SERVICE MANUAL GUIDE

SERVICE MANUAL
199406-13200
for MHI Equipment Europe B.V.
September 2009
Pub. No. 99406-13200
INTRODUCTION
This service manual describes the maintenance and adjustment procedures, and specifi-
cations for Mitsubishi marine 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 it may also be necessary to take measures which involve disassembly, inspection,
repair and assembly of the engine and engine parts.
Read through this manual carefully and understand the work procedures fully before dis-
assembling, inspecting, repairing or assembling 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.
Cautions of emissions requirements
This engine has met the EU's emissions requirements Stage III A.
The specifications of relating important parts are severely managed. Understand the con-
tents of regulation, and perform the defined inspection, maintenance, and note.
I
INTRODUCTION
How to use this manual

This service manual consists of several chapters, which are arranged so as to allow you to make reference quickly to specifica-
tions, maintenance standards, adjustment procedures and service procedures including methods for disassembly, inspection,
repair and assembly of the Mitsubishi Marine Engine.
A short summary describing the content of each chapter is given in the General Contents page, and there is also a detailed table
of contents at the beginning of each chapter.
Regarding the procedures for operation and periodical maintenance of the engine, refer to the Operation and Maintenance Man-
ual. For information on the engine components and ordering of service parts, refer to the Parts Catalogue. Structure and func-
tion of the engine are described in the relevant training manuals.
Methods of presentation
(1) Index numbers allotted to parts in exploded views are not only a call-out of part names listed in the text but also an indica-
tion of the sequence of disassembly.
(2) Inspections to be conducted during disassembly process are indicated in boxes in the relevant exploded views.
(3) Maintenance standards required for inspection and repair works are indicated in the appropriate positions in the 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 oil.
(5) In this manual, important safety or other cautionary instructions are emphasized with the following marks headed.
Indicates an immediately hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
Indicates a potentially hazardous situation which, if not avoided, can result in property
damage.
Note Emphasizes important matter, or indicates information useful for operation or maintenance
of the engine.
II
INTRODUCTION
Terms used in this manual

Nominal
means the rated (design) size or magnitude of a part to be measured.
Standard
means the quantitative requirement for dimension of a part, clearance between parts and performance. This is given in a form of
tolerance. Therefore, the values shown are not in agreement with the design values.
Limit
means that, if this value is reached, the part must be repaired or replaced with a new part.
Abbreviations
BTDC: Before Top Dead Center
ATDC: After Top Dead Center
BBDC: Before Bottom Dead Center
ABDC: After Bottom Dead Center
TIR: Total Indicated Runout
API: American Petroleum Institute
ASTM: American Society for Testing and Materials
JIS: Japanese Industrial Standards
LLC: Long Life Coolant
MIL: Military Specifications and Standards (U.S.A.)
MSDS: Material Safety Data Sheet
SAE: Society of Automotive Engineers (U.S.A.)
P/N: Part Number
Units of measurement
Measurements are based on the International System of Units (SI), and their converted metric values are indicated in parenthe-
ses { }. For metric conversion, the following rates are used.
Pressure:1 MPa = 10.197 kgf/cm2
Torque:1 N•m = 0.10197 kgf•m
Force:1 N = 0.10197 kgf
Horsepower:1 kW = 1.341 HP = 1.3596 PS
Meter of mercury:1 kPa = 0.7 cmHg
Meter of water:1 kPa = 10.197 cmH2O (cmAq)
Rotational speed:1 min-1 = 1 rpm
III
INTRODUCTION
Safety Cautions
Fire and explosions
Keep flames away Care for fuel, oil and exhaust gas leakage
Do not use flames near the engine (in If any fuel, oil or exhaust gas leakage is found, imme-
the engine room). Spilled fuel, oil and diately take corrective measures to stop it. Such leak-
LLC may ignite and cause a fire. ages, if left uncorrected, can cause fuel or engine oil to
Wipe off spilled fuel, oil and LLC reach hot engine surfaces or hot exhaust gas to con-
immediately and thoroughly. Spilled tact flammable materials, possibly leading to personal
fuel, oil and LLC may ignite and cause a fire. Store injury and/or damage to equipment.
fuel and engine oil in a well-ventilated area. Make sure Use explosion-proof lighting apparatus
that the caps of fuel and engine oil containers are When inspecting fuel, engine oil, coolant, battery elec-
tightly closed. trolyte, etc., use a flameproof light. An ordinary lighting
Keep engine surrounding area tidy and apparatus may ignite gas and cause it to explode.
clean Prevent electrical wires from short-circuit-
Do not leave combustible or explosive materials, such ing
as fuel, engine oil and LLC, near the engine. Such Avoid inspecting or servicing the electrical system with
substances can cause fire or explosion. Remove dust, the ground cable connected to the battery. Otherwise,
dirt and other foreign materials accumulated on the a fire could result from short-circuiting. Be sure to dis-
engine and surrounding parts thoroughly. Such materi- connect the battery cable from the negative (-) termi-
als can cause fire or the engine to overheat. In particu- nal before beginning with the work procedure. Short-
lar, clean the top surface of the battery thoroughly. circuits, possibly resulting in fire, may be caused by a
Dust can cause a short-circuit. Always operate the loose terminal or damaged cable/wire. Inspect the ter-
engine at a position at least 1 m [3.28 ft.] away from minals, cables and wires, and repair or replace the
buildings and other equipment to prevent possible fire faulty parts before beginning with the service proce-
caused by engine heat. dure.
Do not open side cover until engine cools Keep fire extinguishers and a first-aid kit
Do not attempt to open the side cover of the crankcase
handy
before the engine cools down. Wait at least 10 minutes
Keep fire extinguishers handy, and
after stopping the engine. Opening the cover when the
become familiar with their usage.
engine is hot allows fresh air to flow into the crank-
Keep a first-aid kit at the designated
case, which can cause oil mist to ignite and explode.
place where it is easily accessible by
anyone at any time. Establish
response procedures to follow in the event of fire or
accident. Provide an emergency evacuation route and
contact points and means of communication in case of
emergency.
IV
INTRODUCTION
Stay clear of all rotating and moving parts
Install protective covers on rotating parts Lockout and tagout

Make sure the protective covers of Be sure to lockout and tagout before starting inspec-
the engine are correctly installed. tion and maintenance. Lockout and tagout are effec-
Repair any damaged or loose covers. tive methods of cutting off machines and equipment
Never remove the protective covers of from energy sources. To accomplish the lockout/
rotating parts during operation. When tagout, remove the starter switch key, set the battery
the engine is coupled to the radiator or other equip- switch to OFF and attach a "Do Not Run" or similar
ment, install protective covers around the exposed caution tag to the starter switch. The starter switch key
connecting belt and coupling. must be kept by the person who performs inspection
and maintenance during the work.
Check work area for safety
Before starting the engine, make sure no one is near Keep engine stopped during servicing
the engine and tools are not left on or near the engine. Be sure to stop the engine before proceeding to
Verbally notify persons within the immediate area inspection and service procedure. Never attempt to
when starting the engine. When the starter device is make adjustments on the engine parts while the
posted with a sign that prohibits startup operation, do engine is running. Rotating parts such as belt can
not operate the engine. entangle your body and cause serious injuries.
Stay clear of moving parts while engine is Always restore engine turning tools after
running use
Do not approach rotating or sliding Be sure to remove all turning tools used during mainte-
parts of the engine while the engine is nance and inspection work. Remember also that the
running. Keep objects likely to be turning gear must be returned to the operating condi-
caught by rotating parts away from tion before starting the engine. Starting the engine with
such parts. If any part of the clothing the turning tools inserted or with the turning gear in
or outfitting is caught by a rotating part, serious bodily engagement can lead to not only engine damage but
injuries could result. also personal injuries.
V
INTRODUCTION
Be careful of exhaust fume poi- Be careful of falling down

soning
Lift engine carefully
Operate engine in a well-ventilated area To lift the engine, use slings capable
If the engine is installed in an of supporting the weight of the
enclosed area, and the exhaust gas is engine. Attach the wire rope to the
ducted outside, ensure that there is hangers provided on the engine using
no exhaust gas leak from duct joints. a correct sling. During lifting process,
Exhaust gas from the engine contains keep the engine in a well-balanced
carbon monoxide and other harmful substances. position by taking the center of gravity of the engine
Operating the engine in an poorly-ventilated area can into consideration.
produce gas poisoning. The hangers equipped with the engine are designed
for lifting the engine only. Be careful not to affect the
Protect ears from noise
hangers by added weight if installing the generator or
marine gear to the engine.
Wear ear plugs
Keep the angle formed by slings attached to hangers
Always wear ear plugs when entering
within 60°. If the angle exceeds this limit, excessive
the machine room (engine room).
load could be imposed on the hangers and this could
Combustion sound and mechanical
damage the hangers and result in a serious accident.
noise generated by the engine can
If the wire rope contacts the engine directly, place a
cause hearing problems.
cloth or other soft padding to avoid damage to the
engine and wire rope.
Do not climb onto the engine

Do not climb onto the engine, nor step on any engine
parts located on the lateral sides. To work on parts
located on the upper section of engine, use a ladder,
stool, etc., that was firmly secured. Climbing on the
engine may not only damage engine parts but also
cause falling down from the engine and result in per-
sonal injuries.
Always prepare stable scaffold

When working on the upper part of
the engine and other hard-to-reach
places, use a stable work platform.
Standing on a decrepit stool or parts
box may result in personal injury. Do
not place any unnecessary objects on a work platform.
VI
INTRODUCTION
Be careful when handling fuel, en- Be careful of burns

gine oil or LLC
Do not touch the engine during or immedi-
Use only specified fuel, engine oil and LLC ately after operation
Use fuel, oil and LLC specified in this manual, and To avoid burns, do not touch the
handle them carefully. Use of any other fuel, oil or engine during or immediately after
LLC, or improper handling may cause various engine operation. To conduct maintenance
problems and malfunctions. Obtain the MSDS issued and inspection work, wait until the
by the fuel, oil and LLC suppliers, and follow the direc- engine has cooled sufficiently by checking the temper-
tions in the MSDSs for proper handling. ature gauge.
Handle LLC carefully Do not open the radiator filler cap when the
When handling LLC, always wear rubber gloves and a engine is hot
protective face mask. If LLC or cooling water contain- Never open the radiator filler cap while the engine is
ing LLC comes into contact with your skin or eyes, or if running or immediately after the engine is stopped.
it is swallowed, you would suffer from inflammation, When opening the cap, stop the engine and allow the
irritation or poisoning. Should LLC be accidentally coolant temperature to lower sufficiently. When open-
swallowed, induce vomiting immediately and seek ing the radiator filler cap, open slowly to discharge the
medical attention. Should LLC enter your eyes, flush pressure inside the tank. Also to avoid a risk of getting
them immediately with plenty of water and seek medi- scalded by steam, wear thick rubber gloves or wrap a
cal attention. If LLC splashes onto your skin or cloth- cloth around the cap. When closing the cap, be sure to
ing, wash it away immediately with plenty of water. tighten securely. The coolant is hot while engine is
Keep flames away from LLC. The LLC can catch running and immediately after the engine stops. If the
flames, causing a fire. Coolant (containing LLC) cap is opened when the coolant is at operating tem-
drained from the engine is toxic. Never dispose of perature, steam and hot coolant may blow out and
coolant into regular sewage. Abide by the applicable result in burns.
law and regulations when discarding drained coolant.
Refill coolant only after the coolant temper-
Proper disposal of waste oil, LLC and cool- ature dropped
ant Do not add coolant immediately after the engine stops.
Do not discharge waste engine oil, LLC and coolant Wait until the coolant temperature lowers sufficiently to
into sewerage, river, lake or other similar places. Such avoid a risk of burns.
a way of disposal is strictly prohibited by laws and reg-
Never remove heat shields
ulations. Dispose of waste oil, LLC and coolant and
The exhaust system, which becomes extremely hot
other environmentally hazardous waste in accordance
while the engine is operating, is provided with various
with the applicable law and regulations.
heat shields. Do not remove these heat shields. If any
of these heat shields have been removed owing to
unavoidable circumstances during the work, be sure to
restore them after the work is completed.
Be careful of burns when changing oil

Wear gloves when draining oil or changing oil filters. If
hot oil or parts touch your skin, it may cause burns.
VII
INTRODUCTION
Service battery When abnormality occurs
Handle the battery correctly Do not add coolant immediately after a sud-
Never use flames or allow sparks to den stop due to overheating
generate near the battery. The bat- If the engine stops suddenly or if you have no choice
tery releases flammable hydrogen but stop the engine suddenly due to overheating, do
gas and oxygen gas. Any flames not add coolant immediately. Adding water while the
or sparks in the vicinity could engine is hot can damage parts such as cylinder
cause an explosion.
heads due to a sudden drop of temperature. Add cool-
Do not use the battery when the battery electrolyte
ant gradually after the engine has completely cooled.
level of which is below the "LOWER LEVEL" line.
Sustained use of the battery could result in an explo- Avoid immediate restart after abnormal
sion. stop
Do not short the battery terminals with a tool or other If the engine stops abnormally, do not restart the
metal object. engine immediately. If the engine stops with an alarm,
When removing battery, always remove the plug from check and remedy the cause of the problem before
the negative (-) terminal first. When connecting bat- restarting. Sustained use of the engine without any
tery, always connect the plug to the positive (+) ter-
remedy could result in serious engine problems.
minal first.
Remove all plugs, then charge the battery in a well-
Avoid continuous engine operation at low
ventilated area. oil pressure
Make sure the cable clamps are securely installed on If an abnormal engine oil pressure drop is indicated,
the battery terminals. A loose cable clamp can stop the engine immediately, and inspect the lubrica-
cause sparks that may result in an explosion. tion system to locate the cause. Continuous engine
Before servicing electrical components or conducting operation with low oil pressure could cause bearings
electric welding, set the battery switch to [Open/ and other parts to seize.
OFF] position or remove the plug from the negative
Stop the engine immediately if belt is bro-
(-) terminal to cut off the electrical current.
Battery electrolyte contains dilute sulfuric acid. Care- ken
less handling of the battery can cause the loss of If the belt breaks, stop the engine immediately. Contin-
sight and/or skin burns. Also, do not consume the uous engine operation with the broken belt could
battery electrolyte. cause the engine to overheat and thereby the coolant
Wear protective goggles and rubber gloves when to boil into steam, which may gush out from the
working with the battery (when adding water, charg- reserve tank or radiator, and you may be scalded with
ing, etc.) it.
If battery electrolyte is spilled onto the skin or cloth-
ing, immediately wash it away with lots of water. Use
soap to thoroughly clean.
The battery electrolyte can cause the loss of sight if
splashing into the eyes. If it gets into the eyes,
immediately flush it away with plenty of clean water,
and seek immediate medical attention.
If the battery electrolyte is accidentally consumed,
gargle with plenty of water, then drink lots of water,
and seek immediate medical attention.
VIII
INTRODUCTION
Other cautions
Never modify engine Never break seals

Unauthorized modification of the engine will void our To ensure proper engine operation, the fuel control
warranty. Modification of the engine may not only links are sealed to prevent accidental change of the
cause engine damage but also produce personal inju- injection volume and rotation speed settings. Operat-
ries. ing the engine without these seals in place can cause
problems described below, and also invalidates the
Perform all specified pre-operation inspec-
warranty.
tions and periodic inspections
Rapid wear of sliding and rotating parts
Conduct the pre-operation inspections and periodic
Engine damage such as seizing of engine parts
inspections as described in this manual.
Considerably increased consumption of fuel and
Failure to conduct the specified inspections may cause
lubricating oil
various engine problems, damage to parts, and seri- Degradation of engine performance due to improper
ous accidents. balance between fuel injection volume and governor
Work clothing and protective gear operation or overrunning of the engine which could
Wear a hardhat, face shield, safety shoes, dust mask, result in a serious accident
gloves and other protective gear as needed. When Inspect the engine after operation
handling compressed air, wear safety goggles, a hard- After engine operation, inspect each part of engine
hat, gloves and other necessary protective gear. once again. If abnormalities still exist, contact a dealer
Works without wearing proper protective gear could of Mitsubishi Heavy Industries, Ltd.
result in serious injuries. Break-in the engine
To break in new engines or overhauled engines, oper-
ate the engine at a speed lower than the rated speed
in a light load condition during the first 50 hours of
operation. Operating new engines or overhauled
engines in a severe condition during the break-in
period shortens the service life of the engine.
IX
INTRODUCTION
Warm up the engine before use Protection of the engine against water entry
After starting the engine, run the engine at low idling Do not allow rainwater, etc. to enter the engine
speeds for 5 to 10 minutes for warming-up. Start the through the air inlet or exhaust openings. Do not wash
work after this operation is completed. Warm-up oper- the engine while it is operating. Cleaning fluid (water)
ation circulates the lubricant through the engine. can be sucked into the engine. Starting the engine with
Therefore, individual engine parts are well lubricated water inside the combustion chambers can cause the
before they are subjected to heavy loads. Warm-up water hammer action which may result in internal
operation circulates lubricants in the engine and con- engine damage and serious accidents.
tributes to a longer service life and economical opera- Properly maintain the air cleaner and pre-
tion. Do not conduct warm-up operation for prolonged cleaner
period of time. Prolonged warm-up operation causes
The major cause of abnormal wear on engine parts is
carbon build-up in the cylinders that leads to incom-
foreign materials from intake air. Worn parts produce
plete combustion.
many problems such as an increase of oil consump-
Never operate the engine in an overloaded tion, decrease of output, and starting difficulties. For
condition effective removal of dust from intake air, maintain the
If the engine shows an overloaded condition such as air cleaner according to the following instructions.
black exhaust smoke, reduce the load immediately to Do not maintain the air cleaner or pre-cleaner while
operate the engine at an appropriate output and load. the engine is running. Operating the engine without
Overloading causes not only high fuel consumption the air cleaner/pre-cleaner allows foreign materials
to enter the turbocharger and could result in serious
but also excessive carbon deposits inside the engine.
damage.
Carbon deposits cause various problems and will
Remove the air cleaner or pre-cleaner slowly to pre-
shorten the service life of the engine.
vent foreign materials accumulated on the element
Conduct cooling operation before stopping from falling off. After removing the air cleaner or pre-
the engine cleaner, immediately cover the opening (inlet port of
Before stopping the engine, idle the engine in low gear air cleaner; port in body for pre-cleaner) with plastic
for 5 to 6 minutes to cool down. Stopping the engine sheet or similar means to prevent foreign materials
immediately after high-load operation will cause from entering the engine.
If the engine is equipped with a dust indicator, con-
engine parts to heat up and shorten the service life of
duct maintenance when the clog warning sign
the engine. During cooling operation, check the engine
appears.
for abnormalities.
X
INTRODUCTION
Observe safety rules at work site Cautionary instructions for transporting the
Observe the safety rules established at your work- engine
place when operating and maintaining the engine. Do When transporting the engine on a truck, consider the
not operate the engine if you are feeling ill, inform your engine weight, width and height to ensure safety.
supervisor of your condition. Operation of the engine Abide by road traffic law, road vehicles act, vehicle
with reduced awareness may cause improper opera- restriction ordinance and other pertinent laws.
tion that could result in accidents. When working in a Do not operate engine continuously under
team for two or more people, use specified hand sig-
low load
nals to communicate among workers.
When operating the engine with a 30 % of rated load
Use of tools optimum for each work or lower, limit each operation to 10 minutes. Operating
Always keep in mind to select most appropriate tools the engine at low load tends to result in unburned fuel,
for the work to be performed and use them correctly. If which can adhere on internal engine parts, and cause
tools are damaged, replace them with new tools. malfunctions and shorten the engine service life.
Avoidance of prolonged time of starter Ventilation of engine room
operation Always provide adequate ventilation in the engine
Do not use the starter for more than 10 seconds at a room. Insufficient air in the room can cause an
time. If the engine does not start, wait for at least 30 increase in the engine temperature and a decrease in
seconds before cranking again. Continuous operation the output power and performance. It is highly recom-
of the starter will drain the battery power and cause mended to calculate the required amount of air supply
the starter to seize. to the engine and install an adequate ventilation sys-
Do not turn off the battery switch during tem before installing the engine.
operation Do not touch high pressure injection fuel

Do not turn off the battery switch during operation If If fuel leaks or sprays out from the high pressure injec-
the battery switch is turned OFF when the engine is tion pipe, do not touch the fuel. Fuel in the fuel injec-
running, not only various meters will stop working but tion pipes is under high pressure and if the fuel contact
also the alternator may have its diode and transistor your skin, it goes into deep tissues and may result
deteriorated. gangrene.
XI
INTRODUCTION
About warning labels
Maintenance of warning labels

Make sure all warning/caution labels are legible. Clean or replace the warning/caution labels when the description
and/or illustration are not clear to read. For cleaning the warning/caution labels, use a cloth, water and soap. Do not
use cleaning solvents, gasoline or other chemicals to prevent the letters from getting blurred or the adhesion from
being weakened. Replace damaged or fractured labels with new ones. If any engine part on which a warning label
is attached is replaced with a new one, attach a new identical warning label to the new part. To obtain new warning
labels, contact a dealer of Mitsubishi Heavy Industries, Ltd.
Warning labels
XII
INTRODUCTION
Tips on disassembling and assembling

