MITSUBISHI DIESEL ENGINE DO4FD-TAA for HYUNDAI HEAVY INDUSTRIES CO.,LTD. November 2006 MITSUBISHI HEAVY INDUSTRIES, LTD.INTRODUCTION This service manual describes the specifications, maintenance and service procedures for Mitsubishi diesel engines. ‘To maintain the performance of the engine for many years and to ensure safe operation, it is important to use the engine correctly and conduct regular inspection and maintenance, ‘and also to take necessary measures which involves the disassembly, inspection, repair and reassembly of the engine and engine parts. Read this manual carefully and understand the work procedures fully before disassembling, inspecting, repairing or reassembling the engine. ‘The contents of the manual are based on the engine models that are being produced at the time of publication. Due to improvements made thereafter, the actual engine that you work on may differ partially from the one described in this manual. Pub.No.99616-H0100INTRODUCTION How to use this manual This service manval consists of several Groups, which are arranged so as t0 allow you to make reference quickly to specifications, maintenance standards, adjust uding methods for disassembly, inspection, repair and reassembly of the Mitsubishi Diese! Engine (standard model for land use). A shor summary describing the content of each Group is given in the General Contents page, and there is also a detailed table of contents a the beginning of each Group. Regarding the procedures for operation and periodical maintenance of the engine, refer to the Operation and Maintenance ‘Manual. For information on the engine components and ordering of sevice pars, refe tothe Parts Catalogue, Structure and function ofthe engine are described in the relevant training manuals. ent procedures and service procedures i Methods of presentation ()fndex sumbers alloted to parts in exploded views are not only acal-out of part names listed in tho text but also an indication of the sequence of disassembly (2)Inspestions to be conducted during disassembly process ae indicated in boxes in the relevant exploded views. (B)Maintenance standards requited for inspection and repair works are indicated inthe appropriate position inthe text. They are also collectively indicated in Group 2, the General Contents group, (4)Fasteners to be tightened in “wet” condition, or with engine oil applied, are identified by [Wet] placed after tightening torque values. If no such indication is suffixed, the fastener should be tightened in “dry” condition, or without lubricating with engine ol (6)ln this manual, important safety or other cautionary instructions are emphasized with the following marks headed Indicates an immeciately hazardous situation which, it nt avoided, will result in death or serious injury Indicates a potentially hazardous situation which, f not avoided, could result in death or serious injury. TAEAGTION, Indicates an immediately hazardous situation which, it nt avoided, may result in minor or maderate injury. caution Indicates a potentially hazardous situation which, if not avoided, can result in property damage. Note: Indicates important information or information useful for operation or maintenance of the engine.INTRODUCTION Terms used in tl Nominal ‘means the rated (design) size or magnitude ofa part to be measured, Standard manual ‘means the quantitative requirement for dimension of a part, clearance between pars and performance. This i given in a form of {olerance, Therfore, the values shown are notin agreement with the desiga values. Limit means that, if this value is reached, the part must be repaired or replaced with a new par. Abbreviations * BTDC: Before Top Dead Center + ATOC: After Top Dead Center + BBDC: Before Bottom Dead Center + ABDC: After Bottom Dead Center + TIR: Total Indicated Runout ‘+ APL: American Petroleum Institute “ASTM: American Society for Testing and Materials + JIS: Japanese Industrial Standards + LLC: Long Life Coolant + MIL: Miltary Specifications and Standards (U.S.) + MSDS: Material Safety Data Sheet + SAE: Socity of Automotive Engineers (U.S.) Units of Measurement Measurements are based on the Intemational System of Units (SD), and their converted metric values ae indicated in parentheses {). For metric conversion, te following rates are used. + Pressure: 1 MPa = 10.197 kal/om? + Torque: 1 Nem = 0.10197 kgtm + Force: 1 N= 0.10197 kgf + Horsepower: 1 KW = 1.341 HP = 1.9696 PS + Meter of mercury: 1 KPa = 0.7 emg + Meter of water: 1 KPa = 10.197 cmH:0 (omAq) + Rotational speed: tmin = 1 rpmINTRODUCTION Safety Cautions Fire and explosion Keep flames away Store fuel and engine oil ina well- ventilated designated area. Make sure that the caps of fuel and engine oil containers are tightly closed. Do not use flames, do not smoke, ‘do not work near heater or other fire hazards where fuel or oll is handled or when cleaning solvent is being used for washing parts. Wipe of spilled fuel, oil and LLC immediately and thor- oughly. Spilled fuel, cil and LLC may ignite and cause aire Keep surrounding area neat and clean Do not leave combustible or explosive materials, such as fuel, engine oll and LLC, near the engine. Such sub- ‘tances can cause fire or explosion, Remove dust, drt and other foreign materials acoumu: lated on the engine and sorrounding parts thoroughly. ‘Such materials can cause fire or the engine to over- heat. In particular, clean the top surface of the battery thoroughly. Dust can cause a short-circuit Always operate the engine at a position at least 1m [8.28 ft] away from buildings and other equipment to prevent possible fre caused by engine heat. Care about fuel, oil and exhaust gas leakage any fuel, cil or exhaust gas leakage is found, immedi- ately take corrective measures to stop it Such leakages, If left uncorrected, can cause fuel or engine oil to reach hot engine surfaces or hot exhaust gas to contact flammable materials, possibly leading to personal injury andlor damage to equipment. Use explosion-proof lighting apparatus When inspecting fuel, engine ol, coolant, battery elec trove, etc, use a lameproot light. An ordinary light, it it accidentally broken, may ignite and cause an explo- sion, Prevent electrical wires from short-circuit- ing ‘Avoid inspecting or servicing the electrical system with the ground cable connected to the battery. Otherwise, a fire could result from short-circuiting. Be sure to dis connect the battery cable from the negative (-) terminal before beginning with the work procedure. ‘Short-circuits, possibly resulting in fire, may be caused by a loose terminal or damaged cable/wire. Inspect the terminals, cables and wires, and repair or replace the faulty parts before beginning with the service proce- dure. Keep fire extinguishers and first- handy Keep a fire extinguisher handy and bbe familiarized with their usage. Keep a firstaid kt at a designated place, and make sure itis easily ac- ‘cessible whenever needed, id kit Establish emergency procedures to follow in the event of fre or accident, and keep the per- sonnel informed of emergency contact locations and contact methods.INTRODUCTION Stay clear of all rotat Install protective covers on rotating parts Make sure the protective covers for engine rotating parts are properly installed as intended. Repair loose or damaged protective covers as necessary. Never remove the covers guarding Personnel from rotating parts, when the engine is oper- ating. When combining the engine with the engine-criven ma- chine or radiator, always provide @ cover on every ex- posed moving part such as driving belt and coupling, Never remove protective covers. Ensure safety of n starting engine Before staring the engine, ensure that there is nobody in the neighborhood and no tools are left on or near the engine. Be sure to give a sign with a shout when star- ing the engine. When a tag saying “Do not operate” is attached on or near the starter switch, never start the engine, hboring people before Stay clear of moving parts during engine running Do not approach rotating or sliding parts of the engine when the engine is in operation. Keep objects likely to be caught by rotating parts away from such parts. Hf any part of the clothing or outfit ting is caught by a rotating part, se- rious bodly injuries could result ting and moving parts Lockout and Tagout Be sure to lockout and tagout before starting inspection ‘and maintenance. Lockout and tagout are effective methods of cutting off ‘machines and equipment from energy sources. To accomplish the lockouttagout, remove the starter ‘witch key, set the battery switch to OFF and attach a “Do Not Run" or similar caution tagto the starter switch, ‘The starter switch key must be kept by the person who performs inspection and maintenance during the work. In the case of pneumatic starting type, close the main valve of the air tank and post a tag saying "Do Not (Open the Valve" or the lke, Keep engine stopped during servicing Be sure to stop the engine before proceeding to Inspec- tion and service procedure. Never attempt to make ad- Justments on the engine parts while the engine is running, Rotating parts such as belt can entangle your body and cause serious injuries. Always restore engine tun use Do not forget to remove the tools which have been used for turning the engine during inspection or servic- ing, aftr the procedure is finished. Remember also thatthe tuming gear must be returned to the operating condition before starting the engine. Starting the engine with the turning too's inserted or withthe turning gear in engagement can lead to not only engine damage but also personal injures. 19 tools afterINTRODUCTION Be careful of burns Do not touch engine during or immediately Det acetal mama inmatoy er operation 1 eee ees feaocea na aac after operation Slowly and carefully open radiator cap [Never attempt to open the radiator cap while the engine is running or immediately ater the engine stops. Give @ sufficient cooling time to the engine coolant before ‘opening the cap. When opening the radiator cap, slowly tum the cap to release intemal pressure. To prevent scalds with steam gushing out, wear thick rubber gloves or cover the cap with a cloth Close the radiator cap tightly without fal The coolant is very hot and under pressure during en- gine running or ust after the engine stops. Ifthe radia tor cap is not closed tightly, steam and hot coolant may {gush out and can cause scelds. ‘Add coolant only after coolant temperature dropped Do not add coolant immediately atter the engine stops. Wait until the coolant temperature lowers sufficiently to avoid @ risk of burns Protect ears from noises Wear ear plugs Always wear ear plugs when enter- ing the machine room (engine room). Combustion sound and me- chanical noise generated by the en- gine can cause hearing problems.INTRODUCTION Be careful of falling down Lift engine correctly For iin the engine, aay use @ conect wie rope capabie of wih- ZL standing the engine weight Aso, attach the wi rope tothe comrect iting hangers orginal ft ted on the engine using a corec sing During iting process, keep the engine in a wol-bal- anced poston by taking the centro ray of the en- dine into corlderaton Dring ting process, keep the engine in a wel-bal- anced poston by taking he center of gray of the en- sine into consideration. If he wire ope contacts the engine drect, place a dlth or other soft pading betweon thom to prevent damage tothe engine and wre rope Do not get on engine Do not got on top of the engine, nor stap on any engine paris located onthe lateral sides. To work on pars located on the upper section of en- sine, use a ladder, stool, etc, firmly secured not to fall down, Falling down of such foctholds could rasult in not only to damage of the engine parts but also personal inju- vies Vi Honea Snes Be careful of handling fuel, engine oil and LLC Use only specified fuel, engine oil and cool- ant (LLC) Use fue, ol and LLC specified inthis manual, and han: de them carefully Use of any other ful, clor LLC, and improper handling may cause various engine problems and malfunctions Obtain the MSDSs issued by the fuel, ci and LLC sup- pliers, and folow the directions in the MSDSs for prop- er handing, Handle LLC (long life coolant) carefully When handling LLC, always wear rubber gloves and protective face mask. IfLLC or cooling water containing LLC comes into contact wth your skin or eyes, oriftis swallowed, you would sutfer from inflammation, iita- tion or poisoning, Should LLC be accidentally swallowed, induce vomit- ing immediately and seek medical attention. Should LLC enter your eyes, flush them immediately with plen- ty of water and seek medical attention. LLC splashes conto your skin or clothing, wash it away immediately with plenty of water. Keep flames away from LLC. The LLC can catch flames, causing a fire. Drained coolant (containing LLC) is harmful Do not dispose of it in unauthorized manner. Abide by the ap- plicable law and regulations when discarding drained coolant. Proper disposal of waste oll and coolant (uc) Do not discharge waste engine ol or coolant into sew: ‘erage, river, lake or other similar places. Such a way of disposal is strictly prohibited by laws and regulations, Dispose of waste ol, coolant and other environmentally hazardous waste in accordance with the applicable law ‘and regulations, or consult a Mitsubishi dealer.INTRODUCTION TEE TSA CAUTIONS Service battery Handle battery correctly + Never use flames or allow sparks to generate near the battery. The battory releases flammable hydrogen gas and oxygen gas. Any flames or sparks in the vicin- ity could cause an explosion, Do not use the battery the fluid level of which is low- fered below the lower limit line. Sustained use of the battery could result in an explosion Do not shor the battery terminals with a tool or other metal object, When disconnecting battery cables, always remove the cable from the negetive (-) terminal frst. When reconnecting the cables, attach the cable tothe posi- tive (4) terminal fist Charge the battery in a well-ventilated area, with all filing hole plugs removed Make sure the cable clamps are securely installed on the battery torminals. A loose cable clamp can cause sparks that may resutin an explosion. Before servicing electrical components or conducting electric welding, set the battery switch to the [Open! OFF} position or disconnect the cable from the nega- tive (-) battery terminal to cut off the electrical cur- rent, Electrolyte (battery fiuid) contains dilute sulfuric acid Careless handling ofthe battery can lead to the loss ‘of sight andlor skin burns. Also, keep the battery fuid off the mouth. Wear protective goggles and rubber gloves when working with the battery (when adding water, charg- ing, etc), If electrolyte is spilled onto the skin of clothing, immediately wash it away with lots of water, Use soap to thoroughly clean The battery fluid can cause blindness if splashing into eyes. If it gets into eyes, immediately flush it away with plenty of clean fresh water, and seek immediate medical attention. It the battery fuid is accidentally swallowed, gargle with plenty of water, then drink lots of water, and seek immediate medical attention, Tita TTT When abnormality occurs ‘Stop overheated engine after cooling run Even ifthe engine comes to overheat, do not stop the ‘engine immediately. Abrupt stopping of an overheated congine oan cause the coolant temperature to rise, 1e- sulting in seized engine parts. If the engine comes to overheat, run the engine at low idling speed (cooling ‘operation), and stop the engine alter the coolant tem perature lowers sufficiently Do not add coolant immediately after stopping the en gine. Adding coolant to hot engine can cause the cy inder heads to crack due to sudden change in temperature. Add coolant lie by litle ator the engine cools down to room temperature. ‘Avoid immediate restart after abnormal stop Ifthe engine stops abnormally, do not restart the en- gine immediately. Ifthe engine stops with an alarm, check and remedy the cause of the problem before re- starting. Sustained use of the engine without any rem- dy could result in serious engine problems. Avoid continued engine operation with too low oil pressure If an abnormal engine oll pressure drop is indicated, stop the engine as immediately as possible, and in- ‘spect the lubrication system to locate the cause. Con tinuing to operate the engine with low oil pressure may ‘cause seizure of the bearings and other parts Stop the engine immediately if fan belt is broken If the fan belt is broken, stop the engine immediately. Continued operation ofthe engine with the fan belt bro- ken could cause the engine to overheat and thereby the coolant to bol into steam, which may gush out from the reserve tank or radiator, and cause personal inju VilINTRODUCTION ESSE eye eee aE SENS UOTE ES EEE Other cautions Modification of engine prohibited Unauthorized modification of the engine will void the manufacturer's warranty, Modification of the engine may not only cause engine damage but also produce personal injuries. Pre-operational check and perio tlon/maintenance Be sure to perform the pre-operational checks and pe- fiodic inspection/maintenance as described in this manual Neglecting the pre-operational check or periodic in- spection’maintenance can arouse various engine trou- bles such as damage to parts, eventually leading to serious accidents, inspec- Break-in operation ‘A new engine needs to be broken in for the first 50 hours of operation. During this period, do not subject the engine to heavy loads. Operating a new engine under high loads or severe conditions during the break-in period can shorten the servos lite of the engine. Warming-up operation After starting the engine, run the engine at low idling speeds for 5 to 10 minutes for warming-up. Start the work after this operation is completed. Warm-up operation circulates the lubricant through the fengine. Therefore, individual engine