] While locking the crankshaft, tighten the crankshaft pulley nut to the specified torque.
  • Page 88: Installing The Rear Plate

    ENGINE MAIN PARTS - REASSEMBLY 2.12 Installing the rear plate Install a new rear plate gasket. Install the rear plate, aligning it with the dowel pins. Tighten the retaining bolts to the specified torque. Note: Install the rear plate complete with the starter. Tightening torque: This will facilitate the subsequent reassembly.
  • Page 89: Cylinder Head, Valve Mechanism

    ENGINE MAIN PARTS - REASSEMBLY Cylinder Head, Valve Mechanism To reassembly, follows the disassembly sequence in reverse. 3.1 Cleaning the bottom face of the cylinder head Scrape off any gasket from the mating faces of the cylinder head and the cylinder block, taking care not to damage the faces.
  • Page 90: Installing The Cylinder Head Gasket

    ENGINE MAIN PARTS - REASSEMBLY 3.5 Installing the cylinder head gasket Ensure that the cylinder block top face and the Guide stud piston top faces are clean. Insert two guide studs (M10• ~ 1.25) into the bolt holes in the cylinder block. Install the cylinder head gasket through the studs and onto the cylinder block.
  • Page 91: Assembling The Rocker Shaft Assembly

    ENGINE MAIN PARTS - REASSEMBLY 3.9 Assembling the rocker shaft assembly Assemble the rocker shaft components to ensure the correct reassembly and tighten the retaining Retaining bolt bolt. Ensue that the rocker arms move smoothly. Assembling the rocker shaft assembly 3.10 Installing the rocker shaft assembly Install the valve caps.
  • Page 92: Fuel System - Removal

    FUEL SYSTEM - REMOVAL 1. Fuel Injection Pipes, Fuel Leak-off Pipe, Fuel Injection Nozzles ········· 3 - 2 ···························································· 3 - 3 1.1 Removing the fuel injection pipes ························································· 3 - 3 1.2 Removing the fuel injection nozzles 2. Governor ····························································································· 3 - 4 ···························································...
  • Page 93: Fuel Injection Pipes, Fuel Leak-off Pipe, Fuel Injection Nozzles

    FUEL SYSTEM - REMOVAL 1. Fuel Injection Pipes, Fuel Leak-off Pipe, Fuel Injection Nozzles Replace: Gasket Removal of fuel injection pipes, fuel leak-off pipe, and fuel injection nozzles <Removal sequence> ‡ @ No. 1 fuel injection pipe ‡ C No. 4 fuel injection pipe ‡...
  • Page 94: Removing The Fuel Injection Pipes

    FUEL SYSTEM - REMOVAL 1.1 Removing the fuel injection pipes Remove the fuel injection pipes and the fuel leak-off pipe. Note: To prevent dirt from entering into the system, plug the fuel injection pump openings and the fuel injection nozzle connectors. Removing the fuel injection pipe 1.2 Removing the fuel injection nozzles Using a wrench, loosen the fuel injection nozzles.
  • Page 95: Governor

    FUEL SYSTEM - REMOVAL 2. Governor Replace: Gasket Removal of the governor <Removal sequence> ‡ @ Bolt ‡ A Governor assembly ‡ B Gasket 3 - 4...
  • Page 96: Removing The Governor Assembly

    FUEL SYSTEM - REMOVAL 2.1 Removing the governor assembly Remove the tie-rod cover. Using a pair of cutting pliers, remove the tie-rod spring. Disconnect the tie-rod from the pumps. Remove the governor assembly. Removing the governor assembly 2.2 Removing the governor weights Remove the sliding sleeve.
  • Page 97: Fuel Injection Pumps

    FUEL SYSTEM - REMOVAL 3. Fuel Injection Pumps Removal of the fuel injection pumps <Removal sequence> ‡ @ Bolt ‡ A Fuel injection pump ‡ B Shim 3 - 6...
  • Page 98: Removing The Fuel Injection Pumps

    FUEL SYSTEM - REMOVAL Removing the fuel injection pumps Remove the tie-rod cover. Using a pair of cutting pliers, remove the tie-rod spring. Disconnect the tie-rod from the pumps. Removing the tie-rod Removing the fuel injection pumps Note: Note the thickness of shim pack for the adjustment of the fuel injection timing.
  • Page 99 FUEL SYSTEM - REMOVAL 3 - 8...
  • Page 100 FUEL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 1. Fuel Injection Nozzles ········································································ 3 -10 ················································· 3 -10 1.1 Disassembling the fuel injection nozzles ························································· 3 -10 1.2 Inspecting the fuel injection nozzle ··················································· 3 -12 1.3 Reassembling the fuel injection nozzle 2.
  • Page 101: Fuel System - Disassembly

    FUEL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 1. Fuel Injection Nozzles 1.1 Disassembling the fuel injection nozzles Replace: Gasket Wear Fatigue, Perpendicularity Wear, Damage Carbon deposit, Clogged nozzle hole Disassembly of the fuel injection nozzle <Reassembly sequence> ‡ @ Nozzle retaining nut ‡...
  • Page 102 FUEL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY If the measured pressure does not conform to the standard value, disassemble and adjust by changing the thickness of the washer. Nozzle tip end Unit: MPa (kgf/cm ) [psi] Standard value 14.22 to 15.00 Injection valve opening (145 to 153) pressure...
  • Page 103: Reassembling The Fuel Injection Nozzle

