ENGINE MECHANICAL
SECTION EM
CONTENTS
ENGINE............................................................................2
Precautions ..................................................................2
PRECAUTIONS ...............................................................3
Parts Requiring Angular Tightening.............................3
Liquid Gasket Application Procedure ..........................3
SERVICE DATA AND SPECIFICATIONS (SDS) ............4
General Specifications (H20-II/H25 Engine) ...............4
General Specifications (TD27 Engine) ........................4
Inspection and Adjustment (H20-II/H25 Engine) .........5
Inspection and Adjustment (TD27 Engine)..................8
Tightening Torque (H20-II/H25 Engine).....................16
Tightening Torque (TD27 Engine) .............................17
TROUBLE DIAGNOSES AND CORRECTIONS...........18
GENERAL DESCRIPTION OF ENGINE .......................20
External View of Engine ............................................20
PTO (Power Take Off) ...............................................25
PREPARATION..............................................................26
Special Service Tools (H20-II/H25 Engine) ...............26
Special Service Tools (TD27 Engine)........................28
 ENGINE

Precautions
AT THE TIME OF DISASSEMBLY
I Use proper tools according to the need. Pay attention not to
damage parts and also to preserve safe in handling.
I Be careful in handling not to damage the mated and sliding
faces.
I Put markings to the disassembled parts in order to facilitate
pinpointing troubles and assembling.
I Unfasten bolts and nuts diagonally starting from the outside
and where the order is specially given, follow the instruction.
EMM0301

AT THE TIME OF INSPECTION, ADJUSTMENT AND

REPLACEMENT
I Following the inspection procedures, inspect the parts thor-
oughly and if replacement is necessary, also check new parts.
I Be sure to use “Genuine parts” for wearing parts such as oil,
filter, non-freeze liquid and spark plug.
AT THE TIME OF ASSEMBLY
I Tighten bolts and nuts according to the following instructions.
Be sure to use torque wrench.
Special bolt: The tightening torque is stipulated in the Service
Manual.
For other bolts and nuts: Tighten with the standard torque for
bolts and nuts.
I Tighten bolts and nuts piecemeal a few times diagonally from
the center to the outside and where the tightening order is
given, follow the instructions.
I Replace parts such as gasket, packing, locking washer, oil seal
and O-ring for new ones.
I Remove bonding agent from the gasket completely and then
mount it.
I Be careful not to damage the sliding and mated face and clean
dirt or dust thoroughly. Apply engine oil to the sliding face.
I Thoroughly clean parts and give air blow. In particular, keep oil
path and cooling water path free from clogging.
I Where instructions are given to use liquid packing and bonding
agent, follow them.
This Service Manual describes the main part of the engine.
OTHERS
It is recommended that engine attachment is to be mounted, using
the engine stand, in order to facilitate the maintenance work as well
as assuring safe. Engine oil and cooling water must be drained
before disassembly.

EM-2
 PRECAUTIONS

Parts Requiring Angular Tightening

I Some important engine parts are tightened using a torque set-
ting method, dispersal of the tightening force (axial bolt force)
will be two or three times that of the dispersal produced by
using the correct torque setting method.
I To assure the satisfactory maintenance of the engine, bolts and
nuts must be tightened using a torque setting method.
I Before tightening the bolts and nuts, ensure that the thread and
seating surfaces are clean and then coated with engine oil.
I The bolts and nuts which require the torque setting method are
as follows:
(1) Cylinder head bolts
(2) Main bearing cap bolts
(3) Connecting rod cap nuts.

Liquid Gasket Application Procedure

a. Before applying liquid gasket, use a scraper to remove all
traces of old liquid gasket from mating surface.
b. Apply a continuous bead of liquid gasket to mating sur-
faces. (Use Genuine Liquid Gasket or equivalent.)
I Be sure liquid gasket is 2.5 to 3.5 mm (0.0984 to 0.1378
in) wide.
c. Apply liquid gasket to inner surface around hole perimeter
area.
(Assembly should be done within 5 minutes after coating.)
SEM371C d. Wait at least 30 minutes before refilling engine oil and
engine coolant.

SEM683B

EM-3
 SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications (H20-II/H25 Engine)

Engine H20-II H25 Valve timing

Classification Gasoline

Cylinder arrangement 4 in-line

3
Displacement cm (cu in) 1,982 (120.94) 2,472 (150.84)

87.2 x 83.0 92.0 x 93.0

Bore x stroke mm (in)
(3.433 x 3.268) (3.622 x 3.661)

Valve arrangement OHV

Firing order 1-3-4-2

Number of piston rings

Compression 2

Oil 1

Number of main bearings 5

Compression ratio 8.7

Compression pressure EM120

kPa (bar, kg/cm2, psi)/rpm
Unit: degree
1,226 (12.26, 1,275 (12.75,
Standard a b c d e f
12.5, 178)/300 13.0, 185)/300
248° 248° 16° 52° 14° 54°
1,030 (10.30, 1,079 (10.79,
Limit
10.5, 149)/300 11.0, 156)/300