parts are well lu- bricatad before they are subjected to heavy loads, This js very important for longer service life, high-perfor- mance and economical operation. Do not conduct warm-up operation for a longer time than necessary. Prolonged warm-up operation causes ‘carbon build-up in the cylinders that leads to incom- plete combustion, Avoid engine operations under overload condition If the engine is considered to be in an overloaded con- dition which is identified by too much black smoke, etc., immediately reduce the load on the engine such that the correct output and load condtions may be achieved. ‘Overloading the engine causes not only high fuel con- sumption but also excessive carbon deposits inside the engine. Excessive carbon deposits can cause various engine problems and shorten the service life of the en gine remarkably. VII Cooling operation before stopping engine Always conduct the cooling operation (low speed idling or 5 t0 6 minutes before stopping the engine. Abruptly stopping the engine immediatly after high- load operation can cause partial overheating and shor on the service ite ofthe engine, During cooling operation, check the engine for abnor malities. Protection of engine against water entry Do not allow rainwater, etc. to enter the engine through the air inlet or exhaust openings. Do net wash the engine while its operating. Cleaning fluid (water) can be sucked into the engine. ‘Starting the engine with water inside the combustion ‘chambers can cause the water hammer action which may resut in intemal engine damage and serious accl- dents, Maintenance of air cleaner or pre-cleaner ‘The major cause of abnormal wear on engine parts is dust entering with intake air. Worn parts produce many problems such as an increase of ol consumption, de~ Crease of output, and starting difficulties. For effective removal of dust from intake air, conduct maintenance of the air cleaner according to the following instruc- tions. + Do not conduct maintenance of the air cleaneripre- cleaner while the engine is operating. Engine opera- tion without the air cleaner/precteaner in place allows, foreign matters to enter the turbocharger, causing it to damage seriously. + Remove the air cleaner/ore-cleaner slowly to prevent dust accumulated on the element from falling oft. ‘After removing the air cleaner or pre-cleaner, imme- diately cover the opening (inlet port in case of ai leaner; port in body in case of pre-cleaner) with plastic sheet or similar means to prevent dust from entering the engine. * Air cleaners equipped with a dust indicator wil issue an alarm if the element gets clogged. Service the cleaner as soon as possible if an alarm is issuedINTRODUCTION Safety rules at work site When operating or servicing the engine, always ob- serve the applicable safely rules established at each work sit, If you are feeling il, donot operate the machine, butin- {orm the supervisor of your condition Unsatisfactory physical condition reduces the concen- tration, Operation of the machine with reduced concen- tration may cause operation errors that may resutt in accidents. \When working ina group, use specified hand signals to communicate among the workers. Work clothing and protective gear Wear a hardhat, face shield, safety shoes, dust mask, loves and other protective gear as needed. When handling compressed air, wear safety goggles, hardhat, gloves and other necessary protective gear. ‘Works without wearing proper protective gear could re- sult in serious injuries. Use of tools optimum for each work Always Keep in mind to select most appropriate tools, for the work to be performed and use them correctly I tools are damaged, replace with new tools. Avoidance of prolonged time of starter oper- ation Do not operate the starter for more than 10 seconds at atime even ifthe engine does not start, Wait fort least 30 seconds before next engine cranking, Continuous operation ofthe starter will drain the battery power and cause seizing ofthe starter. Do not turn off battery switch during opera- tion I the battery switch is turned OFF when the engine is running, not only various meters will stop working but also the alternator may have its diode and transistor deteriorated, Cautionary instructions for transporting en- gine When transporting the engine on a truck, consider the engine weight, width and height to ensure safety. Abide by road trafic law, road vehicles act, vehicle restriction ordinance and other pertinent laws. Avoid continuous engine operation under low load conditions Do not operate the engine continuously for more than 410 minutes with a load of less than 30%, Engine oper- ation under low load conditions increases the emission cof unbumed fuel. Therefore, a prolonged time of engine operation under low load conditions inoreases the uantiy of unburned fuel adhering to engine parts, pro- Voking the possibilty of engine malfunctioning and shortening the service life ofthe engine. Ventilation of engine room Always keep the engine room well-ventilated. Insutf- cient amount of intake alr causes the operating temper- ature {0 rise, resulting in poor output and lowered performance. It is highly recommended to calculate the required ‘amount of air supply to the engine and install an ade- quate ventilation system before putting the engine to Avoid contact with high-pressured fuel ‘Should fel leak from a uel injection pipe, donot touch the spouting fuel directly Fuelin the fuel injection pipes is under high pressure. I high-pressured fuel contacts you ski, it penetrates ‘through the skin and may result in gangrene,INTRODUCTION About warning labels Maintenance of warning labels Make sure all warning/caution labels are legible. Clean or replace the warning/caution labels the description andlor illustration of which cannot be seen clearly. For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvents, gasoline or other chemicals to prevent the letters from getting blurred or the adhesion from being weakened, Replace damaged or fractured labels with new ones, If any engine part on which a waming label is attached is replaced with a new one, attach a new identical warning label to the new part. To obtain replacement waming labels, contact a Mitsubishi dealer. TURNING CAN AOTATIN Pats, CAUSE SEVERE HN CAUSE SEVERE PERSONAL INJURY, PensowaL inuunt, |] [°F + B= SURE No DANGER OIL MIST IS FLAMMABLE” AND EXPLOSIVE. D0 NOT OPEN [AROUND NOVING PARTS KEP AWAY FROM ROTATING BEFORE TURNING. INSPECTION. COVER FLY + Keep TuRNNG device WITHIN 10. MNUTES ‘+ 00 NoT openare wHouT Oe BARN OFF Pos AFTER ENGINE. STOP. Forest COVER ‘TON Wrsen NOT BLUSE. | ACAUTION = HIGH PLACE MAY CAUSE FALLING = BE CAREFUL wHenE YoU Sree oN ScagFOLD, VOLTAGE MAY CAUSE ELECTRIC SHOCK. Toa rrave erone tne On ATEN, nar ruc ay ecm OJON ch 74 ‘© 00 optare m7 0008 ‘ho PROTECT IER 1 ey re SUE = er ee Rue, BR SOU 100 Nor pur ANY WpRopeR DDATERIALS oN EnaINE AND SCAFFOLD, ca FTTH fin ve aa NE MUCIL gan “= RL OF TANS Ef iS, ote iRY ESSA abi Sr | Warning labelesGENERAL CONTENTS Sonar Teena Tn eee ate drawings | system flow ene Engine seria nmber lation 1 Main peiiatons Tips on tnassembling and reasembling ainenance venice da ce List of tightening torque a Basic and special tools ‘Special tools a 3 ae Detenining oval ining a ‘esting compression pressure Disassembling and inspecting eylindsr head and valve mechanism Disassembling an inspecting tiywhee) Disassembling engine main paris psacsembling and inspecting gear case ing gear and camshaft s Disassembling and inspection crankcase, crankshaft an piston Tnspecting and repairing cylinder bead and valve mechanisms Inspecting and repairing engine main | Inspecting and repairing flywhee! 6 parts Inspecting and tepsrin timing gears and camshaft Inspecting and eepsring piston, connecting rod, crankshaft and erankease ‘Reassembling piston, connecting rod, crankshalt nd crankcase RReusembling engine main puns | Ressembling timing ger and eamshalt 7 Reassembling flywheel Reassembling cylinder head and valve mechanism ‘Removing fel stem Poel system Assembling fuel system 8 Installing fut system Removing and inspecting lubrication system Lubrication system Disassembling inspecting and reassembling lubrication system 9 Installing lubrication sysem Removing cooing system Cooling system Disassembling, inspecting and reassembling cooling system 0 Installing cooling system ‘Removing inlet and exhaust stem Init and exhaust systems Disassembling, inspecting and reassembling inet and exhaust " Insalling inlet and exhaust system ‘Removing elecieal system 1 tectrical system Disassembling. inspecting and reassembling electrical system. 2 Installing eletical system Adjusting engine Break-in operation B Performance test (JIS standard) ‘Adjustment, break-in operation and performance test lcaironie woubleshooting Programming parameters System configuration parameters Troubleshooting ‘Troubleshooting without a diagnostic code “ Troubleshooting witha diagnostic code Troubleshooting with an event code Diagnostic functional testsGENERAL 1. Outline drawings ..... 7 -2 1.1 DOSFD-TAA Outine drawings, 12 2. System flow 2.1 Fuel flow. 22 Oilflow 2.3 Cooling water flow. se 2.4 Inlet and exhaust flow... 14 2.5 Electrical wiring diagram... 15 3. Engine serial number location 4. Main specifications. 5. Tips on disassembling and reassemb- ling... 1-10 5.1 Disassembling, 410 5.2 Reassembiing 440 1-1GENERAL, 1. Outline drawings 1.1 DO4FD-TAA Outline drawings Turbocharger Breather Exhaust manifold Thermostat Rear hanger Atemator Front Rear Flywhee! Stator Belt Flywheel housing Oil drain cock Engine lett view Oillevel gauge Oil filer Se eect i fit —_ ) ‘ir heater i a) ae Water pump Oil cooker —_F 3 Rear rs a Front I 1 Fuel pump Relief valve Engine right view 1-2GENERAL 2. System flow 2.1 Fuel flow Taf, kipctr co oS Ns 7 Fuel ter Common ail From fue tank Fuel pump Fuel tum 22 Oilfiow Yate mechanism en Oil fiter a a Relief valve: Oi cooier (Crankshaft il flow 1-3GENERAL 2.3 Cooling water flow Thermostat © Bypass pipe: Water jacket ~~ Water pump Cooling water flow 2.4 Inlet and exhaust flow << Inet A Exhaust Turbocharger Mutter Inlet and exhaust flow 1-4GENERAL, 2.5 Electrical wiring diagram Injector power supply Boost pressure sensor | temperature Speeditiming sensor pane, |) (Crankshaft side) Common rai pressure sensor High pressure pump solenoid Engin ol pressure sensor a\ ecw /~w ‘Speedtiming sensor (Camshaft side) Electrical wiring diagram 1-5GENERAL, 3. Engine serial number location ‘The engine serial number is stamped on the side of the crankcase ‘Engine serial number ‘Stamp location of engine serial number 1-6GENERAL 4. Main specifications Table 1-1. Main specifications (1 /3) Taaeaine rode ; To DOFDSTAR, "Type ‘Water soled, + eyele diesel engine, tarbocharged No.of eylinders arrangement 4 ylinderi-ine ‘Combustion Stem Direct injection ‘Valve mechanism ‘Overhead (2 intake valves, 2 exhaust valves) Gin bore x sroke 102 x 130 mm (4.02 «5.12 in) Displacement S2OL 259 ein] Main ‘Compression ration 1651 spesitication | Fyst Diesel fuel Firing order 7 1342 Direction of rotation Counterlockwise when viewed Irom Mywhesl ide —— Tength B51 mam [3468 in] (varies depending onthe | Wt 703 mam [27.68 in] ee Height | IN] Dy weigh “Approx. 420g 1926 Ist Cylinder sleeve Ope Dry Compression ~ 2 Number of piston ing CORSON Oilring T with expander) Open BTC 1s ee Ce main pans | Valve iming (when Close ABDC A engine is hoo) Open Baca Exhaust valve Close TDC 15 Staring aytem Santer ing aid stem ‘Airheater Tre ‘Common al fl injection system Fuel [Modcinumber—=~=S=~S*~“‘~*~*~“‘“‘“‘~*~é‘~*tCSSCSCi‘itiCtCtCSR System Manufacturer - Caterpillars Fuel filer pe ‘Caridae oe paper element Tabricatine ype Forced Giculation type (oil pur pressre Fed yp8) Classification “API classification CF or above class Engine ol “Toul capaci : antes 1851 [489 US gallons} Te Gear pe oll pump Oit pump poe Delivery capacity ‘61 {ITA US gallons1800 min Oil system We Piston valve PE Relief valve | La | Valve opening pressure L Oil canter ype Oil fiker wpe (35 £05 kgtlem) [50 7 psi] ‘Water-cooled, multi-plate type rirdge Ope paper element Safety valve opening pressure MPa (11 trem) 1: silGENERAL, Table 1-1 Main specifications (2/3) Engram r DoT a tro od craton Cont copay agro wake) | SE 139 US gallo apo Toe oun Water ue THE GUS gallo] cn Disctage apy es se [Waerpump ploy spend al Te ett ne pecan Fale Tide Type ‘Wax type Thermostat falve opening temper: ‘ale opening eps nia 3c i0s3671 Inlet and “Model number 7 TDOAHL fxn | Tubostarger poston __| tem * Qy : Conran [EM Hoa aoe ADEM AER ¢ (Electronic Contr! En ear er m Medale) Manufacturer Caterpillar Ie.GENERAL, Table 1-1 Main specifications (3/3) Manufactrr Misbishi Elearonie Corporation Tee MOORTEOSTI |i sing st | ee a a oy 7 Ting gear wd pinion rato Tone TW etage av a Nosead hare Care BSA erbelow Speed 3300 minor above Vohage W Ladetan eer Tk ore ' ‘Torque ‘88 Nem {9.0 kgfem) [65 Ibf'ft] or above ‘Switching vol 16 or below = we ‘When de peed ange Te phase alematngcurent, with eter Manufaarr ‘isis leaone Corporation Model number ADOT ‘Output ZaVS0A ~ ated volage pneang a Alternator: speed aa co ee Permits spd 60 in Regulued volage SVE ON Se can a a Tye sare aor LS 1-9GENERAL 5. Tips on disassembling and reassem- bling ‘This service manual specifies the recommended procedures to be followed when servicing Mitsubishi engines. ‘The ‘manual also specifies the speci tools that are sequired for the work, and the basic safety precautions to follow when working Note that this manual doesnot exhaustively cover potential hazards that could occur during maintenance, inspection and service work of engine ‘When working on an engine follow the relevant directions given in this manual and observe the following instructions 5.1 Disassembling (1) Use correct tools and instruments. Serious injury or ‘damage to the engine will result from using the wrong tools and instruments. (2) Use an overhaul stand of work beach s nacessary and follow the disassembling procedures described inthis maou (3) Keep the engine parts in order of removal to prevent losing them. (4) Pay attention to assembling marks, Put your marks on tho pats if nocessary, to ensure comect reassembling (6) Carefully check each part for defects during disassembling oF cleaning. Do not miss symptoms which can not be detected alter disassembling or cleaning (6) Whea lifting o carying heavy pats, excercise utmost ‘caution 10 ensure safely. Pay altention to blance of heavy parts when handling. (Get help, and use jacks, chain blocks and guide bolts as necessary.) 5.2 Reassembling (1) Wash all engine parts, except such parts as ol seals, O- rings and rubber sheets in cleaning oil and dry them vwitn compressed att (2) Use correct tools and instruments (8) Use only high-quality lubricating oils and greases of appropriate types. Be sure to apply oil, grease or adhesive to the part wherever specified, (4) Use a torque wrench to tighten pars correctly when their tightening torques are specified. Refer to "Lis of Tightening Torque." (8) Replace all gaskets and packings with new ones unless specified otherwise. Apply adhesive if necessary. Use only the proper amount of adhesive. 1-10SERVICE DATA 1. Maintenance service data 1.1. Engine general... 1.2 Engine main part. 1.3 Lubrication system, 1.4 Cooling system .. 4.5. Inlet and exhaust system 1.6 Electrical system. 2. List of tightening torque... 22 22 23 27 28 28 28 2-9 2.1 Major bolts and nuts tightening torque... 2-9 2.1.1. Basic engine. 2.4.2 Fuel system 2.4.8. Lubrication system 2.1.4 Inlet and exhaust system 2.1.8 Electrical system 2.1.6 Sensors and ECM. 29 29 240 210 240 240 2.2 Standard bolt and nut tightening torque. 2-11 2.8 Standard eyebolt tightening torque 2-12 2.4 Standard union nut tightening torque... 