    FUEL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY Assemble the fuel injection nozzle, tightening the nozzle retaining nut to the specified torque. If the fuel spray pattern is still not good, replace the nozzle tip assembly. Note: (a) Never touch the sliding surface of the needle valve with your hands.
  • Page 104: Fuel Injection Pumps

    FUEL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 2. Fuel Injection Pumps 2.1 Inspecting the fuel injection pump on vehicle Do not disassemble the fuel injection pump unless it is necessary. If the pump is suspected to be faulty, it is recommended that the entire pump assembly be replaced.
  • Page 105 FUEL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY Removing the tappets Open the claws of the lock plate using a screwdriver or other similar tool. Rotate the tappet and the guide pin by 180º to align the guide pin cutout with the mating portion of the pump housing.
  • Page 106 FUEL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY Removing the delivery valve Place the pump upwards in a vice. Remove the delivery valve holder. Remove the delivery valve gasket. Removing the delivery valve holder Using a pair of tweezers, remove the delivery valve.
  • Page 107: Inspecting The Fuel Injection Pumps

    FUEL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 2.3 Inspecting the fuel injection pumps Delivery valve wear, damage Plunger fit, wear, damage, rust, seizure Control rack operation Tappet contact, wear Inspection of the fuel injection pumps 3 - 16...
  • Page 108: Reassembling The Fuel Injection Pumps

    FUEL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 2.4 Reassembling the fuel injection pumps Tightening torque: 39.2 to 49.0 N m (4.0 to 5.0 kgf m) [28.9 to 36.2 lbf ft] Replace: O-ring Tightening torque: 19.6 to 24.5 N m (2.0 to 2.5 kgf m) [14.5 to 18.1 lbf ft] Replace: Lock plate Air bleed plug...
  • Page 109 FUEL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY Installing the control sleeves Center tooth Assemble the control sleeves onto the control (the only tooth visible when viewed from the bottom) rack so that each sleeve is aligned with the notched line. Notched line Installing the control sleeves Insert the plungers into the sleeves.
  • Page 110 FUEL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY Inspecting the control rack for smooth operation With the fuel injection pumps assembled, ensure that the control rack slides smoothly. If not, possible causes include the following. 1) The elements do not slide smoothly. 2) Foreign matter is trapped between the teeth of rack and sleeve.
  • Page 111: Governor

    FUEL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 3. Governor 3.1 Disassembling and inspecting the governor Levers should operate smoothly. Worn or damaged weights Sliding sleeve wear, damage: The sleeve should slide smoothly. Worn or damaged lever contact with sliding sleeve Spring fatigue Scoring Disassembly and inspection of the governor...
  • Page 112: Reassembling The Governor

    FUEL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 3.2 Reassembling the governor Install the levers first. Installing the levers Install the O-ring onto the governor shaft. Grooved pin Tie-rod spring Insert the governor shaft into the governor case, and combine it with the levers. Hold the grooved pin and the spring pin in place, and knock them in with a soft hammer.
  • Page 113: Fuel Pump

    FUEL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 4. Fuel Pump Inspecting the fuel pump The engine is equipped with one of the following three types of fuel pump depending on the engine specifications. Plunger-type fuel pump Replace filter element: There are two types; one is the standard with a every 400 hours filter element and the other, compact-size, Cover...
  • Page 114: Fuel Filter

    FUEL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 5. Fuel Filter Do not remove. 5.1 Disassembling, inspecting reassembling the fuel filter (with a Air bleed plug selector cock) Normally, only remove the filter element. Do not disassemble the cock lever unless so required. If the cock lever is disassembled, clean it and apply silicon oil to the O-ring before reassembly.
  • Page 115 FUEL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 3 - 24...
  • Page 116: Fuel System - Installation

    FUEL SYSTEM - INSTALLATION 1. Fuel Injection Pumps ·········································································· 3 -26 ································································· 3 -27 Installing the fuel injection pumps 2. Governor ···························································································· 3 -28 ······························································ 3 -29 2.1 Installing the governor weights ··································································· 3 -29 2.2 Installing the sliding sleeve ····························································...
  • Page 117: Fuel Injection Pumps

    FUEL SYSTEM - INSTALLATION 1. Fuel Injection Pumps Installing the fuel injection pumps <Installation sequence> ‡ B • ¨ ‡ A • ¨ ‡ @ 3 - 26...
  • Page 118 FUEL SYSTEM - INSTALLATION Installing the fuel injection pumps Install the fuel injection pump housing complete with the pumps onto the cylinder block, and tighten the retaining bolts. Installing the fuel injection pump housing complete with the pumps Install the governor assembly, inserting the tie-rod and the tie-rod spring into the fuel injection pump housing.
  • Page 119: Governor

    FUEL SYSTEM - INSTALLATION 2. Governor Installing the governor <Installation sequence> ‡ B • ¨ ‡ A • ¨ ‡ @ 3 - 28...
  • Page 120: Installing The Governor Weights

    FUEL SYSTEM - INSTALLATION 2.1 Installing the governor weights Install the governor weights onto the rear end of the pump camshaft and tighten the sliding sleeve Tightening torque: shaft to the specified torque. 29.4 to 41.2 N m (3.0 to 4.2 kgf m) [21.7 to 30.4 lbf ft] Installing the governor weights 2.2 Installing the sliding sleeve...
  • Page 121: Fuel Injection Pipes, Fuel Leak-off Pipe, Fuel Injection Nozzles