Difference limit between

98 (0.98, 1.0, 14)/300
cylinders

General Specifications (TD27 Engine)

Engine TD27

Classification Diesel

Cylinders arrangement 4 in-line

3
Displacement cm (cu in) 2,663 (162.50)

Bore x stroke mm (in) 96 x 82 (3.780 x 3.228)

Valve arrangement OHV

Firing order 1-3-4-2

Number of piston rings

Compression 2
Oil 1

Number of main bearings 5

Compression ratio 24.6

Compression pressure
kPa (bar, kg/cm2, psi)/rpm

Standard 2,942 (29.4, 30, 427)/200

Limit 2,452 (24.5, 25, 356)/200

Difference limit between cylin-

294 (2.9, 3, 43)/200
ders

EM-4
 SERVICE DATA AND SPECIFICATIONS (SDS)

Inspection and Adjustment (H20-II/H25 Engine)

ENGINE COMPRESSION PRESSURE Valve guide
Unit: kPa (bar, kg/cm2, psi)/rpm Unit: mm (in)
Engine H20-II H25 Intake Exhaust

1,226 (12.26, 12.5, 1,275 (12.75, 13.0, Standard Limit Standard Limit
Standard
178)/300 185)/300
0.015 - 0.040 -
1,030 (10.30,10.5, 1,079 (10.79, 11.0, Stem to guide clear- 0.048 0.10 0.073 0.10
Limit
149)/300 156)/300 ance (0.0006 - (0.0039) (0.0016 - (0.0039)
0.0019) 0.0029)
Difference limit
98 (0.98, 1.0, 14)/300
between cylinders
Valve spring
CYLINDER HEAD Free height mm (in) 44.9 (1.7677)
Unit: mm (in)
385.4 - 434.5
Standard Limit (39.3 - 44.3,
Standard
Pressure N (kg, lb) at 86.7 - 97.7)
Head surface flatness 0.1 (0.004) 0.2 (0.0008) at 29.3 (1.154)
height mm (in)
330.5 (33.7, 74) at
Limit
VALVE 23.64 (0.9307)

Out-of-square mm (in) Less than 1.5 (0.059)

Valve seat
Intake Exhaust

1.3 - 1.5 1.6 - 1.8

Seat width mm (in)
(0.051 - 0.059) (0.063 - 0.071)

Valve seat angle

45°
degree

SEM188

35.0 - 35.2
Intake
Valve head diameter (1.378 - 1.386)
“D” mm (in) 30.0 - 30.2
Exhaust
(1.181 - 1.189)

108.55 - 108.85
Intake
Valve length “L” (4.2736 - 4.2854)
mm (in) 108.05 - 108.35
Exhaust
(4.2539 - 4.2657)

6.970 - 6.985
Intake
Valve stem diameter (0.2744 - 0.2750)
“d” mm (in) 6.945 - 6.960
Exhaust
(0.2734 - 0.2740)

Valve face angle “α” degree 45°30′

Valve margin “T” limit mm (in) 0.6 (0.0236)

Valve head thickness limit mm (in) 0.5 (0.020)

Valve stem end surface grinding limit mm (in) Less than 0.2 (0.008)

Valve clearance (Hot) Intake

0.38 (0.0150)
mm (in) Exhaust

EM-5
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (H20-II/H25 Engine)
(Cont’d)
CAMSHAFT AND CAMSHAFT BEARING CYLINDER BLOCK
Unit: mm (in) Unit: mm (in)

EM671

Standard Limit

36.750 - 36.800
Cam height “A” (1.4468 - — SEM171DA
1.4488)
Standard Limit
Cam wear limit 0.25 (0.0098) —
Surface flatness
45.434 - 45.447
No. 1 (1.7887 - — Less than
1.7892) Longitudinal direction 0.05 0.1 (0.004)
(0.0020)
43.897 - 43.910
Camshaft jour- No. 2 (1.7282 - — Less than 0.04
Transverse direction
nal dia. 1.7287) 0.02(0.0008) (0.0016)
41.218 -41.231 188.95 -
No. 3 (1.6228 - — 189.05
Height “H” (nominal) —
1.6233) (7.4390 -
7.4429)
Wear limit 0.05 (0.0020) —
Standard
45.472 - 45.485
No. 1 (1.7902 - Inner diameter
1.7907)
87.20 -
Inner diameter 43.948 - 43.961 87.25
H20-II
of camshaft No. 2 (1.7302 - — (3.4331 -
bearing 1.7307) 3.4350)
0.2 (0.008)
41.256 - 41.269 92.00 -
No. 3 (1.6242 - 92.05
H25
1.6248) (3.6220 -
3.6240)
0.025 - 0.051
No. 1 and
(0.0010 - 0.1 (0.004) Less than
Camshaft jour- No. 3
0.0020) Out-of-round (X − Y) 0.02 0.1 (0.004)
nal to bearing (0.0008)
clearance 0.038 - 0.064
No. 2 (0.0015 - 0.15 (0.0059) Less than
0.0025) Taper (A − B) 0.02 0.1 (0.004)
(0.0008)
Camshaft jour- Taper 0.01 (0.0004) 0.03 (0.0012)
nal Difference in inner diameter between 0.05
Out-of-round 0.01 (0.0004) 0.03 (0.0012) 0.2 (0.008)
cylinders (0.0020)
Less than
Camshaft bending 0.05 (0.0020) 0.016 -
0.02 (0.0008)
Valve lifter to cylinder block hole clear- 0.052
0.1 (0.0039)
0.175 - 0.225 ance (0.0006 -
Camshaft end play (0.0069 - 0.20 (0.0079) 0.0020)
0.0087)