212SERVICE DATA 1. Maintenance service data 1.1 Engine general Table 2-1 Maintenance service data table - Engine general Unit: mm fn] Tepecion pont | Nome [Sanaa a Toner lim vein speed "es pending on sestiions Miniawmnrevoienspied———~SCSCS~S~S~*=*zi 29 MPa 26MPa ‘Men i and water tear Compression pressor (0300 min) (20kgten) 2 katt) | apo 7c Uh os) ceetes | (6tio8"F) 204 MPa TNS Raed speed (210 4katem (15 ktm) Lebvionting ol pre [ae 0 $69 pa | 213 pa | ontenpenae sure 7 Oi hia ‘OOS MPa—| (15810 194] Low ing (rege (0.5 tien?) eee tps) a BIDE fate pe san | Cio] __ABD EAE es ate ing pea] BR ‘crank ante me [ose [ames toe a Nate earace 20098 (in col) aa] Exhaust ae S010 efoto wen te Fane destin 19315%0 foveal peed ita 03541 humb ragsSERVICE DATA 1.2. Engine main part Table 22 Maintenance service data table - Engine main pat (1/4) Unit: mm fi] E Teper Torna | Sandara Tat ea 7 Te ison Foie Teal nding cs of Canc | es ot ep ste 0s ono0joriss | 02 (0008) cake op and pine ebm 000] ay | BESTOW IED | op app agen) | mits eta om or es PLO | goret 4017s) | 1270181 are sleeve, and hone to vine : - — ‘soiom sons Sone Sess ToT wooDe ores uae Tcyitoatiy 0015 ame ores one ~ Ifthe measured value tsa dr a ‘eran ein pe Ceaser min being a oos00318 |) gaapioam) | Stan ein sus oe iaooan 60.04) ee ee Panag Smal an ewe Sing \ 7 ‘Replace thrust plate. The wis of tv oa 100100268, ase iT ‘Tint sews) 00% 0109, | °3%)0018) | tm means y 2 wmeeHeA | woos | REM oi 2087) 10.8661 t0 0.8670) 100 108701) | 162.200 4.0236) hoe st rome Reps appt dana ‘Clearance between tappet and tppet ons 0.120 {0.0047} _| tappet hole is +0.10 (0.0039), tore (oontswo0% sz an T Front 0.0410 0.08 ~ cond | Seamaster | id to.atseo.003s) | 215100591 | pie buching bushing | Ping and cam rr (eam if ecessary) Sania Dp 3100000 e ben 10,0016 to 0.0047} ieee cic ajo Teal ning cons of mice | torino ta tc cos toomoyortss | 02(0008) | crnksts top and nse ea ead m2 0c Cranage | aOR | SOTO ceeswas | cao ons Valve stem dames [" 10.2585 10 0.2591} ome 2 sesro2ey MACON seus Eoust Wane | gseoin2ssn valve, 7 ~ 0.020100.050 0.100 10.00: : pe an sem sbi 008s ; [extnue ome] 10000039) Taro op of ave wie RSTSERVICE DATA Table 2-2 Maintenance sorvice data able - Engine main pat (2/4) Unit mm ‘ate sen Ee = ta oso | yagees, | tm001 | sxe Varese oawoa Varese emt 0310013 1908) = = L000 e016 = iam TaoaH Tapa | sex with ee Em T2001 Teroamay | Sede Terns | ogi vere main 70 | dis Weaplot? tnosiowcorm | Sante! ah S| wae 020" ort setsomer | 3 =1800 openly a0 2 Vave | over enti eng t, roe BSNS | astern sot tagiand aN gn | tsa [24.9 0 27.9 bf] a Recterbubiginie dames | o25f00n1 | eB DAgTE, roster eee ETT) over [petra amtr osm) | SENT Gama ae ak alg Tent wo0e Str rooms worozg | 207810001 Tan Rewe aa (oidjorke | oa aia) [TR 310 Te tome oosqoeniseries | 92 Teds iio stove ele bea o moses seas | fuwdancer trian — ae (3.5413 t0 3.5421) (3.5374), ‘the limit, grind the journal soitcototeson ang Sst 101350 Gosesioe | eae ign dec sons | Gasecins | smn, rs re Sacnoun Fannin crank [Patton tetera and om ‘anon Tamia oars coat Taomae um (Giameter difference) eee (0.0012) ny of ala ar om (diameter difference) 001 1.0008] or Tess {0.0012} ile io jar wa] sna vOM ani oie Bupa | =02 00m) Ten yr Wp pes o1cow02se ato ad pay ‘ Meni ply xed ik, foo woot | ooisy | extent tsSERVICE DATA ‘Table 2-2 Maintenance service data table - Engine main part (3/4) Unit: mm fin] To SBeSTOR PO SS Tat Rana 5 ToLsiswioias | 10173 : twomrswsorse) | oosid use damaer ions TRS | i018 Harpisonskiry | 02508 91021800) | iozzzwans4) | 0180 , imstsowees | mma | [o2ses toma woaosss) | eons) — ewig clearance ek cio om ca os on Gasket compresed | Pm m ratse 810081 oanyenee re | 080057 0.00201 Poms | Charansobawen pio ia oleand Toosreo0RT 0050 ison pin (e002 000081 | 100020) ‘Weg iene ne ening 30g l02clries a 00810012 0200 oe tooost wooos7) | (0009, Cannes teres For = psonragand NO? 00819012 aso fnggroove | Samm toot oer; ) 00059 on )aaasoones os oe twaoiore0.00 | (o00s9) T Compson Tao W045 - Pon snes 01s 00171 ts sing | OP 73010050 (00390) [eae (poiis.6 00157 Tuan | Sahw x07 ite daneter emuag | jimmie pon pn | CEBSREEBSWEE na Como ‘ans 005% 08 ml | ed sing toooesieooon | 1000sn saan | Siameseas T Inside diarsterof basting emusn | tigre tion nee Tosi Ts oe toooxos.stjoress | toons ‘leranse bacon rank ad or 0035;0 0100 0200 Connect oct rod arog toa0141000391 | (00079) et om Dis W035 0.30 | Replas conecing od bear bad tosswooarse) | oi | ne. ‘Wea rnc one ea 10 g(04 exter Tene (OE CrsiooosmI orks | eSTOO1N7] ties [Racor : Tus Omori | _OSTOUNT 25SERVICE DATA ‘Table 2.2 Maintenance service data table - Engine main part (4/4) Unit: mm fin] SR 0S ono otrmaorstortss gil, | Repirusing apres, | roms) | Rer Marae Major asia a sicerstoza | esses - 102226) mae ts comin se | Marae Majer asin = const sta ae Ba, | axsnrassioasiy | MAS890 sie 25) (07 TDs wsiI6 399 1 saat Fonemane [#8210 | eiew2iu) | e120) sae ae 9405296 390 “ #8201 | eouae2oxso) | 2007 a0w028 030 Endpley 10003910005) | mans; _| Reverse rence bacon ier basing wl 7009190050 1 prep ia35) | napa bas at 1.006 1000201 [ieee pecan cer | ler eae pay aoe = joe ts ae Wer | ter eres ay woun0taoor | morse, _| Reise sso Tnacncetewernsbahandcank | o0I69-0035 case ae 1136 | co0msi6-00138) Between crankshaft gear 0.051 0.157 0 soir st roeanwonaess; | 009s) ing | Bewen canst ar 10520158 725 peace par etic | ir gar tomr occa) | tooo, _| Reve Bewesn neon pan em 055190208 it gear rooo2zmo.oost | (0.0098)SERVICE DATA 1.3 Lubrication system Table 2 Malnonance sence da table Lbricaton system Unit mm fn) Tecan | Saas] Fame ‘Backlash between the oil pump idler geur 0.086 10 0.228 035 ~ ‘Backlash between the oll pump idler gear (0.057 «0.172 035, ao shitting | eomoeean [nn eerie £-0:0004 10 0.00211 | £0.0059) Radial clearance of peri case eae outrun Giants ara an er os Sods ance bee ha a toooistonomal | 0351 335 | 29 oR ccna to9s1_| 1o9sist009827) 325 | 25000025001 (098) | (09848009881) T0027 10.0039 0.01061 (ll pump idler gar bushing inside dameter i pup idler gear en play Tass nS MPa Rete save ‘Valve opening prosure (33.205 sgtom*) (498271 pall TIMP Salty valve Vale opening presse (ul kgm) 57 psSERVICE DATA, 1.4 Cooling system Table 244 List of maintenance standards - Cooling system Unit: mm fn} Tem Tennal | Sataad | om Foner Tnerfeenceboween pump ToT oe Hemsemblig isnot shaftand flange iovots ines) ton Tnerfeencebewesn pump com 00m Rensembig miedo shaft and impeller | too vaca tele Clearance between impeller TT oasio 182 and ese inate w 00638) Tato pan 730059 Unit e ee ay aa woawaae Fre ti (0813400958 ‘Water pump Inside diameter of pump case iene (2.0468 10 2.0479] ‘bearing fitting portion 2 61.988 t0 62.018 wang (2.4405 to 2.4416) 780 9 3500 tmiseaamcer | asroos | ioe nay Sea | 51987 w 52000 Bearing 528205) (2.0467 t0 2.0872) si canter ome ane) [2.4404 to 2.4409) Tnaedanetr Fa bothe | as gag, | ROW ARON fing portion ; (o9set 0987 7 ‘ate opening emperte ace Tepe wih ave we tess nn [0.099 in} hove cuss 1.5. Inlet and exhaust system “Table 2-5 List of maintenance standards - Inlet and exhaust system Unit: mm tin Tei TL Nemnel Sena Tonio nema. of exhaust manifold 1.6 Electrical system 12 (0.08) or ss Table 2-6 List of maintenance standards - Electrical system Unit: me fn] Tom Tone Sener ime Fema | commun dame os we Commutator diameter 11259) 236) 03 or below 010 Cova ent tooorzerbetow) | (00039) ‘Unde th oa deca ep Be Saree 8 ti eit 7 (ss) Bash DwwNn TIN SUN (35a) Sin tenson Lf (00401) | Uskgt) ou iesossng | Gorn 7 05020 aes (09210008)2. List of tightening torque 2.1 Major bolts and nuts tightening torque 21 Basic engi SERVICE DATA ‘Table 2-7 Major bolts and nuts tightening torque - Basic engine Tres Teena Te spies : item. Die x Pitch ; : “Romar ue 2 ite [kot [be Cynder ned bt Txt c Tor=36 | wet Recker cover bolt “8x15 ie+02 | isla Tchr alt wacko D wales Tex02_| ale ino Besing cep ol aa? e208 | Torsse [iWay Comesing dep at xs “ose0s | 636 fear Fyre bo Tatas asz05 | @=86 Cons a pine Ba was Taa02_| 9s1a 0x15 a6 [wars wane “Cesta aiey ot wus ae) 128 Tart se bake Tox isz0s_| a6 noe sai nace Daas 3sa08 | Bake Oipantat Tos taz02| Dale Oi panda soak Beis S505 Oi pan dan poe Bos wer Tag bat Balas 11205 24.2 Fuel system Table 2-8 Major bolts and nuts tightening torque -Fusl system aS cog ee “Nozale gland ~ tx 125 3203 Wat ‘Rel i pipe unig eye ba me oF | we Felponp sera Eas yas06 | saad Foal at Tas anos] soaane el pump oa Pe [eto 2E0t | S229 Feet bos cota 5 Tax aasoa | ea et npr ako pipe oe BON Tox Ts0a_| l0ssts Fel ore omer Teas ae [et Rieti TG 160 [asses [esa Fl era DS og wes doso1 | 65207 a pnp le pps connec pune 35) xt we | oa rl ppl fs pipe commer canteen) _| 19x10 Tasos] laaSERVICE DATA, 2.3 Lubrication system Table 2-9 Major bolts and nuts tightening torque - Lubrication system Threads Tightening torque tem | Dia Pitch Flemark ‘are Nm L kate ett Rel vale xis a9 S205 362=36 ele valve plug Texts waa9 wsa0s | msaae Sey ave Texts Bao Tz05 ware _ Di pp cover ba Toxts Baa Banos | _2ea2s Turbocharger i feed eye bo Tox 1as a2] 17202 | Baste 2.4.4 Inlet and exhaust aystem ‘Table 2-10 Major bolts and nuts tightening torque - Inlet and exhaust system ee Treas Trgntening torque ‘tem | Dia Pitch | | Remark Nin | totm: [ee Teron ede Tisst | Ise01 | des07 ‘Aico ein mt Shot bar se Tasats | 07001 | Sany “iri ein Mang at T east | a9s01_ | _@5207 Ta naaiolgbor tr? | as02 | ate Eis mani ot eeias_ | a? | tesa] iat 2.4.5. Electrical system “Table 2-11. Major bolts and nuts tightening torque - Electrical system Treads Tigneane oe hem Dia xPitch Remark nm). koten ioe ‘Str 8 ein teas Ts0l | 12207 ‘ienaneEemial ‘| «OT aseor | 3 ‘eer emia Seo oarsass | 20=07 “late ple nt [ters =13 | Wet 2.1.6 Sensors and ECM “Table 2-12 Major bots and nuts tightening torque - Sensors and ECM Thea] Tightening ome tem Dia x Pitch r Remark ie Togm | ben Tater pera souor ise Carpe tempers sensor een ae Boca cme snr Minats 1202 7 Engi ol ese san Misi 1202 Common al ress cor Mines Janos | Maras Spotting sor Ganka 8) | Ms 125 T2018 | U9EII GM connecter nountag bevagon bok] = Dsoaoa | a7=07 Relay connesior mounting hexapoa o2vx0m | 2072022 2-10SERVICE DATA 2.2 Standard bolt and nut tightening torque Table 2-18 Standard bolt and nut tightening torque Ens Twin Description’ | Dia'x Pich.|. across flats: ceiee «ee |} = (eae fin Xm [tate [bet Nw | eam | Méxi2s| ian | 7 |i | @ | 30 | x | 2 Moxie) ps) | = [a4 | o |e | a Metric stomobileserew thread [28125] Wie | @ | o1 | 4 | 08 | no | wo Maxis | 21087) | 97 | 99 | 7% | m6 | 179 | 2D UMisxis | 2470947 | Ms | 148 | 107 | 262 | 267 | 193 misxis | 27106) | 210 | 214 | 158 | 378 | 385 | 278 waoxis | sorts) | 2 | 297 | 28 | S28 | saa | 386 Maxis | s2(26 | 385 | 393 | 284 | we | 708 | 52 Maxis | 36140) | 487 | 87 | 359) 87 | 805 | OAT maxis | amen | 7 | 753 | se | 1928 | 1355 | 980 | tet MiOxES | 14035) a MI2x1.75[ 1710.67) a7 | 58 | @ | m2 | los | 75 “Meas course serow thread Miaxa | moa) | 3 | 95 | @ | 167 | 170 Misx2 | 24(094) | 139 | 142, 103 | 21 | 256 Misxas | 27106) | 194 | 198 | 143 | 350 | 357 | 258 Ma0x25 | 30tLIe] | 22 | 27 | 200 | 499 | 499 | Jel Mix25 | s2{26 | 36 | 370 | 268 | ass | Goo | 482 Maax3 | sono | ae | 477 | us | 3 | a60 | oe Ma7xs | dine | 685 | 700 | 306 | 1286 | 1260 | 9 Note: (@) This able lists the ightening torque for standard bolts and nuts (©) The numerical values in the table ate for fastoners with spring washers. () The table shows the standard values with a maximum tolerance value of =10%. (4) Use the tightening torque in this able unless otherwise specified. (©) Do not apply cil to threaded sections. (Dry) 2-11SERVICE DATA 2.3 Standard eyebolt tightening torque ‘Table 2-14 Standard eyebott tightening torque Threads | i “Dia Pitch “Yecross flats [aT {enn (Geet) MB x [25 12047} 821 Mioxias | Wwioss| | 1322 Mantas | Woe | ms “MuxIs | 91075) | Mad | 35204 | Mixis | 20a | ass Migxis | sos | aes Ma0xIs | 208 | 98=10 MOx 15 32(126) | M7=Is | 180215 | 19=i1 Maxis | wey | 226220 | 20220 | 166=15 om 2.4 Standard union nut tightening torque ‘Table 2-15. Standard union nut tightening torque Monin "Capa ee | rents | Nm | han | = om i A 6 Misxis 19 (0.75) 39 4 2 30, ‘MI6x 1.5 22 [0.87] 49 s Fe wo |) M20x15 2711.06) | 78 8 8 as Pane | BOL aS | aaa ee OL aS | ewe | ae woes senna [ea 354 M36 x LS 41 (1.61) 204 30 217 (Maximum tolerance value: 10%, dry) 2-12BASIC AND SPECIAL TOOLS 1, Special 1001S ..eeessenenreneneeneneenes 3-2 3-1BASIC AND SPECIAL TOOLS 1. Special tools Tootnamne Table 3-1 List of Special Tools (1 /4) Pannonber | Tosa Valve guide installer 3291-00800 ‘Valve guide installation Valve puide remover 32F91-00300 ‘Valve guide removal Inser caulking to! Sleeve installer 32F91-00100 Anled 32F91.00200 (Exhaus0) Valve seat installation Cylinder sleeve installation Piston sing pliers Piston ring removal installation Piston guide 34291-00100 Piston installation Stem seal installer oe & Steam seal instalation 3-2BASIC AND SPECIAL TOOLS Table 3-1 List of Special Tools (2 /4) Tooke DL patmmber Tsien yo es Bridge guide installer sare | Trdg pie naan Injector remover 32F91-03030 Injector removal [ler shaft puller Tater bushing puller Toler bushing removal! ee installation tiosi077 S alr shat removal Connecting rod bushing installer removal/nsalation es ariowso | K2 i (2) | connesing ra bushing Ee Cl fier weench Oil and uel filters removal’ 34591-00100 instalation Universal extension Fuel injection pump emovaVnsalation 30091-01101 3-3BASIC AND SPECIAL TOOLS Table 9-1 List of Special Tools (3/4) Thatnenben Socket 58309-73100 f Engine turing 32F91-00700) Engine compression ps Removal for erankshaft Poller assembly 64309-12900 2 Crankshaft pulley ‘Compression pressure mea- Compression gauge 33391-02100 —— 3 (0 sel sleow installation Rea il sel installer 14291-00020 eran Camshaft busing ‘Camstat bushing removal’ 30691-00010 installer set installation Cximp tool 32891-03100 ‘Terminals replacement 3-4Toanane Table 3-1. List of Special Tools (4/4) [Pat hunber Woeraton BASIC AND SPECIAL TOOLS Extract too! 32691-03300 Hoamess connector terminal removal 3-5OVERHAUL INSTRUCTIONS 1, Determining overhaul timing .....4-2 2, Testing compression pressure.......4-3 a1OVERHAUL INSTRUCTIONS. 1. Determining overhaul timing In most cases, the engine should be ovethabled when the compression pressure of the engine becomes fow. An increase in engine oil consumption and blow-by gas ae also considered to evaluate the engine contin. Besides, such symploms as a decrease in output, nerease in fuel consumption, decrease in ol pressure dificully of engine starting and increas in noise are also considered for judging the overhaul dining, although those symptoms are often affected by other causes, and are not always effective to judge the overhaul timing. Decreased compression pressure shows @ variety of symptoms and engine coneitions, thus making i dificult to accurately determine when the engine needs an overhaul, The following shows typical problems caused by reduced compression pressure (1) Decreased ouput power (2) increased fuel consumption {8) Increased engine oil consumption (4) Tnereased blow-by gas through the breather due to wom eylinder liners and piston rings (Visually chock the blow-by amount) (5) Increased gas leakage due to poor seating of inlet and exhaust valves (6) Diseuty in saing (7) Inceeased noise from engine parts (8) Abnormal exhaust color after warm-up operation The engine ean exhibit these conditions in various combinations. Some ofthese problems ae directly caused by worn engine Pats, while others are not. Phenomena described in items (2) and (6) will result from improper fuel injection volume, fust injection timing, wor plunges, fauky nozzles and also fully conditions of electical devices such as battery and startet. The most valid reason to overhaul an engine is a doorease in compression pressure dve to worn cylinder liners and pistons, as «described in item (4), In adltion fo this item, itis reasonable to take other problems into consideration for making the total judgment. 422. Testing compression pressure ee CAUTION Ta) Measure al oyinders for compression pressure, Do not measure only one cylinder and make assumption about the other cylinders as it wil lead toa wrong conclusion. (©) Compression pressure varies depending on the engine speed. When measuring the compression pressure, be sure to measure the engine speed as well (©) It's important to regularly check the compression pressure so that you can tel the change with time (1) Disconnect the main hamess from the relay connector. (2) Disconnect the high pressure pump solenoid connector from the high pressure pump solenoid sens. (@) Select a cylinder, and remove the injector in the cylinder, (Each cylinder is tested one atime) (4) Install a gauge adapter in the same location that the injector was mounted, and install a compression gauge to the gauge adapter, (5) Start the engine using starter, With the engine running at specified speed, read the compression gauge. (6) 1F the measured value is atthe limit or below, overhaul the engine. Engine speed | 29M | regen) Compression pressure | (30kgHiemey |? en! | Beton OVERHAUL INSTRUCTIONS Gauge adapter PIN:32F91-00700 ‘Compression gauge PIN:33391-023100 Testing compression pressureDISASSEMBLING ENGINE MAIN PARTS 1. Disassembling and inspecting cylinder head and valve mechanism 5-2 1.1, Removing hamess. 54 1.2. Removing injector 54 4.8. Removing rocker €88@ wsnnnnnennnes 54. 14 Removing rocker shaft assembly... 5-5 115. Disassembling rocker shaft assembly... 5-5 1.6 Removing valve bridge .... nn 55: 1.7, Removing cylinder head bot. 56 1.8 Removing cylinder head assembly nn. 5-6 1.9. Removing valves and valve springS...... 5-6 1.10 Removing valve stem seal... oT 1.11 Bridge guide. ST 41.12 Installing bridge guide. 57 2. Disassembling and inspecting flywheel. . 2.1 Removing flywheel 2.2 Removing flywheel housing .. 3. Disassembling and inspecting gear case, timing gear and camshaft .. 3.1. Removing crankshaft pulley 3.2. Removing timing gear case 3.3 Measuring backlash of timing gears... 3.4 Measuring idler gear end play. 3.5 Removing idler gear... 3.6 Removing camshatt 3.7 Separating camshaft goa. 3.8. Instaling camshaft gear and thrust plate 3.9. Removing front plat 4, Disassembling and Inspection crank- case, crankshaft and piston 5-14 4.1. Removing connecting rod cap... 515 4,2. Removing carbon deposit from cylinder sleeve upper area 5-15 48. Pulling out piston. soos BAB 4.4 Removing piston FNg .nnnnmenneein SAB 4.5. Removing piston pi «unineme SAB 4.6 Removing main bearing cap 516 4.7 Removing crankshaft. BAT 5-1DISASSEMBLING ENGINE MAIN PARTS. 1. Disassembling and inspecting cylinder head and valve mechanism Replace 7 4 Replace oe Removing rocker case and injector Disassembling sequence 1 Pipe cover 4 Hamess bracket 7 Injector 2 Rocker cover 5 Injection seal 8 Rocker case 3. Hamess 6 Nozzle gland 5-2DISASSEMBLING ENGINE MAIN PARTS Sse ee eoaeg Local wom damage agua, caon Sopot Disassembling and inspecting cylinder head and valve mechanism Disassembling sequence 1 Adjusting screw 8 Rocker shaft 18 Valve cotter 2 Bolt (shor) 9 Pushrod 16 Vaivo retainer 3. Bolt long) 10 Bridge cap 17 Valve spring 4 Eye bolt, oll pipe 11 Valve bridge 18 Valve , valve seat 5 Snap ring , spacer 12 Oylinder head bolt 19 Stem seal, valve guide 6 Rooker arm 49 Oylinder head 7 ocker shaft spring 14 Gasket 5-3DISASSEMBLING ENGINE MAIN PARTS 1.1, Removing harness (1) Loosen the nuts of hamess, and disconnect the harness from the injector (2) Remove the harness bracket together with the hares. 1.2. Removing injector (1) Remove the injection pipe (2) Remove the injection seal. (3) Using an injector remover, remove the injector together ‘withthe nozzle gland. (4) Remove the gasket from cylinder head injector insertion opening. [Note: Make « note of the injector serial number of each cylinder. reusing the injector, be sue to einstal the injector to the same cylinder. When replacing the injector with anew one, refer to “Troubleshooting.” 