    FUEL SYSTEM - INSTALLATION 3. Fuel Injection Pipes, Fuel Leak-off Pipe, Fuel Injection Nozzles Tightening torque for fuel leak-off pipe nut 20.6 to 24.5 N m Tightening torque for (2.1 to 2.5 kgf m) fuel injection pipe nut [15.2 to 18.1 lbf ft] 24.5 to 34.3 N m (2.5 to 3.5 kgf m) [18.1 to 25.3 lbf ft]...
  • Page 122: Installing The Fuel Injection Nozzles

    FUEL SYSTEM - INSTALLATION 3.1 Installing the fuel injection nozzles Replace: Gasket Tightening torque: 49.0 to 58.8 N m Install the gaskets onto the fuel injection nozzles. (5.0 to 6.0 kgf m) Insert the fuel injection nozzles into the cylinder [36.2 to 43.4 lbf ft] head, and tighten to the specified torque.
  • Page 123 FUEL SYSTEM - INSTALLATION 3 - 32...
  • Page 124: Oil System - Removal

    OIL SYSTEM - REMOVAL 1. Oil Filter, Relief Valve and Oil Pressure Switch ··································· 4 - 2 ··········································································· 4 - 3 1.1 Removing the oil filter ······································································ 4 - 3 1.2 Removing the relief valve ···························································· 4 - 3 1.3 Removing the oil pressure switch 2.
  • Page 125 OIL SYSTEM - REMOVAL 1. Oil Filter, Relief Valve and Oil Pressure Switch Replace: Gasket Replace: Gasket Removal of the oil filter, relief valve and oil pressure switch <Removal sequence> ‡ @ Oil filter ‡ A Relief valve ‡ B Oil pressure switch 4 - 2...
  • Page 126 OIL SYSTEM - REMOVAL 1.1 Removing the oil filter Place an drip pan under the oil filter. Using a filter wrench, remove the oil filter. Removing the oil filter 1.2 Removing the relief valve Remove the relief valve. Removing the relief valve 1.3 Removing the oil pressure switch Using the special tool Oil Pressure Switch Socket MD998054...
  • Page 127 OIL SYSTEM - REMOVAL 2. Oil Pan, Oil Strainer Replace: Gasket Removal of the oil pan and oil strainer <Removal sequence> ‡ @ Oil pan ‡ A Oil strainer 4 - 4...
  • Page 128 OIL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 1. Oil Pump······························································································ 4 - 6 ················································································ 4 - 6 Inspecting the oil pump 2. Relief Valve·························································································· 4 - 6 ············································································· 4 - 6 Inspecting the relief valve 3. Oil Pressure Switch ············································································· 4 - 7 ··································································...
  • Page 129: Oil Pump

    OIL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 1. Oil Pump Inspecting the oil pump Inspect for damage and smooth rotation Check the oil pump for any damage, and whether or not it rotates smoothly. If faulty, replace the entire pump assembly. Inspecting the oil pump 2.
  • Page 130: Oil Pressure Switch

    OIL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 3. Oil Pressure Switch Inspecting the oil pressure switch Check for continuity Connect a tester (ohm meter) between the oil pressure switch terminal and the switch body. The tester should indicate continuity. If not, replace the switch.
  • Page 131 OIL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 4 - 8...
  • Page 132: Oil System - Installation 4

    OIL SYSTEM - INSTALLATION 1. Oil Filter, Relief Valve and Oil Pressure Switch ·································· 4 -10 ···························································· 4 -10 1.1 Installing the oil pressure switch ········································································4 -11 1.2 Installing the relief valve ·············································································4 -11 1.3 Installing the oil filter 2. Oil Pan and Oil Strainer ······································································ 4 -12...
  • Page 133: Oil Filter, Relief Valve And Oil Pressure Switch

    OIL SYSTEM - INSTALLATION 1. Oil Filter, Relief Valve and Oil Pressure Switch Tightening torque: 44.1 to 53.9 N m (4.5 to 5.5 kgf m) [32.5 to 39.8 lbf ft] Tightening torque: 10.8 to 12.7 N m (1.1 to 1.3 kgf m) [8.0 to 9.4 lbf ft] Tightening torque: 7.85 to 11.8 N m...
  • Page 134: Installing The Relief Valve

    OIL SYSTEM - INSTALLATION 1.2 Installing the relief valve Install the relief valve onto the side face of the cylinder block, tightening it to the specified torque. Tightening torque: 44.1 to 53.9 N m (4.5 to 5.5 kgf m) [32.5 to 39.8 lbf ft] Installing the relief valve 1.3 Installing the oil filter Tightening torque:...
  • Page 135: Oil Pan And Oil Strainer

    OIL SYSTEM - INSTALLATION 2. Oil Pan and Oil Strainer Tightening torque: 9.8 to 12.7 N m (1.0 to 1.3 kgf m) [7.2 to 9.4 lbf ft] Installation of the oil pan and oil strainer <Installation sequence> ‡ A • ¨ ‡ @ 4 - 12...
  • Page 136: Cooling System - Removal 5

    COOLING SYSTEM - REMOVAL 1. Cooling Fan, Fan Pulley and V-Belt····················································· 5 - 2 ············································································· 5 - 2 Removing the cooling fan 2. Thermostat and Thermoswitch ···························································· 5 - 3 ······································································ 5 - 3 Removing the thermostat case 3. Water Pump························································································· 5 - 4 ···········································································...
  • Page 137: Cooling Fan, Fan Pulley And V-belt

    COOLING SYSTEM - REMOVAL 1. Cooling Fan, Fan Pulley and V-Belt Cracks, elongation, wear and damage Cracks, deformation and damage Removal of the cooling fan, fan pulley and V-belt <Removal sequence> ‡ @ Cooling fan ‡ A Water pump pulley ‡...
  • Page 138: Thermostat And Thermoswitch