This service manual specifies the recommended procedures Tips on assembling
to be followed when servicing Mitsubishi engines. The Wash all engine parts, except such parts as oil seals, O-
manual also specifies the special tools that are required for rings and rubber seats, in cleaning oil and dry them with
the work, and the basic safety precautions to follow when compressed air.
working. Note that this manual does not exhaustively cover Use correct tools and instruments.
potential hazards that could occur during maintenance, Use only high-quality lubricating oils and greases of
appropriate types. Be sure to apply oil, grease or adhesive
inspection and service work of engine.
to the part wherever specified.
When working on an engine, follow the relevant directions
Use a torque wrench to tighten parts correctly when their
given in this manual and observe the following instructions:
tightening torques are specified. Refer to "Tightening
Tips on disassembling torque table."
Use correct tools and instruments. Serious damage to the Replace all gaskets, packings and O-rings with new ones
engine can result from using the wrong tools and instru- unless specified otherwise. Apply adhesive if necessary.
ments. Use only the proper amount of adhesive.
Do not use jack bolts with sharp edges, as they may cause Use protective gloves when you touch overheated or
damage to the surface. cooled parts. Touching the overheated parts with hands
Use an overhaul stand or work bench if necessary, and fol- directly can cause burns.
low the disassembling procedures described in this man-
ual. Do not place the engine parts on the floor directly.
Place them on the work bench.
Keep the engine parts in their order of removal to prevent
losing them. Keep the engine parts in their order of
installtion.
If the engine parts are reused, install them to the original
position unless there are any specific purpose.
Pay attention to assembling marks. Put your marks on the
parts, if necessary, to ensure correct assembling.
Carefully check each part for defects during disassembling
or cleaning. Do not miss symptoms which can not be
detected after disassembling or cleaning.
When lifting or carrying heavy parts, exercise utmost cau-
tion to ensure safety. Pay attention to the balancing of
heavy parts when handling. (Get help, and use jacks,
chain blocks and guide bolts as necessary.)
Use protective gloves when you touch overheated or
cooled parts. Touching the overheated parts with hands
directly can cause burns.
XIII
GENERAL CONTENTS
Chapter 1 GENERAL
1. External View
2. System flow diagrams
3. The contents of plate and label
4. Main specifications
Chapter 2 SERVICE DATA

1. Maintenance service data
2. Tightening torque table
Chapter 3 SERVICE TOOLS

1. Special tools
Chapter 4 OVERHAUL INSTRUCTIONS

1. Determining overhaul timing
2. Compression pressure - Measure
Chapter 5 DISASSEMBLY OF BASIC ENGINE

1. Cylinder heads and Valve mechanisms - Disassemble and Inspect
2. Rear equipment - Disassemble and Inspect
3. Front equipment - Disassemble and Inspect
4. Cylinder liner, Piston and Connecting rod - Disassemble and Inspect
5. Crankcase, Crankshaft and Main bearing - Disassemble and Inspect
Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

1. Cylinder head and Valve mechanism - Inspect and Repair
2. Rear equipment - Inspect and Repair
3. Front equipment - Inspect and Repair
4. Piston and Connecting rod - Inspect and Repair
5. Crankcase and Crankshaft - Inspect and Repair
Chapter 7 ASSEMBLY OF BASIC ENGINE

1. Crankshaft and Main bearing - Install
2. Cylinder liner, Piston and Connecting rod - Assemble
3. Front equipment - Assemble
4. Rear equipment - Assemble
5. Cylinder head and Valve mechanism - Assemble
Chapter 8 FUEL SYSTEM
1. Fuel system - Remove and Inspect
2. Fuel system - Disassemble and Inspect
3. Fuel system - Install
Chapter 9 LUBRICATION SYSTEM

1. Lubrication system - Remove and Inspect
2. Lubrication system - Disassemble, Inspect and Assemble
3. Lubrication system - Install
Chapter 10 COOLING SYSTEM

1. Cooling system - Remove and Inspect
2. Cooling system - Disassemble, Inspect and Assemble
3. Cooling system - Install
Chapter 11 INLET AND EXHAUST SYSTEMS

1. Inlet and exhaust systems - Remove and Inspect
2. Inlet and exhaust systems - Disassemble, Inspect and Assemble
3. Inlet and exhaust systems - Install
Chapter 12 ELECTRICAL SYSTEM

1. Electrical system - Remove and Inspect
2. Electrical system - Disassemble, Inspect and Assemble
3. Electrical system - Install
Chapter 13 ADJUSTMENT AND OPERATION

1. Engine - Adjust
2. Break-in operation
3. Test and Adjustment for engine
Chapter 1 GENERAL
1. External View ........................................................................................................... 1-3
2. System flow diagrams............................................................................................. 1-5
2.1 Outline of fuel system ............................................................................................................... 1-5
2.2 Outline of lubrication system..................................................................................................... 1-5
2.3 Outline of cooling system.......................................................................................................... 1-6
2.4 Outline of inlet and exhaust system.......................................................................................... 1-6
3. The contents of plate and label .............................................................................. 1-7
3.1 Name plate ............................................................................................................................... 1-7
3.2 Caution plate ............................................................................................................................ 1-7
3.3 The certification label of exhaust emission regulations ............................................................ 1-7
4. Main specifications.................................................................................................. 1-8
1-1
Chapter 1 GENERAL
Chapter 1 GENERAL
1. External View
Thermostat case
Engine coolant outlet
Breather
Water pump
Oil pump
Oil pan
Engine front view
Exhaust pipe
Exhaust air outlet
Turbocharger Turbocharger
Silencer and pre-cleaner

Silencer and pre-cleaner Air inlet
Air inlet
Flywheel
Engine rear view
1-3
Chapter 1 GENERAL
Fuel injection pump

Intercooler coolant outlet Fuel filter
Oil cooler
Rear hanger
Intercooler coolant inlet
Front hanger Governor oil filter
Bypass oil filter

Governor
Front Rear
Fuel feed pump

Damper
Starter
Oil filter
Fuel outlet
Oil filler
Relief valve Oil level gauge Fuel inlet
Engine left view
Fuel injection pump

Fuel filter
Front hanger
Rear hanger
Oil cooler
Stop solenoid Alternator
Rear Front
Water drain cock
Engine coolant inlet

Fuel feed pump
Engine right view
1-4
Chapter 1 GENERAL
2. System flow diagrams

2.1 Outline of fuel system
Fuel leak-off pipe

Fuel injection nozzle
Fuel injection pump
Fuel feed pump
Fuel injection pipe To right side of engine
From right side of engine
Fuel filter
From fuel tank To fuel tank
Outline of fuel system
2.2 Outline of lubrication system
Camshaft Piston Rocker shaft
Main gallery Turbocharger
Relief valve
Governor oil filter
Timing gear
Oil cooler Piston cooling nozzle
Water pump
Oil thermostat
Governor
Safety valve
Fuel injection pump
Oil pump
Crankshaft
Bypass oil filter Oil filter
Oil strainer
Outline of lubrication system
1-5
Chapter 1 GENERAL
2.3 Outline of cooling system
Water pump Oil cooler Water jacket
Water outlet
( Rocker case )
Engine coolant
inlet
Engine coolant Intercooler

outlet
Engine coolant
outlet
Thermostat
Water outlet
Oil cooler Water jacket
( Rocker case )
Intercooler coolant outlet
Intercooler coolant inlet
Outline of cooling system
2.4 Outline of inlet and exhaust system
Intake air Exhaust pipe

Exhaust air outlet
Exhaust air Turbocharger Turbocharger
From pre-cleaner From pre-cleaner
Intercooler
Cylinder
Outline of inlet and exhaust system
1-6
Chapter 1 GENERAL
3. The contents of plate and label

3.1 Name plate
The name plate is attached on the lateral side of the engine.
The followings are described. Left
Engine serial number
Production date
Displacement Rear Front
Engine output
Rated speed
Right
Cylinder No.
Name plate
3.2 Caution plate
The caution plate is attached on the rocker cover of No. 1
cylinder. The followings are described.
Valve clearance
Firing order

Fuel injection timing
Connecting rod weight rank VALVE CLEARANCE (COLD)
INLET 0.6 O O ':*#756 0.8 O O
FIRING ORDER
1-9-6-14-2-10-4-12-8-16-3-11-7-15-5-13
FUEL INJECTION TIMING BTDC
CON-ROD RANK
Caution plate
3.3 The certification label of exhaust emission regulations
The label that indicates the certified exhaust emission regu-
lations is attached on the engine.
1-7
Chapter 1 GENERAL
4. Main specifications
Engine model S16R-Z3MPTAW
Water cooled, 4 stroke cycle diesel,
Type
turbocharged with intercooler
No. of cylinders - arrangement 16-V
Combustion system Direct injection
Valve mechanism Overhead
Cylinder bore × stroke 170×180 mm [6.69×7.09 in.]
Displacement 65.37 L [3989 cu. in.]
Compression ratio 14.5 : 1
Fuel Diesel oil
Firing order 1-9-6-14-2-10-4-12-8-16-3-11-7-15-5-13
Direction of rotation Counterclockwise as viewed from flywheel side
Length 2971 mm [116.97 in.]
Dimensions Width 1512 mm [59.52 in.]
Height 1960 mm [77.16 in.]
Dry weight 6780 kg [14947 lb.]
Type Mitsubishi Heavy Industries, Ltd.: PS8A type
Plunger outside diameter ø17 mm [0.67 in.]
Fuel injection pump
Pre-stroke 2.5 mm [0.098 in.]
Cam lift 15 mm [0.59 in.]
Type Bosch Corporation: KD-Z type
Fuel feed pump
Cam lift 12 mm [0.4724 in.]
Governor Type Japan Woodward Governor: Oil pressure PSG type
Fuel injection nozzle Type Bosch Corporation: hole type
Fuel filter Type Paper element type (spin-on)
Lubrication method Forced circulation (oil pump pressure feed system)
Specification Class CF (API service category)
Engine oil Whole engine: approx. 290 L [76.61 U.S. gal.],
Capacity
Oil pan: approx. 260 L [68.68 U.S. gal.]
Oil pump Type Gear pump type
Relief valve Type Piston valve type
Oil cooler Type Water-cooled, multi-plate type (housed in the crankcase)
Full-flow oil filter Type Paper element type (spin-on)
Bypass oil filter Type Paper element type (spin-on)
Oil thermostat Type Wax type
Cooling method Water-cooled, forced circulation
Coolant capacity (engine) Approx. 170 L [44.91 U.S. gal.]
Water pump Type Centrifugal
Water thermostat Type Wax type
Type TD10 L
Turbocharger
No. of units 4
Voltage, Polarity 24V, earth float
Model number 0-23000-7201
Starter
Type Nikko Electric Industry Co., Ltd.: Pinion shift (Reduction type)
Model number A004TU3687
Alternator Mitsubishi Electric Corporation: 3-phase alternating generator,
Type
IC regulator, brushless
1-8
1. Maintenance service data ....................................................................................... 2-3
1.1 Engine general ......................................................................................................................... 2-3
1.2 Basic engine ............................................................................................................................. 2-4
1.3 Fuel system .............................................................................................................................. 2-9
1.4 Lubrication system.................................................................................................................. 2-10
1.5 Cooling system ....................................................................................................................... 2-10
1.6 Electrical system..................................................................................................................... 2-11
2. Tightening torque table......................................................................................... 2-12
2.1 Basic engine ........................................................................................................................... 2-12
2.2 Fuel system ............................................................................................................................ 2-13
2.3 Lubrication system.................................................................................................................. 2-14
2.4 Cooling system ....................................................................................................................... 2-14
2.5 Inlet and exhaust system ........................................................................................................ 2-14
2.6 Electrical system..................................................................................................................... 2-15
2.7 Standard bolt and nut ............................................................................................................. 2-16
2.8 Standard eyebolt tightening torque......................................................................................... 2-17
2.9 Standard union nut ................................................................................................................. 2-17
2.10 Fuel injection pipe................................................................................................................... 2-17
2-1
1. Maintenance service data

1.1 Engine general
Item Nominal Standard Limit Remarks
Rated speed 1600 min-1
Minimum speed 600 min-1
Compression pressure 1.8 MPa {18.5 kgf/cm²} [263 psi] 1.27 MPa {13 kgf/cm²} [185 psi] When cranking (Approx. 120 min-1)
0.49 to 0.64 MPa
{5 to 6.5 kgf/cm²} [71 to 92 psi] 0.49 MPa {5 kgf/cm²} [71 psi]
(at rated) When oil temperatures at 60 to 70°C
Engine oil pressure
0.20 to 0.29 MPa [140 to 158°F]
{2 to 3 kgf/cm²} [28 to 43 psi] 0.10 MPa {1 kgf/cm²} [14 psi]
(at idling)
Inlet opens BTDC 63°
Inlet closes ABDC 35° ±2°
Valve clearance 0 mm
Exhaust opens BBDC 53° (crank angle)
Exhaust closes ATDC 45°

Valve timing
Inlet opens BTDC 25°
Inlet closes BBDC 3°
Valve clearance 2 mm [0.08 in.]
Exhaust opens BBDC 21°
Exhaust closes ATDC 7°
Valve clearance Inlet 0.6 mm [0.024 in.]

(when cold) Exhaust 0.8 mm [0.032 in.]
BTDC 21±1° Check the caution plate on No. 1 rocker
Fuel injection timing
(crank angle) cover.
2-3
1.2 Basic engine

Unit: mm [in.]
ø36 36.000 to 36.040 36.090
Rocker bushing inside diameter
[1.42] [1.4173 to 1.4189] [1.4209]
Rockers
ø36 35.966 to 35.991 35.940
Rocker shaft outside diameter
[1.42] [1.4160 to 1.4170] [1.4150]
ø10 9.940 to 9.960 9.910
Valve stem outside diameter
[0.39] [0.3913 to 0.3921] [0.3902] Same for both inlet and
ø10 10.000 to 10.015 10.060 exhaust valves.
Valve guide inside diameter
Valve [0.39] [0.3937 to 0.3943] [0.3961]
Clearance between the bottom surface of
valve bridge and the top surface of valve 2.1 [0.083]
rotator
Valve seat angle 30°
Seat width
-0.1 to 0.1 1.0
Valve sinkage 0
[-0.004 to 0.004] [0.040]
2.3 2.21 to 2.42 2.8
Seat width
[0.091] [0.0870 to 0.0953] [ 0.110] Valve
seat Valve
Refacing Valve margin
3.0 2.8 to 3.2 angle
Valve margin permissible up to sinkage
[1.118] [0.110 to 0.126]
2.5 [0.098]
Valve seat and 60.000 to 60.030 60.120
Valve seat fit inside diameter
valve [2.3622 to 2.3634] [2.3669]
60.100 to 60.130
Standard 2 lines, brown
[2.3661 to 2.3673]
Valve seat outside 60.130 to 60.160
0.03 [0.0012] 3 lines, brown
diameter [2.3673 to 2.3685]
60.160 to 60.190
0.06 [0.0024] 4 lines, brown
[2.3685 to 2.3697]
0.070 to 0.130
Valve seat interference
[0.0028 to 0.0051]
Free length 73 [2.87] 71 [2.80]
A
A=1.5° or less B
B=2.2 [0.087]
Squareness B = less than 1.9 [0.075]
Inlet valve over entire length Lf
Lf=73 [2.87]
spring
66.0 [2.60] / 289 to 319

Set length/load
{29.45 to 32.55}
(mm [in.]/N{kgf} [lbf])
[64.97 to 71.71]
Free length 90.6 [3.567] 88.12 [3.4693]
A
A=2.0° or less B
B=3.7 [0.146]
over entire length Lf
Inner spring Lf=90.6 [3.567]
Set length/load 56.0 [2.20] / 137 to 152

(mm [in.]/ {14 to 15.5}
Exhaust valve N{kgf} [lbf]) [30.80 to 34.17]
spring Free length 96.57 [3.8020] 93.92 [3.6976]
A
A=2.5° or less B
B=4.9 [0.193]
over entire length Lf
Outer spring Lf=96.57 [3.8020]
Set length/load 62.0 [2.44] / 496 to 549

(mm [in.]/ {50.6 to 56.0}
N{kgf} [lbf]) [111.5 to 123.4]
Push rod Runout 0.50 [0.0197] or less TIR
Cylinder head Distortion of bottom surface 0.03 [0.0012] or less 0.07 [0.0028]
2-4
Unit: mm [in.]
ø170 170.020 to 170.040 170.500
Inside diameter
[6.69] [6.6937 to 6.6945] [6.7126]
Roundness 0.02 [0.0008] or less
Cylindricity 0.02 [0.0008] or less
Cylinder liner 0.11 to 0.20

Protrusion
[0.0043 to 0.0079]
14.16 to 14.20
Flange thickness
[0.5575 to 0.5591]
0.16 to 0.24
Top ridge height
[0.0063 to 0.0094]
Measure the outside
diameter from lower end
ø170 169.76 to 169.80 169.66
Outside diameter of piston at 40 mm
[6.69] [6.6835 to 6.6850] [6.6795]
[1.57 in.] with right angles
to the piston pin.
Piston Within ±10 g [0.35 oz.]

Weight difference
in one engine
ø70 70.002 to 70.015 70.040
Piston pin bore inside diameter
[2.76] [2.7560 to 2.765] [2.7575]
0.03 to 0.63
Protrusion
[0.0012 to 0.0248]
Cylinder head 1.8 1.77 to 1.83
Thickness when tightened
gasket [0.071] [0.0697 to 0.0720]
Piston cooling 0.10 to 0.15 MPa
nozzle Valve opening pressure {1.0 to 1.5 kgf/cm2}
[14 to 21 psi]
Piston and 1.25 to 2.00
Top clearance
cylinder head [0.0492 to 0.0787]
No.1 0.6 to 0.8 2.0
compression [0.024 to 0.032] [0.078]
No.2 0.6 to 0.8 2.0
Piston ring End gap
compression [0.024 to 0.032] [0.078]
0.3 to 0.45 2.0
Oil
[0.012 to 0.0177] [0.078]
ø70 69.987 to 70.000 69.970
Piston pin Outside diameter
[2.76] [2.7554 to 2.7559] [2.7547]
Inside diameter of the connecting rod ø70 70.020 to 70.040 70.070
bushing [2.76] [2.7567 to 2.7575] [2.7587]
0.05/100
Bend and twist
[0.0020/3.94] or less
0.6 to 0.9 1.4
End play
[0.024 to 0.035] [0.055]
Connecting rod Minimum:

ø131 131.000 to 131.025 130.950 [5.1555]
Inside diameter of big end bore
[5.16] [5.1575 to 5.1585] Maximum:
131.050 [5.1594]
Roundness for inside diameter of big end 0.100
bore [0.0039]
59.7 to 59.8
Big end side (width)
[2.3504 to 2.3543]
2-5
Unit: mm [in.]
3.000 2.957 to 2.970 2.930
Standard
[0.1181] [0.1164 to 0.1169] [0.1154]
3.125 3.082 to 3.095 3.055
-0.25 [-0.0098]
[0.1230] [0.1213 to 0.1219] [0.1203]
Connecting rod 3.250 3.207 to 3.220 3.180
Thickness at center -0.50 [-0.0197]
bearing [0.1280] [0.1263 to 0.1268] [0.1252]
3.375 3.332 to 3.345 3.305
-0.75 [-0.0295]
[0.1329] [0.1312 to 0.1317] [0.1301]
3.500 3.457 to 3.470 3.430
-1.00 [-0.0394]
[0.1378] [0.1361 to 0.1366] [0.1350]
Face runout 0.336 [0.0132] or less
Flywheel
Radial runout 0.130 [0.0051] or less
Face runout 0.5 [0.020] or less
Damper
Radial runout 0.5 [0.020] or less
Inside diameter of bearing fit in ø110 110.000 to 110.035
the oil pump bearing cover [4.33] [4.3307 to 4.3321]
Inside diameter of bearing fit in ø110 109.987 to 110.022
the pump plate [4.33] [4.3302 to 4.3316]
ø110 109.985 to 110.000
Oil pump drive Outside diameter
[4.33] [4.3301 to 4.3307]
Bearing
ø50 49.988 to 50.000
Inside diameter
[1.97] [1.9680 to 1.9685]
Outside diameter of bearing fit in ø50 49.993 to 50.013
the oil pump gear [1.97] [1.9682 to 1.9690]
0.11 to 0.28 0.50
Backlash
[0.0043 to 0.0110] [0.0197]
ø50 50.000 to 50.025 50.060
Front idler bushing inside diameter
[1.97] [1.9685 to 1.9695] [1.9709]
Front equipment
ø50 49.950 to 49.975 49.900
Front idler shaft outside diameter
[1.97] [1.9665 to 1.9675] [1.9646]
0.20 to 0.40 0.60
Front idler gear end play
[0.0079 to 0.0157] [0.024]
0.11 to 0.28 0.50
Backlash
[0.0043 to 0.0110] [0.0197]
ø65 65.000 to 65.030 65.060
Rear idler bushing inside diameter
[2.56] [2.5591 to 2.5602] [2.5614]
Rear equipment
ø65 64.951 to 64.970 64.900
Rear idler shaft outside diameter
[2.56] [2.5571 to 2.5579] [2.5551]
0.3 to 0.6 1.0
Rear idler gear end play
[0.012 to 0.024] [0.040]
9.260 to 9.340 8.45
Cam lift (major axis - minor axis)
[0.3646 to 0.3677] [0.3327]
Runout 0.05 [0.0020] or less 0.08 [0.0031] TIR
ø84 83.92 to 83.94 83.87
Journal diameter
Camshaft [3.31] [3.3039 to 3.3047] [3.3020]
Camshaft bushing inside diameter ø84 84.000 to 84.035 84.100
(as installed in crankcase) [3.31] [3.3071 to 3.3085] [3.3110]
0.10 to 0.25 0.40
End play
[0.0039 to 0.0098] [0.0157]
2-6
Unit: mm [in.]
124.930 to 124.950 124.890
Standard
[4.9185 to 4.9193] [4.9169]
124.680 to 124.700 124.640
-0.25 [-0.0098]
[4.9087 to 4.9094] [4.9071]
Crankpin outside ø125 124.430 to 124.450 124.390
-0.50 [-0.0197]
diameter [4.92] [4.8988 to 4.8996] [4.8972]
124.180 to 124.200 124.140
-0.75 [-0.0295]
[4.8890 to 4.8898] [4.8874]
123.930 to 123.950 123.890
-1.00 [-0.0394]
[4.8791 to 4.8799] [4.8775]
169.920 to 169.940 169.880
Standard
[6.6898 to 6.6905] [6.6882]
169.670 to 169.690 169.630
-0.25 [-0.0098]
[6.6799 to 6.6807] [6.6783]
Crank journal out- ø170 169.420 to 169.440 169.380
-0.50 [-0.0197]
side diameter [6.69] [6.6701 to 6.6709] [6.6685]
169.170 to 169.190 169.130
-0.75 [-0.0295]
[6.6602 to 6.6610] [6.6586]
168.920 to 168.940 168.880
-1.00 [-0.0394]
[6.6504 to 6.6512] [6.6488]
Deviation of
0.03
Parallelism of journal and crankpin 0.01 [0.0004] or less
[0.0012]
over entire pin length
Diameter difference 0.03
Circularity of journal and crankpin
0.01 [0.0004] or less [0.0012]
Diameter difference 0.03
Cylindricity of journal and crankpin
0.01 [0.0004] or less [0.0012]
Crankshaft
R7 6.8 to 7.0
Fillet radius of pin
[0.28] [0.268 to 0.276]
R8.5 8.3 to 8.5
Fillet radius of journals
[0.335] [0.327 to 0.335]
Hardness of journals and crankpins Hv > 590
Surface accuracy Ra0.2 μm
Angular deviation between pins ±20'
120 120.20 to 120.30
Crankpin width
[4.72] [4.7323 to 4.7362]
67.00 to 67.03
Standard
[2.6378 to 2.6390]
One 67.25 to 67.28
0.25 side [2.6476 to 2.6488]
[0.0098] Both 67.50 to 67.53
sides [2.6575 to 2.6587]
Rearmost One 67 67.50 to 67.53
crank journal width 0.50 side [2.64] [2.6575 to 2.6587]
[0.0197] Both 68.00 to 68.03
sides [2.6772 to 2.6783]
One 67.75 to 67.78
0.75 side [2.6673 to 2.6685]
[0.0295] Both 68.50 to 68.53
sides [2.6968 to 2.6980]
Runout 0.04 [0.0016] or less 0.10 [0.0039] TIR
End play 0.200 to 0.400 0.500
(width between webs and thrust bearings) [0.0079 to 0.0157] [0.0197]
2-7
Unit: mm [in.]
4.500 4.467 to 4.480 4.425
Standard
[0.1772] [0.1759 to 0.1764] [0.1742]
4.625 4.592 to 4.605 4.550
-0.25 [-0.0098]
[0.1821] [0.1808 to 0.1813] [0.1791]
4.750 4.717 to 4.730 4.675
Main bearing Thickness at center -0.50 [-0.0197]
[0.1870] [0.1857 to 0.1862] [0.1841]
4.875 4.842 to 4.855 4.800
-0.75 [-0.0295]
[0.1919] [0.1906 to 0.1911] [0.1890]
5.000 4.967 to 4.980 4.925
-1.00 [-0.0394]
[0.1969] [0.1956 to 0.1961] [0.1939]
5.00 4.83 to 4.90 4.76
Standard
[0.1969] [0.1902 to 0.1929] [0.1874]
5.25 5.08 to 5.15 5.01
0.25 [0.0098]
[0.2067] [0.2000 to 0.2028] [0.1972]
Thrust plate Thickness
5.50 5.33 to 5.40 5.26
0.50 [0.0197]
[0.2165] [0.2098 to 0.2126] [0.2071]
5.75 5.58 to 5.65 5.51
0.75 [0.0295]
[0.2264] [0.2197 to 0.2224] [0.2169]
Distortion of top surface 0.1 [0.004] or less 0.2 [0.008]
ø179 179.000 to 179.025 179.045
Inside diameter of main bearing bore
Crankcase [7.05] [7.0472 to 7.0482] [7.0490]
14.00 to 14.05
Depth of counterbore in crankcase
[0.5512 to 0.5531]
2-8
1.3 Fuel system