EM-6
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (H20-II/H25 Engine)
(Cont’d)
PISTON, PISTON RING AND PISTON PIN Piston ring
Unit: mm (in)
Piston
Unit: mm (in) Standard Limit
0.040 - 0.080
Top (0.0016 -
0.0031)
Side clearance 0.1 (0.004)
0.030 - 0.070
2nd (0.0012 -
0.0028)

0.25 - 0.35
Top (0.0098 - 1.0 (0.039)
0.0138)
0.15 - 0.25
End gap
2nd (0.0059 - 1.0 (0.039)
0.0098)

0.3 - 0.9
Oil 1.0 (0.039)
(0.012 - 0.035)
EMM0303

Piston skirt diameter “A” CONNECTING ROD

Standard Unit: mm (in)

87.165 - 87.215 143.97 - 144.03

Center distance
H20-II (3.4317 - (5.6681 - 5.6705)
3.4337)
Less than 0.05
Bend/twist limit [per 100 (3.94)]
91.965 - 92.015 (0.0020)
H25 (3.6207 -
Connecting rod big end play
3.6226)
0.20 - 0.30
Oversize Standard
(0.0079 - 0.0118)
87.655 - 87.715
Limit 0.4 (0.016)
H20-II (3.4510 -
0.50 3.4533) Bearing clearance
(0.0197) 92.465 - 92.515 0.030 - 0.066
H20-II
H25 (3.6403 - (0.0012 - 0.0026)
3.6423) Standard
0.024 - 0.050
H25
88.165 - 88.215 (0.0009 - 0.0020)
H20-II (3.4711 -
Limit 0.1 (0.004)
1.00 3.4730)
(0.0394) Bushing
92.965 - 93.015
H25 (3.6600 - 1.373 - 1.381
3.6620) Standard
(0.0541 - 0.0544)
88.665 - 88.715 1.623 - 1.631
H20-II (3.4907 - 0.25 (0.0098)
(0.0639 - 0.0642)
1.50 3.4927)
1.748 - 1.756
(0.0591) 93.465 - 93.515 0.50 (0.0197)
(0.0688 - 0.0691)
H25 (3.6797 -
3.6817) 1.873 - 1.881
0.75 (0.0295)
(0.0737 - 0.0741)
“a” dimension 9.5 (0.374)
1.998 - 2.006
19.993 - 19.998 1.0 (0.039)
(0.0787 - 0.0790)
H20-II (0.7871 -
0.7873)
Piston pin outer diameter
20.993 - 20.998
H25 (0.8265 -
0.8267)

0.025 - 0.045
Piston to bore clearance (0.0010 -
0.0018)

EM-7
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (H20-II/H25 Engine)
(Cont’d)
CRANKSHAFT DRIVE PLATE
Unit: mm (in) Unit: mm (in)

Main journal dia. Runout [TIR*] Less than 0.1 (0.004)

62.942 - 62.955 *: Total indicator reading

Standard (2.4780 -
2.4785)
Undersize
62.692 - 62.705
0.25 (0.0098) (2.4682 -
2.4687)
62.422 - 62.455
0.50 (0.0197) (2.4576 -
2.4589)
62.192 - 62.205
0.75 (0.0295) (2.4485 -
2.4490)
61.942 - 61.955
1.00 (0.0394) (2.4387 -
2.4392)
Pin journal dia.
44.961 - 44.974
H20-II (1.7701 -
1.7706)
49.961 - 49.974
H25 (1.9670 -
1.9675)
Oil clearance
0.020 - 0.062
Standard (0.0008 -
0.0024)
Limit 0.1 (0.004)
Crankshaft bend
Less than 0.02
Standard
(0.0008)
Limit 0.05 (0.0020)
Taper (A − B)
Standard 0.01 (0.0004)
Limit 0.03 (0.0012)
Free end play
0.05 - 0.18
Standard (0.0020 -
0.0071)
Limit 0.2 (0.008)

Inspection and Adjustment (TD27 Engine)

COMPRESSION PRESSURE
Unit: kPa (bar, kg/cm2, psi)/rpm

Standard 2,942 (29.4, 30, 427)/200

Minimum 2,452 (24.5, 25, 356)/200

Differential limit between cylin-
294 (2.9, 3, 43)/200
ders

CYLINDER HEAD
Unit: mm (in)

Limit

Head surface distortion 0.2 (0.008)

Nominal cylinder head height 89.7 (3.531)

EM-8
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (TD27 Engine)
(Cont’d)
VALVE Valve guide
Unit: mm (in)
Standard Service