    COOLING SYSTEM - REMOVAL 2. Thermostat and Thermoswitch Cracks, water leaks, damage Replace: Gasket Cracks, deterioration, damage Removing the thermostat and thermoswitch <Removal sequence> ‡ @ Bolt ‡ B Gasket ‡ A Thermostat ‡ C Thermoswitch Removing the thermostat case Remove the thermostat case with thermostat.
  • Page 139: Water Pump

    COOLING SYSTEM - REMOVAL 3. Water Pump Replace: Gasket Replace: Gasket Cracks, water leaks, damage Removing the water pump <Removal sequence> ‡ @ Bolt ‡ C Water pump plate ‡ A Water pump ‡ D Gasket ‡ B Gasket Removing the water pump Remove the water pump.
  • Page 140 COOLING SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 1. Thermostat ·························································································· 5 - 6 ································································ 5 - 6 1.1 Disassembling the thermostat ······································································ 5 - 6 1.2 Inspecting the thermostat 2. Thermoswitch ······················································································ 5 - 7 ········································································· 5 - 7 Inspecting the thermoswitch 3.
  • Page 141 COOLING SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 1. Thermostat 1.1 Disassembling the thermostat Replace: Gasket Disassembly of the thermostat <Disassembly sequence> ‡ @ Thermostat cover ‡ B Thermostat ‡ A Gasket ‡ C Thermostat case 1.2 Inspecting the thermostat Stir the water for even temperature Place the thermostat in a container filled with water.
  • Page 142 COOLING SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 2. Thermoswitch Inspecting the thermoswitch Dip the temperature sensing element of the thermoswitch in oil as illustrated. While warming the oil, measure the resistance at the oil temperature of 105• Ž (221• ‹ ‚ e ). If the measured value is substantially out of the standard value, replace the thermoswitch.
  • Page 143 COOLING SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 5 - 8...
  • Page 144: Cooling System - Installation 5

    COOLING SYSTEM - INSTALLATION 1. Water Pump························································································ 5 -10 ············································································ 5 -10 Installing the water pump 2. Thermostat and Thermoswitch ····························································5 -11 ·································································5 -11 2.1 Installing the thermostat case ·····································································5 -11 2.2 Installing the thermoswitch 3. Cooling Fan, Fan Pulley and V-Belt···················································· 5 -12 ·············································································...
  • Page 145: Water Pump

    COOLING SYSTEM - INSTALLATION 1. Water Pump Installation of the water pump <Installation sequence> ‡ D • ¨ ‡ C • ¨ ‡ B • ¨ ‡ A • ¨ ‡ @ Installing the water pump Install the water pump with a new gasket onto the cylinder block.
  • Page 146: Thermostat And Thermoswitch

    COOLING SYSTEM - INSTALLATION 2. Thermostat and Thermoswitch Tightening torque: 18.6 to 26.5 N m (1.9 to 2.7 kgf m) [ 13.7 to 19.5 lbf ft] Tightening torque: 39.2 to 49.0 N m (4.0 to 5.0 kgf m) [28.9 to 36.2 lbf ft] Installation of the thermostat and thermoswitch <Installation sequence>...
  • Page 147: Cooling Fan, Fan Pulley And V-belt

    COOLING SYSTEM - INSTALLATION 3. Cooling Fan, Fan Pulley and V-belt Installation of the cooling fan, fan pulley and V-belt <Installation sequence> ‡ B • ¨ ‡ A • ¨ ‡ @ Installing the cooling fan Install the pulley onto the water pump. Install the cooling fan onto the water pump pulley, and tighten the retaining bolts.
  • Page 148: Inlet And Exhaust Systems - 6

    INLET AND EXHAUST SYSTEMS - REMOVAL 1. Inlet Cover ··························································································· 6 - 2 ············································································· 6 - 2 Removing the inlet cover 2. Exhaust Manifold ················································································· 6 - 3 ···································································· 6 - 3 Removing the exhaust manifold...
  • Page 149: Inlet Cover

    INLET AND EXHAUST SYSTEMS - REMOVAL Inlet Cover Replace: Gasket Removal of the inlet cover and air pipe <Removal sequence> ‡ @ Inlet cover ‡ B Air pipe ‡ D Breather pipe ‡ A Gasket ‡ C Gasket Removing the inlet cover Remove the inlet cover.
  • Page 152: Exhaust Manifold

    INLET AND EXHAUST SYSTEMS - REMOVAL Exhaust Manifold Replace: Gasket Removal of the exhaust manifold and gasket <Removal sequence> ‡ @ Exhaust manifold ‡ A Gasket Removing the exhaust manifold Remove the exhaust manifold. Removing the exhaust manifold 6 - 3...
  • Page 153 INLET AND EXHAUST SYSTEMS - REMOVAL 6 - 4...
  • Page 154 INLET AND EXHAUST SYSTEMS - DISASSEMBLY, INSPECTION AND REASSEMBLY 1. Inlet Cover and Exhaust Manifold························································ 6 - 6 ········································· 6 - 6 1.1 Inspecting the inlet cover and exhaust manifold ···························· 6 - 6 1.2 Measuring the exhaust manifold mounting face distortion...
  • Page 155: Inlet Cover And Exhaust Manifold