Unit: mm [in.]
Free length of nozzle spring 30 [1.18]
Squareness of nozzle spring Less than 0.6 [0.024]
Parallelism of top and bottom nozzle spring Less than 0.1 [0.004 ]
34.32 to 34.81 MPa
Fuel 34.32 MPa {350 to 355kgf/cm²}
injection Fuel injection start pressure {350 kgf/cm²} [4978 to 5049 psi]
nozzle [4978 psi] (When new nozzle is
measured)
Spray angle 158°
No. of spray holes 10
Spray diameter ø0.27 [0.0106]
ø90 89.987 to 90.022
[3.54] [3.5428 to 3.5442]
Inside diameter of case bearing fit
ø100 99.987 to 100.022
[3.94] [3.9365 to 3.9379]
ø90 89.985 to 90.000
Small
[3.54] [3.5427 to 3.5433]
Outside diameter
Fuel ø100 99.985 to 100.000
injection Large
[3.94] [3.9364 to 3.9370]
pump Bearing
accessory ø45 44.988 to 45.000
Small
drive [1.77] [1.7712 to 1.7717]
Inside diameter
ø50 49.988 to 50.000
Large
[1.97] [1.9680 to 1.9685]
ø45 45.002 to 45.013
[1.77] [1.7717 to 1.7722]
Outside diameter of drive shaft bearing fit
ø50 50.002 to 50.013
[1.97] [1.9686 to 1.9690]
ø52 51.988 to 52.018
Inside diameter of driving shaft case bearing fit
[2.05] [2.0468 to 2.0479]
ø52 51.987 to 52.000
Outside diameter
[2.05] [2.0467 to 2.0472]
Drive shaft bearing
ø25 24.990 to 25.000
Inside diameter
[0.98] [0.9839 to 0.9843]
Drive shaft ø25 25.002 to 25.011
Governor Outside diameter of bearing fit [0.98] [0.9843 to 0.9847]
drive ø47 46.989 to 47.014
Inside diameter of idler shaft case bearing fit
[1.85] [1.8500 to 1.8509]
ø47 46.986 to 47.000
Outside diameter
[1.85] [1.8498 to 1.8504]
Idler shaft bearing
ø20 19.990 to 20.000
Inside diameter
[0.79] [0.7870 to 0.7874]
ø20 20.002 to 20.011
Outside diameter of idler shaft bearing fit
[0.79] [0.7875 to 0.7878]
2-9
1.4 Lubrication system

Unit: mm [in.]
0.100 to 0.200 0.400
Drive gear and driven gear backlash
[0.0039 to 0.0079] [0.0157]
0.100 to 0.148 0.350
Clearance between gear teeth and case bore
[0.0039 to 0.0058] [0.0138]
Clearance between gear width and case 0.040 to 0.116 0.210
depth [0.0016 to 0.0046] [0.0083]
29.887 to 29.900 29.840
Drive shaft outside diameter
[1.1767 to 1.1772] [1.1748]
29.947 to 29.960 29.920
Driven shaft outside diameter ø30 [1.18]
Oil pump [1.1790 to 1.1795] [1.1780]
30.000 to 30.021 30.055
Bushing inside diameter
[1.1811 to 1.1819] [1.1833]
1.3 ± 0.13 MPa
Safety valve opening pressure {13 ± 1.3 kgf/cm²}
[189 ± 19 psi]
65.8 [2.591]/314 N
65.8 [2.591]/359 N
Safety valve spring installation length/load {32.0 kgf}
{36.6 kgf} [80.7 lbf]
[70.6 lbf]
Free length of safety valve spring 78 [3.07]
0.51 ± 0.02 MPa
Valve opening pressure {5.2 ± 0.2 kgf/cm²}
Relief valve [74 ± 3 psi]
Spring free length 188 [7.40]
80 to 84°C
Valve opening temperature
[176 to 183.2°F]
Oil thermostat
Temperature at which valve lift becomes
95°C [203°F]
11 [0.43] or more
1.5 Cooling system

Unit: mm [in.]
ø120 119.987 to 120.022
Pump case
Inside diameter [4.72] [4.7239 to 4.7253]
of bearing fit ø110 110.005 to 110.040
Bearing cover
[4.33] [4.3309 to 4.3323]
Outside ø120 119.985 to 120.000
diameter [4.72] [4.7238 to 4.7244]
Large
Inside ø55 54.985 to 55.000
diameter [2.17] [2.1648 to 2.1654]
Bearing
Outside ø110 109.985 to 110.000
Water pump
diameter [4.33] [4.3301 to 4.3307]
Small
Inside ø50 49.988 to 50.000
diameter [1.97] [1.9680 to 1.9685]
ø55 55.011 to 55.024
[2.17] [2.1658 to 2.1663]
Outside diameter of shaft bearing fit
ø50 50.011 to 50.024
[1.97] [1.9689 to 1.9694]
1.04 0.58 to 1.50
Clearance of front impeller
[0.0409] [0.0228 to 0.0591]
69 to 73°C
[156.2 to 163.4°F]
Thermostat
Temperature at which valve lift 85°C
becomes 9 [0.35] or more [185°F]
2-10
1.6 Electrical system

Unit: mm [in.]
ø30 30.002 to 30.011
Rear shaft outside diameter
[1.18] [1.1812 to 1.1815]
ø19 18.90 to 18.94
Pinion shaft Front shaft outside diameter
[0.75] [0.7441 to 0.7457]
0.2 to 0.8
End play
[0.008 to 0.031]
ø19 19.000 to 19.033
Front shaft receiver
[0.75] [0.7480 to 0.7493]
Bearing
ø19 19.000 to 19.033
Pinion
[0.75] [0.7480 to 0.7493]
Clearance between bearing and shaft 0.25 [0.0098]
Voltage drop between terminals B and M
0.3 V
(load current 100 A)
Brush length 22 to 23 [0.87 to 0.91] 13 [0.51]
Starter
40.2 N
44.1 N
Brush spring load {4.1 kgf} With brush installed
{4.5 kgf} [9.9 lbf]
[9.0 lbf]
Shaft runout 0.04 [0.0016] TIR
ø20 20.002 to 20.011
Front shaft outside diameter
[0.79] [0.7875 to 0.7878]
Armature ø10 10.001 to 10.007
Rear shaft outside diameter
[0.39] [0.3937 to 0.3940]
0.2 to 0.7
End play
[0.008 to 0.028]
Outside diameter ø43 [1.69] 42[1.65]
Runout 0.06 [0.0024] 0.1[0.004] TIR
Commutator
0.7 to 0.9 0.2
Undercut depth
[0.028 to 0.035] [0.008]
30 A or more
2500
Output current Rotational speed (when cooling)
(at 27 V) (min-1) 35 A or more
5000
(when warming)
Regulator adjusting voltage
28.5 ± 0.5 V
Alternator (Alternator 5000 min-1, load at 5 A or lower)
Field coil resistance (20 °C [68 °F]) 7.3 to 8.5 ohm
When the center of the belt
10 to 15 is pressed at approx.
Belt tension
[0.39 to 0.59] 98 to 147 N {10 to 15 kgf}
[22 to 33 lbf]
2-11
2. Tightening torque table

2.1 Basic engine
Thread Torque
Description Dia. × Pitch Remarks
(M-thread) N·m kgf·m lbf·ft
[Wet] 2-time tightening method,

Cylinder head bolt 22 × 2.5 539 ± 27 55 ± 2.75 398 ± 20
Note (a)
Apply Loctite 272 to the female screw
Cylinder head nozzle gland (studs) 14 × 2.0 73.5 ± 4.5 7.5 ± 0.5 54 ± 3.6
on the cylinder head
Rocker case 12 × 1.25 108 ± 5.4 11 ± 0.55 80 ± 3.98
Rocker shaft 14 × 2.0 147 ± 7.4 15 ± 0.75 108 ± 5.46
Rocker arm (lock nut) 12 × 1.25 64 ± 3.2 6.5 ± 0.33 47 ± 2.4
Bridge (lock nut) 10 × 1.25 55 ± 2.8 5.6 ± 0.28 40.5 ± 2.07
Camshaft gear (rear) 12 × 1.25 127 ± 6.4 13 ± 0.65 94 ± 5 Use 12T bolt + hard washer
Camshaft thrust plate 12 × 1.25 59 ± 5.9 6 ± 0.6 43 ± 4.3
Main bearing cap 24 × 3.0 588 ± 29.4 60 ± 3.0 434 ± 22 [Wet], Note (b)
Main bearing cap (side bolt) 20 × 2.5 392 ± 19.6 40 ± 2.0 289 ± 14 [Wet], Note (b)
20 × 1.5 392 ± 19.6 40 ± 2.0 289 ± 14
Hanger
16 × 1.5 216 ± 10.8 22 ± 1.1 159 ± 8
Piston cooling nozzle 12 × 1.75 34 ± 1.7 3.5 ± 0.18 25 ± 1.2 Note (c)
Timing gear case 16 × 1.5 255 ± 12.8 26 ± 1.3 188 ± 9.4 Use hard washer
12 × 1.25 108 ± 5.4 11 ± 0.55 80 ± 3.98
Rear plate
16 × 1.5 255 ± 12.8 26 ± 1.3 188 ± 9.4 Use hard washer
392 ± 19.6 40 ± 2.0 289 ± 14
Front mounting bracket 20 × 1.5 Only front end lower bolt of right
245 ± 12.3 25 ± 1.25 180 ± 9
front mounting bracket
Rear mounting bracket 20 × 1.5 392 ± 19.6 40 ± 2.0 289 ± 14
Connecting rod cap 22 × 1.5 Note (e) [Wet]
Balance weight 22 × 1.5 490 ± 24.5 50 ± 2.5 361 ± 18 [Wet]
Flywheel 22 × 1.5 588 ± 29.4 60 ± 3.0 434 ± 22 [Wet]
Ring gear 10 × 1.25 33 ± 1.7 3.4 ± 0.17 24 ± 1.25
Damper 22 × 1.5 490 ± 24.5 50 ± 2.5 361 ± 18
Rear idler shaft 20 × 1.5 392 ± 19.6 40 ± 2.0 289 ± 14 Apply Molykote
Rear idler shaft thrust collar
18 × 1.5 196 ± 9.8 20 ± 1.0 145 ± 7
(nut)
12 × 1.25 59 ± 3.0 6 ± 0.3 43 ± 2.2
Front gear case
16 × 1.5 255 ± 12.8 26 ± 1.3 188 ± 9.4 Use hard washer
Front plate 12 × 1.25 59 ± 5.9 6 ± 0.6 43 ± 4.3
Front idler shaft 12 × 1.25 108 ± 10.8 11 ± 1.1 80 ± 8.0
Front idler shaft thrust plate 10 × 1.25 60 ± 3.0 6.1 ± 0.31 44 ± 2.2
Oil pump and water pump mounting plate 12 × 1.25 59 ± 5.9 6 ± 0.6 43 ± 4.3
Oil pump and bearing cover for water
12 × 1.25 108 ± 10.8 11 ± 1.1 80 ± 8.0
pump drive
Fuel injection pump Case 12 × 1.25 108 ± 5.4 11 ± 0.55 80 ± 4

accessory drive Gear (nut) 30 × 1.5 490 ± 24.5 50 ± 2.5 361 ± 18
Governor drive case 12 × 1.25 108 ± 5.4 11 ± 0.55 80 ± 4
2-12
Note:(a) When tightening the cylinder head bolts according to the angle method, follow the sequence described below.
1) Tighten it with a snug torque 294 ± 14.7 N·m {30 ± 1.5 kgf·m} [217 ± 11 lbf·ft].
2) Tighten to the angle 65 ± 3°.
3) Loosen all bolts, then retighten them according to the sequence 1) and 2).(2-time tightening method)
For tightening the cylinder head bolt, refer to "Cylinder head bolt - Tighten" of "ASSEMBLY OF BASIC EN-
GINE".
(b) Tighten the main bearing cap bolt and main bearing cap side bolt with specified sequence. Tighten them to the half of
specified torque, then tighten them to the specified torque.
For tightening the main bearing cap bolt and main bearing cap side bolt, refer to "Main bearing cap - Install" of "AS-
SEMBLY OF BASIC ENGINE".
(c) Be sure to tighten piston cooling nozzle check valves to the specified torque. Tightening over the specified torque could
result in excessive tightening force, which could cause the check valve to malfunction, possibly leading to piston sei-
zure.
(d) When [Wet] is indicated, apply engine oil to the threads and bolt seat surface.
(e) When tightening connecting rod cap bolt, follow the sequence described below.
Bolt mark Torque method (2-time tightening method) Angle method (2-time tightening method)
AU Snug torque 245 ± 12.3 N·m {25 ± 1.25 kgf·m} [180 ± 9 lbf·ft] → 60 ± 3°
637 ± 31.9 N·m {65 ± 3.25 kgf·m} [470 ± 24 lbf·ft]
AL Snug torque 294 ± 14.7 N·m {30 ± 1.5 kgf·m} [217 ± 11 lbf·ft] → 60 ± 3°
2.2 Fuel system

Thread Torque
Fuel injection pump

12 × 1.25 108 ± 5.4 11 ± 0.55 80 ± 4
Accessory drive case
Fuel injection pump
30 × 1.5 490 ± 24.5 50 ± 2.5 361 ± 18
accessory drive gear (nut)
Fuel injection pump coupling shaft 14 × 1.5 172 ± 5 17.5 ± 0.5 126.6 ± 3.6 Tighten the slit part.
Fuel injection pump
14 × 1.5 118 ± 5 12 ± 0.5 87 ± 3.6 2-time tightening method
laminated plate
Fuel injection pump 12 × 1.25 108 ± 5.4 11 ± 0.55 80 ± 4
Fuel injection pump
12 × 1.25 108 ± 5.4 11 ± 0.55 80 ± 4
bracket
Fuel injection pump
24 × 1.5 392 ± 19.6 40 ± 2.0 289 ± 14
flywheel (nut)
Plunger assembly 12 × 1.25 80.5 ± 2.5 8.2 ± 0.25 59.37 ± 1.8
Delivery valve holder 30 × 1.5 245 ± 10 25 ± 1 180 ± 7
Fuel injection pipe
18 × 1.5 59 ± 10 6±1 43 ± 7
(nozzle and pump side)
Fuel rack control lever 8 × 1.25 25 ± 1.25 2.5 ± 0.13 18 ± 0.9 2-time tightening method
Fuel filter air vent plug 8 × 1.25 9±1 0.9 ± 0.1 6.5 ± 0.7
Nozzle tip retaining nut 28 × 1.5 186.5 ± 9.5 19 ± 1 137 ± 7
Nozzle inlet connector 16 × 1.5 69 ± 5 7 ± 0.5 50 ± 3.6
Nozzle holder cap nut 14 × 1.5 73.5 ± 4.5 7.5 ± 0.5 54 ± 3.3
Nozzle holder set screw 10 × 1.5 39 ± 5 4 ± 0.5 28 ± 3.6
Nozzle gland (nut) 14 × 1.5 98 ± 4.9 10 ± 0.5 72 ± 3.6
2-13
2.3 Lubrication system

Thread Torque
Oil pump 12 × 1.25 108 ± 10.8 11 ± 1.1 80 ± 8.0

Oil pump cover 10 × 1.25 33 ± 3.3 3.4 ± 0.34 25 ± 2.5
Safety valve plug 24 × 1.5 88 ± 10 9 ± 1.0 65 ± 7.4
Safety valve assembly 32 × 2.0 74 ± 10 7.5 ± 1.0 54 ± 7.4
Governor oil filter air vent plug 8 × 1.25 9.8 ± 1.96 1 ± 0.2 7 ± 1.5
Governor oil filter drain plug 8 × 1.25 9.8 ± 1.96 1 ± 0.2 7 ± 1.5
Governor oil filter center bolt 14 × 1.5 34.3 ± 6.86 3.5 ± 0.7 25.3 ± 5.0
Oil pan 12 × 1.25 59 ± 5.9 6 ± 0.6 43 ± 4.3
2.4 Cooling system

Thread Torque
Water pump 12 × 1.25 108 ± 10.8 11 ± 1.1 80 ± 8.0

Water pump shaft pulley (nut) 30 × 1.5 392 ± 19.6 40 ± 2.0 289 ± 14 For alternator
2.5 Inlet and exhaust system

Thread Torque
Exhaust manifold coupling

6 × 1.0 9 ± 0.45 0.9 ± 0.05 6.5 ± 0.33
(nut)
Exhaust manifold mounting bolt 10 × 1.5 98 ± 4.9 10 ± 0.5 72 ± 3.6
Turbocharger mounting bolt 12 × 1.25 108 ± 5.4 11 ± 0.55 80 ± 3.98
Intercooler 10 × 1.25 44 ± 4.4 4.5 ± 0.45 32.45 ± 3.25
Exhaust pipe V-clamp 1/4-28UFN 9 ± 0.45 0.9 ± 0.045 6.5 ± 0.33 Unify screw
2-14
2.6 Electrical system

Thread Torque
Starter 12 × 1.25 59 ± 5.9 6 ± 0.6 43 ± 4.3

Magnetic switch
4.5 ± 0.6 0.46 ± 0.06 3.3 ± 0.4
assembly
Lever assembly 10.9 ± 1.4 1.1 ± 0.14 8.0 ± 1.0
Front bracket 5.85 ± 0.75 0.6 ± 0.07 4.3 ± 0.55
Safety switch 4.2 ± 0.4 0.43 ± 0.03 3.1 ± 0.3
Center bracket 14 ± 1.7 1.4 ± 0.17 10.3 ± 1.2 Hexagon socket bolt
Starter Brush holder 3.2 ± 0.4 0.33 ± 0.04 2.4 ± 0.3
Through bolt 8.7 ± 1.1 0.9 ± 0.11 6.4 ± 0.8
B terminal 10 × 1.25 17.7 ± 1.9 1.8 ± 0.19 13.0 ± 1.4
M terminal 10 × 1.25 22.6 ± 2.9 2.3 ± 0.3 16.6 ± 2.1
10 × 1.25 22.6 ± 2.9 2.3 ± 0.3 16.6 ± 2.1 Rear bracket side
Rear bracket side (connecting with the
E terminal 14 ± 1.7 1.4 ± 0.17 10.3 ± 1.2
magnet switch assembly E terminal)
3.2 ± 0.4 0.33 ± 0.04 2.4 ± 0.3 Magnet switch assembly side
Alternator pulley 30 × 1.5 147 ± 15 15 ± 1.5 108 ± 11
E terminal 2.8 ± 0.35 0.28 ± 0.03 2.0 ± 0.25
Rectifier assembly 6.9 ± 0.9 0.7 ± 0.09 5.0 ± 0.7
Alternator Regulator assembly 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.7
Field coil 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.7
Front bracket 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.7
Through bolt 5.4 ± 1.5 0.6 ± 0.1 4.0 ± 1.1
2-15
2.7 Standard bolt and nut