12.033 - 12.044
Valve guide outside diameter (0.4737 - —
0.4742)

Valve guide inner diameter 8.000 - 8.015

(Finished size) (0.3150 - 0.3156)

12.00 - 12.011
Cylinder head valve guide hole
(0.4724 - —
diameter
0.4729)

0.022 - 0.044
Interference fit of valve guide
(0.0009 - 0.0017)

Standard Max. tolerance

SEM188
Stem to guide clearance
Valve head diameter “D” mm (in)
0.02 - 0.05
Intake 43.5 (1.713)
Intake (0.0008 - 0.15 (0.0059)
Exhaust 38.0 (1.496) 0.0020)
Valve length “L” mm (in)
0.04 - 0.07
Intake Exhaust (0.0016 - 0.20 (0.0079)
117 (4.61)
Exhaust 0.0028)
Valve stem diameter “d” mm (in) Valve deflection limit
Intake 8.0 (0.315)
Intake 0.30 (0.0118)
Exhaust 8.0 (0.315)
Valve seat angle “α” degree Exhaust 0.40 (0.0157)

Intake
45°
Exhaust Valve spring
Valve margin “T” limit mm (in) 1.0 (0.039)
Free length mm (in) 46.8 (1.843)
Valve stem end surface grinding
0.2 (0.008)
limit mm (in) 42.3/123.6 - 330.5
Assembled height
Valve clearance (Hot) mm (in) (42.3/12.6 - 33.7,
mm/N (mm/kg, in/lb)
1.665/27.8 - 74.3)
Intake
0.35 (0.0138)
Exhaust Out of square mm (in) 2.0 (0.079)

VALVE LIFTER AND PUSH ROD

Unit: mm (in)

Standard Limit

Valve lifter outer 25.960 - 25.970

—
diameter “A” (1.0220 - 1.0224)

Cylinder block valve

26.000 - 26.033
lifter hole diameter —
(1.0236 - 1.0249)
“B”

Valve lifter to lifter 0.030 - 0.073

0.20 (0.0079)
hole clearance (0.0012 - 0.0029)

Push rod bend (TIR)* Less than 0.3 (0.012) 0.5 (0.020)
*: Total indicator reading

EM-9
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (TD27 Engine)
(Cont’d)
Rocker shaft and rocker arm
Unit: mm (in)

Standard Limit

Rocker shaft

19.979 - 20.00
Outer diameter —
(0.7866 - 0.7874)

Rocker shaft bend (TIR) 0.06 (0.0024) 0.10 (0.0039)

Rocker arm

20.02 - 20.04
Inner diameter —
(0.7882 - 0.7890)

Clearance between
0.02 - 0.06
rocker arm and rocker 0.20 (0.0079)
(0.0008 - 0.0024)
shaft

CYLINDER HEAD TO VALVE DISTANCE

Unit: mm (in)

SEM724C

Standard Limit

0.225 - 0.725
Intake 1.25 (0.0492)
(0.0089 - 0.0285)

0.255 - 0.745
Exhaust 1.25 (0.0492)
(0.0100 - 0.0293)

EM-10
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (TD27 Engine)
(Cont’d)
Valve seat CAMSHAFT AND CAMSHAFT BEARING
Unit: mm (in) Unit: mm (in)

Standard Limit

Camshaft journal to
0.020 - 0.109
bushing clearance 0.15 (0.0059)
(0.0008 - 0.0043)
[Oil clearance]

Camshaft journal diam-

eter

50.721 - 50.740
Front —
(1.9969 - 1.9976)

50.521 - 50.540
2nd —
(1.9890 - 1.9898)

50.321 - 50.340
3rd —
(1.9811 - 1.9819)

50.121 - 50.140
SEM953C 4th —
(1.9733 - 1.9740)
Intake 49.921 - 49.940
Rear —
(1.9654 - 1.9661)
44.535 - 44.545
Outer diameter “D1”
(1.7533 - 1.7537) Camshaft bend (Total Less than
0.03 (0.0012)
indicator reading) 0.02 (0.0008)
37.9 - 38.1
Inner diameter “D2”
(1.492 - 1.500) 0.08 - 0.28
Camshaft end play 0.50 (0.0197)
(0.0031 - 0.0110)
42.4 - 42.6
Diameter of seat “D3”
(1.669 - 1.677)

44.500 - 44.515
Cylinder head valve seat diameter
(1.7520 - 1.7526)

Valve seat face angle “φ” 89° - 91°

Exhaust

Outer diameter “D1”

39.535 - 39.545
Standard
(1.5565 - 1.5569)

0.2 (0.008) 39.735 - 39.745 EM671

Oversize (Service) (1.5644 - 1.5648)
Standard Limit
0.4 (0.016) 39.935 - 39.945
Oversize (Service) (1.5722 - 1.5726) Cam height “A”
32.9 - 33.1 41.88 - 41.92
Inner diameter “D2” Intake 41.4 (1.630)
(1.295 - 1.303) (1.6488 - 1.6504)
36.90 - 37.10 41.88 - 41.92
Diameter of seat “D3” Exhaust 41.4 (1.630)
(1.4528 - 1.4606) (1.6488 - 1.6504)
Cylinder head valve seat diameter