    INLET AND EXHAUST SYSTEMS - DISASSEMBLY, INSPECTION AND REASSEMBLY 1. Inlet Cover and Exhaust Manifold 1.1 Inspecting the inlet cover and exhaust manifold Cracks Cracks, Damage Cracks, Damage Inspecting the inlet cover and exhaust manifold 1.2 Measuring exhaust manifold Thickness gauge mounting face distortion Using a straight edge across the exhaust manifold mounting face and a thickness gauge, measure any distortion.
  • Page 156 INLET AND EXHAUST SYSTEMS - INSTALLATION 1. Exhaust Manifold ················································································· 6 - 8 ······································································ 6 - 8 Installing the exhaust manifold 2. Inlet Cover ··························································································· 6 - 9 ··············································································· 6 - 9 Installing the inlet cover...
  • Page 157: Exhaust Manifold

    INLET AND EXHAUST SYSTEMS - INSTALLATION 1. Exhaust Manifold Tightening torque: 14.7 to 21.6 N m (1.5 to 2.2 kgf m) [10.8 to 15.9 lbf ft] Installation of the exhaust manifold and gasket <Installation sequence> ‡ A • ¨ ‡ @ Installing the exhaust manifold Install the exhaust manifold and tighten the retaining bolts to the specified torque.
  • Page 158: Inlet Cover

    INLET AND EXHAUST SYSTEMS - INSTALLATION 2. Inlet Cover Tightening torque: 14.7 to 21.6 N m (1.5 to 2.2 kgf m) [10.8 to 15.9 lbf ft] Installation of the inlet cover and air pipe <Installation sequence> ‡ D • ¨ ‡ C • ¨ ‡ B • ¨ ‡ A • ¨ ‡ @ Installing the inlet cover Install the inlet cover and tighten the retaining bolts to the specified torque.
  • Page 159 INLET AND EXHAUST SYSTEMS - INSTALLATION 6 - 10...
  • Page 160: Electrical System - Removal

    ELECTRICAL SYSTEM - REMOVAL 1. Starter ·································································································· 7 - 2 2. Alternator ····························································································· 7 - 3 3. Stop Solenoid ······················································································ 7 - 4 4. Glow Plug ···························································································· 7 - 5...
  • Page 161: Starter

    ELECTRICAL SYSTEM - REMOVAL 1. Starter Removal of the starter <Removal sequence> ‡ @ Harness ‡ A Bolt ‡ B Starter 7 - 2...
  • Page 162: Alternator

    ELECTRICAL SYSTEM - REMOVAL 2. Alternator Removal of the alternator <Removal sequence> ‡ @ Harness ‡ B Retaining bolt ‡ D Adjusting plate ‡ A Adjusting bolt ‡ C Alternator 7 - 3...
  • Page 163: Stop Solenoid

    ELECTRICAL SYSTEM - REMOVAL 3. Stop Solenoid w/ rubber cap and plugs w/ 3-pole waterproof connector Removal of the stop solenoid <Removal sequence> ‡ @ Stop solenoid ‡ A Nut 7 - 4...
  • Page 164: Glow Plug

    ELECTRICAL SYSTEM - REMOVAL 4. Glow Plug Removal of the glow plug <Removal sequence> ‡ @ Glow plug ‡ A Connection plate 7 - 5...
  • Page 165 ELECTRICAL SYSTEM - REMOVAL 7 - 6...
  • Page 166 ELECTRICAL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 1. Starter ·································································································· 7 - 8 ············································································ 7 - 8 1.1 Removing the starter ······················································· 7 -12 1.2 Inspecting and correcting the starter ······································································ 7 -16 1.3 Reassembling the starter 2. Alternator ···························································································· 7 -18 ·································································...
  • Page 167: Starter

    ELECTRICAL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 1. Starter 1.1 Removing the starter M008T70471A M008T81071A Magnet switch circuit Armature bend, runout, Bearing loose, open or short circuit open or shorted noisy, binding Worn pinion gear Wear Brush wear, insulation Yoke circuit Gear worn, Overrunning clutch Bearing loose, noisy,...
  • Page 168 ELECTRICAL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY M001T68281 Coil open, shorted, continuity; Rough surface of commutator, Bearing loose, noisy, Coil open worn; binding Gear damaged, worn Wear Worn pinion gear Gear worn, damaged Worn metal Overrunning clutch Worn brush; Worn brush operation Spring rust, fatigue;...
  • Page 169 ELECTRICAL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY Removing the magnet switch Connector Loosen the nut at M terminal, and disconnect the connector. Loosen the two magnet switch retaining bolts, Magnet switch and remove the magnet switch. Retaining bolt Removing the magnet switch Removing the rear bracket Rear bracket Loosen the two through bolts and the two brush...
  • Page 170 ELECTRICAL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY Removing the center bracket Center bracket Loosen the bolt and remove the center bracket. Behind the center bracket, there is a washer for adjusting the pinion shaft end play. Adjusting washer Removing the center bracket Removing the pinion (a) Place an appropriate tube on the pinion stopper.
  • Page 171: Inspecting And Correcting The Starter

    ELECTRICAL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 1.2 Inspecting and correcting the starter Inspecting the brushes Brush wear Measure the length of the brushes. If the measured value is equal to or less than the Replace if the measured brush length is equal to limit, replace both the brush assembly and the or less than the limit.
  • Page 172 ELECTRICAL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY Inspecting the armature Using a dial gauge, measure the commutator Commutator for radial runout. If the measure value is equal to or exceeds the limit, correct (within the diameter limit) or replace. Unit: mm (in.) Standard Limit value...
  • Page 173 ELECTRICAL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY Armature coil continuity Measure between the commutator segment and the armature coil. There should be no continuity. If continuity is indicated, replace the armature. Testing the armature coil Armature coil open circuit Measure between the segments in various combinations.
  • Page 174 ELECTRICAL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY Inspecting the overrunning clutch The shaft should rotate smoothly in one direction, but should not rotate in the opposite direction. (b) Check the pinion for wear or damage. If faulty, replace. Do not wash the overrunning clutch in wash oil. Inspecting the overrunning clutch Front bracket The ball bearing should rotate smoothly without...
  • Page 175: Reassembling The Starter