Thread Width across Strength classification
Threads Dia. × Pitch flats
(M-thread) (mm) 7T 10.9
7 10
N·m kgf·m lbf·ft N·m kgf·m lbf·ft
8 × 1.25 12 17 1.7 12 30 3.1 22
10 × 1.25 14 33 3.4 25 60 6.1 44
12 × 1.25 17 60 6.1 44 108 11.0 80
Metric automobile screw thread
14 × 1.5 22 97 9.9 72 176 17.9 129
16 × 1.5 24 145 14.8 107 262 26.7 193
18 × 1.5 27 210 21.4 155 378 38.5 278
20 × 1.5 30 291 29.7 215 524 53.4 386
22 × 1.5 32 385 39.3 284 694 70.8 512
24 × 1.5 36 487 49.7 359 878 89.5 647
27 × 1.5 41 738 75.3 544 1328 135.5 980
N·m kgf·m lbf·ft N·m kgf·m lbf·ft

10 × 1.5 14 32 3.3 24 58 5.9 43
12 × 1.75 17 57 5.8 42 102 10.4 75
Metric course screw thread 14 × 2 22 93 9.5 69 167 17.0 123
16 × 2 24 139 14.2 103 251 25.6 185
18 × 2.5 27 194 19.8 143 350 35.7 258
20 × 2.5 30 272 27.7 200 489 49.9 361
22 × 2.5 32 363 37.0 268 653 66.6 482
24 × 3 36 468 47.7 345 843 86.0 622
27 × 3 41 686 70.0 506 1236 126.0 911
Note:(a) This table lists the tightening torque for standard bolts and nuts.
(b) The numerical values in the table are for fasteners with spring washers.
(c) The table shows the standard values with a maximum tolerance value of ±10%.
(d) Use the tightening torque in this table unless otherwise specified.
(e) Do not apply oil to threaded portions. (Dry condition)
2-16
2.8 Standard eyebolt tightening torque

Strength classification
Thread Width across
Dia. × Pitch flats 4T
(M-thread) (mm)
N·m kgf·m lbf·ft
8 × 1.25 12 8±1 0.8 ± 0.1 5.8 ± 0.7
10 × 1.25 14 15 ± 2 1.5 ± 0.2 11 ± 1.5
12 × 1.25 17 25 ± 3 2.5 ± 0.3 18 ± 2.2
14 × 1.5 19 34 ± 4 3.5 ± 0.4 25 ± 2.9
16 × 1.5 22 44 ± 5 4.5 ± 0.5 33 ± 3.6
18 × 1.5 24 74 ± 5 7.5 ± 0.5 54 ± 3.6
20 × 1.5 27 98 ± 10 10.0 ± 1.0 72 ± 7.2
24 × 1.5 32 147 ± 15 15.0 ± 1.5 109 ± 11
27 × 1.5 41 226 ± 20 23.0 ± 2.0 166 ± 15
(Dry condition)
2.9 Standard union nut

Cap nut Width across
Nominal
Dia. × Pitch flats N·m kgf·m lbf·ft
diameter
(M-thread) (mm)
63 14 × 1.5 19 39 4 29
80 16 × 1.5 22 49 5 36
100 20 × 1.5 27 78 8 58
120 22 × 1.5 30 98 10 72
150 27 × 1.5 32 157 16 116
180 30 × 1.5 36 196 20 145
200 30 × 1.5 36 196 20 145
220 33 × 1.5 41 245 25 181
254 36 × 1.5 41 294 30 217
(Maximum tolerance value: ±10%, dry condition)
2.10 Fuel injection pipe

Cap nut
Dia. × Pitch N·m kgf·m lbf·ft
(M-thread)
12 × 1.5 39 ± 5 4 ± 0.5 29 ± 3.6
14 × 1.5 49 ± 5 5 ± 0.5 36 ± 3.6
18 × 1.5 59 ± 10 6 ± 1.0 43 ± 7.2
(Dry)
2-17
1. Special tools............................................................................................................. 3-3
3-1
1. Special tools
Maintenance Tool name Part No. Illustration Use
item
General Tool box 49160-90501 Tool box
(75 × 203 × 360 mm)
[2.95 × 7.99 × 14.17 in.]
Adjustable wrench F9611-15000 Max. open width 20 mm [0.79 in.]
Torque wrench 32191-03100 Tightening to the specified torque

Measurement range:0 to 539 N·m
{0 to 55 kgf·m} [0 to 398 lbf·ft]
Ring pliers 45191-08400 Snap ring installation/removal
Overhaul Compression gauge 33A91-01700 Compression pressure measurement

determination Measurement range: 0 to 7 MPa
and test {0 to 71 kgf/cm2} [0 to 1015 psi]
3-3

item
Overhaul Gauge adapter 37591-02200 Compression pressure measurement
determination U5/8
and test 18-threads
Inspection Belt gauge 32591-09100 Belt tension measurement

30
25
20
15
10
5
Basic engine Nozzle remover 33591-10101 Fuel injection nozzle removal
Eye nut 37591-02400 Cylinder head assembly installation/

removal
Valve spring pusher 33591-04500 Valve spring installation/removal

Length of handle plate: 600 mm
[23.6 in.]
Rocker bushing tool 37591-02600 Rocker bushing replacement
Valve guide remover 33591-04300 Valve guide removal
Guide & seal installer 37191-11500 Install the valve guide and stem seal
With single valve spring
Guide & seal installer 37191-12300 Install the valve guide and stem seal
With single valve spring
3-4

item
Basic engine Valve lapper 30091-08800 Lapping valve
Valve seat cutter shaft 37591-06400 Refacing the valve seat
Valve seat cutter 37591-06430
Head bolt plate 37598-08900 Tightening cylinder head bolt with

angle method
Valve seat puller 32591-04200 Valve seat removal
Jack bolt 64362-68500 Flywheel removal

Pump plate removal
Damper removal
M12 × 1.25㨺95mm
Idler bushing puller 32591-02500 Front idler bushing replacement
Rear seal installer assembly 37791-06010 Rear oil seal installation
Front seal installer 37591-05010 Front oil seal installation

assembly
3-5

item
Basic engine Piston remover MM321420 Piston removal
M10 × 1.5 mm
Ring expander 37191-03200 Piston ring installation/removal

Range of use: ø101.6 to 177.8 mm
[4.00 to 7.00 in.]
Cylinder liner remover 37591-04100 Cylinder liner removal
Liner pusher 37591-06200 Cylinder liner flange protrusion

measurement
Bolt 37591-06300 Cylinder liner flange protrusion

measurement
Projection plate 37598-09201 Depth of counterbore in

crankcase measurement
Piston installer 37191-07100 Piston installation
Crankcase grinder 37591-07010 Refacing the depth of counterbore in

crankcase
Cap remover 37791-02100 Main bearing cap removal
M27 × 1.5 ｰ 30 mm
3-6

item
Basic engine Connecting rod bushing 37591-01010 Connecting rod bushing installation/
installer removal
Connecting rod gauge 0.5 mm Keep the connecting rod end play
[0.020 in.]
37791-01500
0.6 mm
[0.024 in.]
37791-01600
Slinger installer 37491-02100 Rear oil seal slinger installation
Installer guide 37491-02200
Fuel system Nozzle tester 83091-03301 Measuring the opening pressure of

fuel injection nozzle
Socket 58309-73100 Fuel injection pump gear and

water pump gear installation/
removal
Fuel injection pump 37591-06100 Clearance of fuel injection pump

coupling gauge coupling adjustment
GO :48.75 mm [1.9193]
NO GO:49.25 mm [1.9390]
3-7

item
Cooling Water pump pliers 37591-03100 Water pump cover snap ring removal
system
Impeller remover 37591-03200 Impeller of water pump removal

M18 × 1.5 mm
Ring remover 37791-03400 Water pump unit seal removal
Unit seal installer 37191-06300 Press fitting the unit seal of

water pump
Ring installer 37791-03300 Press fitting the unit seal ring of water
pump
3-8
1. Determining overhaul timing .................................................................................. 4-3
2. Compression pressure - Measure.......................................................................... 4-4
4-1
1. Determining overhaul timing

In most cases, the engine should be overhauled when the compression pressure of the engine becomes low. An increase in
engine oil consumption and blow-by gas should be considered when evaluating engine condition.
Symptoms like a decrease in output, increase in fuel consumption, decrease in oil pressure, difficulty of engine starting and
increase in noise should be considered when evaluating overhaul timing, although those symptoms are often affected by other
causes, and are not always effective to evaluate overhaul timing.
Decreased compression pressure shows a variety of symptoms and engine conditions, thus making it difficult to accurately
determine when the engine needs an overhaul.
The following shows typical problems caused by reduced compression pressure.
(1) Decreased output power
(2) Increased fuel consumption
(3) Increased engine oil consumption
(4) Increased blow-by gas through the breather due to worn cylinder liners and piston rings(Visually check the blow-by
amount)
(5) Increased gas leakage due to poor seating of inlet and exhaust valves
(6) Difficulty in starting
(7) Increased noise from engine parts
(8) Abnormal exhaust color after warm-up operation
The engine can exhibit these conditions in various combinations.
Some of these problems are directly caused by worn engine parts, while others are not.
Phenomena described in items (2) and (6) can result from improper fuel injection volume and timing of the fuel injection pump,
worn plunger, faulty nozzles and also faulty conditions of electrical devices such as battery and starter.
The most valid reason to overhaul an engine is a decrease in compression pressure due to worn cylinder liners and pistons, as
described in item (4), and once this is determined, it is reasonable to take other problems into consideration for making a final
evaluation.
4-3
2. Compression pressure - Measure
Compression gauge
(a) Be sure to measure the compression pressure P/N:33A91-01700
for all the cylinders. It is not a good practice to
measure the compression pressure for two or Gauge adapter
three cylinders, and to assume the compression P/N:37591-02200
pressure is the same for all cylinders.
(b) Also be sure to check engine speed when mea-
suring the compression pressure, as compres-
sion pressure varies with engine speed.
(c) Measuring the compression pressure at regular Compression pressure - Measure
intervals is important to obtain correct data.
(1) Remove the injection nozzle from the cylinder head
where the compression pressure is to be measured.
(2) Attach the compression gauge adapter to the fuel injec-
tion nozzle mount and connect compression gauge.
(3) Crank the engine with the starter at the no-injection
position.
Read the engine speed and compression pressure while
the engine is running at the specified speed.
Note: Check that the battery is fully charged when cranking
the engine with the starter.
The reduction of battery voltage fails to reach a speci-
fied rotational speed and measure the correct compres-
sion pressure.
(4) If the measured value exceeds the limit, overhaul the
engine.
Item Standard Limit Remarks

1.8 MPa 1.27 MPa
Compression When cranking
{18.5 kgf/cm2} {13 kgf/cm2}
pressure (Approx. 120 min-1)
[263 psi] [185 psi]
4-4
1. Cylinder heads and Valve mechanisms - Disassemble and Inspect .................. 5-3
1.1 Fuel inlet connector - Remove.................................................................................................. 5-4
1.2 Nozzle assembly - Remove ...................................................................................................... 5-4
1.3 Valve clearance - Inspect ......................................................................................................... 5-4
1.4 Fuel injection timing - Inspect ................................................................................................... 5-5
1.5 Rocker shaft assembly - Remove............................................................................................. 5-5
1.6 Clearance between the bottom surface of valve bridge and the top surface of valve rotator -
Inspect ...................................................................................................................................... 5-5
1.7 Valve bridge - Remove ............................................................................................................. 5-6
1.8 Rocker case - Remove ............................................................................................................. 5-6
1.9 Cylinder head assembly - Remove........................................................................................... 5-6
1.10 Valve sinkage - Measure .......................................................................................................... 5-6
1.11 Valve and Valve spring - Remove ............................................................................................ 5-7
1.12 Stud bolt and Bridge guide - Remove....................................................................................... 5-7
2. Rear equipment - Disassemble and Inspect ......................................................... 5-8
2.1 Governor drive - Remove ......................................................................................................... 5-9
2.2 Flywheel face and radial runouts - Measure............................................................................. 5-9
2.3 Flywheel - Remove ................................................................................................................... 5-9
2.4 Rear idler shaft thrust collar - Remove ................................................................................... 5-10
2.5 Timing gear case - Remove.................................................................................................... 5-10
2.6 Timing gear backlash - Measure ............................................................................................ 5-10
2.7 Rear idler gear end play - Measure ........................................................................................ 5-11
2.8 Rear idler gear - Remove ....................................................................................................... 5-11
2.9 Accessory drive - Remove...................................................................................................... 5-11
2.10 Camshaft end play - Measure................................................................................................. 5-11
2.11 Camshaft gear - Remove........................................................................................................ 5-12
2.12 Camshaft - Remove................................................................................................................ 5-12
2.13 Rear idler shaft - Remove....................................................................................................... 5-12
2.14 Rear plate - Remove............................................................................................................... 5-12
3. Front equipment - Disassemble and Inspect ...................................................... 5-13
3.1 Damper face and radial runouts - Measure ............................................................................ 5-14
3.2 Damper - Remove .................................................................................................................. 5-14
3.3 Pump plate (for water pump and oil pump) - Remove ............................................................ 5-14
3.4 Oil pump gear - Remove......................................................................................................... 5-14
3.5 Breather case - Remove......................................................................................................... 5-15
3.6 Front gear case - Remove ...................................................................................................... 5-15
3.7 Water pump bearing cover and Oil pump bearing cover - Remove........................................ 5-15
3.8 Front idler gear backlash - Measure ....................................................................................... 5-15
3.9 Front idler gear end play - Measure........................................................................................ 5-16
3.10 Front idler gear - Remove....................................................................................................... 5-16
3.11 Front idler shaft - Remove ...................................................................................................... 5-16
3.12 Coupling - Remove ................................................................................................................. 5-17
5-1
4. Cylinder liner, Piston and Connecting rod - Disassemble and Inspect............ 5-18
4.1 Piston protrusion - Measure.................................................................................................... 5-19
4.2 End play of connecting rod big end - Measure ....................................................................... 5-19
4.3 Hard carbon from the upper part of cylinder liner - Remove................................................... 5-19
4.4 Connecting rod cap - Remove ................................................................................................ 5-19
4.5 Piston - Remove ..................................................................................................................... 5-20
4.6 Piston ring - Remove .............................................................................................................. 5-21
4.7 Piston pin and Piston - Remove ............................................................................................. 5-22
4.8 Cylinder liner inside diameter - Measure ................................................................................ 5-22
4.9 Cylinder liner flange protrusion - Measure.............................................................................. 5-22
4.10 Cylinder liner - Remove .......................................................................................................... 5-22
5. Crankcase, Crankshaft and Main bearing - Disassemble and Inspect ............. 5-23
5.1 Crankcase - Invert .................................................................................................................. 5-24
5.2 Crankshaft end play - Measure............................................................................................... 5-24
5.3 Piston cooling nozzle - Remove ............................................................................................. 5-24
5.4 Main bearing cap - Remove.................................................................................................... 5-24
5.5 Crankshaft - Remove.............................................................................................................. 5-25
5-2
1. Cylinder heads and Valve mechanisms - Disassemble and Inspect

Understanding the current condition of the engine before disassembling is very important in order to investigate the faulty
engine part and to maintain the engine efficiently.
Depending on the maintenance purpose, inspect the following items before disassembling the engine.
Valve clearance - Inspect
Fuel injection timing - Inspect
Clearance between the bottom surface of valve bridge and the top surface of valve rotator - Inspect
Valve sinkage - Measure
1
16
3
Replace
4
Replace
Replace 5
Crack, oil leakage,
2
fatigue
Replace
17 6
18 Wear
Crack, oil leakage, 7
scale deposit
Replace Crack, carbon deposit Replace
Damage, scale deposit
9
19
Wear,
clogged of oil hole
Damage 20
12 15
Wear Contact, wear
11 14 30 Wear on both ends,
10 Wear of stem and seat surfaces bend
8 Corrosion, damage,
13 carbon deposit 32
21
21 14 25 Wear of cam and
22 26 circumference contact
23 Fatigue, crack
27
24 28
Inlet side Crack, damage, fatigue Replace
29 31
Exhaust side Crack of rubber
Cylinder heads and Valve mechanisms - Disassemble and Inspect

Disassembling sequence
1 Rocker cover 12 Rocker shaft 22 Valve rotator
2 Fuel inlet connector 13 Bridge cap 23 Valve spring
3 Washer, nut 14 Valve bridge 24 Stem seal
4 Nozzle gland 15 Push rod 25 Upper rotator
5 Fuel injection nozzle 16 Water outlet connector 26 Inner valve spring
6 Gasket 17 Rocker case 27 Outer valve spring
7 O-ring 18 Cylinder head bolt 28 Lower retainer
8 Adjusting screw 19 Cylinder head 29 Stem seal
9 Bolt (Approx. 35 kg [77.2 lb.]) 30 Valve
10 Rocker arm 20 Inlet port packing 31 Cylinder head gasket
11 Spacer 21 Valve cotter 32 Tappet
5-3
1.1 Fuel inlet connector - Remove

Remove the fuel inlet connector.
Fuel inlet connector
Fuel inlet connector - Remove

1.2 Nozzle assembly - Remove
When removing the nozzle assembly using a nozzle Gasket

remover, be careful not to get caught your fingers
between the nozzle remover weight, bar and the Nozzle gland
plate.
Nozzle remover
P/N:33591-10101
When removing a nozzle holder, check the foreign

substance for the nozzle assembly, and prevent the
foreign substance from entering the cylinder head. Nozzle assembly - Remove
Keep the nozzle and the fuel inlet connector
together, and handle the nozzle with care to avoid
damage to the nozzle tip.
(1) Remove the nozzle gland.
(2) Remove the nozzle holder using the nozzle remover.
(3) Clear the remaining gasket from inside the cylinder
head.
1.3 Valve clearance - Inspect
Inspect the valve clearance, and recognize the current condi-
tion.
Valve clearance
For the inspection procedure, refer to "Valve clearance -
Inspect and Adjust" of "ASSEMBLY OF BASIC
ENGINE".
Valve clearance - Inspect
5-4
1.4 Fuel injection timing - Inspect

Inspect the fuel injection timing, and recognize the current
condition. Pointer
For the inspection procedure, refer to "Fuel injection timing
- Check and Adjust" of "ASSEMBLY OF BASIC
ENGINE".
Line mark on the flywheel

Fuel injection timing - Inspect
1.5 Rocker shaft assembly - Remove
(1) Loosen the adjusting screw on each rocker arm.
Lock nut
(2) Remove the rocker shaft assembly from the rocker
case.
Note: Keep the removed rocker shaft assembly together with
the bolts. Loosen
(3) Remove the push rod.
Adjusting screw
Rocker shaft assembly - Remove

(4) Disassemble the rocker shaft assembly.
Note: Do not remove the rocker bushing unless it is defective
Rocker shaft
or its inside diameter exceeds the limit. Rocker arm
Spacer
Lock nut
Adjusting screw
Rocker shaft assembly - Disassemble

1.6 Clearance between the bottom surface of valve bridge and the top surface of valve rotator - Inspect
Inspect the clearance between the bottom surface of valve
Hold the top of bridge
bridge and the top surface of valve rotator, and recognize by hand
the current condition. Valve bridge Bridge cap Clearance between
For the inspection procedure, refer to "Clearance between the bottom surface
Valve rotator of valve bridge and
the bottom surface of valve bridge and the top surface of the top surface of
valve rotator
valve rotator - Measure" of "ASSEMBLY OF BASIC
ENGINE".
Clearance between the bottom surface of valve bridge

and the top surface of valve rotator - Inspect
5-5
1.7 Valve bridge - Remove

Remove the valve bridge and bridge cap.
Note: Do not drop the bridge cap to the push rod hole. Screw
Bridge cap
Valve bridge - Remove

1.8 Rocker case - Remove
(1) Remove the snap ring of water outlet connector.
Water outlet connector
(2) Slide the water outlet connector to the snap ring groove, Snap ring groove
separate the adjacent rocker case.
(3) Remove the rocker case from the cylinder head.
Rocker case
Rocker case - Remove

1.9 Cylinder head assembly - Remove
Eye nut
P/N:37591-02400
When removing the cylinder head gasket, be careful
not to damage the cylinder head or crankcase sur-
face with the screwdriver or other tool.
(1) Remove cylinder head bolts.
(2) Remove the cylinder head by lifting it up using the
sling.
Note: Each cylinder head is positioned properly by dowel
pins, so the cylinder head must be lifted perpendicular-
ly. Cylinder head assembly - Remove
(3) Remove the cylinder head gasket.
1.10 Valve sinkage - Measure
Measure the valve sinkage, and recognize the current condi-
tion.
Seat width
For the measurement procedure, refer to "Valve sinkage -
Measure" of "ASSEMBLY OF BASIC ENGINE".
Valve seat
Valve margin
angle
Valve sinkage
5-6
1.11 Valve and Valve spring - Remove

Using a valve spring pusher, compress the valve spring
Valve spring pusher
evenly and remove the valve cotters.
P/N:33591-04500
Note: If valves are reusable, mark each valve seat and the
mating valve guide for identifying their original posi-
tions. Do not mix valve seats with other valves.
Valve spring - Compress
Exhaust Inlet
Valve cotter
Valve cotter
Upper rotator
Valve rotator
Inner valve
spring Valve spring
Outer valve
spring Stem seal
Lower retainer
Stem seal
Valve and Valve spring - Remove