1.3. Removing rocker case (1) Disconnect the elay connector from the main hamess, (2) Loosen the rocker case mounting bolts, and remove the rocker ease from the eylinder head, 5-4 Removing hamess Injection pipe 3° Tete gana Iecton a Y Oring Wjecto” casket Removing injector Tecerenmer Bi PIN:32F91-03030 ~~} Injector__ Main harness Removing rocker case1.4 Removing rocker shaft assembly ‘Always loosen shorter bolts first. Falling that may cause the damage to the rocker shaft bracket, (1) Loosen the rocker arm adjusting serews by rotating about one turn (2) Loosen shorter rocker bracket bolts first (8) Then, loosen longer rocker bracket bolts. (4) Remove the rokcer bracket bolls, and remove the rocker shaft assembly from the cylinder head, (8) Remove push rods 1.5. Disassembling rocker shaft assembly (1) Remove eye bolt oil pipe, and snap ring. (2) Separate the rocker shaft assembly into the rocker arms, bakers, rocker shaft springs and rocker shaft Note: Be sure 0 arrange the disassembled rocker shaft assembly inthe order. When reassembling the rocker shaft assembly, reassemble it in the reverse order of disassembling. This is to ensure the correct order of locker arms to restore orginal ances between the rocker arms and rocker shalt on reassembly 1.6 Removing valve bridge Remove the valve bridge and bridge cap. Note: Be careful not to drop bridge caps into the crankcase ‘through the pushrod holes. DISASSEMBLING ENGINE MAIN PARTS Adjusting Rocker dracket bolt (shor) Removing rocker shaft assembly ol a Rocker arm Rocker ey ting Rocker shaft Rocker shaft spring Bracket Disassembling rocker shaft assembly Removing valve bridgeDISASSEMBLING ENGINE MAIN PARTS. 1.7, Removing cylinder head bolt Loosen eylinder head bolts inthe numerical order as shown inthe illustration, 1.8 Removing cylinder head assembly (1) Littup the cylinder head assembly to remove, "Note: Ifthe eylinder head assembly cannot be removed due to crimping of the cylinder head gasket, rap the thick area onthe side ofthe eylinder head to give a shock. (2) Remove the gasket from the eylinder head. Note: (@) Be careful not to damage the fitting surfaces of the gasket when removing the gasket from the cylinder head, (&) Before removing the cylinder head bolts, check. the cylinder head components for any defects or faults, Ifany of them is faulty or defective, check ‘the bolts for tightness witha torque wrench, 1.9. Removing valves and valve springs (1) Using a vatve spring pusher, compress the valve spring equally, and remove the valve cotter, (2) Remove the valve retainer, valve spring and valve, Note: If the valves are reusable, marke them so that their ‘original postions are easily identified. Never change the combination of valve sheet and valve guide when assembling, 5-6 Removing valves and valve springs1.10 Removing vaive stem seal Grab the stem seal with pliers and remove, Note: Be sure to replace the stem seal when reassembling the valve and valve spring, 1.11 Bridge guide Do not remove bridge guides from the eylinder head unless itis necessary. 1.12 Installing bridge guide If bridge guides have been removed, install bridge guides, using abridge guide installer DISASSEMBLING ENGINE MAIN PARTS ‘Stem seal Bridge guide [Bridge guide installer PIN:32F91-00600 Installing bridge guide asDISASSEMBLING ENGINE MAIN PARTS 2. Disassembling and inspecting flywheel Wear, creck, damag Disassembling and inspecting flywheel Disassembling sequence 1. Flywheet 2. Flywheel housing 2.1 Removing flywheel Tie ess ek CAUTIONS IIINEIE (@) Be careful not to cut your hands withthe ring gear hen pulling out the fywheel Be careful not to drop or hit the flywheel when removing (b) The personnel who holds the pulley must pay due attention to safety ‘Also, personnel must stay in close contact with each other during work. (1) One personnel must firmly hold the pulley with a wweench fo prevent the flywheel fom tuning (2) Remove one bolt from the flywheel. (3) Screw guide bo into the threaded hoe ofthe bol that has boon removed, (4) Remove remaining bolts from the flywheel. (5) Hold the lywheet firmly with both hands, and by moving it back and forth, pull it ou sigh, [Note:The ring gear i sink fited 1 the iywheel, Do not remove it unless defective 5-8 3 Ollseal 4 Pick up f Crankshatt ge \ PaXer x oon Guide bolt Removing flywheel22 Removing flywheel housing CAUTION Bo careful not to damage the oil seal (1) Remove bolts rom the Aywhest housing (2) Remove the ywhee! housing, DISASSEMBLING ENGINE MAIN PARTS Removing flywheel housing 5-9DISASSEMBLING ENGINE MAIN PARTS 3, Disassembling and inspecting gear case, timing gear and camshaft Gilhote clogging. wear, Flaking, contact, damage, abnormality [Wear E ®8 (Crack, dowel hoie defect, oll hole clogging Disassembling and inspecting gear case, timing gear and camshaft Disassembling sequence 1 Crankshaft pulley 5 dir gear 2 Timing gear case 6 Thrust plate 3 Oil seal 7 Camshaft 4 Thwust plate 8 Camshaft gear 3.1. Removing crankshaft pulley ak CAUTION ‘The bar serving as a stopper of the crankshaht may come aff. Pay due attention to saety (1) Screw two guide otis the threaded hoes athe end ofthe crankshaft. Use these bolts and a har placed across them to prevent the erankshaf from rating. (2) Remove the crankshaft pulley. (@) ‘Takeout the wood key ofthe crankshaft 5-10 9 Tapoet 10 Fuel pump gear 11 Front plate S> Prevent crankshaft from otalng (Ret) Removing crankshaft pulley3.2 Removing timing gear case Siena _ CAUTION The front plate Is bolted to the crankcase from inside the gear case. Do not attempt to remove the front plate by tapping itwith the gear case, (1) Remove bolts from the timing gear case (2) Remove the timing gear case, Note: Bolts have different lengths. Pay attention to the positions of bots to ensure correct reassembling, 3.3. Measuring backlash of timing gears ‘To measure backlash, apply a dial gauge to the gear shaft circle at the eight angle to the shat, or insert feeler gauges into the meshing between two gears. Replace the gear i the limit is exceeded. Tan Sinner Tae Backus ranishah gear and | 0.05110 0457 am] 025 mn ‘ier eae (0.020 0.062 in} | (0.0098 in Backla comsat gearend | 0052100158 mm | 025 mem ie go (9.0021 o .0062%n, | (00058 1 Bocklas Fock ijecion pump | 0056100208 mm_ | 025mm ear and ier gear {0.0022 60.0081 in} | 00058 in} —_SETHEOEeTrereeercre ‘Note: With the fusl pump gear atlacked tothe pump, install the fuel pump gear tothe froat plate 3.4 Measuring idler gear end play Using thickness gauge or dial gauge, measure the end play of idler gear If the measured value exceeds the limit, replace the idler gest wil ew pos Toten Se Tmt (05t0020mm | 035mm [0.0020 0 0.0079 in.) | [0.0138 ind End play DISASSEMBLING ENGINE MAIN PARTS ‘Timing gear case Removing timing gear case Measuring backlash of timing gears Idler gear Measuring idler gear end play 5-11DISASSEMBLING ENGINE MAIN PARTS. 3.5 Removing idler gear (1) Remove the thrust plate bolt. (2) Remove the iler gear while uring the gear. 3.6 Removing camshaft Ba CAUTION Be careful not to damage the cams of camshaft and the bushings. (1) Reverse the erankease (2) Remove the thrust plate bolt. () Remove the camshaft from the erankease. (4) Remove the tappet. 3.7. Separating camshaft gear Using a puller, remove the camshaft gear and thrust plate from the camshaft Note: Do not remove the camshaft gear from the camshaft unless the camshaft gear or the thrust plate is defective 5-12 Thrust pate Removing idler gear Removing camshaft Puller PIN: 64309-12900 Camshaft gear Separating camshaft gear3.8 Installing camshaft gear and thrust plate (1) Install the woodruff key and dhe thrust plate on the crankshaft, ‘Note: Be sure to install the thrust plate before installing the camshaft gear (2) Heat the camshaft gear with a gear heater to a tare of about 250 °C [482°F} (3) Instat the camshaft gear into the crankcase by tapping with a plastic hammer, 3.9 Removing front plate (1) Remove the front plate bolts, (2) Remove the front plate from the erankcase. Note: Ii is difficult to remove the front plat, lightly tap it witha plastic hammer, DISASSEMBLING ENGINE MAIN PARTS ay ‘Thrust plate Camshaft gear Instaling camshaft gear and thrust plate Front plate, ” Flemoving front plata 513DISASSEMBLING ENGINE MAIN PARTS. 4. Disassembling and inspection crankcase, crankshaft and piston (ron daa ear ink ° Faia eal z a S |Top surtace distortion| = ‘Scratch, orack, damage, wear, carbon deposit ‘Seale depos corrosion, faking Wear, crack, oil hole clogging hole ciogging| [Damage Wear, seizure, faking, damago| 7 + . ay S eee i oi hole clogging, wear| ; A eT ayy “ om Iw, A G sia vasa ie \s [Seraish, selzure, faking] [Damage] (Crack "1 Disassembling and inspection crankcase, crankshaft and piston Disassembling sequence 1 Nut 8 Piston pin 18 Main beating (lower) 2 Connecting rod cap 9 Piston 16 Crankshatt 3 Connecting rod bearing 10 Connecting rod 17. Main bearing (upper) 4 Compression ring, No. 1 11 Main bearing cap bolt 18 Piston cooling nozzle 5 Compression ring, No. 2 12. Main bearing cap 19 Crankease 6 Ollting 19. Side seal 7 Snap ring 14 Thrust plate 5-144.1, Removing connecting rod cap (1) Lay the engine by its side (2) Mack the cylinder number on the connecting rod and connecting rod cap so that their combination is not changed when reassembling (3) Remove the connecting rod caps. Note: Mack the cylinder No, and uppeellower on connecting ‘od bearings to ensure comect reassembling, 4.2 Removing carbon deposit from cylinder sleeve upper area Carbon deposits at the upper section of the cylinder sleeve will not only make the piston removal work dificult but also cause damage to the piston or piston ring when removing the piston. Before removing the piston, be sure fo remove the carbon deposits at the upper section of cylinder s or sand paper, e with a cloth 4.3. Pulling out piston (1) Tum the crankshaft and place the piston 10 top dead (2) Push the mating surface ofthe connecting rod cap with, 4 piece of wood such a handle of a hammer and push ‘out the piston and connecting. rod upward of the eylinder. DISASSEMBLING ENGINE MAIN PARTS BOSE S MBPLEP > Comecting ro cap <> Ae Removing earbon deposit from cylinder sleeve upper Pulling out piston 5-15DISASSEMBLING ENGINE MAIN PARTS. 4.4 Removing piston ring ‘Remove the piston rings using piston ring pliers. 4.5 Removing piston pin (1) Remove the snap ring using snap ring pliers. (2) Remove piston pin, and separate piston from ‘connecting rod. Note: If the piston pin is stubborn, heat the piston with piston heater or hot water, 4.6 Removing main bearing cap (1) Reverse the engine. {2) Remove the main hearing cap bolt (8) Remove the main bearing cap together with the lower sain bearing ‘Use a sliding hammer to remove main bearing caps on the front and rear ends, Note: (@) Be eareful noo damage min beatings, (6) Mark each main bearing with the cylinder umber for reassembly Piston ring pliers IN30091-07100 Sliding hammer Main bearing ‘ap batt Removing main bearing cap4.7 Removing crankshaft Attach a sling to the crankshaft, hold it horizontally, and hoist the crankshaft slowly. Note: (a) When lifting the crankshaft, do not allow wire chain to come into contact with the erankshatt shaft when lifting, To avoid damage to the cr tse a cloth belt or pa, (@) Be careful not to damage main bearings. (©) Mark each main beating to the corresponding cylinder number for identification. DISASSEMBLING ENGINE MAIN PARTS Removing crankshaftINSPECTING AND REPAIRING ENGINE MAIN PARTS 1. Inspecting and repairing cylinder head and valve mechanism 6-2 1.1. Measuring clearance between rocker bushing and rocker shaft 62 1.2 Replacing rocker bushing 62 1.3. Measuring valve stem outside diameter and valve guide inside diameter 0 6-3 1.4 Replacing valve QUide..nnnneennnens 63 1.5. Inspecting valve face sone 84 1.6 Refacing valve face. 64 1.7. Refacing valve seat. 65 1.8 Replacing valve seat... .nnn 66 1.9 Lapping valve and valve S€8t nnn 7 1.10 Measuring perpendicularity and free length of valve spring 67 1.11 Measuring distortion of cylinder head bottom faC€ vnsnnsnnnnnnnns 6B 1.12 Measuring pushrod runout. 2, Inspecting and repairing flywheel....6-9 2.1 Measuring flatness of flywheel .nnccn 68 2.2 Measuring flywheel face runout and radial runout 2.3 Inspecting ring gear 2.4 Replacing ring gear... 2.4.1 Removing ring gear 2.4.2. Instaling ring gear. 3, Inspecting and repairing timing gears and camshaft. lessee 3.1. Measuring backlash of timing gear....6-10 8.2. Measuring cam lift. seennse 610 3.3 Measuring camshatt runout ...mnenm 6-10 3.4 Measuring camshaft journal outside diameter. ett 3.5 Measuring camshaft bushing inside diameter, ett 8.6 Replacing camshatt bushing.......nnee6-14 3.6.1. Removing camshaft bushing tt 3.6.2 Installing camshaft bushing 612 3.7 Measuring idler bushing inside diameter and idler shaft outside diameter. 612 3.8 Replacing idler bushing. seo 138, 3.9 Replacing idler shatt.. 3.10 Inspecting tappet..... . 8.11 Measuring clearance between tappet and tappet guide Ole ..nnnnnnnnnn O44 613 13 4, Inspecting and repairing piston, connecting rod, crankshaft and crankcase 6-15 4.1 Measuring distortion of crankcase top surface BAS 4.2. Measuring cylinder inside diameter......6-16 4.3. Replacing cylinder sleeve .. 4.3.1. Removing cylinder sleeve. 617 4,32 Installing cylinder sleeve. e17 4.4 Measuring piston outside diameter......6-18 4.5. Measuring piston ring end gap. 618 4.6 Measuring clearance between Piston ring groove and piston ting..m.n6-19 4.7 Measuring piston pin bore diameter and piston pin outside diameter 619 4,8. Measuring piston protrusion..nenn 6-20 4.9 Measuring clearance between connecting rod bearing and crankpin.....6-21 4,10 Measuring clearance between connecting rod bushing and piston pin...6-21 4.11 Replacing connecting rod bushing. 4.12 Removing connecting rod bushing. 4.13 Installing connecting rod bushing 4.14 Inspecting connecting rod bend. and twist. 4.18 Inspecting connecting rod bearing 4.16 Measuring connecting rod end play ...6-24 4.17 Weight difference of connecting rod assembly in one engine. 4.18 Measuring crankshaft joumal outside diameter. = 4.19 Measuring crankshaft crankpin outside diameter. 4.20 Grinding orankehaft . 4.21 Measuring crankshaft end play 4.22 Measuring crankshaft runout. 6-26 4.28 Replacing crankshaft gear... 6-27 4.23.1 Removing crankshaft gear 627 4.23.2 Installing crankshaft gear. 27 4.24 Replacing front oil seal. 6-28 4.25 Replacing rear oil seal sen 28 4.26 Inspecting main bearing sutface ...neu-6-28 4.27 Measuring clearance between main bearing and crankshaft journal.....6-29INSPECTING AND REPAIRING ENGINE MAIN PARTS. 1. Inspecting and repairing cylinder head and valve mechanism 1.1. Measuring clearance between rocker bushing and rocker shaft Measure te rocker bushing inside diameter and the rocker shat diameter. If the clearance exceeds the limit, replace either rocker bushing or rocker shaft witha new one. >: sae Measuring Sees Ten] Nenmel |) Sanaa a Rockerbushing | 025mm | 269001024975 mm @ measuring inside diameter | (058in) | (098221009883.n} | rections cutie diameter | [088in} | [098091909814 m) Simcnmaier | =| 062k 00K0mm | Sy” ‘Measuring rocker bushing and rocker shat (0.008 0.0024 ing bushing and shat ind 1.2 Replacing rocker bushing ‘To eplace rocker bushings, use a hydraulic jack ‘With the rocker bushing and the rocker arm oi holes mated, and the bushing joint faced upward, press fit the rocker bushing, Direction of bushing press ft a ~ Ol 025 388 mm [00.98 248 inj (inside diameter with bushing press fited) Ra 0.8 um (0.034 w ind Replacing rocker bushing Bushing notchINSPECTING AND REPAIRING ENGINE MAIN PARTS: 1.3. Measuring valve stem outside diameter and valve guide inside diameter Measure the diameter at the top and bottom ends at right angles to the outer and inner surfaces, since valve stems and valve guides are subject to wear at both ends. Ifthe outside diameter is less than the limit, or the clearance exceeds the limit, replace either the valve or the valve guide with a now ave mm | S65mm | 638 063800m stem [0260in} | (025851002591 in} ae ‘sebam | S50 weSs0mm diameter | Es] 0.260 ing | (02571 100.2579 in) | 102559 in ‘iewe= | i, | 2020.9 005mm | 0.100 mm ‘etwoea {0.0008 .0020 m4 | 000391 sake semand | one 0030100085 mm | 0.150 um valve | Esha (0.00201 0.034 | (00039 in} ie Valve guide mount | 9 Team ~ 7 ing diension ios3in 1.4 Replacing valve guide £ ‘CAUTION. Because valve guides must be inseried to the spec {ied amount, be sure to use a valve guide installer (1) To remove valve guides, use a valve guide remover. (2) To press-fit valve guides, use a valve guide installer. (8) Check contacts between valves and valve seas afer replacing valve Measuring rections eas Grectons’ Measuring points Measuring valve guide inside diameter Valve guide remover PIN:32F91-00300 Removing valve guide Valve guide installer PIN:34491-00400, Press-fitting valve guideINSPECTING AND REPAIRING ENGINE MAIN PARTS 1.5. Inspecting valve face Apply & thin coat of Shinmyoutan or equivalent lead-free coloring paste on the valve face, and strike the valve face against the valve seat using a val pper to check if they make an even contact with each other. IF no even contact is ‘obiained or any other abnormalities ae found, or ithe limit is exceeded, eface or replace the valve, Note: (a) Pecform the valve face check only after checking the valve g and replacing it as necessary, (b) Be careful not to rotate the valve when pressing the valve face coated with Shinmyoutan of equivalent lead-free dye against the valve seat. (6) Be sure to lap the valve and valve seat whenever the valve is refaced or replaced. Ky vave appr, Shinmyoutan q Inspecting valve face eT tem Nominal nt ee [Baa | _ : dzw0s osm | om | t.tom tale | fooiina | ro00810 | rossins vate 016m) alae [| Tae o3mm | mm) ttm Expat | (on.2iai | (00081 | (0043in) ising arr Taam ine 3 width aie (00393 (o0ssiny beck ia Tm Te xtaust | (oon 0063 L | (00630) lave | Reon a 7mm | Lssmam | Pemisle ce woosring | roosi0w | SP oarenin) oostind Valve seat 1.6 Refacing valve face Grind remarkably worn valve faces with a valve Note: (@) Grind the valve face