    ELECTRICAL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 1.3 Reassembling the starter Reassembly follows the disassembly procedures in reverse while observing the following. Lubrication M008T70471A, M008T81071A When the starter is overhauled, apply grease to Apply grease to the contact faces of the overrunning clutch and the lever the following sliding surfaces, gears and bearings.
  • Page 176 ELECTRICAL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY Adjusting the pinion shaft end play Reduction gear Adjust the end play (thrust gap) to 0.5 mm (0.02 Adjusting in.) or less as illustrated by inserting an washer appropriate washer between the center bracket Washer and the reduction gear.
  • Page 177: Alternator

    ELECTRICAL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 2. Alternator 2.1 Disassembling the alternator Dirty, damaged or seized slip rings; Coil resistance Binding Binding Cracks, Damage Cracks, Damage Open or short circuit Brush slidability, wear Coil open, continuity Disassembling the alternator <Disassembly sequence>...
  • Page 178 ELECTRICAL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY Separating the front bracket from the stator core With flat-head screwdrivers positioned between the front bracket and the stator core, pry them away from each other. Do not insert the screwdrivers too deep, as it can damage the stator core.
  • Page 179: Inspecting And Correcting The Alternator

    ELECTRICAL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 2.2 Inspecting and correcting the alternator Inspecting the diodes Perform continuity test on each of the rectifier diodes in the following manner. Connect a tester between the diode lead terminal and the casing of that diode. A great resistance should be indicated in one direction and a small resistance in the opposite direction.
  • Page 180 ELECTRICAL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY Inspecting the stator core Measure between the stator leads in various combinations. Replace if no continuity is indicated (open circuit). Testing the stator core for open circuit Measure between each lead and the stator core. Replace if continuity is indicated.
  • Page 181: Reassembling The Alternator

    ELECTRICAL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY Push a new brush into the brush holder before soldering the brush lead. Installing a new brush 2.3 Reassembling the alternator To reassembly, follows the disassembly sequence in reverse and do the following steps. The rear bearing has an eccentric groove around the periphery.
  • Page 182: Stop Solenoid

    ELECTRICAL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY 3. Stop Solenoid 3.1 Reassembling the stop solenoid Tightening torque: 39.2 to 49.0 N m Stop solenoid with rubber cap and plugs These areas must be (4.0 to 5.0 kgf m) Apply sealant onto the threaded portion of the free of sealant.
  • Page 183: Checks After Reassembly

    ELECTRICAL SYSTEM - DISASSEMBLY, INSPECTION AND REASSEMBLY Stop solenoid with 3-pole waterproof connector Apply sealant onto the threaded portion of the Tightening torque: 39.2 to 49.0 N m These areas should be stop solenoid. (4.0 to 5.0 kgf m) free of sealant. Note: Apply sealant only to the area that will be [28.9 to 36.2 lbf ft] concealed by the governor case when installed.
  • Page 184: Electrical System - Installation

    ELECTRICAL SYSTEM - INSTALLATION 1. Glow Plug ··························································································· 7 -26 2. Stop Solenoid ····················································································· 7 -27 3. Alternator ···························································································· 7 -28 4. Starter ································································································· 7 -29...
  • Page 185: Glow Plug

    ELECTRICAL SYSTEM - INSTALLATION Glow Plug Tightening torque: 14.7 to 19.6 N m (1.5 to 2.0 kgf m) [10.8 to 14.5 lbf ft] Installation of the glow plug <Installation sequence> ‡ A • ¨ ‡ @ 7 - 26...
  • Page 186: Stop Solenoid

    ELECTRICAL SYSTEM - INSTALLATION Stop Solenoid w/ rubber cap and plugs Tightening torque: 39.2 to 49.0 N m Tightening torque: (4.0 to 5.0 kgf m) 39.2 to 49.0 N m [28.9 to 36.2 lbf ft] (4.0 to 5.0 kgf m) [28.9 to 36.2 lbf ft] w/ 3-pole waterproof connector...
  • Page 187: Alternator

    ELECTRICAL SYSTEM - INSTALLATION Alternator Tightening torque: 9.81 to 11.8 N m (1.0 to 1.2 kgf m) [7.2 to 8.7 lbf ft] Installation of the alternator <Installation sequence> ‡ D • ¨ ‡ C • ¨ ‡ B • ¨ ‡ A • ¨ ‡ @ 7 - 28...
  • Page 188: Starter

    ELECTRICAL SYSTEM - INSTALLATION Starter Tightening torque: 9.81 to 11.8 N m (1.0 to 1.2 kgf m) [7.2 to 8.7 lbf ft] Installation of the starter <Installation sequence> ‡ B • ¨ ‡ A • ¨ ‡ @ 7 - 29...
  • Page 189 ELECTRICAL SYSTEM - INSTALLATION 7 - 30...
  • Page 190 ENGINE - INSPECTION / ADJUSTMENT, RUNNING-IN TRIAL AND PERFORMANCE TEST 1. Inspection and Adjustment of Engine ·················································· 8 - 2 ························ 8 - 2 1.1 Preparations for valve clearance inspection and adjustment ······························································· 8 - 2 1.2 Inspecting the valve clearance ·································································...
  • Page 191: Inspection And Adjustment Of Engine