1.12 Stud bolt and Bridge guide - Remove
Do not remove the parts that indicated in the right figure
from cylinder head unless it is necessary. If removing,
Stud bolt
install the bridge guide with a new one, and apply the screw
Bridge guide Bridge guide
locker to the stud bolt.
Stud bolt and Bridge guide - Remove
5-7
2. Rear equipment - Disassemble and Inspect

Flywheel face and radial runouts - Measure
Timing gear backlash - Measure
Rear idler gear end play - Measure
Camshaft end play - Measure
Damage, wear, Damage, wear

key groove defect 10
Replace
Replace
12
15
13
16 Clogged
11
Flaking, wear
Key groove defect
11 9
7 Replace
Crack, 8
14
defect of knock hole
Replace
9
10 8
14
Replace
Clogged, wear
4
Replace
3 Wear, damage, aging
Replace
6
Replace 2
5 Damage
4
1
Replace 3
Crack, defect of knock hole,

damage, abnormal wear
Rear equipment - Disassemble and Inspect

1 Governor drive 9 Idler gear
(Refer to the section of "FUEL SYSTEM" for disassembly, 10 Accessory drive (Approx. 21 kg [46 lb.])
inspection and assembly.) (Refer to the section of "FUEL SYSTEM" for disassembly,
2 Flywheel (Approx. 140 kg [309 lb.]) inspection and assembly.)
3 Cover 11 Camshaft gear
4 Thrust collar 12 Thrust plate
5 Timing gear case (Approx. 150 kg [331 lb.]) 13 Camshaft (Approx. 47 kg [103 lb.])
6 Oil seal 14 Idler shaft
7 Oil seal slinger 15 Rear plate (Approx. 28.5 kg [62.8 lb.])
8 Thrust plate 16 Nozzle plate
5-8
2.1 Governor drive - Remove

Remove the governor drive from the rear plate.
(Refer to the section of "FUEL SYSTEM" for disassembly, O-ring
inspection and assembly.)
Governor drive
Governor drive - Remove

2.2 Flywheel face and radial runouts - Measure
Measure the face and radial runouts of the flywheel, and
recognize the current condition.
For the measurement procedure, refer to "Flywheel face and Face runout
measurement
radial runouts - Measure" of "ASSEMBLY OF BASIC
Radial runout
ENGINE". measurement

2.3 Flywheel - Remove
(a) Be careful not to drop or hit the flywheel. Not

only damage it but also lead to personnel inju-
ries.
(b) Be careful not to cut yourself with the ring gear
when pulling out the flywheel.
Flywheel
Jack bolt
Be sure to remove the pickups before removing the P/N:64362-68500
flywheel. Flywheel - Remove
(1) Attach a hoisting tool to the flywheel to prevent from
falling out.
(2) Screw two jack bolts evenly into the jack bolt holes,
and remove the flywheel.
5-9
2.4 Rear idler shaft thrust collar - Remove

(1) Remove the cover from the timing gear case.
(2) Screw bolts (M6×1.0 mm) into the rear idler shaft
thrust collar removing holes, and pull out the rear idler
shaft thrust collar.
Note: Mark each collar right and left to ensure correct posi- Rear idler shaft
thrust collar
tion so that the same backlash and end play can be re-
Cover
stored at assembly.
Put a right
and left identification mark.
Rear idler shaft thrust collar - Remove
2.5 Timing gear case - Remove
(a) Be careful not to damage the oil seal when

removing timing gear case.
(b) Be careful not to drop or hit the timing gear case.
Not only damage it but also lead to personnel
injuries.
(1) Attach a hoisting tool to the timing gear case to prevent
it from falling out. Timing gear case
(2) Dismount the timing gear case by suspending and pull-
ing it out until the timing gear case is disengaged from Timing gear case - Remove
the dowel pins.
(3) Remove the oil seal from the timing gear case.
2.6 Timing gear backlash - Measure
Measure the timing gear backlash, and recognize the current
condition. Camshaft gear
For the measurement procedure, refer to "Timing gear back- Injection
pump gear
lash - Measure" of "ASSEMBLY OF BASIC ENGINE".
Rear idler gear

5-10
2.7 Rear idler gear end play - Measure

Measure the rear idler gear end play, and recognize the cur-
rent condition.
For the measurement procedure, refer to "Rear idler gear
end play - Measure" of "ASSEMBLY OF BASIC
ENGINE".

2.8 Rear idler gear - Remove
(1) Remove the oil seal slinger from the crankshaft.
(2) Remove the thrust plate.
(3) Remove the rear idler gears (right and left).
Thrust plate
Rear idler gear
Slinger
Rear idler gear - Remove
2.9 Accessory drive - Remove
Remove the accessory drive from the rear plate.
(Refer to the section of "FUEL SYSTEM" for disassembly,
inspection and assembly.)
Note: Dismount the cam cover of left side cylinder before-
hand since the bolt contacts to the cam cover when re-
moving the fuel injection pump accessory drive case
on the left side.
Fuel injection pump

accessory drive
Accessory drive - Remove

2.10 Camshaft end play - Measure
Measure the camshaft end play, and recognize the current
condition. Camshaft gear
For the measurement procedure, refer to "Camshaft end
play - Measure" of "ASSEMBLY OF BASIC ENGINE".
5-11
2.11 Camshaft gear - Remove

Remove the camshaft gear from the camshaft.
Camshaft gear
Camshaft gear - Remove

2.12 Camshaft - Remove
Support the camshaft with a bar inserted through the

side cover mounting section when removing the
camshaft. Hitting the camshaft could cause damage
to the camshaft bushing.
(1) Remove the thrust plate.
(2) Support the camshaft from the side cover mounting sec- Camshaft
Thrust plate
tion, remove the camshaft from the crankcase.
Note: Remove the oil seal case, oil seal and coupling that in-
stalled on the cam shaft front end before removing Camshaft - Remove
camshaft.
2.13 Rear idler shaft - Remove
Install the sliding hammer to the rear idler shaft removal
hole (M22×1.5 mm), and remove the rear idler shaft. Rear idler shaft
Sliding hammer
Rear idler shaft

Rear idler shaft - Remove
2.14 Rear plate - Remove
(1) Remove the rear plate from the crankcase.
(2) Remove the nozzle plate from the crankcase. Nozzle plate
Rear plate
Rear plate - Remove
5-12
3. Front equipment - Disassemble and Inspect

Damper face and radial runouts - Measure
Front idler gear backlash - Measure
Front idler gear end play - Measure
Replace
5
Replace Crack, defect of knock hole
4
Crack,
defect of knock hole Replace
6 Replace
Crack, oil leakage
Replace
Wear on the lip,

damage, aging
Replace
1
Wear on the lip 7
8
7
13 15
Replace 12
11 14
Flaking, damage,
defect of spline 3 Replace
10
Wear on the lip
9
Wear Clogged
Rotation of oil hole, wear Replace
Front equipment - Disassemble and Inspect

1 Damper (Approx. 50 kg [110 lb.]) 9 Oil pump bearing cover
2 Pump plate 10 Thrust plate
3 Oil pump gear 11 Idler gear
4 Breather case 12 Idler shaft
5 Front gear case (Approx. 70 kg [154 lb.]) 13 Front plate (Approx. 25 kg [55 lb.])
6 Oil seal 14 Oil seal case
7 Water coupling 15 Coupling
8 Water pump bearing cover
5-13
3.1 Damper face and radial runouts - Measure

Measure the face and radial runouts of the damper, and rec-
ognize the current condition.
For the measurement procedure, refer to "Damper face and
radial runouts - Measure" of "ASSEMBLY OF BASIC
ENGINE".
Face runout
Radial runout

3.2 Damper - Remove
Jack bolt
P/N:64362-68500
Be careful not to drop or hit the damper. Not only Guide bolt (M12 × 1.25)
damage it but also lead to personnel injuries.
(1) Screw the guide bolts to the damper mounting hole of
crankshaft.
(2) Install a hoisting tool and lift the damper. Screw two
jack bolts evenly into the jack bolt holes, and remove
the damper. Damper
Damper - Remove
3.3 Pump plate (for water pump and oil pump) - Remove
Screw two jack bolts evenly into the jack bolt holes, and
remove the pump plate.
Jack-bolts
P/N:64362-68500
(M12 × 1.25)
Pump plate (for water pump and oil pump) - Remove

3.4 Oil pump gear - Remove
Remove the oil pump gear with bearing.
Oil pump gear
Oil pump gear - Remove
5-14
3.5 Breather case - Remove

Remove the breather case from the front gear case.
Breather case
O-ring
Breather case - Remove

3.6 Front gear case - Remove
Hoisting
tool
When removing the front gear case, be careful not to
damage the oil seal or bend the pointer by hitting.
(1) Attach a hoisting tool to the front gear case.
(2) Dismount the front gear case by suspending and pulling
it out until the front gear case is disengaged from the
dowel pins.
(3) Remove the oil seal from the front gear case. Front gear case
Front gear case - Remove

3.7 Water pump bearing cover and Oil pump bearing cover - Remove
Remove the water pump bearing cover and oil pump bear-
Water pump
ing cover from the front plate.
bearing
cover
Oil pump
bearing cover
Water pump bearing cover and Oil pump bearing
cover - Remove
3.8 Front idler gear backlash - Measure
Measure the front idler gear backlash, and recognize the
current condition.
For the measurement procedure, refer to "Front idler gear
backlash - Measure" of "ASSEMBLY OF BASIC
ENGINE".
Front
idler gear
5-15
3.9 Front idler gear end play - Measure

Measure the end play of front idler gear, and recognize the
current condition. Front
For the measurement procedure, refer to "End play of front idler gear
idler gear - Measure" of "ASSEMBLY OF BASIC

ENGINE".

3.10 Front idler gear - Remove
Remove the thrust plate and front idler gear from the front
idler shaft.
Front
idler gear
Front idler gear - Remove

3.11 Front idler shaft - Remove
Do not remove the front idler shaft unless it is necessary. If
necessary, screw two jack bolts evenly into the jack bolt
holes, and remove the front idler shaft.
Jack-bolts
(M101.25 mm)
Front idler shaft - Remove
5-16
3.12 Coupling - Remove

(1) Remove the oil seal case and oil seal from the crank-
case.
Oil seal case
Note: Inspect the oil seal. If any defect is found, replace it
with a new one.
O-ring
Oil seal
Oil seal case - Remove

(2) Screw two jack bolts evenly into the jack bolt holes,
and remove the coupling from the camshaft.
Jack bolt
(M12×1.25 mm)
Coupling - Remove
5-17
4. Cylinder liner, Piston and Connecting rod - Disassemble and Inspect

Piston protrusion - Measure
End play of connecting rod big end - Measure
Cylinder liner inside diameter - Measure
Cylinder liner flange protrusion - Measure
Wear, damage
5
9
6
7
Scratches on the outer surface, crack,

damage, wear, carbon deposit
10
8
11 Crack, clogged of oil hole
Scratches on the inner surface,
wear, rust on the outer surface
and O-ring groove, cavitation
Wear on the inner surface, 12

damage, discoloration
Replace, deformation, wear

Damage on inner
and outer surface,
adhesion, flaking
4
Wear on the serration, crack 3
1
Damage
Cylinder liner, Piston and Connecting rod - Disassemble and Inspect

1 Connecting rod cap bolt 7 Oil ring
2 Connecting rod cap 8 Snap ring
3 Lower connecting rod bearing 9 Piston pin
4 Upper connecting rod bearing 10 Piston
5 No. 1 compression ring 11 Connecting rod
6 No. 2 compression ring 12 Cylinder liner (Approx. 16 kg [35 lb.])
5-18
4.1 Piston protrusion - Measure

Measure the piston protrusion, and recognize the current
condition. Piston protrusion
For the measurement procedure, refer to "Piston protrusion -
Measure" of "ASSEMBLY OF BASIC ENGINE".
Piston protrusion - Measure

4.2 End play of connecting rod big end - Measure
Measure the end play of connecting rod big end, and recog-
nize the current condition.
Connecting rod
For the measurement procedure, refer to "End play of con-
necting rod big end - Measure" of "ASSEMBLY OF BASIC
ENGINE".
Connecting rod
end play
End play of connecting rod big end - Measure

4.3 Hard carbon from the upper part of cylinder liner - Remove
Be sure to remove hard carbon deposits from the Hard carbon
upper part of the cylinder liner before removing the

piston. They could cause damage to the piston and
piston ring.
Remove hard carbon deposits from the upper part of cylin- Cylinder liner
der liner using a carbon remover.
Note: Be careful not to damage the inner surface of the cyl-
inder liner.
Hard carbon from the upper part of cylinder liner -
Remove
4.4 Connecting rod cap - Remove
Using a socket wrench, remove the connecting rod bolts
through the inspection window on the side of the crankcase,
and remove the connecting rod cap and connecting rod bear-
Connecting
ings. rod cap
Note:(a) Be careful not to drop the connecting rod bearings
into the oil pan, as it could cause damage.
(b) Mark the connecting rod bearings for their cylinder
numbers and the upper or lower position.
Connecting rod cap - Remove
5-19
4.5 Piston - Remove
When holding the connecting rod with your hand to prevent it from swinging, be very careful, as you may suffer
hand injuries from accidental movement of the connecting rod.
(a) When pulling out the piston, be careful not to drop the upper connecting rod bearing.
(b) Use care not to damage the cylinder liner by the swing of the connecting rod when pulling out the piston and
connecting rod from the cylinder liner.
(c) When only a few pistons are left in the cylinders, the crankshaft tends to turn by itself. Be sure to hold the
crankshaft to prevent it from rotating while removing pistons.
(d) Remove the piston cooling nozzle and connecting rod.
(e) Hold the piston with your hand when pulling up it from the cylinder liner to prevent from damaging.
4.5.1 When removing the piston while lifting with

Piston remover
chain block P/N:MM321420
(1) Bring the piston that removed connecting rod cap to top
dead center with rotating the crankshaft.
(2) Install the eye bolt to the screw hole at the piston top,
pull the piston not to drop.
(3) Rotate the crankpin to the inspection window side to
prevent connecting rod big end from hitting the cylin-
Weight of piston with
der liner. connecting rod:
Crank pin approx. 24 kg [53 lb.]
(4) Make sure that the connecting rod big end is inserting
When removing the piston while lifting with chain block
in the cylinder liner. Pull up the piston gently.
5-20
4.5.2 When removing the piston while pushing the

connecting rod big end
(1) Bring the piston that removed connecting rod cap to top
dead center with rotating the crankshaft.
(2) Install the eye bolt to the screw hole at the piston top,
pull the piston not to drop.
(3) Rotate the crankshaft gently till the crankpin is
Piston remover
removed from the connecting rod and the lower bolt P/N:MM321420
hole is viewed from the inspection window.
(4) Insert the long rod. Then, use the crankpin as a fulcrum,
and push up the bottom of connecting rod gently.
Note: Protect the crankpin and connecting rod big end with a
cloth or rubber.
(5) Push up the connecting rod and piston with adjusting Weight of piston with
fulcrum. connecting rod:
Crank pin approx. 24 kg [53 lb.]
When the oil ring is removed from the cylinder liner,
Rotate the crankshaft
place the oil ring on the cylinder liner gently.
(6) Lift the piston to use the eye bolt on the piston top,
remove the piston from the cylinder liner.
Wrap a cloth
Turning bar
Push up the connecting rod big end

4.6 Piston ring - Remove
Ring expander
When removing the piston ring, be careful not to get P/N:37191-03200
caught your fingers between the piston and cylinder
wall by the swing of the piston.
If the piston is forcibly moved and interfered with the

connecting rod, the piston could be damaged.
Hold the piston and connecting rod in a vise bench, and
remove the piston ring with a ring expander. Piston ring - Remove
5-21
4.7 Piston pin and Piston - Remove

(1) Remove the snap ring with ring pliers.
(2) Using a wooden block and mallet, remove the piston Ring pliers
P/N:45191-08400
pin, and separate the piston from the connecting rod.
Note:(a) Do not tap the piston pin directly with a mallet.
(b) If the piston is stubborn, heat the piston with a heat-
er or in hot water.
Piston pin and Piston - Remove

4.8 Cylinder liner inside diameter - Measure
Measure the cylinder liner inside diameter, and recognize
the current condition.
Cylinder liner
For the measurement procedure, refer to "Cylinder liner
inside diameter - Measure" of "ASSEMBLY OF BASIC
ENGINE".

4.9 Cylinder liner flange protrusion - Measure
Measure the cylinder liner flange protrusion, and recognize
Bolt Cylinder liner
the current condition. P/N:37591-06300 flange protrusion
For the measurement procedure, refer to "Cylinder liner Tightening
torque
flange protrusion - Measure" of "ASSEMBLY OF BASIC
98 N·m
ENGINE". {10 kgf·m}
[72 lbf·ft]
Liner pusher
P/N:37591-06200
4.10 Cylinder liner - Remove
(1) Install the cylinder liner remover to the cylinder liner.
Note: Do not hit to the piston cooling nozzle when installing
Cylinder liner
the plate to the bottom of cylinder liner. remover
(2) Turn the handle, and remove the cylinder liner. Removing P/N:37591-04100
margin
80 mm
[3.15 in.]
Cylinder liner
Cylinder liner - Remove
5-22
5. Crankcase, Crankshaft and Main bearing - Disassemble and Inspect

Crankshaft end play - Measure
11
Scale deposit, damage, Uneven contact,

crack, clogged oil hole crack on counterbore,
fretting and corrosion
on fitting bore of cylinder liner
2 Damage
Valve operation, Replace
clogged of oil hole 8
Wear
10
Damage on inner
9
and outer surface,
corrosion, flaking
Flaking, wear,
6 uneven contact
Wear, damage, crack 7
4
Wear
5
Crack
Damage
3
1
Crankcase, Crankshaft and Main bearing - Disassemble and Inspect

1 Main bearing cap bolt 4 Lower main bearing 8 Upper thrust plate
2 Side bolt 5 Lower thrust plate 9 Eyebolt
3 Main bearing cap (Approx. 16 kg [35 lb.]) 6 Crankshaft (Approx. 620 kg [1367 lb.]) 10 Piston cooling nozzle
7 Upper main bearing 11 Crankcase
(Approx. 1850 kg [4079 lb.])
5-23
5.1 Crankcase - Invert

Lay the crankcase on a turntable and invert the crankcase.
Weight of crankshaft with crankcase:
When the turntable is not available, use a square wooden approx. 2615 kg [5765 lb.]
block or a cloth to lay the crankcase on it to prevent the
crankcase from damage, and using a crane and wire ropes,
hoist the crankcase and lay it on the wooden block with its
side facing downwards. Then, change the positions of the
wire ropes, and turn over and invert the crankcase.
Crankcase - Invert
5.2 Crankshaft end play - Measure
Measure the crankshaft end play, and recognize the current
condition.
For the measurement procedure, refer to "Crankshaft end
play - Measure" of "ASSEMBLY OF BASIC ENGINE".