with a refacer at the specified angle. (b) Secure the valve margin width equal 1 or greater than the limit, Replace valves with new ones if their dimensions after rofacing do not meet the standard Good Bad Contact between valve seat and valve Valve margin Valve sinkage angle c Measuring positions of valve seat and valve Sat the valve face “angie at the specified angle. Refacing valve faceINSPECTING AND REPAIRING ENGINE MAIN PARTS lve seat cuter or valve seat grinder to reface the valve seat, After refacing, grind the seat lightly using #400-grade sandpaper insered between the cuter and valve seat (2) Lap the valve in the valve seat. Note: (a) Grind the valve seat as lite as possible. (©) Ifthe seat width excoeds the limit as a result of ‘inding, replace the valve seat. (e) After lapping, if the valve sinkage exceeds the limit, replace the valve seat with a mew one. Refacing valve seatINSPECTING AND REPAIRING ENGINE MAIN PARTS 1.8 Replacing valve seat (1) To remove the valve seat, weld a stud to the valve seat illustrated, Then, insert a rod into the valve guide hole from the top ofthe eylindar head, and press out the valve seat with the rod. Note: Be careful not to allow spatters 10 adhere to the machined surface of the cylinder head during welding. (2) Before inserting a new valve seat, measure the eylinder ‘head bore diameter and valve seat outside diameter to ‘make sure the clearance is within the clearance standard Removing valve seat (8) Cool the valve seat forfour minstes or more in guid nitogen (at approximately -170°C [-278°F)) before Eihaust fitting it into the cylinder head, while keeping the ioe AA. VY a] ea cylinder head at room temperature. Or heat the cylinder UL po yy Z ‘head t0 8010 100°C (176 10 212°F] and cool the valve V dk YZ seat sient in eter or slahol mixed with dy ice 77) 4 before fing iti the hot eylnder head lag Yj (4) Fit the cold valve seat into the cylinder head using f 4 A MS insert caulking 10 otto EES een eee) SE ore Gy Valve seat fiting bore Insert caulking too! (Init) PIN:32F91-00100 (Exhaust) PIN32FS1-00200, (es Installing valve seat 6-61.9 Lapping valve and valve seat Always lap valves against valve seats after valve seat refacing or valve replacement (1) Apply a thin coat of lapping compound evenly to the valve face tobe lapped. Note: (2) Do not allow the compound to adhere on the valve sem, (©) Compound spreads more evenly if it is mixed ‘witha small amount of engine cil (©) Use medium-grain compound (120 to 150 mesh) for inital lapping, then use fine-grain compound (200 mesh or finer) for finishing, (2) Use a valve lapper for lapping. Strike the valve against, the valve seat while otating the valve little by lite (8) Wash off the compound with diesel fuel (4) Coat the contact surface of the valve with engine cil, then lap the valve again, (8) Check valve face contact. 1.10 Measuring perpendiculari of valve spring Measure the pespendicularity and free length of the valve and free length spring. Replace the valve spring ifthe limit is exceeded. INSPECTING AND REPAIRING ENGINE MAIN PARTS. ‘Compound Coating valve with lapping compound Valve lapper Spring perpensiclaty (gap) J Tan Saas ae 48.7 mm ~ | 473mm Fee oat jester wal tate Perpendio + inn [tite lay % wetsroortia3 | 8 i Lee487mm | 07 iad tari Bian sewn | OSemuemannumnion | Can ee [24910 27.9 Ibf) {10.5 ket} (2316 "7 Z 1 Measuring spring perpendicularity and free lengthINSPECTING AND REPAIRING ENGINE MAIN PARTS. 1.11 Measuring tom face istortion of cylinder head bot Tn CAUTION: ne ‘Timitthe depth of surface grinding of cylinder head to a necessary minimum. If the surface of cylinder head is ground more than, specified, it may result in defects such as defective ‘combustion and stamping (contact between piston and valve). ‘With a straight edge placed on the bottom face of the cylinder head, measure the bottom face distortion with a feeler gauge. Ifthe measurement exceeds the limit, grind the ‘ortom face with a surface grinder Tem Sanuad | ok distrtion ‘005 mum {0.0020 in} or ess 020 mm [0.008 in} Nove: Do not grind tho surfaces moro than 0.2 mm [0.008 in] in total (eylinder head botiom surface plus crankcase top surface), 1.12 Measuring pushrod runout ‘Measure the runout of each pushrod. Replace ifthe limit is excoeded. Item. ‘Standard Limit Remark. Oem Paso oda rom | (20183 | aowemy | TR 6-8 Measuring distortion of cylinder head bottom surface TL v ‘Measuring pushrod runoutINSPECTING AND REPAIRING ENGINE MAIN PARTS 2. Inspecting and repairing flywheel 2.1, Measuring flatness of flywheel Place the flywheel on a surface plate and move a dial gauge fn the fiction surface of the flywheel to measure the flatness. Grind the friction surface of the flywheel if the Kimit is exceeded ESET Tem Sandee "ine 0.15 mm 050 mm Flywheel lamest 1 o,0059in Jor ess | (0.0197 in] 2.2 Measuring flywheel face runout and radial runout Measuee the munouts of the flywheel in the installed condition. If any of the measurements exceeds the standard, ccheck the flywheel for loosened bolts and foreign matter accumulation on the mounting face. Tem Sandee ‘Within 0.15 mm (0.0059 in} Tne 0.50 mm (00197 in) Flywheel face runout and radial ranout 2.3 Inspecting ring gear Replace the ring gear if missing or abnormally worn teeth are found by inspection. 2.4 Replacing ring gear 2.4.1 Removing ring gear (1) Heat the ring gear evenly using an acetylene torch oF other appropriate heat source, (2) witn a rod placed on the periphery of ring gear. ap the rod with a hammer evenly around the ring gear, and remove the ring gear 2.4.2. Installing ring gear (1) Heat the ring gear evenly up to approx. 150°C [176°F] ‘with an appropriate heater (2) Inst cchamfering sie faced tothe flywheel the ring gear onto the flywheel with the no-gear- Note: Do not heat the ring gear excessively Face runout measuring pont + Radial runout ‘measuring point Measuring flywheel face runout and radial runout Ring gear —— T° Removing ring gearINSPECTING AND REPAIRING ENGINE MAIN PARTS 3. Inspecting and repairing timing gears and camshaft 3.1, Measuring backlash of timing gear ‘Measure the backlash of the timing gears by using one of the following two methods: measure the gear play with the dial gauge plunger applied to a tooth flank on the pitch circle at a right angle to the tooth axis, or measure the clearance between gears by inserting afeeler gauge between the gears atthe tooth-t-tooth contacting area, Replace the faulty gear par if the limit is exceeded. Tem Sanaa [an “Backash crankshaft gearand | 0081 (0057 mm | 025 am iter gear 100020 © 00062 | 100098 int Takia comshat gearand | 0052100158 mm | 025mm ler gear [0021 00062} | (0.0058 in BicklashFoetijecion pump | 00560208 am | 023 am sear ond idler gear [0.002216 0.0081 in} | (0.0098 ia} ‘Note: With the fuel pump gear attached tothe pump, install ‘the fuel pump gear othe Front 3.2 Measuring cam lift ‘Measure the minor and major axes of cam using a micrometer to determine cam lobe lift. If the lift isles than the limi, replace the camshaft with @ new one. —————EE Them Rona | Sanda] un | ‘Major axis ‘Major axis— | Majoraxis — oe (usan6 ‘tint | foasasin) | fo2m6inl sist Major axis | Major axis Major ane atta | Minorans | Minera ata 146137 im | gomm |= 6069 mm cutee Sing | foasasint | toztst int 3.3 Measuring camshaft runout “Measure the camshaft runout with a ial gauge. I the limit is exceeded, correct the camshaft using a press or replace the camshatl Note: With dial gauge set on the camshaft, rotate the camshaft one tum and read the gauge indication. Camsbaft runout oes 6-10 Measuring backlash of timing gear Major axis we f Measuring Measuring directions points Measuring cam it Measuring camshaft runout3.4 Measuring camshaft journal outside diame- ter Measure the diameter of each camshaft joumal in two rection at right angles to each other: Replace the camshaft if the limit is excoeded Tem 7 Sandra tan noa.3 | 3338109396 mm_) $390 cm CCamsaftjounat {8°23 | 21236002 1244503 | (21220in1 cutie diameter |" 1" saan 296m | S250 | 1208421020880in3 | 20827} 3.5 Measuring camshaft bushing inside diame- ter With the camshaft bushings installed in the crankcase, measure the inside diameters with a eylinder gauge. If the limit is exceeded, replace the bushing Saree tne Clearance beineen | Float, | 00410 009 mm cama journal | Midile | (0.001610.00035in1 | q.15 mm scams’ [con oo mam | (00089in) bushing [0001610 00047 ny INSPECTING AND REPAIRING ENGINE MAIN PARTS Measuring points Oo Measuring rections Measuring camshaft journal outside diameter Measuring directions: 3.6 Replacing camshaft bushing 3.6.1 Removing camshaft bushing (1) Install a camshaft bushing installer set to the camshaft bushing. (2) Remove the camshaft bushing by tapping the end ofthe 0d of camshaft bushing installer sot, ‘Measuring camshaft bushing inside diameter nore Adapter 5 Camshaft bushing installer set IN:30691-00010 2 r Rod Removing camshaft bushing 6-11INSPECTING AND REPAIRING ENGINE MAIN PARTS 3.6.2 Installing camshaft bushing (1) Install the camshaft bushing t0 a camshaft bushing Piece ,. Bushing installer set. (2) When driving in a bushing, tap the end of rod of ‘camshaft bushing installer et so that the oil hole in the ‘bushing aligns wit th oil hole tothe oil gallery Camshaft bushing installer set IN: 30691-00010 Instaling camshaft bushing 3.7 Measuring idler bushing inside diameter and idler shaft outside diameter ‘Measure the idler bushing inside diameter and the iler shaft ouside diameter. Ifthe inside diameter is larger than the limit, replace the idler bushing, and if the outside diameter is smaller than the limit, replace the idler shaft. Tam Sanaa Tmt “CsaranceFetmeen 1009%00050 mm | 0.100mm ‘ler bushing and idler shart | [0.00040 0.0020 in} | [0.0039 in}3.8 Replacing idler bushing (1) Use the idler bushing puller to replace idler bushing. (2) To instal the bushing, dive it from the boss side so that, itis flush with the gear boss face. (3) Afterinstalling the bushing, measure the bushing inside iameter, and if the inside diameter exceeds the standard, ream the bushing 3.9 Replacing idler shaft ‘To remove the idler shaft, use the idler shat puller. Note: When installing the idler shaft into the crankcase, ‘orient the idler shaft so that it ol hole faces the upper crankcase 3.10 Inspecting tappet Check the camshaft sliding surface of each tappet for uneven weat. Ifa defect is found, replace the tappet INSPECTING AND REPAIRING ENGINE MAIN PARTS. Idler bushing puller IN:30081-07300 EE Removing Installing Replacing idler bushing Dwe0am oow0n, meagre {iiegartensor\ Direction of pross ft pL T=] Ra 0.8 pm [0.031 pin] Idler bushing press fiting dimension Idler shat puller. PIN'MHO61077 Removing idler shatt Good Bad Bad ‘Tappet surface in contact with camshaft 6-13INSPECTING AND REPAIRING ENGINE MAIN PARTS. 3.11 Measuring clearance between tappet and tappet guide hole ‘Measure clearance between the tappet and tappet hole Replace the tappet with a new one ifthe limit is exceeded. Loe sae pues Tappet ole BL000 20.021 mm | 72.10 me inside diameter (0.8661 08670%n} | (08701 ind Clearance bewecolappet | 003800 mm | Olam sd tppet bole (00014 600034 in} | [0.0047 in} Measuring Measuring pojnts eotons Measuring clearance between tappet and tappet guide holeINSPECTING AND REPAIRING ENGINE MAIN PARTS 4, Inspecting and repairing piston, connecting rod, crankshaft and crankcase 4.1, Measuring distortion of crankcase top sur- face i CAUTION Tinitthe depth of surface grinaing of crankcase to @ necessary minimum, If the surface of crankcase is ground more than speci- fied, it may result in defects such as defective combus- tion and stamping (contact between piston and valve), “Apply a straight edge tothe top surface ofthe crankcase and measure its distortion with thickness gauges. IF the Aistortion exceeds the limit, grind the eylinder head with a surface grinder. Note: The grinding, depth is limited so that the piston protrusion may not exceed the standard value ul Sa ‘Dstorton of rankease 105 am 020mm top surface (o.0020in}oriss | f0008 int ‘Note: Do not grind the surfaces more than 2 mm [02008 in, in tox crankease top surface), (cylinder head bottom surface plus ‘Measuring distortion of crankcase top surface 6-15INSPECTING AND REPAIRING ENGINE MAIN PARTS 4.2 Measuring cylinder inside diameter (1) Measure the inside diameter of the cylinder at three levels, ie. upper (with much stepped wear), middle, and lower levels, in both directions parallel to and perpendicular tothe crankshaft direction. (2) If the measurement is between the repair limit and replacement limit, re-bore the cylinder to +0.25 mm {0.0098 in} or +0.5 mm (0.0197 in. oversize, Hone the re-bored cylinder tothe accuracy ofthe standard (3) Use an oversize piston and piston rings to fit the re= bored cylinder (4) If the cylinder is worn unevenly, select an oversize that ensures complete cylindricity when the cylinder is re bored to the maximum. All eylinders most be re-bored to the same oversize if one cylinder is re-bored (6) If the cylinder has a sight wear and is reused after replacing only the piston rings, remove the steps in ‘wom potion in the upper part of the cylinder using a ‘idge reamer. Hone it as necessary. Tom Saad a = "Repair init Cylinder stove | 102.010 9 102.085 mm | 102.200 en (4.0236 in laude diameter | (40161 040175 in}. | Replacement iit 102.700 mam [4.0833 in} cos amen (0.0004 | oress Gotinanciy | (0.0006 in ortess - "Note: The roughness of eylinder sleeve inner surface is, Ra63 jm [0.248 win] 6-16 ‘Measuring points Unit: mm fin Refacing using a ridge reamer4.3. Replacing cylinder sieeve I the inside diameter of a cylinder sleeve exceeds the limit fr a cinder is found defective, replace the cylinder sleeve only, provided thatthe defective eylinder has no effets on the other eylinders, 43.1, Removing cylinder sleeve (1) Setup a boring machine on the crankcase by aligning it with the center of the less-wom area ofthe sleeve a the bottom, (2) Bore the sleeve until its stock thickness. becomes approximately 0.5 mm [0.020 in} (8) Carefully break and remove the sleeve, taking care not to cause damage to the inside surface of crankcase 4.3.2 Installing cylinder sleeve (1) Use acylinder sleeve installer to instal a sleeve. (2) Put the sleeve into the crankcase, eaving a protrusion 0 0.3 10 0.5 mm [0.012 to 0.020 in, atthe top. Then ‘make it flush with the erankcase top. (8) Bore aad hone the sleeve tothe specified diameter INSPECTING AND REPAIRING ENGINE MAIN PARTS Simm [0.020%] Boring cylinder sleeve Removing cylinder sleeve ‘Sleeve installer IN;34291-00200 Installing cylinder sieeve 6-17INSPECTING AND REPAIRING ENGINE MAIN PARTS 4.4 Measuring piston outside diameter (1) Measure the piston outside diameter at the skirt perpendicular to the piston pin, If itis less than the Timit, replace with a new part. At this ime, do not forgot to select a piston which allows the piston weight ilference in one engine to be within O Measuring point Measuring piston outside diameter (2) The piston weight is stamped on the piston head. nah Bon eae (The prefix letter "E" piston [SP | orrewsarssint | (60051 sights of part number) diameter 0.25 OS | ‘4.022210 40234 in] | [4.0150in} iskist) Front mark Piston weight stamp location 4.5 Measuring piston ring end gap lace the piston ring in a gauge ora new sleeve to measur Gauge inside diameter: the ring end gap. If the limit is exceeded, replace all the S1OLs teem rings as ast, [oa tein} Note: Use a piston to push the piston ring squarely into the gauge othe sleeve Piston ring Tem Sandee Ta Compress | 03010045 mm Piston | sion ing | 1001181000177 in} | 1.50 mm eat 5 (0.0891 in nd gop D200030mm | I 1 [0.0118 1 0.0197 in ‘Measuring piston ring end gap 6-184.6 Measuring clearance between piston ring groove and piston ring CAUTION ‘Remove carbon deposits from pistons and check the piston ring grooves over the entire circumference of the piston. (1) Remove deposits such as carbon from each ring groove (2) Check each ring groove for wear or damage. If faulty, replace the ring, (8) Insert the piston ring into the piston ring groove. Apply ‘straight edge and insert thickness gauges to measure the clearance between ring and ring groove. I the limit i exceeded, replace the piston ring with a (4) If the piston ring was replaced with a new one, measure the clearance again, and if the limit is exceeded, then replace the piston witha new one, Tem Sanaa) ca Compression | 0081002 mn | 0200 am ring. No.1 | (40031 to 0.0047 | 10.0079. tearance : eee ‘between pi [Comprenion | 008100 12mm | 0150s tomringand | ring, No2 | (4003110 0.0047 | (0.0059 ia lee Ors e00emm | O150mm Ming | f0.0010:%90.0026 in] | 100059 in} 4.7 Measuring piston pin bore diameter and piston pin outside diameter Measure the piston pin bore diameter and piston pin outside diameter Replace ifthe limit is exceeded LT ee tem oa ‘Standard Umit: Pawar ['ssemm | sgsiwssemm | cuss | (rin | (1338210 1388 ny Clearance — betwen pon 005% 0021 wm | 00s0.m Faboeiad | | (o00z0.0008in | roatzoin) risoapin INSPECTING AND REPAIRING ENGINE MAIN PARTS Piston Feeler gauge ‘Straight edge EN] Piston ring Measuring clearance between piston ring groove and piston ring : =) T T Measuring piston pin bore and piston pinINSPECTING AND REPAIRING ENGINE MAIN PARTS. 