    ENGINE - INSPECTION / ADJUSTMENT, RUNNING-IN TRIAL AND PERFORMANCE TEST 1. Inspection and Adjustment of Engine 1.1 Preparations valve clearance inspection and adjustment S4L,S4L2 Inspection and adjustment of valve clearance should be performed when the engine is cold. Slightly loosen the cylinder head bolts. Then, Front of engine Tightening torque: tighten them to the specified torque in the order...
  • Page 192: Adjusting The Valve Clearance

    ENGINE - INSPECTION / ADJUSTMENT, RUNNING-IN TRIAL AND PERFORMANCE TEST 1.3 Adjusting the valve clearance Loosen the rocker arm nut. Using a thickness gauge, set the valve clearance to the standard value by screwing in or out the adjusting screw. Unit: mm (in.) Standard value...
  • Page 193: Inspecting And Adjusting The Fuel Injection Timing

    ENGINE - INSPECTION / ADJUSTMENT, RUNNING-IN TRIAL AND PERFORMANCE TEST 1.4 Inspecting adjusting fuel injection timing Preparations Close the fuel filter cock. Disconnect the No. 1 fuel injection pipe at both ends. Remove the No. 1 delivery valve holder. Take out the delivery valve and the spring.
  • Page 194 ENGINE - INSPECTION / ADJUSTMENT, RUNNING-IN TRIAL AND PERFORMANCE TEST Adjusting the fuel injection timing If the fuel injection timing does not conform to above specified BTDC, adjust the shim thickness under the fuel injection pump housing. Changing the shim thickness by 0.1 mm (0.004 in.) will change the fuel injection timing by approx.
  • Page 195: Alternative Adjustment Method

    ENGINE - INSPECTION / ADJUSTMENT, RUNNING-IN TRIAL AND PERFORMANCE TEST 1.5 Alternative adjustment method Removing the delivery valve to check and adjust the fuel injection timing is a sure way to observe fuel coming out and stop. However, this also runs the risk of allowing foreign matter to enter into the system.
  • Page 196: Bleeding The Fuel Filter Of Air

    ENGINE - INSPECTION / ADJUSTMENT, RUNNING-IN TRIAL AND PERFORMANCE TEST 1.7 Bleeding the fuel filter of air Press the push button several Fuel filter with selector cock (push-button type) times Open the cock lever and press the push button several times. Fuel will automatically come down into the filter.
  • Page 197: Adjusting The Low And High Idle Speeds

    ENGINE - INSPECTION / ADJUSTMENT, RUNNING-IN TRIAL AND PERFORMANCE TEST High speed Low speed position 1.8 Adjusting the low and high idle speeds position (low idle) Preparations Warm up the engine until the coolant temperature reaches 60• Ž (140• ‹ ‚ e ) or above. Note: Ensure that the valve clearance and the fuel injection timing are correctly adjusted and that the nozzles operate normally.
  • Page 198: Inspecting The Fuel Injection Nozzle

    ENGINE - INSPECTION / ADJUSTMENT, RUNNING-IN TRIAL AND PERFORMANCE TEST 1.9 Inspecting the fuel injection nozzle Nozzle tester Perform the following inspections and, if faulty, repair or replace as required. Injection valve opening pressure Install the fuel injection nozzle onto the nozzle tester.
  • Page 199 ENGINE - INSPECTION / ADJUSTMENT, RUNNING-IN TRIAL AND PERFORMANCE TEST Clean or replace when spraying badly Loosen the nozzle retaining nut and remove the nozzle tip assembly. Clean the needle valve and the nozzle tip body. Needle When removing the nozzle tip assembly, never valve Nozzle tip tap on the end of the assembly.
  • Page 200: Inspecting The V-belt Tension

    ENGINE - INSPECTION / ADJUSTMENT, RUNNING-IN TRIAL AND PERFORMANCE TEST 1.10 Inspecting the V-belt tension Adjusting bolt Press the V-belt at the midpoint of the alternator pulley and the crankshaft pulley, and measure the 10 to 12 mm deflection of the belt. (0.4 to 0.5 in.) Unit: mm (in.) Standard...
  • Page 201: Running-in Trial

    ENGINE - INSPECTION / ADJUSTMENT, RUNNING-IN TRIAL AND PERFORMANCE TEST 2. Running-in Trial 2.3 Running-in timetable The following table shows the running-in Whenever the engine is reassembled after overhaul, phases together with the relevant load and time run in the engine on a dynamometer. While the duration for each phase.
  • Page 202: Performance Test

    Correcting the engine output Standard format of specifications and tests methods Measured brake power and torque should be of diesel engines (JIS D0006-2).” corrected by multiplying them by the diesel Test items will need to be expanded in a manner engine correction coefficient described below.
  • Page 203 ENGINE - INSPECTION / ADJUSTMENT, RUNNING-IN TRIAL AND PERFORMANCE TEST ‡ A Application range of engine coefficient 37.2 • … qc • … 65 mg/( l cycle) qc • … 37.2 mg/( l cycle): fm=0.2(constant) 65 mg/( l cycle) • … qc: fm=1.2(constant) Application range of correction equation Application range...
  • Page 204 MISCELLANEOUS 1. Disassembly and Reassembly of General Parts ································· 9 - 2 ····························································································· 9 - 2 1.1 Oil seals ······························································································· 9 - 2 1.2 O-rings ····························································································· 9 - 3 1.3 Bearings ························································································· 9 - 3 1.4 Lock plates ··········································································· 9 - 3 1.5 Split pins, Spring pins...
  • Page 205: Disassembly And Reassembly Of General Parts