5.3 Piston cooling nozzle - Remove
Remove the piston cooling nozzle from the crankcase.
5.4 Main bearing cap - Remove
Main bearing cap

When removing the main bearing cap from the
crankcase, be careful not to damage the lower main
Cap remover
bearing or the lower thrust plate that are attached to P/N:37791-02100
the cap. Also be careful not to drop those parts,
which may damage the crankshaft.
(1) Remove the main bearing cap bolt and side bolt. Side bolt
(2) Install the cap remover on the bolt hole that located out- Main bearing cap bolt
side of the main bearing cap.
(3) Pull and remove the main bearing cap while vibrating Main bearing cap - Remove
the main bearing cap lightly.
(4) Remove the lower thrust plate from the rearmost main
bearing cap.
5-24
5.5 Crankshaft - Remove
(a) Remove the upper front thrust plate first, other- Crankshaft assembly
wise the front upper thrust plate will fall off onto
the crankcase when removing the crankshaft.
(b) When placing the crankshaft onto a pallet or
other stands, be careful not to damage the
crankshaft. Once placed on a pallet, the crank-
shaft should be locked in place to prevent it from
rotating.
(1) Press the mating faces of the front upper thrust plate, Crankshaft - Remove
pull out the crankshaft while rotating.
(2) Keeping the crankshaft in a horizontal position, slowly
raise the crankshaft.
Note: Do not attach a metal chain or other hoisting devices
directly onto the crankshaft, as they could damage the
crankshaft. Place cloth belts or pads in position where
a chain or other hoists are hooked before raising crank-
shaft.
(3) Remove the upper main bearing from the crankcase,
paying attention to the lug position, and remove the rear
upper thrust plate.
5-25
1. Cylinder head and Valve mechanism - Inspect and Repair ................................. 6-3
1.1 Rocker bushing inside diameter and Rocker shaft outside diameter - Measure ...................... 6-3
1.2 Rocker bushing - Replace ........................................................................................................ 6-3
1.3 Valve stem outside diameter and Valve guide inside diameter - Measure ............................... 6-4
1.4 Valve guide - Replace............................................................................................................... 6-4
1.5 Valve face - Inspect .................................................................................................................. 6-5
1.6 Valve face - Reface .................................................................................................................. 6-5
1.7 Valve seat - Reface .................................................................................................................. 6-6
1.8 Valve seat - Replace................................................................................................................. 6-6
1.9 Valve and Valve seat - Lap....................................................................................................... 6-8
1.10 Valve bridge, Bridge cap, Valve cotter and Valve rotator - Inspect .......................................... 6-8
1.11 Squareness and free length of valve spring - Measure ............................................................ 6-9
1.12 Tappet - Inspect........................................................................................................................ 6-9
1.13 Push rod runout - Measure ..................................................................................................... 6-10
1.14 Distortion of cylinder head bottom surface - Measure ............................................................ 6-10
2. Rear equipment - Inspect and Repair .................................................................. 6-11
2.1 Rear idler bushing inside diameter and Rear idler shaft outside diameter - Measure ............ 6-11
2.2 Rear idler bushing - Replace .................................................................................................. 6-11
2.3 Cam lift of camshaft - Measure............................................................................................... 6-11
2.4 Camshaft runout - Measure .................................................................................................... 6-11
2.5 Camshaft journal outside diameter - Measure........................................................................ 6-12
2.6 Camshaft bushing - Inspect .................................................................................................... 6-12
2.7 Camshaft bushing - Replace .................................................................................................. 6-12
3. Front equipment - Inspect and Repair ................................................................. 6-13
3.1 Damper - Inspect visually ....................................................................................................... 6-13
3.2 Outside diameter and inside diameter of oil pump drive bearing fit - Inspect ......................... 6-13
3.3 Front idler bushing inside diameter and Front idler shaft outside diameter - Measure........... 6-13
3.4 Front idler bushing - Replace.................................................................................................. 6-14
4. Piston and Connecting rod - Inspect and Repair ............................................... 6-15
4.1 Piston - Inspect visually .......................................................................................................... 6-15
4.2 Piston outside diameter - Measure ......................................................................................... 6-15
4.3 Piston ring groove - Inspect .................................................................................................... 6-15
4.4 Piston pin bore inside diameter - Measure ............................................................................. 6-16
4.5 Piston ring - Inspect visually ................................................................................................... 6-16
4.6 Piston ring end gap - Measure................................................................................................ 6-16
4.7 Piston pin outside diameter - Measure ................................................................................... 6-16
4.8 Connecting rod bushing inside diameter - Measure ............................................................... 6-17
4.9 Connecting rod bushing - Replace ......................................................................................... 6-18
4.10 Weight difference of connecting rod assembly in one engine ................................................ 6-20
4.11 Connecting rod big end bore diameter and roundness - Measure ......................................... 6-20
4.12 Side of connecting rod big end (width) - Measure .................................................................. 6-20
4.13 Connecting rod big end serration and bolt holes - Inspect ..................................................... 6-21
4.14 Connecting rod bearing - Inspect............................................................................................ 6-21
4.15 Connecting rod bearing thickness - Measure ......................................................................... 6-21
4.16 Connecting rod bend and twist - Inspect ................................................................................ 6-22
6-1
5. Crankcase and Crankshaft - Inspect and Repair ................................................ 6-23

5.1 Crankcase top surface distortion - Measure ........................................................................... 6-23
5.2 Inside diameter of main bearing bore - Measure .................................................................... 6-23
5.3 Cylinder liner fitting section of crankcase - Inspect................................................................. 6-23
5.4 Counterbore in crankcase - Repair......................................................................................... 6-24
5.5 Crankpin and Crank journal outside diameters - Measure ..................................................... 6-25
5.6 Crankpin and Rearmost crank journal width - Measure.......................................................... 6-26
5.7 Crankshaft runout - Measure .................................................................................................. 6-26
5.8 Crankshaft gear - Inspect ....................................................................................................... 6-26
5.9 Crankshaft gear - Replace...................................................................................................... 6-27
5.10 Oil seal slinger - Inspect ......................................................................................................... 6-27
5.11 Oil seal slinger - Replace........................................................................................................ 6-28
5.12 Main bearing - Inspect ............................................................................................................ 6-28
5.13 Thickness of main bearing shell - Measure ............................................................................ 6-29
5.14 Thrust plate - Inspect .............................................................................................................. 6-29
5.15 Thickness of thrust plate - Measure........................................................................................ 6-30
5.16 Piston cooling nozzle - Inspect ............................................................................................... 6-30
6-2
1. Cylinder head and Valve mechanism - Inspect and Repair

1.1 Rocker bushing inside diameter and Rocker shaft outside diameter - Measure
Measure the inside diameter of the rocker bushing and the
Measurement
outside diameter of the rocker shaft. If the measurement Measurement direction
direction
exceeds the limit, replace the rocker bushing or rocker shaft
Measurement
with a new one.
point
Item Nominal Standard Limit

Rocker bushing ø36 mm 36.000 to 36.040 mm 36.090 mm
inside diameter [1.42 in.] [1.4173 to 1.4189 in.] [1.4209 in.]
Rocker shaft ø36 mm 35.966 to 35.991 mm 35.940 mm
outside diameter [1.42 in.] [1.4160 to 1.4170 in.] [1.4150 in.]
Rocker bushing inside diameter and Rocker shaft

outside diameter - Measure
1.2 Rocker bushing - Replace
(1) Pull out the rocker bushing using the rocker bushing
tool. Removal
Rocker bushing tool

P/N:37591-02600
Rocker arm
Rocker bushing
Rocker bushing - Remove

(2) Install a new rocker bushing using the rocker bushing
Bushing inside surface Turn up
tool. roughness the notch.
Face the cut of the rocker bushing upward, and align Ra0.8μm{ ▽▽▽
3.2S }
the position indicated in the right figure. Press fit the Rocker bushing tool
P/N:37591-02600 Press-fit it from
rocker bushing from the chamfered side of the rocker chamfered side
bushing hole. Rocker bushing
[0.59 in.] [0.79 in.]

(3) Make sure the rocker arm and rocker bushing has the 15 mm 20 mm
same oil hole. Press-fit
(4) Measure the inside diameter of installed rocker bush-

Rocker arm
ing. If the measurement is out of tolerance, ream the
Rocker bushing - Insert
bore to the standard.
Rocker bushing
notch Rocker arm
Rocker bushing
matching mark
Rocker bushing
Press-fit the rocker bushing parallel to

rocker bushing notch and screw hole center line.
The position of rocker bushing notch
6-3
1.3 Valve stem outside diameter and Valve guide inside diameter - Measure
Measure the outside diameter of the valve stem and the
inside diameter of the valve guide at the respective top and Measuring
bottom ends in two crossing directions, since they are likely direction
to wear more rapidly at both ends. If the measurement
exceeds the limit, replace the valve guide or valve with a
new one.
Note: Always lap the valve and valve seat after the valve has Measuring
points
been refaced.

Valve stem ø10 mm 9.940 to 9.960 mm 9.910 mm Valve stem outside diameter - Measure
Valve guide ø10 mm 10.000 to 10.015 mm 10.060 mm Measurement
inside diameter [0.39 in.] [0.3937 to 0.3943 in.] [0.3961 in.] direction
Measurement
point
Valve guide inside diameter - Measure

1.4 Valve guide - Replace
Valve guide remover

P/N:33591-04300
The valve guide must be inserted to the specified
depth. Be sure to use the guide & seal installer when
press-fitting the valve guide.
(1) Remove the valve guide using the valve guide remover.
Valve guide - Remove

(2) Using the guide & seal installer, press-fit a new valve
guide slowly into position. Guide & seal installer
P/N:37191-11500
31.5 mm [1.240 in.]
Valve guide
Cylinder head
Valve guide - Press fit
6-4
1.5 Valve face - Inspect

Inspect the valve face after the valve guide is repaired or
replaced. Always lap the valve and valve seat after the valve
Seat width
has been refaced or replaced.
Valve seat
Valve margin
angle
Valve sinkage
Valve face - Inspect

1.5.1 Valve margin - Inspect
Measure the valve margin. If the measured value is less than
the limit, repair or replace with a new one.
1.5.2 Seat width - Inspect
Apply a thin lead-free coloring paste on the valve seat, and Valve lapper
P/N:30091-08800
strike the valve face against the valve seat using a valve lap-
per to check for contact condition. If the contact is not even,
or any defects are found, or if the limit is exceeded, reface Lead-free
or replace the valve. coloring paste
Note: Do not rotate the valve when pressing the valve face
coated with lead-free coloring paste against the valve
seat.
Item Standard Limit Seat width - Inspect

Valve seat
30° (nominal) -
Valve angle
seat 2.21 to 2.42 mm 2.8 mm
Seat width
[0.0870 to 0.0953 in.] [0.1102 in.]
Refacing permissible
2.8 to 3.2 mm
Valve margin 2.5 mm
[0.1102 to 0.1260 in.]
[0.098 in.]
Good Bad
Contact condition between valve seat and valve

1.6 Valve face - Reface
If the valve face is significantly worn out, reface the valve
face using a valve refacer. Valve refacer
Note:(a) Grind the valve face using the valve refacer at the
specified angle.
(b) Secure the valve margin width equal to or greater
than the limit. If the dimensions after refacing does
Grind the valve face
not meet the specified values, replace the valve with using the valve refacer
a new one. at the specified angle.
Valve face - Reface
6-5
1.7 Valve seat - Reface

(1) Use the valve seat cutter or valve seat grinder to reface
the valve seat. After refacing, sand the valve seat lightly
using 400 grit sandpaper, inserting it between the cutter
and valve seat.
If the seat width exceeds the standard, grind the valve Valve seat cutter
seat with the 60 degree valve seat cutter. P/N:37591-06400
37591-06430
(2) Lap the valve in the valve seat.
Note:(a) Valve seat refacing should be kept to an absolute
minimum.
(b) If the seat width cannot be repaired to the standard
Valve seat - Reface
value, or valve contact surface moves to outside pe-
riphery of valve seat, replace the valve seat with a
new one.
(c) If the valve sinkage exceeds the limit after refacing,
replace the valve seat with a new one.
1.8 Valve seat - Replace
Ensure the proper interference. Improper interfer-

ence could cause the valve seat to fall off or the cyl-
inder head to crack.
Be careful not to damage the machined surface of cylinder
head when removing the valve seat.
1.8.1 Valve seat - Remove (by the valve seat puller)
Valve seat puller
Remove the valve seat insert using the valve seat puller. P/N:32591-04200
Valve seat - Remove (by the valve seat puller)

1.8.2 Valve seat - Remove (by welding)
To remove the valve seat, weld a stud or replaceable tools to Welding
the valve seat as illustrated. Then, insert a shaft into the
Shaft
valve guide hole from the top of the cylinder head, and press
out the valve seat with the shaft. Valve seat
Note: Be careful not to allow spatters to adhere to the ma-
chined surface of the cylinder head during welding.
Stud
Valve seat - Remove (by welding)
6-6
1.8.3 Valve seat - Install

Unit: mm [in.]
]
(1) Before installing the valve seat, measure the inside
11.6 0 +0.004
[0.457 0
+0.1
diameter of the valve seat fit of cylinder head and the Cylinder head
[0.32]
outside diameter of the valve seat. Check that the speci-
8
fied amount of interference is assured. If the measured
[0.142]
3.6
value exceeds the standard value, use an oversize valve
60°
seat. The valve seat fit inside diameter at cylinder head Valve seat fitting
bore inside diameter
exceeds the limit, replace a cylinder head with a new
Valve seat outside diameter
one.
Same in size on inlet and exhaust sides.
Note: Replacement oversized valve seats are available 0.03,
Valve seat fit
0.06 mm [0.0012, 0.0024 in.].

60.000 Valve seat
Valve seat fit inside to 60.030 mm 60.120 mm
-
diameter [2.3622 [2.3669 in.]
to 2.3634 in.]
60.100
to 60.130 mm 2 lines,
Standard -
[2.3661 brown
to 2.3673 in.]
Valve 60.130
seat 0.03 mm to 60.160 mm 3 lines,
-
outside [0.0012 in.] [2.3673 brown
diameter to 2.3685 in.] Valve seat - Install
60.160
0.06 mm to 60.190 mm 4 lines,
-
[0.0024 in.] [2.3685 brown
to 2.3697 in.]
0.070
to 0.130 mm
Valve seat interference - -
[0.0028
to 0.0051 in.]
(2) Cool the valve seat at least for four minutes in liquid
nitrogen before fitting it into the cylinder head that is
kept at room temperature.
(3) Install the valve seat into the cylinder head using a
valve seat caulking tool.
6-7
1.9 Valve and Valve seat - Lap

Always lap the valve against the valve seat after refacing the
valve seat or after replacing the valve.
(1) Apply a thin coat of lapping compound evenly to the
valve face.
Note:(a) Do not allow the compound to adhere on the valve
stem.
(b) Compound spreads more evenly if it is mixed with Compound
a small amount of engine oil.
(c) Use medium-grain compound (125 to 150 mesh)
for initial lapping, then use fine-grain compound
Compound to valve face - Apply
(200 mesh) for finishing.
(2) Use a valve lapper for lapping. Valve lapper
Strike the valve against the valve seat while rotating the P/N:30091-08800
valve little by little.
(3) Wash off the compound using diesel oil.
(4) Apply engine oil to the contact surface of the valve,
then lap the valve again.
(5) Check valve face contact condition.
Valve and Valve seat - Lap

1.10 Valve bridge, Bridge cap, Valve cotter and Valve rotator - Inspect
(1) Inspect the contact surface between valve bridge and
valve stem, and the sliding surface between valve
Bridge cap
bridge and bridge guide. If they are significantly worn
Valve bridge
or there is any evidence of uneven contact, replace Bridge guide
them with new ones. Valve stem
Valve
(2) Check the bridge cap for wear. If it is significantly worn Valve cotter rotator
out, replace the bridge cap with a new one.
(3) Check the valve rotator for rotation. If any defect is
found, replace the valve rotator with a new one.
(4) Inspect the contact surface between valve bridge and
Valve bridge, Bridge cap, Valve cotter and Valve
valve stem, and valve cotter and valve rotator. If there is
rotator - Inspect
any evidence of uneven contact or dent, replace them
with new ones.
6-8
1.11 Squareness and free length of valve spring - Measure

Measure the squareness and free length of valve spring. The
free length or squareness exceed limit, replace a valve Squareness of the spring
spring with a new one.
Free length
Squareness and free length of spring - Measure

Nominal Standard Limit
Free length 73 mm [2.87 in.] 71 mm [2.80 in.]
A
A=1.5° or less B B = 2.2 mm [0.087 in.]
Squareness B = less than 1.9 mm [0.075 in.]
Inlet valve spring Lf over entire length
Lf=73 mm [2.87 in.]
66.0 mm [2.60 in.]/ 289 to 319 N

Set length/load -
{29.45 to 32.55 kgf} [64.97 to 71.71 lbf]
Free length 90.6 mm [3.567 in.] 88.12 mm [3.4693 in.]
A
A=2.0° or less B B = 3.7 mm [0.146 in.]
Inner spring Lf over entire length
Lf=90.6 mm [3.567 in.]
56.0 mm [2.20 in.] / 137 to 152 N

Set length/load -
{14 to 15.5 kgf} [30.80 to 34.17 lbf]
Exhaust valve spring
Free length 96.57 mm [3.8020 in.] 93.92 mm [3.6976 in.]
A
A=2.5° or less B B = 4.9 mm [0.193 in.]
Outer spring Lf over entire length
Lf=96.57 mm [3.8020 in.]
62.0 mm [2.44 in.]/496 to 549 N

Set length/load -
{50.6 to 56.0 kgf} [111.5 to 123.4 lbf]
1.12 Tappet - Inspect

Inspect the cam contact surface of the tappet. If the tappet is
worn unevenly, replace it with a new one.
Uneven worn Uneven worn
Good Bad Bad
Cam contact surface of the tappets - Inspect
6-9
1.13 Push rod runout - Measure

Measure the runout of push rod by TIR. If the runout
exceeds the standard, replace the push rod with a new one.
Item Standard Remarks

Push rod runout 0.50 mm [0.0197 in.] or less TIR V-block
Push rod
1/2 1/2
Surface plate
Push rod runout - Measure

1.14 Distortion of cylinder head bottom surface - Measure
Refacing of cylinder head should be kept to an abso-

lute minimum. Excessive grinding of the cylinder
head may result in defects such as contact between
piston and valve.
With a straight edge placed on the bottom face of the cylin-
der head, measure the bottom face distortion using a thick-
Cylinder head
ness gauge. If the limit is exceeded, replace with a new one
or grind and repair it.
Distortion of cylinder head bottom surface - Measure
Note the maximum grinding if grind and repair it. The total
maximum grinding when grind and repair the bottom of cyl-
inder head and the top of crankcase must be 0.50 mm [0.020 The height of cylinder head
in.] or less.
Item Standard Limit

Distortion of cylinder head 0.03 mm 0.07 mm
bottom surface [0.0012 in.] or less [0.0028 in.]
The height of cylinder head 154.9 to 155.1 mm
-
(reference) [6.098 to 6.106 in.]
The height of cylinder head - Measure
6-10
2. Rear equipment - Inspect and Repair

2.1 Rear idler bushing inside diameter and Rear idler shaft outside diameter - Measure
Measure the rear idler bushing inside diameter and the rear
idler shaft outside diameter. If the measurement exceeds the Measuring
direction
limit, replace the rear idler bushing or rear idler shaft with a
Measuring
new one.
points

Rear idler bushing ø65 mm 65.000 to 65.030 mm 65.060 mm
Rear idler shaft ø65 mm 64.951 to 64.970 mm 64.900 mm
Rear idler bushing inside diameter and Rear idler shaft

outside diameter - Measure
2.2 Rear idler bushing - Replace
(1) Pull out the rear idler bushing. 1 mm
Rear idler bushing inside roughness
(2) Turn the oil groove of rear idler bushing to the direction 3.2S [0.04 in.]
Ra 0.8μm {ٖٖٖ }
shown in the illustration. Press-fit the large gear until it Lower the rear idler bushing from
the end of gear boss by 1 mm [0.04 in.].
becomes flush with the end of gear boss. Lower the rear
idler bushing from the end of gear boss by 1 mm [0.04 Rear idler gear
in.].
(3) Measure the inside diameter of installed rear idler bush-
ing. If the measurement is out of tolerance, ream the Rear idler
bore to the standard. bushing
Rear idler bushing - Replace

2.3 Cam lift of camshaft - Measure
Measure the major axis and minor axis of cam to determine
cam lift. If the limit is exceeded, replace the camshaft with a
new one.
Major axis
Item Standard Limit
Cam lift of camshaft 9.260 to 9.340 mm 8.45 mm
(major axis - minor axis) [0.3646 to 0.3677 in.] [0.3327 in.]
Minor
axis
Cam lift of camshaft - Measure

2.4 Camshaft runout - Measure
Measure the runout of camshaft by TIR. If the limit is
exceeded, correct the camshaft using a press, or replace the
V-block
camshaft with a new one.
Note: With a dial gauge set on the camshaft, rotate the cam-
shaft one turn and read the gauge indication.
Item Standard Limit Remarks Surface plate

0.05 mm 0.08 mm 1/2 1/2
Camshaft runout TIR
[0.0020 in.] or less [0.0031 in.]
Camshaft runout - Measure

6-11
2.5 Camshaft journal outside diameter - Measure

Measure the diameter of each camshaft journal in two direc-
tion at right angles to each other. If the limit is exceeded,
replace the camshaft with a new one.

Camshaft journal ø84 mm 83.92 to 83.94 mm 83.87 mm
outside diameter [3.31 in.] [3.3039 to 3.3047 in.] [3.3020 in.] Measuring
direction
Camshaft journal outside diameter - Measure

2.6 Camshaft bushing - Inspect
(1) Check the inside surface of each bushing for damage,
corrosion, flaking and other abnormalities. If any defect
is found, replace the camshaft bushing with a new one. Measuring
direction
(2) Measure the camshaft bushing inside diameter with the
bushing installed in the crankcase. If the limit is
exceeded, replace the camshaft bushing with a new one.
Note: Do not damage the inside of camshaft bushing when
measuring the inside diameter.