39.495 - 39.510
Standard
(1.5549 - 1.5555)

39.695 - 39.710
0.2 (0.008) Oversize
(1.5628 - 1.5634)

39.895 - 39.910
0.4 (0.016) Oversize
(1.5707 - 1.5713)

Valve seat face angle “φ” 89° - 90°

EM-11
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (TD27 Engine)
(Cont’d) Unit: mm (in)

CYLINDER BLOCK AND CYLINDER LINER

Unit: mm (in)

SEM427

Cylinder liner diameter “D” (ser- 96.050 - 96.070

vice)* (3.7815 - 3.7823)
EMM0304
*: Before installing in cylinder block
Surface flatness
(Without cylinder liner)

Standard Less than 0.05 (0.0020)

Limit 0.2 (0.008)

Cylinder bore

Inner diameter

99.000 - 99.020
Standard
(3.8976 - 3.8984)

Cylinder bore
(With cylinder liner)

Inner diameter

Standard
96.000 - 96.010
Grade No. 1
(3.7795 - 3.7799)

96.010 - 96.020
Grade No. 2
(3.7799 - 3.7803)

96.020 - 96.030
Grade No. 3
(3.7803 - 3.7807)

Wear limit 0.20 (0.0079)

Out-of-round (X − Y) Less than 0.040 (0.0016)

Taper (A − B) Less than 0.040 (0.0016)

Projection “S” 0.02 - 0.09 (0.0008 - 0.0035)

Division of each cylinder “S” Less than 0.05 (0.0020)

−0.01 to 0.03
Interference fit cylinder liner to block
(−0.0004 to 0.0012)

EM-12
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (TD27 Engine)
(Cont’d)
PISTON, PISTON RING AND PISTON PIN Piston ring
Unit: mm (in)
Available piston
Standard Limit
Unit: mm (in)
Side clearance

0.06 - 0.10
Top 0.50 (0.0197)
(0.0024 - 0.0039)

0.04 - 0.08
2nd 0.30 (0.0118)
(0.0016 - 0.0031)

0.02 - 0.06
Oil 0.15 (0.0059)
(0.0008 - 0.0024)

Ring gap
0.30 - 0.45
Top
(0.0118 - 0.0177)

0.30 - 0.45 1.5 (0.059)

2nd
(0.0118 - 0.0177)

0.25 - 0.45
Oil (rail ring)
(0.0098 - 0.0177)
SEM778A

Piston skirt diameter “A” Piston pin

Unit: mm (in)
Standard
27.993 - 28.000
95.940 - 95.950 Piston pin outer diameter
Grade No. 1 (1.1021 - 1.1024)
(3.7772 - 3.7776)
Piston pin to piston clearance
95.950 - 95.960
Grade No. 2
(3.7776 - 3.7779) −0.008 to 0.007
Standard
(−0.0003 to 0.0003)
95.960 - 95.970
Grade No. 3*
(3.7779 - 3.7783) Limit 0.1 (0.004)
“a” dimension 70 (2.76) Piston pin to connecting rod clearance
27.992 - 28.000 0.025 - 0.045
Piston pin hole diameter Standard
(1.1020 - 1.1024) (0.0010 - 0.0018)
0.05 - 0.07 Limit 0.15 (0.0059)
Piston to cylinder liner clearance
(0.0020 - 0.0028)
*: Grade No. 3 piston is not provided as a service part.

EM-13
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (TD27 Engine)
(Cont’d)
CONNECTING ROD CRANKSHAFT
Unit: mm (in) Unit: mm (in)

156.975 - 157.025
Center distance
(6.1801 - 6.1821)
Bend, torsion [per 100 (3.94)]

Limit 0.05 (0.0020)

28.025 - 28.033
Piston pin bore dia.
(1.1033 - 1.1037)

Side clearance

0.10 - 0.22
Standard
(0.0039 - 0.0087)
Limit 0.22 (0.0087)

SEM100A

70.907 - 70.920
Journal diameter “A”
(2.7916 - 2.7921)

56.913 - 56.962
Pin diameter “B”
(2.2407 - 2.2426)

Center distance “S” 46.00 (1.8110)

EM715

Taper of journal and pin “A − B”

Standard 0.01 (0.0004)

Limit 0.02 (0.0008)

Out-of-round of journal and pin “X − Y”

Standard 0.01 (0.0004)

Limit 0.02 (0.0008)

Crankshaft bend

Standard 0 - 0.03 (0 - 0.0012)

Limit 0.10 (0.0039)

Crankshaft end play

0.055 - 0.180
Standard
(0.0022 - 0.0071)
Limit 0.40 (0.0157)

EM-14
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (TD27 Engine)
(Cont’d)
AVAILABLE MAIN BEARING AVAILABLE THRUST WASHER
Bearing clearance Thrust washer undersize
Unit: mm (in) Unit: mm (in)