    MISCELLANEOUS 1. Disassembly and Reassembly of General Parts 1.1 Oil seals When installing oil seals, pay particular attention to the following points. Installing oil seals into the housing Check the seal, including for damage to the lip. When installing the seal, ensure that the lip faces the correct direction.
  • Page 206: Bearings

    MISCELLANEOUS 1.3 Bearings When installing a bearing, always tap on the inner or outer race whichever will seat against a stop. Use a tool like the one illustrated that aligns with the inner or outer race whichever is appropriate. Bearing installer With a press, the installation will be smoother and more accurate.
  • Page 207 MISCELLANEOUS 9 - 4...
  • Page 208: Engine Inspection Sheets

    Engine Inspection Sheet No.0 Engine Inspection Sheets Cylinder bore Valve stem-to-guide clearance and valve stem diameter Valve seat angle and width Cylinder head bottom face distortion Connecting rod bearings oil clearance Rocker arm inner diameter and rocker shaft diameter Piston pin boss inner diameter and piston pin diameter Valve clearance Fuel injection nozzle opening pressure 10.
  • Page 209 Engine Inspection Sheet No.1 Engine model Date Customer Engine number Item to be Unit Cylinder bore mm (in.) measured Measuring location Standard value Square with piston pin Nominal Standard Limit value value 78.00 Standard Cylinder ƒ Ó 78 to 78.03 value bore (3.0732...
  • Page 210 Engine Inspection Sheet No.2 Engine model Date Customer Engine number Item to be Valve stem-to-guide clearance and Unit mm (in.) measured valve stem diameter Measuring location Standard value Nominal Standard Limit value value ƒ Ó 6.6 6.600 to 6.615 Inlet (0.2600 to 0.2606) Valve guide (0.260)
  • Page 211 Engine Inspection Sheet No.3 Engine model Date Customer Engine number Item to be Unit Valve seat angle and width mm (in.) measured Measuring location Standard value Valve seat width Standard Limit value Valve seat 45• ‹ angle Valve seat 1.3 to 1.8 width (0.0512 to 0.0709) (0.0985)
  • Page 212 Engine Inspection Sheet No.4 Engine model Date Customer Engine number Item to be Unit Cylinder head bottom face distortion mm (in.) measured Measuring location Standard value Standard Limit value Cylinder head 0.05 0.10 bottom face (0.002) (0.004) distortion or less Measurement Name Cylinder head bottom face distortion...
  • Page 213 Engine Inspection Sheet No.5 Engine model Date Customer Engine number Item to be Unit Connecting rod bearings oil clearance mm (in.) measured Measuring location Standard value Nominal Standard Limit value value Connecting rod bearings inner ƒ Ó 48 47.950 to 47.965 diameter (1.8892 to 1.8898) (1.89)
  • Page 214 Engine Inspection Sheet No.6 Engine model Date Customer Engine number Item to be Unit Rocker arm inner diameter and rocker shaft diameter mm (in.) measured Measuring location Standard value Nominal Standard Limit value value Rocker arm ƒ Ó 19 18.910 to 18.930 inner (0.7450 to 0.7458) (0.749)
  • Page 215 Engine Inspection Sheet No.7 Engine model Date Customer Engine number Item to be Unit Piston pin boss inner diameter and piston pin diameter mm (in.) measured Measuring location Standard value Nominal Standard Limit value value Piston pin 23.006 to 23.012 ƒ...
  • Page 216 Engine Inspection Sheet No.8 Engine model Date Customer Engine number Item to be Unit Valve clearance mm (in.) measured Measuring location Standard value Standard value Inlet 0.25 (0.01) Valve clearance Exhaust 0.25 (0.01) Measurement Valve clearance Inlet Exhaust Before adjustment After adjustment Before...
  • Page 217 Engine Inspection Sheet No.9 Engine model Date Customer Engine number Item to be MPa (kgf/cm Unit Fuel injection nozzle opening pressure measured [psi] Measuring location Standard value Nominal Standard Nozzle tester value value 14.22 14.22 to 15.00 Valve opening (145) (145 to 153) pressure [2062]...
  • Page 218 Engine Inspection Sheet No.10 Engine model Date Customer Engine number Item to be Camshaft journal diameter and Unit mm (in.) measured camshaft bushing inner diameter Standard value Measuring location Nominal Standard Limit value value Camshaft bushing ƒ Ó 45 45.000 to 45.055 No.1 inner diameter (107730 to 1.7751)
  • Page 219 Engine Inspection Sheet No.11 Engine model Date Customer Engine number Item to be Unit Crankshaft end play mm (in.) measured Measuring location Standard value Standardvalue Limit 0.050 to 0.175 0.500 Crankshaft end play (0.0020 to 0.0069) (0.0197) Measurement On disassembly On reassembly Remarks Approved by...

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  • Boniface Musonda Jul 12, 2018 05:56:
    I cant find out whats wrong with Diesel pump in the D434 engine in my 1997 model Rosa bus. The engine just stopped and i thought it was airlock but no. when i loosened the pipes connected to injector nozzles, i discovered that the fuel was not reaching the nozzles. in short no fuel coming from the pump durring cranking.

    please help, what could be wrong with the pump?