4.8. Measuring piston protrusion an ne The piston proon is voy Tmparan ac To proper engine operation and must avaye be kept a8 Species. Too much piston protsion can cause he piston tntetere wih re valves Measure the protrision of each piston as follows: IF the measurement does not conform (0 the standard, the clearances between various parts concemed must be checked. (1) Bring the piston to the top dead center. (2) Apply the dil gauge plunger tothe top surface of the crankcase, and zero the dial gauge. (3) Measure the protrusion at four points on the piston oad, and cafcurate the moan value. Note: Subtract the mean value from the thickness of the ‘gasket compressed by tightening the cylinder head, and the clearance between the piston top and eylinder head will be determined Tem Sanaa 08 mm Piston protrusion Ra ‘Compressed thickness oF T7205 mm cylinder head gasket [0.067 = 0.022 in 6-20 ‘Measuring piston protrusion4.9 Measuring clearance between connecting rod bearing and crankpin (CAUTION: ee When grinding crank pins, be sure to grind all the pins tothe same size, Finish the fillet radius to the specified dimension, INSPECTING AND REPAIRING ENGINE MAIN PARTS Connecting rod cap tightening torque 103:¢5N-m Measuring Measuring (10.520 5kgt-m) directions points (1) Reassemble the bearing into the big end of the connecting rod (2) Tighten the connecting sod cap bolts to the specified torque, (8) Measure the inside diameter of che connecting rod bearing. (4) Measure the outside diameter of the erank pin, (8) Calculate the clearance from the difference between the inside diameter of the connecting rod bearing and ‘ouside diameter of the crank pin. (6) Replace the connecting rod bearing if the clearance exceeds the limit. (7) Measure the clearance between the connecting rod bearing and the crank pin again, Use the undersize bearing if the limit is exceeded. (8) If an undersize bearing is used, grind the crank pin to the specified undersiz. tl - Measuring Measurin directions: points ° ‘Measuring crank pin diameter E Neninal | Sanda] ume Cranipincuside | 963mm | G1545 w64908 mm | 61800 mm ameter (o.0a6ina | (255694025877 im] | (2.55121 Cleaance beeen crankpin and _ | 003se00,00mm | 0:200%m onnacig od [00141000039 in) | [0.0079 in} bearing 4.10 Measuring clearance between connecting rod bushing and piston pin Measure the inside diameter of the connecting rod bushing, and the outside diameter of the piston pin. Replace ifthe limit is exceeded. Toten Na] Sneed =| o Bushing inside 34.0200 34.085 mm] = ie] [ew mort |” Cexanabance 002390084 | 0080mm Sarinesosonon |= | oomnoocmat is | nt a) Measuring directions © 3 Measuring connecting rod bushing inside diameter Measuring points 6-21INSPECTING AND REPAIRING ENGINE MAIN PARTS. 4.11 Replacing connecting rod bushing (1) Use a connecting rod bushing installer to replace the connecting rod bushing. (2) Align the oil hole of the bushing and connecting rod Position the joint of the bushing as shown in the diagram, (8) After installation, inser the piston pin and make sure the pin rotates freely without rain. 4.12 Removing connecting rod bushing (1) Apply engine oi to the inner surface ofthe connecting rod bushing (2) Install the collar Ato the connecting rod bushing. (3) Install the collar A and B to the mandrel, and tighten the nut. (4) Align the match mark (ed ine) on the collar A withthe ‘match mark on the base. sad of the ‘mandrel to force out the connecting rod bushing. (8) Using a press, apply pressure slowly on the 4.13 Installing connecting rod bushing (1) With the oif hole o busing aligned with the match mark (onthe collar A, install the new connecting rod bushing ‘nto the collar A. (2) Install the collars A and B to the mandrel, and tighten the nat (3) Apply engine oil to the outer periphery of the connecting rod bushing. Align the oil bole in the connecting rod bushing with the match mark (redline) ‘on the collar, then press the bushing into the connecting rod, 6-22 Oihole 30° \ L thot a0 NY Bushing ont Replacing connecting rod busting ‘Connecting ros ‘bushing installor PIN:32E91-03050 Mandrel Collar A onectng fi Ri bushing sion mater | mark. ‘Connecting rod ‘Collar 8 Nut Li ~Base QR Removing connecting rod bushing ‘Connecting rod ‘Connecting rod bushing installer bushing Pin:32e91-03050 | ° ==) Align matoh mark. +H |! TP ~cotara Installing connecting rod bushing 1 Connecting rod = bushing installer 7 PIN:32E91-03050, ——Mandrel —Collr B ‘Connecting rod bushing Connecting tod ColarA ‘Alon match + Nut ce \ Base Installing connecting rod bushing 2INSPECTING AND REPAIRING ENGINE MAIN PARTS 4.14 Inspecting connecting rod bend and twist (1) Measure C and L as shown in the diagram to check the ‘Connecting rod cap tightening torque: tng rod bend and twist I'the value is out of the 103 #5 Nim (10.8 0.5 kgf-m} perseuray «0.05 0.003} standard value, straighten the connecting rod with a ce $700 8.9) press. L Ifthe limit is exceeded, replace the connecting rod Lc. 005j000 |» eo (2) {In general, connecting rod bend and twist are checked fee L "100 9] c: by the connecting rod aligner. aaa Note: Before inspecting bend, install tho cap © the ‘connecting rod connecting rod, then tighten the cap bolts to the Bend of pected one 7 connecting roo Unit: mm fn (8) To inspect the connecting rod assembled with the piston, place the piston ona surface plate, insert around ‘bar having the same diameter as the erankpin into the Inepecting connecting rod bend and twist big-end bore, then measure the height ofthe bar with a dial gauge. Tem Banca tt “Coansctingrod | ——~00S/I00mm | 0.18 mm bend and wist | [0.002039 in) or tess. | 10.0059 in} ee eeEOreee eee Measuring with a dial gauge 4.15 Inspecting connecting rod bearing ‘Check the connecting od bearings and replace the damaged bearings with new ones. ‘\ Flaking y Ingpecting connecting rod bearing 6-23INSPECTING AND REPAIRING ENGINE MAIN PARTS. 4.16 Measuring connecting rod end play (1) Install the connecting rods onto the respective crankpins and tighten the connecting rod cap bolts to the specified torque, (2) Measure the clearance to the crank arm (end play) at {wo positions (above and below the crankpin), (8) Replace the connecting rod ifthe limit is exceeded. Ten Ccmatiogvosenapiey | 01s003Saun | 050mm — Connecting ovend 8 | 059 90138 in} | (00197 in} 4.17 Weight difference of connecting assembly in one engine When replacing a connecting rod, be sure to check the weight rank of the connecting rod. In one engine, all the Sanda Tt rod connecting rods must be of the same weight rank. won ee “Weight difference of connecting rod [ 10g[040z] vee micrometer. Check the crankshalt journal for eicularity, cylindricality and the clearance with the bearing. IF the ‘measurement value is below the repair limit, grind the Joumal (0 fit the undersize bearing. If the measurement value is below me service iit, replace the crankshaft with tem. ‘Standard ‘Umit Tar 90mm | w9tv0 91mm | tam (79) Diameter | 13.54. | (3.5413 0 3.5421 in} | Service limit = Sn 37a) O01 mm 003 me fm = 10.0004 in.] or tess {0.0012 in) Oat Oia Cxtoaricity | [0.0004inJ orfess | (0.0012in.} Ds Peiton 01m 0804} sate 6-24 Connecting rod cop tightening torque 1032 5Nm (105205 kgm) frez3einen ‘Measuring connecting rod end play eT Measuring Measuring directions points Measuring crankshaft journal outside diameter4.19 Measuring crankshaft crankpin outside diameter “Measure the crankpin outside diameter using a micrometer. Check the crankpin for circularity, cylindrcality, and the clearance with the bearing. If the measurement value is below the limit, grind the journal to fit the undersize bearing. the measurement value is below the service lin replace the crankshaft with a new one a eee 7 [0.0004 in. or less. (0.0012 in] siindsicity {0.0004 in.) or tess. (0.0012 in} rrtaen | - | aameune Grind the crankshaft joumals (oF pins) to the diameter matching the inside diameter of the next undersize main (or connecting) bearing, and the fitness check with an actual bearing will become omissible When grinding, be careful not to change the fillet radius and Width, Ifthe surface hardness is considered to have been reduced considerably, resharden the crankshaft and check for flaws by means of magnetic particle inspection. Ensure that the surface finish accuracy of the crankpins and journals is kept within the standard even after the correction by grinding, Ton uneenee" Fretedsee 0.25 mm | 69.7010 89-72 mm (010098 in} | (8.5315 103.5323 ing crank 030mm | 894308947 mm Journal footing | (521635224 in) ‘075mm | 8920008922 mm (00295in) | (35118t035126in} 025mm | 6569510 68.715 mm (0.0098 in} | (2.586810 2 5872 in} 050mm — | 65445 19 65.465 mm ae [o.0197 in | (2.5765102.5774in) O7Smm | 651951068215 mm (0.0295in.) | (2.5667 102.5675 in} INSPECTING AND REPAIRING ENGINE MAIN PARTS Measuring Measuring directions points, ‘Measuring crank pin diameter 6-25INSPECTING AND REPAIRING ENGINE MAIN PARTS. 4.21 Measuring crankshaft end play (1) Check the crankshaft end play (clearance between the crank arm at the trust force receiving journal and the bearing cap with thrust plate attached), and replace the thrust plate with a new one ifthe limit is exceeded, (2) Use an oversize thrust plate ifthe limit is stil exceeded even after a new thrust plate is installed, Note: In general, the rear thrust bearing wears faster than the front thrust bearing. Ther fore, in most cases, the correction is achieved by replacing the rear thrust plate with a next oversize one. Tem an 333°" [ Tasting 0.10010 0.246 mm | 0.300 mm Crankshaft end play | 19 9939 9 00104 in} | {000118 in} Crankahan Init ae Aer nan FOS; weed | “08, used : tom | enone | on both. | Tolerance ie sides, “215 mm Bian | 0mm {0009iaj0s | (10st | (310i) 0.30 am 330mm [sav mm | 0100089 nm joonsiayos | candi) | (.336im) | (0100013 m) am Basan | sed mm 0017708 | (131i) | (13228) 4.22 Measuring crankshaft runout Support the crankshaft at the front and rear journals with V- blocks, and measure the crankshaft deflection radial runout at the center journal) with a dial gauge. If the runout deviates from the standard only slightly, comect it by grinding the crankshaft. If the runout is a litle large, straighten the crankshaft using a press. Replace the crankshaft if the limit is exceeded, If the crankshaft has been repaired by grinding or pressing, inspect its various parts for cracks and other harmful damage with a magnetic particle examination Re item | Standare tiie | ate ranishaht | 008 mm T10m Te uncut | [0.0016 in} orks | 10.0039in or ess 6-26 ‘Measuring crankshaft end play Measuring crankshaft runout4.23 Replacing crankshaft gear 4.23.1 Removing crankshaft gear Using the gear puller, remove the gear from the crankshaft Note: Do not remove the gear by hiting it with a hammer 4.28.2 Installing crankshaft goar (1) Instat the key on the crankshaft (2) Press-fit the gear fully in alignment with the key. INSPECTING AND REPAIRING ENGINE MAIN PARTS Crankshaft gear LN key (* QW WL yy ‘Crankshaft gear Installing crankshaft gear 6-27INSPECTING AND REPAIRING ENGINE MAIN PARTS. 4.24 Replacing front 2 CAUTION. Be careful not to damage the crankshaft pulley with & cchisel when breaking the sleeve. Be careful not to dent CF scratch the outer surface of sleeve, ‘When a ill leaks from the ol seal, replace both sleeve and oil seal with new ones, (1) Removing sleeve Apply a chisel at right angles to the end surface of the sleeve and stike it with a hammer at three locations 10 loosen the sleeve and then remove the sleve. Note: Ifthe sleeve cannot be removed, apply the chisel to the sleeve in the axial direction ofthe sleeve and tap it lightly to make a cut and remove erankshaft-to-sleeve interference (2) installing sleeve Install the sleeve using a press so thatthe end of pulley becomes flush. 4.25 Replacing rear oil seal : __ CAUTION — Be careful not to damage the crankshaft when remov- ing the rear oil seal, ‘When a oill leaks from the oil seal, replace the oil seal with (1) Removing rear oil seat ‘Remove the oil seal witha puller. (2) Installing rear side oil seal Apply an oil on the slinger inner surface of oil sea. Install the oil seal with an oil sea installer, Note: The oil seal is united with the slinger. Removing front sleeve + | Crankshaft pulley Rear slinger Removing oil seal (ear side) Rear ol sea installer PIN:34281-00020, Oil seal Installing oll seal_ (rear side)4.26 Inspecting mai 19 surface Check the inside surface of each main bearing shell for abnormal contact signs, scratches and corrosion resulting from foreign matter intrusion, coating delamination, ete.Also check the outside surface of each bearing shell Which contacts with the crankcase of main bearing cap for abnormal seating signs. 4.27 Measuring clearance between main bear- ing and crankshaft journal far Wher giana aark puri be sue gaa the joumas oe same size (Fish th et ras tote speed émenson () Remonblomintexigs SSS (2) Tighten the main bearing caps to the specified torque. (8) Measure the inside diameter of the main bearings. (4) Measure the outside diameter of the crank journal. (5) Calculate the clearance between the inside diameter of the man bring mo oui dane of e mak (6) Replace the main bearing if the clearance exceeds the Use the undersize bearing if the limit is exceeded, (8) If an undersize bearing is used, grind the crank journal ‘o the specified undersize. Ta To Sianaara Ta ‘Clearance between main | 0050100118 mm | 020mm earing an crakshat journal | (0.0020 00046 in} | (0.0079 in} INSPECTING AND REPAIRING ENGINE MAIN PARTS ‘Seratch on the inner ‘and outer circumference, ‘corrosion, and detachment Inspecting main bearing surface ‘Measuring Measuring] directions points Main bearing cap bo lightening torque 137 #5Nem (14 £0.5 kgfm) [101 + 36 tA] ‘Measuring inside diameter of lower hole of main bearing tt rt \ Messuring Measuring S recions "poms ‘Measuring crank journal outside diameter 6-29REASSEMBLING ENGINE MAIN PARTS 1. Reassembling piston, connecting rod, crankshaft and crankcase 7-2 1.4 Installing main BeALING .rnnsnnnnesnnne FR 1.2. Installing thrust plate ..nnmnmnnernn 72 1.3. Installing crankshaft... 72 1.4 Instaling main bearing caps 73 1.5. Inserting side seal er 16. Instaling main bearing cap bot 73 1.7. Measuring orankshatt end play.. 4 1.8 Reassembling piston and connecting rod. ve — 74 41.9 Installing piston ring 74 1.10 Preparation for Installing PistOn$ wns 7-5 41.11 Installing connecting rod bolt and connecting rod beating vex oT B 1.12 Installing PIStONS nnn 76 41.13 Installing connecting rod cap 76 2. Reassembling timing gear and camshaft. 2.1. Instaling front plate... 2.2. Installing tappet. 23. Installing camshaft 2.4 Installing idler gear... 78 2.5. Inspecting and adjusting timing gear after installation. 78 2.5.1. Inspecting backlash and end play ...unn7B 2.8. Installing front ol seal . 2.7. Installing timing gear €88€ e..n 79 2.8. Installing crankshaft pulley... 3. Reassembling Flywheel 8.1. Installing flywheel housing... 3.2 Installing flywheel. 4, Reassembling cylinder head and valve mechanism .. TAY 4.1. Cleaning cylinder head bottom surface.. 7-11 4.2 Installing valve stem seal. 74 4.3. Installing valve and valve Spring wrnnne7=11 4.4 Installing cylinder head gasket... TAR 45. Installing cylinder head assembly ....- 7-12 4.6 Tightening cylinder head bolts 712 4.7. Inserting pushrod 743 4.8 Reassembling rocker shaft assembly... 7-13, 4.9 Installing rocker shaft assembly... 7-18 4,10 Installing rocker case... enna TAS 4.11 Installing haMess@ .nrrnmnnnernnne TAA 4.12 Installing injector. TA 4.18 Adjusting valve clearance 4.14 Installing rocker cover. TAS TASREASSEMBLING ENGINE MAIN PARTS. 1, Reassembling piston, connecting rod, crankshaft and crankcase 1.1 Installing main bearing CAUTION Bomnot apply olfto the bearing outer surface, as the il may cause the bearing seizure. (1) Fit the main bearings (upper halves) into the lug grooves inthe crankcase. Note: The oil holes in the bearings and crankcase are Aligned when the bearings are installed as described above. (2) Apply a small amount of engine oil to each bearing 1.2 Installing thrust plate (1) Insta the thrust plates to the cxankease outside face of rearmost bearing and tothe main bearing cap with their goorves faced outside. 1.3. Installing crankshaft (1) Wash the crankshaft thoroughly with cleaner, and dry it with compressed ait "Note: When washing the crankshaft, be sure to clean the oil holes and make sure they foreign particles. (2) Hold the crankshaft horizontally with a hoist, then carefully place it into the crankcase. (8) Apply a small amount of engine oil to the crankshaft journals. not clogged with dust of a Main bearing upper ‘Align with ug groove, ‘Thrust plate Installing main bearing upper Thrust pate, upper Thrust pate, lower Thrust plate lower} Installing thrust plate1.4 Installing main bearing caps pu ‘CAUTION, ‘pata tho ovomost and earmost caps So hat Thoy ave flush with the crankcase surface. Install tbe main bearing caps from the fron side in the order of the numbers marked on them, (1) Apply engine oil to lower main them tothe main bearing caps (2) Apply ThreeBond 1212 to the mating surface of the foremost and rearmost caps and the crankcase mating ings and install {aces before installing the main bearing caps Note: Do not apply ThreeBond 1212 any other area other than the mating surfaces of the foremost and rearmost caps and the crankcase mating faces. (8) Install the main bearing caps and temporarily tighten bolts 1.5 Inserting side seal (1) Apply a sealant to the circumference of new side seals. Sealant THREEBOND 1212 01211 (2) With roundings of the side seals facing outward, posh them inthe front and rear caps to some extent by hands, (8) When the side seals are pushed-in to some extent, use a tool with fla surface such as fla-head screwdriver to ‘completely push them in, taking eare not to bend them, 1.6 Installing main bearing cap bolt (1) Tighten the main bearing cap bolts alternately and progressively to the specified torque. (2) Make sure thatthe crankshaft rotates smoothly. REASSEMBLING ENGINE MAIN PARTS ‘Apply ThreeBond 1212. Installing main bearing cap Side seal [1 Crankcase Bearing cap +S 1 1 1 1 —---—[) R section] Inserting side seal Main bearing cap bolt tightening torque 187 45 Nem {11 £05 kgf} (101 2 36 brn Installing main bearing cap bolt 7-3REASSEMBLING ENGINE MAIN PARTS 1.7. Measuring crankshaft end play Apply a dial gauge to the tip of the crankshaft to measure the en play. If the end play is out ofthe standard value, loosen the main ‘bearing cap bolts and tighten them again Te To Senda] enn 0.100 «0 0.258 mm | 0.300 am [0.0039 9 0.0104 in} | (0.0118in} ‘Crankshaft end play 1.8 Reassembling piston and connecting rod (1) Apply engine oil tothe piston pin. (2) With the matching mark on the connecting rod oriented con the tight side of piston when facing the piston top front mark “F", assemble the connecting rod and the piston, and secure them with te piston pin (3) Install each snap ring into the ring groove of the piston using sing pliers. Check snap rings for tension and seating condition inthe groove. (4) Ovient the split of each snap ring toward the bottom of the piston 1.9 Installing piston ring CAUTION Bi ‘Rrmarking such as "Ais stamped near the end gap tO indicate the top face of piston ring. Install all piston rings with the mark faced upward If piston rings are assembled wrong side up, it will ‘cause malfunctions such as increase of cil consump tion or engine seizure. (1) Tastall the piston rings © the piston with a ving expander (2) Install te oil ring spring so that its joint is 180° away from the oil ring end gap as shown in the illustration. Measuring crankshaft end play - Piston pin. FtOn Me ‘Snap ring, 7 Ng ; Apply engine ol | Matching mark Reassembling piston and connecting rod No. compression ring Td /. a \ yo S5 a il ein CE ove Reassembling piston and piston ring Coll spring butted ends ‘ol ring abutment Reassembiing ol ing1.10 Preparation for Installing Pistons (1) Lay the engine along its sie, (2) Clean the cylinder sleeve inner surface and the erank pin with a cloth, and apply engine cil t them. 1.11 Installing connecting red bolt and conneot- 19 rod bearing (1) Press fit the connecting rod bolts into the connecting rod. Note: When press fitting the boll, make sure that the bolt fully contacts is seating position without any imerference with the shoulder of mounting surface, (2) Install the upper connecting rod bearing with its lug ‘ted in the lug groove of connecting rod. (8) Install te lower connecting rod bearing with its lug fitted in the lug groove of connecting od cap. (4) Apply engine oil tothe inner surface of bearing. REASSEMBLING ENGINE MAIN PARTS Cleaning and lubricating cylinder sleeve inner surface Lug grogve Installing lower connecting rod bearingREASSEMBLING ENGINE MAIN PARTS. 