Main bearing clearance Thrust washer thickness

Standard 0.035 - 0.087 (0.0014 - 0.0034) Standard

Limit 0.15 (0.0059) Stamped mark A 2.275 - 2.325 (0.0896 - 0.0915)

Connecting rod bearing clearance Stamped mark B 2.300 - 2.350 (0.0906 - 0.0925)

Standard 0.035 - 0.081 (0.0014 - 0.0032) Stamped mark C 2.325 - 2.375 (0.0915 - 0.0935)

Limit 0.15 (0.0059) Oversize

0.20 (0.0079) 2.475 - 2.525 (0.0974 - 0.0994)

Main bearing undersize 0.40 (0.0157) 2.675 - 2.725 (0.1053 - 0.1073)
Unit: mm (in)

Crank journal diameter MISCELLANEOUS COMPONENTS

70.907 - 70.920 (2.7916 - Unit: mm (in)
Standard
2.7921)
Gear train
Undersize
Backlash of each gear 0.07 - 0.11 (0.0028 - 0.0043)
70.657 - 70.670 (2.7818 -
0.25 (0.0098) Limit 0.20 (0.0079)
2.7823)
Drive plate
70.407 - 70.420 (2.7719 -
0.50 (0.0197)
2.7724) Runout (Total indicator reading) Less than 0.15 (0.0059)
70.157 - 70.170 (2.7621 - Front plate
0.75 (0.0295)
2.7626)
Warpage limit 0.2 (0.008)
69.907 - 69.920 (2.7522 -
1.00 (0.0394)
2.7528)

AVAILABLE CONNECTING ROD BEARING

Connecting rod bearing undersize
Unit: mm (in)

Crank pin journal diameter

56.913 - 56.926
Standard
(2.2407 - 2.2412)

Undersize

56.663 - 56.676
0.25 (0.0098)
(2.2308 - 2.2313)

56.413 - 56.676
0.50 (0.0197)
(2.2210 - 2.2313)

56.163 - 56.176
0.75 (0.0295)
(2.2111 - 2.2116)

55.913 - 55.926
1.00 (0.0394)
(2.2013 - 2.2018)

EM-15
 SERVICE DATA AND SPECIFICATIONS (SDS)

Tightening Torque (H20-II/H25 Engine)

N⋅m kg-m ft-lb in-lb

Cylinder head bolts 74 - 83 7.5 - 8.5 55 - 61 —

Rocker cover nuts 1.8 - 2.7 0.18 - 0.28 — 16 - 24

Rocker shaft 49 - 58 5.0 - 6.0 37 - 43 —

Connecting rod cap bolts

H20-II 32 - 37 3.2 - 3.8 24 - 27 —

H25 39 - 44 3.9 - 4.5 29 - 32 —

Main bearing cap bolt 84 - 93 8.5 - 9.5 62 - 68 —

Flywheel housing fixing bolts 44 - 57 4.4 - 5.9 32 - 42 —

Driving plate fixing bolts 133 - 142 13.5 - 14.5 98 - 104 —

Camshaft sprocket bolt 30 - 39 3.0 - 4.0 22 - 28 —

Oil pan bolts 6.4 - 7.4 0.65 - 0.76 — 57 - 65

Oil pan pump bolts 21 - 34 2.1 - 3.5 16 - 25 —

Oil pan drain plug 30 - 39 3.0 - 4.0 22 - 28 —

Carburetor nuts 14 - 17 1.4 - 1.8 11 - 13 —

Manifold nuts 16 - 18 1.6 - 1.9 12 - 13 —

Fuel pump nuts 14 - 17 1.4 - 1.8 11 - 13 —

Crank pulley bolt 138 - 147 14.0 - 15.0 102 - 108 —

Cover for hydraulic pump chain 3.8 - 5.0 0.38 - 0.51 — 33 - 44

Engine front cover bolts 16 - 18 1.6 - 1.9 12 - 13 —

Alternator bolts 45 - 58 4.5 - 6.0 33 - 43 —

EM-16
 SERVICE DATA AND SPECIFICATIONS (SDS)

Tightening Torque (TD27 Engine)