Camshaft bushing ø84 mm 84.000 to 84.035 mm 84.100 mm Camshaft bushing inside diameter - Measure
2.7 Camshaft bushing - Replace
No. 1 to 8 journals No. 9 journal

(right and left) (right and left)
Before tightening the set bolt, be sure to check that
the set bolt is in alignment with the set bolt hole in
Front Rear
the camshaft bushing. of engine of engine
Make sure that the oil hole in the camshaft bushing
is in alignment with that in the oil gallery.
Camshaft Camshaft
(1) Remove the set screws from the side of the crankcase bushing bushing
and then remove the camshaft bushings. Sealing washer Sealing washer
(2) Install the camshaft bushing with aligning the set bolt Set bolt
hole of crankcase and camshaft bushing, then secure Camshaft bushing - Install
the camshaft bushing with the set bolt.
Note: Make sure that the oil hole in the camshaft bushing is
in alignment with that in the crankcase.
6-12
3. Front equipment - Inspect and Repair

3.1 Damper - Inspect visually
Check the damper for cracks around the outer periphery,
swelling in the end plate, silicone oil leakage and discolor-
ation and separation of coating due to overheating. If any
defect is found, replace the damper with a new one.
Damper - Inspect visually

3.2 Outside diameter and inside diameter of oil pump drive bearing fit - Inspect
Turn the bearing and if the turning is not smooth, replace the
bearing with a new one. Bearing
Inspect the fit of oil pump bearing cover and bearing. If
heavy wear is found, replace them with new one.
Inspect the fit of the pump plate and the bearing. If heavy
wear is found, replace them with new one. Oil pump bearing
Inspect the fit of oil pump gear and bearings. If any of these cover
parts is badly worn, replace them. Oil pump gear
Pump plate
Item Nominal Standard
Inside diameter of bearing fit Oil pump drive bearing fit - Inspect
ø110 mm 110.000 to 110.035 mm
in the oil pump bearing
[4.33 in.] [4.3307 to 4.3321 in.]
cover
Inside diameter of bearing fit ø110 mm 109.987 to 110.022 mm
in the pump plate [4.33 in.] [4.3302 to 4.3316 in.]
ø110 mm 109.985 to 110.000 mm
Outside diameter
[4.33 in.] [4.3301 to 4.3307 in.]
Bearing
ø50 mm 49.988 to 50.000 mm
Inside diameter
[1.97 in.] [1.9680 to 1.9685 in.]
Outside diameter of bearing ø50 mm 49.993 to 50.013 mm
fit in the oil pump gear [1.97 in.] [1.9682 to 1.9690 in.]
3.3 Front idler bushing inside diameter and Front idler shaft outside diameter - Measure
Measure the front idler bushing inside diameter and the
front idler shaft outside diameter. If the measurement Measuring
direction
exceeds the limit, replace the front idler bushing or front
idler shaft with a new one. Measuring
points
Front idler bushing ø50 mm 50.000 to 50.025 mm 50.060 mm
Front idler shaft ø50 mm 49.950 to 49.975 mm 49.900 mm
Front idler bushing inside diameter and Front idler

shaft outside diameter - Measure
6-13
3.4 Front idler bushing - Replace

(1) Use the removing side of the idler bushing puller, and
Drive the bushing farther until Front idler bushing
remove the front idler bushing. it sinks approx. 1mm [0.04 in.] inner surface
below the end face of the gear roughness
(2) Use the installing side of the idler push puller, and boss. Ra0.8 μm { ▽ 3.2S
▽▽ }
press-fit the front idler bushing at the 1 mm [0.04 in.] Idler bushing puller
[0.04 in.]
chamfered side to flush with the end of gear boss. Use C1 P/N:32591-02500
1 mm
[0.04 in.]
the removing side of the idler bushing puller, lower the
Front idler bushing
rear idler bushing from the end of gear boss by 1 mm
[0.04 in.].
(3) Measure the inside diameter of installed front idler (5 mm) Front idler gear
bushing. If the measurement is out of tolerance, ream [0.20 in.] C3 [0.12 in.]
Front idler bushing - Replace
the bore to the standard.
6-14
4. Piston and Connecting rod - Inspect and Repair

4.1 Piston - Inspect visually
Check the combustion surface, piston pin bore, ring groove,
sliding surface and bottom surface of the piston. If any
defect are found, replace the piston with a new one.
Piston - Inspect visually

4.2 Piston outside diameter - Measure
(1) Measure the piston outside diameter of the piston skirt
[1.57 in.]
40 mm
at right angles to the piston pin. If the measured value is
less than the limit, replace the piston with a new one.
Measuring
When replacing a piston in an engine, be sure to select a points
replacement piston with a weight difference in the per-
missible range for that engine.
Piston outside diameter - Measure

(2) The piston weight is stamped on the top of piston head.
Item Nominal Standard Limit Parts number

Piston outside ø170 mm 169.76 to 169.80 mm 169.66 mm
diameter [6.69 in.] [6.6835 to 6.6850 in.] [6.6795 in.]
Piston weight ±10 g [0.35 oz.]
- -
difference or less in one engine
&$0
Direction mark Piston weight
Piston weight stamping position

4.3 Piston ring groove - Inspect
Remove carbon from pistons and check the entire

circumference of the piston. Ring carrier
No.1 compression ring
(1) Remove all deposits such as carbon from each ring groove
groove.
(2) Visually check each ring groove for wear or damage. If No.2 compression ring
groove
faulty, replace the piston with a new one. Check the Oil ring groove
color of the ring carrier of No. 1 compression ring
groove, and check for crack and flaking.
Piston ring groove - Inspect
6-15
4.4 Piston pin bore inside diameter - Measure

Measure the piston pin bore inside diameter. If the measured
value is less than the limit, replace the piston with a new
one.

Piston pin bore ø70 mm 70.002 to 70.015 mm 70.040 mm
Measuring Measuring
directions points
Piston pin bore inside diameter - Measure

4.5 Piston ring - Inspect visually
Check the sliding surface and the top and bottom surfaces
for seizing, abnormal wear, foreign substance biting and
plating delamination. If any such traces are found, replace
the piston rings with new ones.
4.6 Piston ring end gap - Measure
Place the piston rings in a gauge or a new cylinder liner, and
measure the end gap. If the limit is exceeded, replace all the
rings as a set.
Note: Using a piston, push the piston ring squarely into the Thickness
gauge
gauge or the cylinder liner.
Item Standard Limit

No.1 0.6 to 0.8 mm
compression [0.024 to 0.032 in.]
Piston ring No.2 0.6 to 0.8 mm 2.0 mm End gap
end gap compression [0.024 to 0.032 in.] [0.078 in.] Gauge bore diameter: 170 ± 0 mm [6.69 ± 0 in.]
0.3 to 0.45 mm Piston ring end gap - Measure
Oil
[0.012 to 0.0177 in.]
4.7 Piston pin outside diameter - Measure

Measure the piston pin outside diameter.
If it is less than the limit, replace the piston pin with a new
one.
Measuring
Item Nominal Standard Limit direction
Piston pin outside ø70 mm 69.987 to 70.000 mm 69.970 mm
diameter [2.76 in.] [2.7554 to 2.7559 in.] [2.7547 in.]
Measuring
points
Piston pin outside diameter - Measure
6-16
4.8 Connecting rod bushing inside diameter - Measure

Measure the inside diameter of the connecting rod bushing.
If the limit is exceeded, replace the connecting rod bushing Measuring
directions
with a new one.
Measuring
Item Nominal Standard Limit points
Inside diameter of
ø70 mm 70.020 to 70.040 mm 70.070 mm
the connecting rod
[2.76 in.] [2.7567 to 2.7575 in.] [2.7587 in.]
bushing
Connecting rod bushing inside diameter - Measure
6-17
4.9 Connecting rod bushing - Replace

Use the connecting rod bushing installer to replace the con-
necting rod bushings.
4.9.1 Installer base and Connecting rod - Fix
Matching mark on the base Matching mark
(1) Install the plate to adjust the matching mark of plate to on the base
(red scribed line)
(red ø4 mm [0.16 in.])
the matching mark of the base.
Plate
Base Matching mark
on the plate
Connecting rod bushing installer
(red ø4 mm [0.16 in.])
P/N:37591-01010
Usage of connecting rod bushing installer (1)
(2) Install the connecting rod cap to the plate with remov-
ing the connecting rod bearing from the connecting rod. Oil hole of
connecting rod Bolt Plate
(3) Install the connecting rod to the plate with adjusting the
matching mark.
(4) Tighten the connecting rod bolts to the specified torque.
(5) Secure the connecting rod in place with the bracket.
Matching mark Bracket Matching mark

(red scribed line) on the plate
4.9.2 Connecting rod bushing - Remove Applying pressure by
(1) Apply engine oil to the inner surface of connecting rod a pressing machine
bushing.
(2) Attach the collar A to the mandrel and insert the assem- Mandrel
bly into the connecting rod bushing while aligning the

Collar A
matching mark (red scribed line) on the collar A with
that on the base.
(3) Using a pressing machine, apply pressure slowly on the
head of the mandrel to pull out the connecting rod bush-
ing. Bushing to
be pulled out
Bracket
Matching
mark
Removing direction
6-18
4.9.3 Connecting rod bushing - Insert
(a) Confirm that the matching marks (red scribed Oil hole of
connecting rod bushing
lines) on collars A and B are in alignment.
(b) Confirm that the oil hole in the connecting rod
bushing is in alignment with the matching mark Matching mark on collar A
(red ø4 mm [0.16 in.])
(red ø4 mm [0.16 in.]) on collar A.
(1) Adjust the oil hole with the matching mark on collar A
(ø4 mm [0.16 in.] red), and install a new connecting rod
bushing on collar A. Usage of connecting rod bushing installer (4)
(2) Assemble the collar A and B to the mandrel, and Applying pressure by a
tighten them with nuts. pressing machine
Mandrel
Matching mark
(red scribed Collar A
lines)
Bushing to
be pressed
Collar B
Nut
Matching mark
(red scribed
lines)
Removing direction
(3) Apply engine oil to the outer periphery of the connect-
Matching mark on collar A
ing rod bushing. Align the oil hole in the connecting (red ø4 mm [0.16 in.])
Oil hole of connecting rod
rod bushing with the matching mark (red scribed line)
on the collar A and B, then press the bushing into the
connecting rod.
Oil hole of connecting rod
6-19
(4) Measure the inside diameter of the connecting rod

Bushing inner surface
bushing. Inside diameter of
roughness
If the measurement is out of tolerance, ream the bore to 1.6S
Ra0.4ȣm ^`
‫ۃۃۃ‬
connecting rod
bushing
the standard.
Connecting rod
bushing
Item Standard
70.020 to 70.040 mm
Inside diameter of the connecting rod bushing
[2.7567 to 2.7575 in.]
Connecting rod
Connecting rod bushing inside diameter - Measure

4.10 Weight difference of connecting rod 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
connecting rods must be of the same weight rank.
Weight rank list

Weight rank Weight Allowable value
M 15420 g [543 oz.] ±30 g [±1.05 oz.]
Weight rank mark location
Connecting rod weight rank mark position

4.11 Connecting rod big end bore diameter and roundness - Measure
Measure the connecting rod bore diameter at the front and
rear ends respectively in the directions A, B and C as shown
in the illustration. The out-of-roundness is determined by A
B
subtracting the minimum value from the maximum value
among the measurements of A, B and C. C Front Rear
If the limit is exceeded, replace it with a new one.

Measuring Measuring
Roundness directions points
limit
Minimum:
131.000 to
Connecting 130.950 mm
131.025
rod big end ø131 mm [5.1555 in.] 0.100 mm Connecting rod big end bore diameter - Measure
mm
bore [5.16 in.] Maximum: [0.0039 in.]
[5.1575 to
diameter 131.050 mm
5.1585 in.]
[5.1594 in.]
4.12 Side of connecting rod big end (width) - Measure

(1) Inspect the side of connecting rod big end visually. If
any defect such as wear or damage, replace the con-
necting rod with a new one. Side of connecting rod big end (width)
(2) Measure the side of connecting rod big end (width). If
the measured value exceeds the standard value, replace
it with a new one.
Item Standard
59.7 to 59.8 mm
Side of connecting rod big end (width)
[2.3504 to 2.3543 in.]
Side of connecting rod big end (width) - Measure

6-20
4.13 Connecting rod big end serration and bolt holes - Inspect
Inspect the connecting rod big end serration and bolt holes
with magnetic particle method. If any defect such as cracks,
fretting and foreign substance biting is found, replace it with
new ones.
4.14 Connecting rod bearing - Inspect
Inspect the sliding surface, back surface and end surface of
connecting rod bearing. If any defect such as poor contact,
sliding scratches, corrosion and foreign substance biting is
found, replace it with a new one.
Flaking Scratches
Adhesion
End face
Connecting rod bearing - Inspect

4.15 Connecting rod bearing thickness - Measure
Measure the thickness of connecting rod at its center.
If the measurement exceeds the limit, replace both upper
and lower connecting rod bearing shells with new ones as a
set. Measure at
the center of bearing
When regrinding and reusing the crankshaft, use the under-
size bearing.
For grinding the crankshaft, refer to "Crankpin and Crank
journal - Grind" of "INSPECTION AND REPAIR OF
BASIC ENGINE".
Note: Replacement shells for undersized connecting rod
Connecting rod bearing thickness - Measure
bearing are available -0.25, -0.50, -0.75 and -1.00 mm
[-0.0098, -0.0197, -0.0295 and -0.0394 in.].
Item Size Nominal Standard Limit

2.957 to
3.000 mm 2.970 mm 2.930 mm
Standard
[0.1181 in.] [0.1164 to [0.1154 in.]
0.1169 in.]
3.082 to
-0.25 mm 3.125 mm 3.095 mm 3.055 mm
[-0.0098 in.] [0.1230 in.] [0.1213 to [0.1203 in.]
0.1219 in.]
3.207 to
Connecting
-0.50 mm 3.250 mm 3.220 mm 3.180 mm
rod bearing
[-0.0197 in.] [0.1280 in.] [0.1263 to [0.1252 in.]
thickness
0.1268 in.]
3.332 to
-0.75 mm 3.375 mm 3.345 mm 3.305 mm
[-0.0295 in.] [0.1329 in.] [0.1312 to [0.1301 in.]
0.1317 in.]
3.457 to
-1.00 mm 3.500 mm 3.470 mm 3.430 mm
[-0.0394 in.] [0.1378 in.] [0.1361 to [0.1350 in.]
0.1366 in.]
6-21
4.16 Connecting rod bend and twist - Inspect

(1) Measure the dimensions of C and L as shown in the
C Unit: mm [in.]
illustration to check the bend and twist of the connect-
C 0.05 0.0020
L [ ]
ing rod. Straighten the connecting rod with a press to L 100 3.94
meet the standard. Piston C 0.05 0.0020 L
pin [ ]
L 100 3.94
If the measured value exceeds the standard value, C
replace it with a new one.
Connecting rod bend Connecting rod twist
Note: Before checking bend, tighten the connecting rod cap
Tightening torque
to the specified torque. ○Bolt mark “AL” ,“AU”
637 ± 31.9 N·m {65 ± 3.25 kgf·m}
(2) To inspect the connecting rod with the piston installed, [470 ± 24 lbf·ft]
turn the piston upside down and place it on a surface 2-step tightening [wet]
Connecting rod bend and twist - Inspect
plate. Insert a round bar having the same diameter as
the crankpin into the big-end bore, and measure the D
height of the bar using a dial gauge.
C
Item Standard
0.05/100 mm
Connecting rod bend and twist (C/L, C/D) C 0.05 [ 0.0020 ]
[0.0020/3.94 in.] or less
D 100 3.94
Surface plate Unit: mm [in.]

Deflection of connecting rod - Measure
6-22
5. Crankcase and Crankshaft - Inspect and Repair

5.1 Crankcase top surface distortion - Measure
Straight edge
Refacing of crankcase should be kept to an absolute
minimum.
Excessive grinding of the crankcase may result in
defects such as defective combustion and contact
between piston and valve.
Apply a straight edge to the top surface of the crankcase and
measure its distortion using a thickness gauge. If the limit is
exceeded, replace with a new one or grind and repair it. Thickness gauge
Note the maximum grinding if grind and repair it. The total Crankcase top surface distortion - Measure
maximum grinding when grind and repair the top of crank-
case and the bottom of cylinder head must be 0.50 mm
[0.020 in.] or less.
Item Standard Limit

Crankcase top surface 0.1 mm 0.2 mm
distortion [0.004 in.] or less [0.008 in.]
The height from the center of
549.45 to 549.55 mm
crank journal to the top of -
[21.6318 to 21.6358 in.]
crankcase(reference)
The height from the center of crank journal to the top

of crankcase
5.2 Inside diameter of main bearing bore - Measure

(1) Assemble the main bearing cap to the crankcase in the
specified method. 588 ± 29.4 N·m
{60 ± 3.0 kgf·m}
(2) Measure the housing diameter in vertical and two diag- [434 ± 22 lbf·ft] [wet]
onal directions.

Inside diameter of
ø179 mm 179.000 to 179.025 mm 179.045 mm
main bearing
[7.05 in.] [7.0472 to 7.0482 in.] [7.0490 in.]
fitting bore
392 ± 19.6 N·m
{40 ± 2.0 kgf·m}
[289 ± 14 lbf·ft] [wet]
Inside diameter of main bearing bore - Measure

5.3 Cylinder liner fitting section of crankcase - Inspect
(1) Inspect the counterbore in crankcase. Check that the
cracks in edges, uneven between the counterbore and Fitting bore of cylinder liner Counterbore in crankcase
in crankcase
the bottom of cylinder liner flange protrusion. If any
defects are found, reface the counterbore in crankcase.
(2) Inspect the cylinder liner fit in crankcase. Check that
there are no defect such as the fretting and corrosion. If
any defects are found, reface it with sandpaper.
Cylinder liner fitting section of crankcase - Inspect

6-23
5.4 Counterbore in crankcase - Repair

If there is any evidence of uneven contact in the counterbore
File
in crankcase, grind and repair it. Grind the counterbore
using the crankcase grinder such that the difference in depth
at the circumference is less than 0.05 mm [0.0020 in.].
After grinding the counterbore in crankcase, measure the
cylinder liner flange protrusion at each cylinder.
Counterbore
in crankcase
Crankcase grinder
P/N:37591-07010
Counterbore in crankcase - Repair
6-24
5.5 Crankpin and Crank journal outside diameters - Measure

(1) Measure the outside diameter of the crankpins and
Measuring Measuring
crank journals. directions points
If the limit is exceeded, use the undersize bearing, and
grind the crankshaft to fit the undersize bearing.
If the limit is exceeded though the -1.00 mm [-0.0394
in.] undersize bearing is used, replace the crankshaft
with a new one.
(2) Determine the out-of-roundness and the out-of-cylin-
dricity (taper) based on the outside diameters that have
been measured.
Crankpin outside diameter - Measure
5.5.1 Crankpin and Crank journal - Grind Measuring Measuring

directions points
When using the undersize bearing, grind the crankshaft to
adjust to the standard size bearing.
Do not change the fillet radius and the width of shaft when
grinding. If the hardness is decreased, quench the crankshaft
again and inspect it with magnetic particle method. Ensure
that the surface finish accuracy of the crankpins and crank
journals is kept within the standard even after the correction
by grinding.
After grinding, measure the width of crankpin and crank Crank journal outside diameter - Measure
journal.
Item Nominal Size Standard Limit

Standard 124.930 to 124.950 mm [4.9185 to 4.9193 in.] 124.890 mm [4.9169 in.]
-0.25 [-0.0098 in.] 124.680 to 124.700 mm [4.9087 to 4.9094 in.] 124.640 mm [4.9071 in.]
ø125 mm
Crankpin outside diameter -0.50 [-0.0197 in.] 124.430 to 124.450 mm [4.8988 to 4.8996 in.] 124.390 mm [4.8972 in.]
[4.92 in.]
-0.75 [-0.0295 in.] 124.180 to 124.200 mm [4.8890 to 4.8898 in.] 124.140 mm [4.8874 in.]
-1.00 [-0.0394 in.] 123.930 to 123.950 mm [4.8791 to 4.8799 in.] 123.890 mm [4.8775 in.]
Standard 169.920 to 169.940 mm [6.6898 to 6.6905 in.] 169.880 mm [6.6882 in.]
-0.25 [-0.0098 in.] 169.670 to 169.690 mm [6.6799 to 6.6807 in.] 169.630 mm [6.6783 in.]
ø170 mm
Crank journal Outside diameter -0.50 [-0.0197 in.] 169.420 to 169.440 mm [6.6701 to 6.6709 in.] 169.380 mm [6.6685 in.]
[6.69 in.]
-0.75 [-0.0295 in.] 169.170 to 169.190 mm [6.6602 to 6.6610 in.] 169.130 mm [6.6586 in.]
-1.00 [-0.0394 in.] 168.920 to 168.940 mm [6.6504 to 6.6512 in.] 168.880 mm [6.6488 in.]
Deviation of 0.01mm [0.0004 in.]
Parallelism - - 0.03 mm [0.0012 in.]
or less over entire pin length
Diameter difference 0.01 mm [0.0004 in.]
Roundness - - 0.03 mm [0.0012 in.]
or less
Diameter difference 0.01 mm [0.0004 in.]
Pin and Cylindricity - - 0.03 mm [0.0012 in.]
or less
journal
Fillet Pin R7 [0.28] - 6.8 to 7.0 mm [0.268 to 0.276 in.] -
radius Journal R8.5 [0.335] - 8.3 to 8.5 mm [0.327 to 0.335 in.] -
Hardness - - Hv > 590 -
Surface accuracy - - Ra0.2 μm -
Angular deviation between pins - - ±20' -
6-25
5.6 Crankpin and Rearmost crank journal width - Measure

(1) Inspect the either end of crankpin and crank journal
width for harmful scratch and wear.
(2) Measure the crankpin and rearmost crank journal Rearmost crank
Crankpin width journal width
width.
If using oversize thrust plate because of the wear of
rearmost crank journal width, grind the crankshaft to
adjust the oversize thrust plate.
Crankpin and Rearmost crank journal width - Measure

5.6.1 Rearmost crank journal width - Grind
When using the oversize thrust plate, grind the rearmost crank journal width to adjust to the standard size bearing.
Do not change the fillet radius when grinding. If the hardness is decreased, quench the crankshaft again and inspect it with mag-
netic particle method. Ensure that the surface finish accuracy of the crankpins and crank journals is kept within the standard
even after the correction by grinding.
Note: The difference of thickness for two thrust plates must be 0.25 mm [0.0098 in.] or less.
Item Nominal Size Standard

Crankpin width 120 mm [4.72 in.] - 120.20 to 120.30 mm [4.7323 to 4.7362 in.]
Standard 67.00 to 67.03 mm [2.6378 to 2.6390 in.]
One side 67.25 to 67.28 mm [2.6476 to 2.6488 in.]
0.25 mm [0.0098 in.]
Both sides 67.50 to 67.53 mm [2.6575 to 2.6587 in.]
Rearmost crank journal width 67 mm [2.64 in.] One side 67.50 to 67.53 mm [2.6575 to 2.6587 in.]
0.50 mm [0.0197 in.]
One side 67.75 to 67.78 mm [2.6673 to 2.6685 in.]
0.75 mm [0.0295 in.]
5.7 Crankshaft runout - Measure

Support the crankshaft at the front and rear journals with V-
blocks, and measure the crankshaft runout at the center jour-
V-block
nal using a dial gauge. If the runout deviates from the stan-
dard only slightly, grind the crankshaft to repair. If the
runout exceeds the standard considerably, straighten the
crankshaft using a press.
If the limit is exceeded, replace the crankshaft with a new
Surface plate
one. 1/2 1/2
If the crankshaft has been repaired by grinding or pressing,
inspect the crankshaft for cracks and other harmful damage
Crankshaft runout - Measure
using a magnetic particle method.