1.12 Installing Pistons Sula in eOAUMIOME eaetnienng ‘Do not forcefully insert the piston. It may cause dam- age to the piston rings and crank pin. (1) Apply engine ofl to the circumference of the piston and piston sings. (2) Orient the ring end gaps diagonally opposite each other avoiding the piston pin direction and its right angle direction, (3) Tum the crankshaft to bring the erank pin of the cylinder to the top dead center, (4) Orient the front mark on the top of piston toward engine front (5) Using a piston guide, inser the piston from the top face of crankcase into the eylinder sleeve. 1.13 Installing connecting rod cap (1) When the big end of the connecting rod comes into ‘contact with the crank pin turn the crankshaft 180° While pressing the piston head (2) Install the connecting rod cap with its match mark facing on the same side as the match mark on the connecting rod. (3) Tighten the connecting rod cap nuts evenly and progressively tothe specified torque, (4) Inspect end play of the connecting rod. Loosen the cap ‘nuts and retighten them if end play is smal 7-6 Camshat side Not 18077 % Compression il * fing ene 99 No2 ‘Compression iting end gap tnoendesn oo G0" Combustion chamber side ‘Orientation of piston ring end gap PIN:34297-00100, Tnstaling piston Camshaft e Zo Matehing mark lO Connecting rod cap ut tightening torque 103£5.N-m CZ (10.5 £05 kof) e236 005) ‘Wood blook Installing connecting rod capREASSEMBLING ENGINE MAIN PARTS 2, Reassembling timing gear and camshaft 2.1 Installing front plate (1) Clean the mounting surface ofthe gasket (2) Apply sealant othe gasket to prevent fling (3) Install the gasket. (4) Install the front plate, and secure it with mounting bolts. 2.2 Installing tappet Coat the periphery of tappets with engine oil, insert them imo the tappet holes and ccamshatts place them gently on the 2.3. Installing camshaft CAUTION. ‘Bo careful not to damage camshaft journals, cams and camshatt holes during insertion (1) Apply engine ol to the camshaft jourals and cams (2) Slowly inser the camshaft assembly. (8) Tighten the thrust plate bolt the spesifiod torque. (4) Make sure thatthe camshaft rotates lightly. Move the camshaft gear back and forth, and make sure there is end play Front plate bolt tightening torque Front plate Installing front plate Camshaft gear ‘Camshaft thrust plate 3}. bolt tightening torque 1242 Nem{1.2£0.2 kgm) S oe 1.4 6h) Installing camshaftREASSEMBLING ENGINE MAIN PARTS, 2.4 Installing idler gear (1) Apply engine oil to the idle gear shat evenly. (2) Install the idler gear with its match marks aligned with ‘the marks on the crankshaft and camshaft gears. (8) Install the thrust plate tothe idler gear, and tighten the ‘mounting bolt to the specified torque. 2.5 Inspecting and adjusting timing gear after installation Be sure to inspect and adjust the timing gear when the timing gear has been reassembled, 2.8.1 Inspecting backlash and end play ‘After installing the timing gears, be sure to inspect and ‘adjust the backlash and end play between gears 7-8 Thrust plate bolt Thrust plate Installing idler gear Idler gear crank gar“ Timing gear train “Measuring backlash of timing gear2.6 Installing front oil seal Using an installer, install new oil seal in the timing gear case. Make sure the ol seal is flush withthe gear ease 2.7 Installing timing gear case (1) Install he baile plate tothe front end of erankshaf (2) Apply sealant vo the gasket to prevent it from displacing and install the gasket on the front plate (8) Apply engine otto the oil seal lip. (4) Orient the cutaway of the bale plate so that the baftle plate does not overlap the oil pump idler gea. (8) Instat the timing gear case, and secure it withthe bolts. 2.8 Installing crankshaft pulley A caution ae ‘The bar could come off. Bo very caret (G1) Screw wo guide bots ito the threaded boles atthe ear end ofthe crankshaft Use these bots and bar placed across them to prevent he crankshaft from rotating. (2) Install dhe woodruff Key on the eras, (3) Insal the crankshaft pulley and tighten the nas tothe specified torque REASSEMBLING ENGINE MAIN PARTS Instaling front ol seal Timing gear ease tightening torque 35 + 5 Nim {3.60.5 kgm) oe Instaling timing gear case (Ol pump idler gear Bats plate cvtaway Battle plate cutaway position Grankshet pulley nat tightening torus 06359 N-m (726 kgt-m). isarsaaibrn) (Front) << The bar that prevents > Rerankshat rotation (Guide bolt (M12 125mm) Rear) Installing crankshaft pulley 7-8REASSEMBLING ENGINE MAIN PARTS. 3. Reassembling Flywheel 3.1. Installing flywheel housing (1) Clean the mounting surface of the gasket. (2) Apply sealant to prevent the gasket from fling oft (3) Install the gasket. (4) Instat the flywheel housing, aligning its dive pn holes and dowel pins, and tighten the bot Note: When the dowel pins are wom or the Aywheel housing is replaced, replace the dowel pins with new 3.2 Installing flywheel TA CAUTION, ‘The person who holds the pulley must be very care to assure safety by communicating with the person wha i installing the fywhee! (1) One person must firmly hold the pully with a wrench to prevent the erankshaf from tuning, (2) Screw the guide bolt nto the rear end of the crankshaft (3) Align the bot ote of Aywheel withthe guide bolt and install the Mywheel wo the crankshaft (4) Temporarily tighten bolts. (5) Remove the guide bolt and temporarily tighten the last bolt (6) Tehten the fywhee! bots othe specified torque 7-10 Installing flywhee! housing ae FS eS [PS torque: 85:25 N-m FS i6.5205 kot) 162436161) (Front) Installing flywheelREASSEMBLING ENGINE MAIN PARTS 4, Reassembling cylinder head and valve mechanism 4.1. Cleaning cylinder head bottom surface ‘Taking care not to damage the eylinder head bottom surface, remove gasket residue (Note: Fist, roughly scrape off the residue using a seraper Then, grind off remaining residue using an engine-cil immersed oil stone. 4.2 Installing valve stem se: a ‘CAUTION —™ Do not apply off or liquid gasket to the inner side of ‘stom seal that comes in contact withthe valve guide. Stem seal installer PIN:32F91-00500 (4) Aly engine clio the lp of ow valve sem se | (2) Push the shoulder of the valve stem seal and fit the valve stem tal into the valve guide. eet (@) Insert the valve stem sel into the valve guide using the f Ym ote YW Instaling valve stem seal valve stem seal installer. 4.3 Installing valve and valve spring (1) Insta the valve spring and retainer on the valve guide, Tnsall de valve cotter using a valve spring pusher (2) ‘Tap the valve stem top lightly several times with a soft hammer to make sure that the valve spring and valve cotter are properly installed and seated firmly.REASSEMBLING ENGINE MAIN PARTS 4.4 Installing cylinder head gasket (1) Make sure that there is no dirt or dents on the top surfaces of the erankease and pistons (2) Place new gasket on the crankcase by aligning it with dowel pins on the crankcase, 4.5 Installing cylinder head assembly Install the eylinder head on the crankease by aligning it with the dowel pins. Note: Be careful not to displace the cylinder gasket when installing 4.6 Tightening cylinder head bolts In the numerical order as shown in the illustration, tighten cylinder head bolts progressively to the specified torque 7-12 Installing cylinder head assembly Cylinder head bot tightening torque: 137 45 Nem (140.5 kgf+m} [101 # 3.6 ff] Tightening order of cylinder head bolt4.7 Inserting pushrod (1) Insert each pushrod into its hole inthe cylinde head. (2) Make sure that the ball end of each pushrod is placed coroetly on the tappet cup. 4.8 Reassembling rocker shaft assembly (1) Apply engine ol othe rocker shat (2) When reassembling, arange the rocker shaft assembly as it was before disassembly. Note: If the amangemen is different from the original srrangement, the clearance becomes different, and it ‘may result in a defect such as wear increase, (8) After reassembling, make sure the rocker arms and oll pipes move lightly. 4.9. Installing rocker shaft assembly (1) Install the valve caps on the valve heads. (2) Tighten the Jong bolts of the rocker bracket to the specified torque (8) Tighten the short bolts ofthe rocker bracket. REASSEMBLING ENGINE MAIN PARTS Pushrod L Me Inserting pushrod Tappet ol “30° Rocker arm A a) at a ring Rocker shaft Rocker shaft spring Rocker i Reassembiing rocker shaft assembly Spreckot nee 1822 Nm(1.8 0.2 kg) [13 + 1.4 bf) Installing rocker shaft assembly TABREASSEMBLING ENGINE MAIN PARTS 4.10 Installing rocker case (1) Insta the rocker case tothe cylinder head, (2) Press fc the injection pipe seal into the rocker case until the seal plate portion contacts the rocker case. 4.11 Installing harnesse (1) Connset the harness bracket and harness to the rocker shaft assembly. (2) Connect the harness to the fuel injection nozzle, 4.12 Installing injector (1) Install the O-ring tothe injector. Apply grease to the O- sing, (2) Install the gasket tothe injector. (8) Install the injector with the nozzle gland to the eyinder head. (4) Install he injection sea (5) Instat! the ayection pipe. (6) With the washer spherical side faced toward nozzle ‘land, install the washer, and secure it by tightening the hexagon socket head bolt tothe specified torque. Note: Make sure that the injector is reassembled into the ‘same cylinder that it was. ‘When replacing the injector with a new one, refer to “Troubleshooting.” 7-14 Main amness Installing hamess Injection pipe Do rs Injection seat’ Ye YO Inocto” Ss Gasket Installing fuel injection nozzle4.19 Adjusting valve clearance Adjust the valve clearance. For adjusting. procedures, refer to “Adjusting. Engine Inspecting an Adjusting Valve Clearance." 4.14 Installing rocker cover (1) Make sure that the gasket is comectly reassembled to the rocker over, (2) Tighten the rocker cover mounting nuts tothe specified torque. REASSEMBLING ENGINE MAIN PARTS ‘Adjusting valve clearance Rocker cover bol tightening torque: 1822N-m (1.8402 kgf-m) [13 41.4 IbFeR] Installing rocker cover 7-15FUEL SYSTEM 4, Removing fuel system. 82 1.1 Removing fuel system (Part 1). 82 1.2 Removing fuel system (Part 2).......-..0. 8-3 2. Assembling fuel system 2.4. Installing fuel iter 3. Installing fuel system 3.1. Installing fuel system (Part 4).. 3.2. Installing fuel system (Part 2... 8.3. Replacing fuel pump 3.3.1, Removing fuel pump... 3.3.2 Replacing fue fuel pump gear 3.3.3 Instaling fuel pumpFUEL SYSTEM 1, Removing fuel system ie a Sete eRe EEA UOM creer azine wien ereuee (a) Keep open flame or heat away from fuel system before conducting the removal work, It could cause a fire. (b) Wipe off any spilled fuel. Spilled fuel could cause a fire. (©) Cover or plug any inlet and outlet openings to prevent dust from entering the fuel system, (3) Fortuel pump, common rail, and injector, have a specialized maintenance shop do the maintenance work 1.1, Removing fuel system (Part 1) [Ciogging, crack Repiace : Every 500 hrs [Apply engine ollto the. Po esta woun ting ~s o 8 é Removing fuel system (Part 1) Removing sequence 1 Spiral tube 4 Fuel iter bracket 7. Fuel pump 2 Spiral 5 Ol pipe 3 Fuel fiter element 6 Pump bracket 8-2FUEL SYSTEM 1.2. Removing fuel system (Part 2) 4 ™1 Removing fuel system (Part 2) Removing sequence 1 Pipe clamp 7. Hexagon head bot 13. Common ral 2 No.1 injection pipe 8 Nozzle gland 14 Fuel outlet pipe 3 No.2 injection pipe 9 Injector 18 Fuel let block 4 No.3 injection pipe 40 Pump pipe 16 Fuel pipe 5 No. injection pipe 11 Check valve 6 Injection seal 12 Reliet pipe 8-3FUEL SYSTEM 2. Assembling fuel system 2.1. Installing fuel filter (@) When handling a fuel, make sure to keep any open flames or heat away from fuel, as it may cause fre hazard. (0) Thoroughly wipe off any spilled fuel, as it may cause a fire. (©) Do notuse the fiter that has a dent on its case. A dented fter may be damaged during operation, resulting in a ‘uo! leakage, and eventually a fire [CAUTION Tew {f@) When instaling the fuel fier, do not use a fiter eee ory ‘wrench, Tighten the fuel fiter by hand. SQ, 98420Nm (b) Be careful not to dent or scratch the fuel fiter sur EY (10.2 atm) face. [7281.5 ttR] (1) Prepare a new fuel filter, and make sure that the gasket is properly fitted in ts groove (2) Apply a clean fuel oil the gasket. (8) Instat the fuel filter to the filter bracket. When the fuel filter gets contact with the bracket mounting surface, tighten the fuel filter about three fourth to one turn, (4) Blood the ful fier (6) Start and operate the engine at idling speed for several Replacing fuel fiter ‘Apply fuel minutes to gasket. (6) Check for fuel leakage from the fuel filter mounting surface, If fuel leakage is found, loosen the fuel filter, check the gasket for damage and retighten the fuel filter Fuel fter3. Installing fuel system 3.1. Installing fuel system (Part 1) FUEL SYSTEM 3484 Nem {84204 kgh-m) (24622 8 A \v stm (aso 46m) paseo iG ec mN 25°%3°Nm (2.5°E kgtm} [18°44 oF] (204 0.4kgtm} ee {axa5Nm [423 0rtl Replace: Sealing washer .' O-Ring oe é {1,840.35 kgtm} [13251068] 8881.0 N-m i i {0,940.1 kgf-m} $ (6.520.7 bt] a 344 Nem {8440.4 kgf-m} Rasizg brag 8 18438Nm be S (1.5°3" kgtm) , \ (11 9 ibe] Installing fuel system (Part 1) 8-5FUEL SYSTEM 3.2 Installing fuel system (Part 2) {3 + 0.3 kgfm} i a7 goo® Tl 4125Nm {4.24058 kofim) ee 3 [30.4 +36 brn) | Uz sostatm D7 180.4 + 36 or a 3424Nm 4 7 (8.4404 kot) NN [24.6 +29 bbFn} oe 344Nm (24204 kgtm) (246 229 1bFR] 25*8Nm / 25%8* kgtm) erytorn Valve opening pressure: 352 15kPa 10.35: 0.15 kglem} 2521.1 ben] {15202 kgtm) =e: 4 Replace’ Sealing wacher Gasket Oxing Installing fuel system (Part 2) 8-6FUEL SYSTEM 3.3. Replacing fuel pump 3.3.1 Removing fuel pump (1) Remove the inspection cover for fuel pump gear and {der gear from the timing gear case (2) Pota mating mark on the idler gear and pump gear with white paint, (8) Disconnect fuel pipe and el pipe from the fuel pump (4) Remove the harness connector. (8) Remove the fuel pump. 3.3.2 Replacing fue fuel pump gear (1) Remove the fuel pump gear (2) Pura matching mask on the new fuel pump gear at the same position the removed Fuel pump gear was marked. (8) Install the new fuel pump gear, aligning with the fuel pump shaft key. (4) Install and tighten the fuel pump gear mounting nut to the specified torque, 3.3.3 Installing fuel pump (1) Install the O-ring tothe fuel pump. (2) With the match marks on the idler gear and the pump ‘gear aligned, install the fuel pump to the timing gear (8) Connect the harness connector (4) Install the fuel pipe and the oil pipe, and tighten to the specified torque, (6) Install the pump gear inspection cover to the timing gear case. Fuel pump gear Idler gear ™~ me Flemoving fuel pump 90£6Nm Tightening torque Fuel pump gear Replacing fuel pump gear Installing fuel pump 8-7LUBRICATION SYSTEM 1. Removing and inspecting lubrication system... 2. Disassembling, inspecting and reassembling lubrication system... 2.1 Disassembling and inspecting oil pump... 9-3 2.1.1 Removing oi! pump gear... 23 2.1.2 Removing spindle and idler geer. oa 2.2 Inspecting and adjusting oll pump. og 2.2.1 Measuring end clearance between goars and case. a4 2.2.2 Measuring side clearance between gears and CAC... o 9-4 2.2.3 Measuring clearance between outside diameter of gear shat and inside diameters of pump body and ump cover 2s 2.2.4 Measuring spindle outside diameter and idler bushing inside diameter 9s 2.3. Reassembling oll PUMP. rrr nnn OB 2.3.1. Reassembling ol pump gear and hive gear assembly 96 24 Inspecting ol fit. 27 25 Inspecting celief valve 97 26 Inspecting safety valve. 