ENGINE OUTER PARTS

N⋅m kg-m ft-lb

Manifold nut

Intake 15 - 19 1.5 - 2.0 11 - 14

Exhaust 25 - 29 2.5 - 3.0 18 - 21

Injection pump nut 20 - 24 2.0 - 2.5 15 - 18

Injection pump to bracket bolt 31 - 41 3.1 - 4.2 23 - 30

Injection nozzle to cylinder head 54 - 63 5.5 - 6.5 40 - 47

Injection pump drive gear nut 59 - 68 6.0 - 7.0 44 - 50

Injection tube flare nut 20 - 24 2.0 - 2.5 15 - 18

Spill tube with cap nut 30 - 39 3.0 - 4.0 22 - 28

Alternator bracket bolt 31 - 41 3.1 - 4.2 23 - 30

Alternator to adjusting bar bolt 16 - 20 1.6 - 2.1 12 - 15

ENGINE PARTS

N⋅m kg-m ft-lb in-lb

Main bearing cap bolt 167 - 176 17.0 - 18.0 123 - 130 —
Connecting rod big end nut 79 - 83 8.0 - 8.5 58 - 61 —
Crank pulley nut 295 - 323 30 - 33 217 - 238 —
Flywheel bolt 148 - 166 15.0 - 17.0 109 - 122 —
Timing gear case bolt 16 - 20 1.6 - 2.1 12 - 15 —
Timing gear case nut 16 - 20 1.6 - 2.1 12 - 15 —
Front end plate bolt 10 - 12 1.0 - 1.3 — 87 - 112
Camshaft gear bolt 45 - 49 4.5 - 5.0 33 - 36 —
Camshaft locating plate bolt 4.0 - 5.8 0.4 - 0.6 — 35 - 52
Idler gear shaft bolt 26 - 35 2.6 - 3.6 19 - 26 —
Oil pan bolt 6.9 - 8.8 0.7 - 0.9 — 61 - 78
Oil pan drain plug 54 - 58 5.5 - 6.0 40 - 43 —
Cylinder head bolt —
Glow plug 15 - 19 1.5 - 2.0 11 - 14 —
Rocker shaft bracket bolt 20 - 24 2.0 - 2.5 15 - 18 —
Rocker arm lock nut 15 - 19 1.5 - 2.0 11 - 14 —
Rocker cover screw 1-2 0.1 - 0.2 — 9 - 17

EM-17
 TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

I. Noisy engine
Knocking of crankshaft and Loose main bearing. Replace.
bearing Seized bearing. Replace.
Bent crankshaft. Repair or replace.
Uneven wear of journal. Correct.
Excessive crankshaft end play. Replace center bearing.
Piston and connecting rod Loose bearing. Replace.
knocking Seized bearing. Replace.
Loose piston pin. Replace pin or bushing.
Loose piston in cylinder. Recondition cylinder.
Broken piston ring. Replace.
Improper connecting rod alignment. Realign.
Camshaft knocking Loose bearing. Replace.
Excessive axial play. Replace bearing thrust plate.
Rough gear teeth. Repair.
Broken cam gear. Replace.
Timing chain noise Improper chain tension. Adjust.
Worn and/or damaged chain. Replace.
Worn sprocket. Replace.
Worn and/or broken tension adjusting mechanism. Replace.
Excessive camshaft and bearing clearance. Replace.
Camshaft and valve Improper valve clearance. Adjust.
mechanism knocking Worn adjusting screw. Replace.
Worn rocker face. Replace.
Loose valve stem in guide. Replace guide.
Weakened valve spring. Replace.
Seized valve. Repair or replace.
Water pump knocking Improper shaft end play. Replace.
Broken impeller. Replace.
II. Other mechanical troubles
Sticking valve Improper valve clearance. Adjust.
Insufficient clearance between valve stem and Clean stem or ream guide.
guide.
Weakened or broken valve spring. Replace.
Seized or damaged valve stem. Replace or clean.
Poor fuel quality. Use better fuel.
Seized valve seat Improper valve clearance. Adjust.
Weakened valve spring. Replace.
Thin valve head edge. Replace valve.
Narrow valve seat. Reface.
Overheating Repair or replace.
Over speeding. Drive within proper speed.
Stuck valve guide. Repair.

EM-18
 TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

Excessively worn cylinder Shortage of engine oil. Add or replace oil.
and piston Dirty engine oil. Clean crankcase, replace oil and oil filter element.
Use right oil.
Poor quality of oil. Repair or replace.
Overheating. Repair or replace.
Wrong assembly of piston with connecting rod.
Improper piston ring clearance. Adjust.
Broken piston ring. Replace.
Dirty air cleaner. Clean.
Mixture too rich. Adjust.
Engine over run. Drive at proper speeds.
Stuck choke valve. Clean and adjust.
Overchoking. Start correctly.
Malfunctioning connecting Shortage of engine oil. Add oil.
rod Low oil pressure. Correct.
Poor quality engine oil. Use right oil.
Rough surface of crankshaft. Grind and replace bearing.
Clogged oil passage. Clean.
Bearing wear or damage. Replace.
Improper bearing assembly. Correct.
Loose bearing. Replace.
Connecting rod alignment incorrect. Repair or replace.
Malfunctioning crankshaft Shortage of engine oil. Add or replace.
bearing Low oil pressure. Correct.
Poor quality engine oil. Use right oil.
Crankshaft journal worn or out-of-round. Repair.
Clogged oil passage in crankshaft. Clean.
Bearing wear or damage. Replace.
Improper bearing assembly. Correct.
Damaged crankshaft or bearing. Replace.