97 3, Installing lubrication system 98LUBRICATION SYSTEM 1. Removing and inspecting lubrication system (Clogging, crack 10-17 ‘ Replace: Every 500 rs ° j 8 ee —\\ Removing and inspecting lubrication system Removing sequence 1 Olfiter @ Relief valve 18 Oi drain pipe 2 Drain hose Breather hose 16 Drain plug 2. Fier bracket 10 Breather pipe 17 Drain cock 4 Fiterbaso 11 Vinyl tube 18 ll pan 5 Oil cooler cover, 12 Broather 19 Oil strainer 6 Oil cooler element 13 Oillevel gauge 20 Satety valve 7 Cover 14 Ollpipe 9-2LUBRICATION SYSTEM 2. Disassembling, inspecting and reassembling lubrication system 2.1 Disassembling and inspecting oil pump (Gear defect, wear (Once removed, replace the gear| with a new one. (Gear detect wear] Crack, damage] Disassembling and inspecting oll pump Disassembling sequence 1 Gear cover 8 Oil pump gear 2 Driven gear 4 Drive gear Note: Inspect the oi pump prine to the removal af gears 2.4.4 Removing oil pump gear pena ¢ IN ‘Soe the ol pump gear is removed, he ol pump gear and the drive gear are no longer reusable. Replace them with new ones Remove the ol pump gear with a puller. 5 Spindle 6 Idler gear assembly 7 Plug ‘Oil pump gear Puller PIN:64309-12900 Removing oll pump gear 9-3LUBRICATION SYSTEM 2.4.2 Removing spindle and idler gear Remove the spindle and the idler gear as a unit, Remove the spindle and the idler gear by tapping the edge of idler gear with a wood rod inserted through the cil seal mounting hole of timing gear case, Note: When tapping the idler gear with a wood rod, turn the ear 2.2 Inspecting and adjusting oil pump 2.2.1 Measuring end clearance between gears and case Measure the end clearance between gear width and case depth witha dial gauge placed as shown in the illustration. If the limit is exceeded, replace the drive and driven gear assemblies. Tom a Endcleaace between | 00110005 mm | 0.150mm sear with and case depth | [0.0004 0.00021 in} | (00059 in. 2.2.2 Measuring side clearance between gears and case “Measure the side clearance between gear teeth and ease bore with fecler gauges. Ifthe limits exceeded, replace the drive and driven gear assemblies Tea Tae one Sie cearnce Baween | OOS 098mm] 0100 mn eat teath acne ove | [000201906039%n) | (0039in) 4 Spindle Idler gear Removing spindle and idler gear Measuring clearance between gear teeth and caseLUBRICATION SYSTEM 22.3 Measuring clearance between outside diameter of gear shaft and inside diameters Pump body Pump cover ‘of pump body and pump cover Measuring - [aE locations 1 ‘hen replacing crve and aren gears, replace Bis yD) gear assembles ~ (1) Check gear teeth for condition. IF the tooth ae 1 + } deecsive, replace the gear asembis pot (2) Measure the inside diameters of pump body (over and ease pots the diameter of gear shafts Ihe clearance is more than the limit, replace the gear assemblies, pump body, and pump cover whichever is badly worn. Te Se Cravace beeen erst) 00410007 wen | 1S apap by ene | (0001610000283 | (00089 im) 22.4 Measuring spindle outside diameter and idler bushing inside diameter Measure the spindle outside diameter and the idler bushing inside diamoer. If excessive wear is found, replace the part with a new one, EE Tp henna | Sawee veousdedameer | 025mm | 43390296 aan Seine me {osein} | josie 09827 in) 25mm] 25.000%025021 mim Busing mide dames | Tossing | 10984310 038811M] ‘Measuring clearance between gear shaft outside diameter and pump body, pump cover inside diameter ‘Measuring spindle outside diameter and idler gear ‘bushing inside diameterLUBRICATION SYSTEM 2.3 Reassembling oll pump Heat to 180 to 220°C [256 to 428°, Cl pump gear should be fush with the shaft Backlash ‘Standard: 0,057 to 0.172.mm [9.0022 to 0.0068 in} Limit: 0.35 mm [0.0138 in] 39293Nm (8.4 £0.34 kgm). a [24.625 Ibn] (‘Reply ThreeBond 1278 (@sh color) to the mating Make sure the ol pump | gear rotates smoothly surface withthe case and Apply engine oil to every sliding section, Reassembiing oll pump 2.3.1. Reassembling oil pump gear and drive gear assembly ___ CAUTION. i ‘The of pump gear and drive gear assembly is nonre- sable parts. Replace the assembly with a naw ona, (1) Heat the oil pump gear between 180 10 220°C [356 10 48°F] (2) Support the shaft at end and force the gear onto the shaft until its end face is flush withthe end of shaft Flush - im 4 Reassembling oll pump gear and drive gear assemblyLUBRICATION SYSTEM 2.4 Inspecting oil filter ‘When replacing the oil filter, sample the oil (500 mL. (30.5 cu.inJ) and check for metal and other panicles. If metal or other particles are found, cut and unfold the element, and inspect the color and shape of metal particles trapped in the clement to identify the cause, 2.5 Inspecting relief valve (1) Check the relief valve and its seat for comtact. Check the spring for fatigue and damage. If fault, replace the relief valve with new one (2) Measure the rele valve opening pressure. If the pressure does not fall within the standard range, replace the relief valve with new one, LL ee 352005 Me Rete vave opening ese | 5. gayopene) aie 271 ps 2.6 Inspecting safety valve (1) Make sure thatthe stel ball inside safety valve slides smoothly. If faulty, replace the safety valve with new (2) Measure the safety valve opening pressure. If the pressure does not fall within the standard range, replace the safety valve with new one, Tsiandarg) [EEMPS (17 keem™ 1157 psi RL] ~ Tightening torque / 49£4.9Nm {6 + 0.8kghm) (36.2 +36 IbFny Sa Tightening torque. {> 44249Nm {4.5 + 0.5kghm) fs2.5236 brn Relief valve Inspecting relief valve Tightening torque G54 42N'm (7 05kgFm) A ase s0 0m Inspecting oil pump safety valve 9-7LUBRICATION SYSTEM 3. Installing lubrication system [When instaling, apy engine Jot tothe gach and nten "Ge 48) Installing lubrication system ‘To install the lubrication system, follow the removal procedure in reverse order, observing the followings: (1) Use new gaskets and O-rings when reinstalling, (2) Crean oit passage of each part thoroughly in wash oil, and dry it completely using compressed ai. (8) Install the bracket frst, them install the ot filter, 9-8COOLING SYSTEM 1, Removing cooling system oA OZ 2, Disassembling, inspecting and reassembling cooling system.......10-3 2.1 Disassembling and inspecting water pump... 2.2 Removing flange... 2.3 Removing impeller and shaft 2.4 Inspecting unit seal 2.5 Inspecting water pump shalt... 2.6 Inspecting water pump. 2.7. Reassembling water pump ... 2.7.1. Instaling unit sea! 108 10-4 10-4 10-4 10-4 sn 10-5, 10-6 10-7 2.8 Checking water pump for smooth rotation seeeeaseetants 2.9 Inspecting thermostat... 3. Installing cooling system E07) 107 10-8 10-1COOLING SYSTEM 1. Removing cooling system (Crack, water leakage, damage) Removing cooling system Removing sequence 1 Batt 2 Water pump assembly 3 Thormostat assembly 10-2COOLING SYSTEM 2. Disassembling, inspecting and reassembling cooling system 2.1. Disassembling and inspecting water pump " ‘° »\S\ = Q B® \ contact samage [Corrosion, crack, damage| Bond | \Betteroove wear aamage 4 Disassembling and inspecting water pump Disassembling sequence 1, Water pump pulley 5 Unitseal 9 Washer 2 Flange 6 Bearing 10. Shaft 3 Snap ring 7 Spacer 11 Case 4 Impeller 8 Boating 10-3COOLING SYSTEM 2.2 Removing flange ‘Remove the lange with a puller. 2.3 Removing impeller and shaft (1) Remove the snap ring. (2) Using a pross, remove the shaft together with the bal bearing, and remove the impeller. Note: To facilitate the removal work, heat the case 10 a tempeature of 80°C [176°F] 2.4 Inspecting unit seal excessively worn unit sel or water Ieak during operation is observed, replace the unit seal with new one, Term Sana en Carbon protrusion | 1.5mm (0.059 in] | Omm{Oin] 2080 22.8 mm [0819 10 0.898 in Height (ree) 2.5 Inspecting water pump shaft When the flange and the iny x are removed from the water pump shaft, the interference may be reduced and results in the loose fitting. Even if the reassembling is the second time or less, replace the part with new one when the interference is less than the standard value ee Tnerference between water (0.035 to 0.065 mm pomp shaft and flange [0.0014 to 0.0026 in Tnierfeence between water 0.022 0.069 mam pump and impeller [02.0009 to 6.0024 in] 10-4 Puller PIN:64309-12900 Impeller Removing impeller and shaft Sealring = ‘Matching ring ann a Ss< (Ceramics) BR, Immpelior |\—_y Inspecting water pump shattCOOLING SYSTEM 2.6 Inspecting water pump “Measure the water pump case bore and the shaft diameter at the bearing fitting portions as well asthe inside and outside diameters ofthe bearings. Ifany of the measurements is out of the standard, replace the part with a new one Tem Nena amp case being osiny bee diameter easing (0.98 in) or [20sini Inside dimer esc side diameter "Sanaa 51988 1052018 mm (2.046810 20479 in G1 98a ie DATE ram (24405 92451610 348001095000 0m (097951009883 ial | Si9sT 10 2.000% [20467 620872. asin ‘hal bering S250m iting section outer diameter | (098 in} Goa 6 BOON em [24041624409 in} 25002025011 mam [09843 1909847 in} 10-5COOLING SYSTEM 2.7, Reassembling water pump [Apply ThreeBond 1102 0 the outer casing of unit seal Make sure the end surface |ofwater pump shaftis us with the end surface of impeller. f__ (Pack WPH grease (Kyodo Vashi tc.) into rong contact suriace. Reassembiing water pump a CAUTION 8 me ) After reassembling, install the water pump to the timing gear case, and make sure that the impeller does not contact with the timing gear case. {b) Reassembling of the water pump shaft, the flange and the impeller is restricted to only twice. (1) For reassembly, reverse the ordor of the disasscebly procedure (2) Use a hydraulic press to press fit bearings (3) After reassembling, make sure that the pulley rotates smoothly without any looseness, eccentricity, or abnormal noise.COOLING SYSTEM 2.7.1 Installing unit seal (1) Apply sealant (ThreeBond 1102) to the circumference of the unit seal \ (2) Drive the unit seal into the case using a unit seal install Note: Always replace the unit seal with a new one once it has been removed from the pump case Installing unit seal 2.8 Checking water pump for smooth rotation Check to make sure that the impeller and shaft of water pump rotate smoothly without noise and irregularities. If faulty, replace the water pump assembly 2.9 Inspecting thermostat y A CAUTION Be careful of ums or a fre when measuring tompora- ture, as itinvolves a high-temperature and open flame, ‘Totes the thermostat operation, immerse the thermostat in a container filed with water, Heat the water, while measuring the water temperature, Record the temperature at the conditions show not within the stan the table below. the temperatures are xd range, replace the thermostat Note: (a) Scr the water in the container with a stick to ensure uniform temperature distribution, (©) Prior to installing the thermostat, be sure to check the valve opening temperature stamped on the thermostat valve end face. Inspecting thermostat z Meee Slandara “Temperature at which valve stats | opening [160 3.6) “Temperature at which valve lit becomes 10 mm (0.39 in] or more 85°C [185°F) Note: When assembling, orient the thermostat with its air breed hole faced upward, 10-7COOLING SYSTEM 3. Installing cooling system Installing cooling system 10-8INLET AND EXHAUST SYSTEM 1, Removing inlet and exhaust sysytem.. 1-2 4.1 Removing inlet system. M2 1.2 Removing exhaust system 113 2, Disassembling, inspecting and reas- sembling inlet and exhaust systemn11-4 2.1 Measuring exhaust manifold distortion 11-4 3. Installing inlet and exhaust system11-5 3.1 Installing inlet system. 11-5 8.2. Installing exhaust system. 116 11-1INLET AND EXHAUST SYSTEM 1. Removing inlet and exhaust sysytem 1.1, Removing inlet system Removing inlet syste Removing sequence 1 Alrinlet elbow 2 Air heater 3 Inlet manifold 11-2INLET AND EXHAUST SYSTEM 1.2. Removing exhaust system Removing exhaust system Removing sequence 1 Turbocharger 2. Exhaust manifold 11-3,INLET AND EXHAUST SYSTEM 2. 2.1, Measuring exhaust manifold distortion (1) Check the flange for crack. (2) Check the flange suface for distortion. Ifthe distortion excoods the standard, retouch the surface, Ter [Exhaust manifold distortion 11-4 isassembling, inspecting and reassembling inlet and exhaust system ‘Measuring exhaust manifold distortionINLET AND EXHAUST SYSTEM 3, Installing inlet and exhaust system 3.1. Installing inlet system 1842Nm7 {1.8202 kot} [13 «1.4 oF] Installing inlet systemINLET AND EXHAUST SYSTEM 3.2 Installing exhaust system Cylinder head 1822Nm (5.8202 kgtm)_ (1321.4 FA) ——*e Installing exhaust system 11-6ELECTRICAL SYSTEM 1, Removing electrical system 12.2 1.1, Removing starter... 122 1.2 Inspection betore removing alternator. 12-8 41.2.1. Inspecting alternator operation 128 1.2.2. Handling precaution 1.3 Removing alternator. 2. Disassembling, inspecting and reassembling electrical system .....12-5 2.1. Inspection before disassembling starter. 125 2.1.1. Inspecting magnet switch... 125 21.2 Noload test. NDE 2.2. Disassembling and inspecting starter... 12-7 2.2.1 Removing pinion set 128 222 Removing magnet switch. 128 2.2.3 Removing brush holder and brush assembly. 28 2.2.4 Removing rear bracket vn nnsnnnninnt 28 2.2.5 Removing armature and yoke 12.8 2.2.6 Removing overrunning clutch. 129 2.3. Inspecting and repairing starter warn. 12-10 2.3.1. Inspecting brushes for wear 1210 2.3.2 Measuring brush spring load.. set 10 2.8.3. Inspecting brush holder for insulation ...12-10 2.8.4 Inspecting commutator radial runcut.....12-10, 2.3.5 Measuring commutator outside diameter 12.41 2.3.8 Measuring undercut depth .. eatON 2.3.7 Checking armature coil 1241 2.3.8 Inspecting rear bracket. 12-12 2.3.9. Inspecting overtunning Clute «nnn 1212 2.3.10 Inspecting front bracket. 1212 2.3.11 Inspecting gears of starter. 1212 2.3.12 Inspecting continuity of magnet switch (between M terminal and 6882) nn et242 2.8.13 Inspecting insulation of magnet switch (between M terminal and B terminal) ...12-12 2.4 Reassembling starter... soo 2B 2.4.1. Installing gear shaft 1243 2.4.2. Installing pinion 12.14 2.4.3. Installing yoke and armature .....nnuet@14 2.4.4. Installing brush holder and brush assembly. : 4244 2.5. Disassembling and inspecting alternator. 1245 2.5.1. Separating front bracket from stator...12-15 2.5.2 Removing field coil... 12.46 2.5.3 Removing pulley. 12-46 2.5.4 Removing rear bearing 2.8.5 Removing front bearing 2.8.6 Removing stator. 2.5.7 Removing regulator assembly. 2.8.8 Removing rectifier assembly 2.6 Inspecting and repairing altemator. 2.6.1. Inspecting stator 2.62 Inspecting rectitior 2.6.3 Measuring field coll 2.7 Reassembling alternator 2.7.4. Installing reetiier assembly and regulator assembly 2.7.2 Installing stator 273 Installing front bearing 2.7.4 Installing rear bearing 2.75 Installing pulley. 2.7.6 Assombing stator and front bracket 2.7.7. Inspecting ait heater 3. Installing electrical system.. 3.1. Instaling starter... 3.2 Instaling altemator nnn 3.3. Installing various sensors. 1216 1217 1247 1247 12.47 12-18 12418 12418 1219 12-20 12-20 12.21 12.21 12-21 12.21 12.22 12-22 12-23 12-28 12.24 12.25 12-1ELECTRICAL SYSTEM 1. Removing electrical system 1.1 Removing starter Removing sequence 1. Starter, bolt, washer and O-ingELECTRICAL SYSTEM 1.2. Inspection before removing alternator 1.2.1 Inspecting alternator operation Locate the cause of faulty charging ftom malfunctions described below, Do not remove the altemator for inspeetion and repair unless inspection eannot be performed with the alternator installed on the engre. "Adjusted value of voliage regulators high Ocha reer oul bat TLow adjused value of voliage ry. | Faulty alternator outpat Over dis Sue [Htc power consumption i extremely hgh ‘Special load is used Faulty wiring 1.22 Handling precaution Improper handing could cause damage or fire tothe aerator. (1) Connect battery cables correctly. The (-) cable is for rounding {2) Do not use any high voltage tester such as megger. (3) Disconnect tater cables before recharging (4) Do not disconnect lead wire from B terminal of the aerator while the engines runing (8) Battery voltage is constantly applied to B terminal of the atematoe Do not ground a this ermial (6) Do not shor circuit or ground at L terminal, (For wilt in IC egulatorsype) (7) When a steam cleaner is used, do not allow the steam directly contact the arto. 12-3ELECTRICAL SYSTEM 1.3. Removing alternator Removing alternator Removing sequence + Set bolt 3 Adjusting plate 2 Puller 4 Attemator 12-4ELECTRICAL SYSTEM 2. Disassembli 2.1. Inspection before disassembling starter 2.1.1 Inspecting magnet switch Perform the inspection as descried below. If faulty, replace ‘the magnet switch with a new one. eae ‘CAUTION : a Do not apply current continuously for longer than 10 seconds. (1) Disconnect the connector of M terminal (2) Pullin test Connect the starter to the circuit as shown in the itlstration. The magnet switch is normal ifthe pinion springs out when the switch is med ON. (3) Holding test, Connect the starter to the circuit as shown in the itlusration. Pull out the pinion fully by hand. The ‘magn switch is normal if the pinion does not retum when itis release. (4) Roum est Connect the starter to the circuit as shown in the illustration. Pull out the pinion fully by hand. The magnet switch is normal if the pinion returns ‘immediately when iis released 1g, inspecting and reassembling electrical system Starter Holding test Return test, 12-5ELECTRICAL SYSTEM 24.2 Noload test _ CAUTION. = ah Tse as thick a wire as possible and firmly ighten each terminal When detecting the rotation atthe tp of the pinion, be careful, as the pinion pops out during operation (1) Connect the starter 10 the circuit as. sho itstration, (2) In normal condition, the pinion pops out when the switch is turned ON, and the stater rotates ator above the specified rotation speed, If the terminal voltage, current or rotation speed does ‘ot meet the standard, disassemble, inspect and repair Ten Banda “Starter mode type ——SS=«Y:S«MOORT QO aera ee Telos | Nelo ere A Take Toalonsed_aint| 00 12-6 Bate J Baten “Vor meter Novload testELECTRICAL SYSTEM 2.2 Disassembling and inspecting starter ‘Overunning

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