EM-19
 GENERAL DESCRIPTION OF ENGINE

External View of Engine

H SERIES ENGINE

EMM0305

EM-20
GENERAL DESCRIPTION OF ENGINE
External View of Engine (Cont’d)

EMM0306

EM-21
GENERAL DESCRIPTION OF ENGINE
External View of Engine (Cont’d)

EMM0307

EM-22
 GENERAL DESCRIPTION OF ENGINE
External View of Engine (Cont’d)
TD27 ENGINE

EMM0309

EM-23
GENERAL DESCRIPTION OF ENGINE
External View of Engine (Cont’d)

EMM0308

EM-24
GENERAL DESCRIPTION OF ENGINE

PTO (Power Take Off)

EMM0310

EM-25
 PREPARATION

Special Service Tools (H20-II/H25 Engine)

Tool number
Description
Tool name
ST05240001 When overhauling engine
Engine attachment

EMM0271

ST0501S000 When overhauling engine

Engine stand assembly
q
1 ST05011000
Engine stand
q
2 ST05012000
Base

EMM0272

KV101041S0 Removing crankshaft main bearing cap

Crankshaft main bearing
cap puller
q1 KV10104110
Crankshaft main bearing
puller
q2 ST16512001
Adapter
q3 ST16701001
Adapter

EMM0273

ST12070000 Disassembling and assembling valve

Valve lifter components

EMM0274

ST1102S000 Reaming valve guide

Valve guide reamer set
q
1 ST11021000
Valve guide reamer
8.90 mm (0.3504 in)
q
2 ST11022000
EMM0275
Valve guide reamer
9.10 mm (0.3583 in)
KV10102600 Finishing valve seat dimensions
Valve seat cutter set

EMM0276

EM-26
 PREPARATION
Special Service Tools (H20-II/H25 Engine)
(Cont’d)

Tool number
Description
Tool name
q
1 ST1524S000
Front oil seal drift
q
2 KV10105500
Rear oil seal drift
q
3 ST15243000
Drift rod
EMM0277

EM-27
 PREPARATION

Special Service Tools (TD27 Engine)

*: Special tool or commercial equivalent
Tool number
Description
Tool name
ST0501S000* Disassembling and assembling
Engine stand assembly
q
1 ST05011000
Engine stand
q
2 ST05012000
Base

EMM0278

KV10106500* When overhauling engine

Engine attachment

EMM0279

KV11103200* When overhauling engine

Engine sub-attachment

EMM0280

KV101092S0 Disassembling and assembling valve

q
1 KV10109210* components
Valve spring compressor
q
2 KV10111200*
Adapter

EMM0281

KV10107900* Removing valve oil seal

Valve oil seal puller

EMM0282

KV11103400 Installing valve oil seal

Valve oil seal drift

EMM0283

EM-28
 PREPARATION
Special Service Tools (TD27 Engine) (Cont’d)
*: Special tool or commercial equivalent
Tool number
Description
Tool name
ST11033000* Removing valve guide
Valve guide drift

EMM0284

KV11103900* Installing valve guide

Valve guide drift

EMM0285

ST11032000* Reaming valve guide

Valve guide reamer
8.0 mm (0.315 in) dia.

EMM0286

q
1 KV11101110 Removing valve seat
Valve seat remover
q
2 KV11103610
Adapter (Intake)
q
3 KV11103620
Adapter (Exhaust)

EMM0287

EM-29
 PREPARATION
Special Service Tools (TD27 Engine) (Cont’d)
*: Special tool or commercial equivalent
Tool number
Description
Tool name
q
1 ST15243000 Installing valve seat
Valve seat drift
q
2 KV11103710
Adapter (Intake)
q
3 KV11103720
Adapter (Exhaust)
q
4 KV11103810
Adapter (Intake)
q
5 KV11103820
Adapter (Exhaust)

EMM0288

q
1 KV11104010 Removing and installing cylinder liner
Cylinder liner tool
q
2 KV11104110
Adapter for removing
q
3 KV11104030
Adapter for installing

EMM0289

EM03470000* Installing piston assembly into cylinder

Piston ring compressor bore

EMM0290

KV111033S0 Preventing crankshaft from rotating

Engine stopper
q
1 KV11103310
Stopper plate
q
2 KV10105630
Stopper gear

EMM0291

EM-30
 PREPARATION
Special Service Tools (TD27 Engine) (Cont’d)
Tool number
Description
Tool name
ST16610001* Removing crankshaft pilot bushing
Pilot bushing puller

EMM0292

KV111045S0 Removing and installing cam bushing

Cam bushing replacer set
q
1 KV11104510
Replacer bar
q
2 KV11104520
Guide plate
q
3 KV11104530
Adapter
(1st bushing)
q
4 ST15243000
Drift

EMM0293

KV10109300* Preventing drive gear from rotating (VE-

Injection pump drive gear type)
holder

EMM0294

KV11103000* Removing drive gear (VE-type)

Injection pump drive gear
puller

EMM0295

WS39930000* Pressing the tube of liquid gasket

Tube presser

EMM0296

EM-31
 PREPARATION
Special Service Tools (TD27 Engine) (Cont’d)
Tool number
Description
Tool name
ED19601000 Checking compression pressure
Compression gauge

EMM0297

ED19600600 Checking compression pressure

Compression gauge
adapter (for glow plug hole)

EMM0298

ED19600700 Checking compression pressure

Compression gauge
adapter (for injector hole)

EMM0299

EM-32