0.04 mm 0.10 mm
Crankshaft runout TIR
[0.0016 in.] or less [0.0039 in.]
5.8 Crankshaft gear - Inspect

If there are faults on the crankshaft gear tooth, such as flak-
ing, wear, uneven contact, replace the crankshaft gear with a
new one.
6-26
5.9 Crankshaft gear - Replace
Use protective gloves when you touch overheated Crankshaft gear

parts.
Touching the overheated parts with hands directly
can cause burns.
5.9.1 Crankshaft gear - Remove
Using a gear puller, pull out the crankshaft gear from the
crankshaft.
Note: The heating temperature must be 180°C [356 °F] or
less when heating and pulling out the crankshaft gear. Crankshaft gear - Remove
5.9.2 Crankshaft gear - Install
Align dowel pin
and notch
(a) Check the installing direction and position of
crankshaft gear.
(b) When performing the shrink fitting for crankshaft
gear, heat it evenly under the specified tempera-
ture.
(1) Measure the outside diameter of crankshaft and inside

diameter of crankshaft gear, and check the interference.
(2) Heat the crankshaft gear evenly under the specified Crankshaft gear - Install
temperature. Check the direction and position of gear Temperature for shrink fitted: Fitting direction
and drive in the gear. 200 °C [392 °F] or less
Fitting direction
Standard value Standard value

of interference of interference
0.106 to 0.171 mm 0.274 to 0.358 mm
[0.0042 to 0.0067 in.] [0.0108 to 0.0141 in.]
Front Rear
Installation directions
5.10 Oil seal slinger - Inspect
If any defect such as dent, damage, wear and backlash that
Front Rear
can lead to oil leakage are found, replace the oil seal slinger
with a new one. Timing
gear case
Front
gear case
Oil seal Oil seal

slinger slinger
Oil seal Oil seal
Oil seal slinger - Inspect
6-27
5.11 Oil seal slinger - Replace
Use protective gloves when you touch overheated Oil seal slinger
parts.
Touching the overheated parts with hands directly
can cause burns.
5.11.1 Oil seal slinger - Remove
Using a gear puller, pull out the oil seal slinger from the
crankshaft.
Note: The heating temperature must be 100°C [212°F] or
less when heating and pulling out the oil seal slinger. Oil seal slinger - Remove
5.11.2 Oil seal slinger - Install
Identification mark Identification mark
(1) Measure the outside diameter of crankshaft and inside (37425-08201) (37411-04200)
diameter of oil seal slinger, and check the interference.
(2) Heat the oil seal slinger evenly under 110ºC [230 °F].
Check the direction and position of slinger and drive in
the slinger.
Contact to the gear. Contact to the gear.
Standard value Standard value
of interference: of interference:
0.064 to 0.163 mm 0.210 to 0.294 mm
[0.0025 to 0.0064 in.] [0.0083 to 0.0116 in.]
Front Rear
Oil seal slinger - Install (1)
Oil seal slinger
Rear side installing tool

Slinger installer
P/N:37491-02100
Installer
Installer guide
P/N:37491-02200
Oil seal slinger - Install (2)

5.12 Main bearing - Inspect
main bearing. If any defect such as poor contact, sliding
scratches, corrosion and foreign substance biting is found, Damage, corrosion,
flaking
End face
Main bearing - Inspect
6-28
5.13 Thickness of main bearing shell - Measure

Measure the thickness of each main bearing shell at its cen-
ter.
If the measurement exceeds the limit, replace both upper
and lower main bearing shells with new ones as a set. Measure at
the center of bearing
When regrinding and reusing the crankshaft, use the under-
size bearing.
For grinding the crankshaft, refer to "Crankpin and Crank
journal - Grind" of "INSPECTION AND REPAIR OF
BASIC ENGINE".
Note: Replacement shells for undersized main bearing are
Thickness of main bearing shell - Measure
available -0.25, -0.50, -0.75 and -1.00 mm [-0.0098, -
0.0197, -0.0295 and -0.0394 in.].

4.467 to
4.500 mm 4.480 mm 4.425 mm
Standard
[0.1772 in.] [0.1759 to [0.1742 in.]
0.1764 in.]
4.592 to
-0.25 mm 4.625 mm 4.605 mm 4.550 mm
[-0.0098 in.] [0.1821 in.] [0.1808 to [0.1791 in.]
0.1813 in.]
Main 4.717 to
bearing -0.50 mm 4.750 mm 4.730 mm 4.675 mm
thickness [-0.0197 in.] [0.1870 in.] [0.1857 to [0.1841 in.]
at center 0.1862 in.]
4.842 to
-0.75 mm 4.875 mm 4.855 mm 4.800 mm
[-0.0295 in.] [0.1919 in.] [0.1906 to [0.1890 in.]
0.1911 in.]
4.967 to
-1.00 mm 5.000 mm 4.980 mm 4.925 mm
[-0.0394 in.] [0.1969 in.] [0.1956 to [0.1939 in.]
0.1961 in.]
5.14 Thrust plate - Inspect

thrust plate. If any defect such as poor contact, sliding
scratches, corrosion and foreign substance biting is found, End face
Damage, corrosion,
flaking
Thrust plate - Inspect
6-29
5.15 Thickness of thrust plate - Measure

Measure the thickness of thrust plate.
If the limit is exceeded, replace the thrust plate with a new
one. Regrind and reuse the crankshaft, use the oversize
thrust plate.
For grinding the crankshaft, refer to "Rearmost crank jour-
nal width - Grind" of "INSPECTION AND REPAIR OF
BASIC ENGINE".
Note:(a) Replacement thrust plates are available in three
oversizes: 0.25, 0.50, 0.75 mm [0.0098, 0.0197,
0.0295 in.].
Thickness of thrust plate - Measure
(b) Since the oversize thrust plate is can be used only
one side, the crankshaft end play can be adjusted
with minimum grinding.

4.83 to
5.00 mm 4.90 mm 4.76 mm
Standard
[0.1969 in.] [0.1902 to [0.1874 in.]
0.1929 in.]
5.08 to
0.25 mm 5.25 mm 5.15 mm 5.01 mm
[0.0098 in.] [0.2067 in.] [0.2000 to [0.1972 in.]
Thickness 0.2028 in.]
of thrust
plate 5.33 to
0.50 mm 5.50 mm 5.40 mm 5.26 mm
[0.0197 in.] [0.2165 in.] [0.2098 to [0.2071 in.]
0.2126 in.]
5.58 to
0.75 mm 5.75 mm 5.65 mm 5.51 mm
[0.0295 in.] [0.2264 in.] [0.2197 to [0.2169 in.]
0.2224 in.]
5.16 Piston cooling nozzle - Inspect

Inspect the piston cooling nozzle.
Spray holes
If any defect are found such as valve malfunctions and oil
hole clogging, replace the piston cooling nozzle with a new
one.
Item Standard
Valve opening pressure of 0.10 to 0.15 MPa
piston cooling nozzle {1.0 to 1.5 kgf/cm2} [14 to 21 psi]
Oil hole
Valve
Piston cooling nozzle - Inspect
6-30
1. Crankshaft and Main bearing - Install.................................................................... 7-3
1.1 Crankcase - Invert .................................................................................................................... 7-3
1.2 Piston cooling nozzle - Install ................................................................................................... 7-3
1.3 Upper main bearing - Install...................................................................................................... 7-4
1.4 Rear upper thrust plate - Install ................................................................................................ 7-4
1.5 Crankshaft - Install.................................................................................................................... 7-5
1.6 Front upper thrust plate - Install................................................................................................ 7-5
1.7 Lower main bearing and Lower thrust plate - Install ................................................................. 7-5
1.8 Main bearing cap - Install.......................................................................................................... 7-6
1.9 Crankshaft end play - Measure................................................................................................. 7-7
1.10 Crankcase - Invert .................................................................................................................... 7-7
2. Cylinder liner, Piston and Connecting rod - Assemble........................................ 7-8
2.1 Cylinder liner top ridge height - Measure.................................................................................. 7-8
2.2 Cylinder liner flange protrusion - Calculate (when removing cylinder liner).............................. 7-8
2.3 Cylinder liner - Install ................................................................................................................ 7-9
2.4 Cylinder liner flange protrusion - Measure (when installing cylinder liner).............................. 7-10
2.5 Cylinder liner inside diameter - Measure ................................................................................ 7-10
2.6 Piston and Connecting rod - Assemble .................................................................................. 7-11
2.7 Piston ring - Install .................................................................................................................. 7-11
2.8 Rotating crankshaft................................................................................................................. 7-12
2.9 Piston installation - Prepare.................................................................................................... 7-12
2.10 Upper connecting rod bearing - Install.................................................................................... 7-12
2.11 Piston - Install ......................................................................................................................... 7-13
2.12 Connecting rod cap - Install .................................................................................................... 7-15
2.13 Connecting rod end play - Measure........................................................................................ 7-16
2.14 Piston protrusion - Measure.................................................................................................... 7-17
3. Front equipment - Assemble ................................................................................ 7-18
3.1 Coupling - Install ..................................................................................................................... 7-18
3.2 Front plate - Install .................................................................................................................. 7-18
3.3 Front idler shaft - Install .......................................................................................................... 7-18
3.4 Front idler gear - Install........................................................................................................... 7-18
3.5 Front idler gear backlash - Measure ....................................................................................... 7-19
3.6 Front idler gear end play - Measure........................................................................................ 7-19
3.7 Water pump bearing cover and Oil pump bearing cover - Install............................................ 7-19
3.8 Water coupling - Install ........................................................................................................... 7-19
3.9 Front gear case - Install .......................................................................................................... 7-20
3.10 Front oil seal - Install............................................................................................................... 7-20
3.11 Oil pump gear and Pump plate (for water pump and oil pump) - Install ................................. 7-20
3.12 Breather case - Install............................................................................................................. 7-21
3.13 Damper - Install ...................................................................................................................... 7-21
3.14 Damper face and radial runouts - Measure ............................................................................ 7-21
3.15 Pointer - Install and Adjust...................................................................................................... 7-21
7-1
4. Rear equipment - Assemble ................................................................................. 7-22

4.1 Rear plate - Install................................................................................................................... 7-22
4.2 Rear idler shaft - Install........................................................................................................... 7-22
4.3 Camshaft - Install.................................................................................................................... 7-22
4.4 Camshaft gear - Install............................................................................................................ 7-23
4.5 Camshaft end play - Measure................................................................................................. 7-23
4.6 Fuel injection pump accessory drive - Assemble.................................................................... 7-23
4.7 Idler gear - Install .................................................................................................................... 7-24
4.8 Rear idler gear end play - Measure ........................................................................................ 7-24
4.9 Timing gear backlash - Measure ............................................................................................ 7-24
4.10 Timing gear case - Install........................................................................................................ 7-25
4.11 Rear idler shaft thrust collar - Install ....................................................................................... 7-25
4.12 Rear oil seal - Install ............................................................................................................... 7-26
4.13 Flywheel - Install ..................................................................................................................... 7-26
4.14 Flywheel face and radial runouts - Measure........................................................................... 7-26
4.15 Governor drive - Install ........................................................................................................... 7-27
5. Cylinder head and Valve mechanism - Assemble .............................................. 7-28
5.1 Cylinder head - Assemble....................................................................................................... 7-28
5.2 Valve sinkage - Measure ........................................................................................................ 7-29
5.3 Tappet - Install ........................................................................................................................ 7-29
5.4 Liquid gasket - Apply .............................................................................................................. 7-29
5.5 Cylinder head gasket - Install ................................................................................................. 7-30
5.6 Cylinder head assembly - Install............................................................................................. 7-30
5.7 Cylinder head bolt - Tighten.................................................................................................... 7-30
5.8 Rocker case - Install ............................................................................................................... 7-31
5.9 Bridges and Bridge cap - Install.............................................................................................. 7-31
5.10 Valve bridge and Adjusting screw - Adjust ............................................................................. 7-31
5.11 Clearance between the bottom surface of valve bridge and the top surface of valve rotator -
Inspect .................................................................................................................................... 7-32
5.12 Rocker shaft assembly - Install............................................................................................... 7-32
5.13 Valve clearance - Inspect and Adjust ..................................................................................... 7-33
5.14 Fuel injection timing - Check and Adjust................................................................................. 7-33
5.15 Valve timing - Inspect ............................................................................................................. 7-35
5.16 Fuel injection nozzle assembly - Install .................................................................................. 7-36
7-2
1. Crankshaft and Main bearing - Install

side facing downwards. Then, change the positions of the
wire ropes, and turn over and invert the crankcase.
Crankcase - Invert
1.2 Piston cooling nozzle - Install
Be sure to tighten the piston cooling nozzle to the 34 ± 1.7 N·m {3.5 ± 0.18 kgf·m} Eye bolt
[25 ± 1.2 lbf·ft]
specified torque. Tightening without using a torque
wrench could result in excessive tightening force,
which could cause the check valve to malfunction,
possibly leading to piston seizure.
Install the piston cooling nozzle onto the crankcase and
tighten the eye bolts to the specified torque.
Piston cooling nozzle
Piston cooling nozzle - Install
7-3
1.3 Upper main bearing - Install
(a) Do not apply engine oil to the back of the shells and main bearing fitting bores in the crankcase when installing
the main bearing shells. Install the main bearings after cleaning off foreign matters as well as oil and grease
from these surfaces using cleaning solvent.
(b) Install the main bearings correctly. Do not confuse upper shells with lower shells.
The upper shells are identified by a machined oil groove. The lower shells have no oil groove and are finished
flat. It is possible to install the main bearing to wrong side, but it damages the crankshaft.
(c) Do not damage the bearings when installing.
(1) Clean the main bearing fitting bores and main bearing
cap seating surface, and make sure that these surfaces
are free from any foreign matter.
(2) Make sure that the main bearings are neither damaged
nor contaminated. Lug groove
(3) Fit the upper main bearing shells in the crankcase bores
while aligning their lugs with the corresponding
notches in the crankcase. Oil hole
Note:(a) Make the main bearing end protrusion from the
Upper main bearing
crankcase bore even at both ends.
Upper main bearing - Install
(b) The oil hole in the upper main bearing will be
aligned with the oil hole in the crankcase by fitting
the lug of the upper shell into the notch in the crank-
case.
(4) Apply an even coat of engine oil to the sliding surface
of each upper main bearing.
1.4 Rear upper thrust plate - Install
Do not damage the rear thrust plate when installing.

(1) Install the rear upper thrust plate to the dowel pin on the
rearmost end of crankcase with facing the oil groove to
the engine rear side.
(2) Apply engine oil evenly to the sliding surface.
Note: Insert the front upper thrust plate after installing the
crankshaft. Oil
grooves
Rear upper thrust plate - Install
7-4
1.5 Crankshaft - Install

(1) Check that an even coat of engine oil is applied to the
sliding surface of each upper main bearing that has
installed crankcase.
(2) Wash the crankshaft thoroughly with cleaning oil and
clean it completely by blowing compressed air. Then,
apply an even coat of fresh engine oil to the crank jour- After cleaning,
apply engine oil
nals. to crank journals.
Note: When cleaning the crankshaft, pay special attention to After cleaning,
the oil holes in the crank journals and crankpins. Make dry with
compressed air.
sure that oil holes are free from any burrs.
Crankshaft - Clean
(3) Keeping the crankshaft in a horizontal position, slowly
install into the crankcase.
Note: When lifting the crankshaft horizontally, place cloth Crankshaft assembly
belts or pads in position, not to damage the crankshaft.
(4) Make sure that the crankshaft turns freely.
Crankshaft - Install
1.6 Front upper thrust plate - Install
Do not damage the front upper thrust plate when Front upper thrust
plate
installing.
(1) Push the installed crankshaft to the engine front, con-
tact the installed rear upper thrust plate and end of
crank journal to the crankcase gently.
(2) Face the oil groove of front upper thrust plate to the
Insert it between
engine front. Insert the front upper thrust plate between the crankshaft and
the crankshaft and crankcase. crankcase.
(3) Move the crankshaft back and forth, and check the end Front upper thrust plate - Install
play.
1.7 Lower main bearing and Lower thrust plate - Install
(1) Install the lower main bearing, aligning with the lug
Lower main
groove of the main bearing cap. bearing
Note: Make a protrusion amount of bearings even.
Lower thrust
(2) Apply an even coat of engine oil to the sliding surface plate
of each lower main bearing. Lug groove
(3) Install the lower thrust plate to the dowel pin on the
Lower thrust
rearmost main bearing cap. plate
Note: Install the lower thrust plate so that its oil groove faces
outward. Main bearing cap
Oil groove Dowel pin
Lower main bearing and Lower thrust plate - Install
7-5
1.8 Main bearing cap - Install
Be sure to observe the specified tightening

sequence when installing the main bearing cap bolts
and side bolts.
(1) Make sure the main bearing and thrust plate that were
"FRONT" mark
installed to the main bearing cap are lubricated with an
even coat of fresh engine oil.
(2) Install the main bearing cap from the front side to the
rear side of the engine with the "FRONT" mark on the
Main bearing caps
bottom of the main bearing cap facing the front side of
the engine. All of the lug grooves on the main bearing
cap should be in the same position.
(3) Coat the threads of the main bearing cap and washer
with engine oil, and tighten the bolts temporarily.
Main bearing cap - Install
(4) Tap on each main bearing cap with a soft-head hammer
to drive it into position.
(5) Coat the guide bolt and O-ring with engine oil, and
install the bolts and washer temporarily.
(6) Tighten temporary the main bearing cap bolt and side First
Main bolt: 294 ± 15 N·m
bolt except for rearmost one to the half of specified {30 ± 1.5 kgf·m} [217 ± 11 lbf·ft]
Tighten to the specified Side bolt: 196 ±10 N·m
torque in the illustrated order. torque in the numerical {20 ± 1 kgf·m} [144.66 ± 7.23 lbf·ft]
Second
(7) Tighten temporary the main bearing cap bolt except for order in two steps.
Main bolt: 588 ± 29.4 N·m
[Wet]
{60 ± 3.0 kgf·m} [434 ± 22 lbf·ft]
rearmost one to the specified torque in the illustrated Side bolt: 392 ±19.6 N·m
{40 ± 2.0 kgf·m} [289 ± 14 lbf·ft]
order. 31 24 41 32
(8) Tighten temporary to place the rearmost main bearing
5 6 5 6
cap.
or
Measure the crankshaft end play in this condition.
Tightening sequence for main bearing cap bolt
588 ± 29.4 N·m

392 ± 19.6 N·m {60 ± 3.0 kgf·m}
{40 ± 2.0 kgf·m} [434 ± 22 lbf·ft]
[289 ± 14 lbf·ft] [Wet]
[Wet]
Main bearing cap bolt - Install
7-6
1.9 Crankshaft end play - Measure

(1) Make sure that each crankshaft rotates freely.
(2) Attach a dial gauge to the end of the crankshaft.
(3) Move the crankshaft with a pinch bar to front side and
rear side. Measure the difference between front side and
rear side. Measure the end play.
If the measured value is over the standard, inspect the
thrust plate and crankshaft.
If the measured value is under the standard, move the
crankshaft back and forth with loosing the tightening
bolt of rearmost main bearing cap.
Note: In general, the rear thrust bearing wears faster than the
front thrust bearing. Therefore, in most cases, the cor-
rection is achieved by replacing the rear thrust plate
with a next oversize one.
(4) Tighten the rearmost main bearing cap fully, and mea-
sure the end play again.
(5) Make sure that each crankshaft rotates freely.
(6) Check that the all main bearing cap bolts and side bolts
are tighten fully.
Item Standard Limit

0.200 to 0.400 mm 0.500 mm
Crankshaft end play
[0.0079 to 0.0157 in.] [0.0197 in.]

side facing downwards. Then, rehang the wire ropes. Invert
the crankcase on the wooden blocks and turn it to the stan-
dard position.
Crankcase - Invert
7-7
2. Cylinder liner, Piston and Connecting rod - Assemble

2.1 Cylinder liner top ridge height - Measure
(1) Place the dial gauge on the top surface of the cylinder
Ridge height
liner flange, and zero the dial gauge.
(2) Measure the height of the annular top ridge of the cylin-
der liner at four locations.
(3) If the measured value does not meet the standard, or the
ridge is lacked, replace the cylinder liner with a new Cylinder liner top
one.
Item Standard
0.16 to 0.24 mm
Cylinder liner top ridge height
[0.0063 to 0.0094 in.]
Cylinder liner top ridge height - Measure
2.2 Cylinder liner flange protrusion - Calculate (when removing cylinder liner)
If the amount of protrusion is insufficient, the cylinder

head gasket will fail to seal hermetically, resulting in
gas or water leakage.
(1) Inspect the cylinder liner contact surface on the crank-
case. If there is any evidence of uneven contact, reface
the counterbore using the crankcase grinder such that
the difference in depth at the circumference is less than Projection plate
0.05 mm [0.0020 in.]. P/N:37598-09201
For repairing, refer to "Counterbore in crankcase -

Counterbore depth
Repair" of "INSPECTION AND REPAIR OF BASIC
ENGINE".
(2) Make sure that the top and bottom of cylinder liner
flange, the top surface of crankcase and the contact sur-
face of cylinder liner are clean before measurement.
(3) Measure the depth of counterbore in crankcase. Depth of counterbore in crankcase - Measure
Item Standard
14.00 to 14.05 mm
Depth of counterbore in crankcase
[0.5512 to 0.5531 in.]
(4) Measure the thickness of cylinder liner flange.
Item Standard
14.16 to 14.20 mm
Thickness of cylinder liner flange
[0.5575 to 0.5591 in.]
Cylinder liner
Thickness of cylinder liner flange
7-8
(5) Calculate the cylinder liner flange protrusion by sub-

tracting the Depth of counterbore in crankcase from the Crankcase
Shim
thickness of the cylinder liner flange.
Cylinder liner
If the measured value exceeds the standard value, insert
a shim under the cylinder liner flange. Select a shim
which makes the cylinder liner flange projection the
largest within the tolerance of the standard.
Note:(a) The thickness of shim are available 0.05, 0.10 and
0.15 mm [0.0020, 0.0039 and 0.0059 in.].
(b) Do not use the shims stacked in pairs.
Shim - Insert
Item Standard
Cylinder liner protrusion 0.11 to 0.20 mm [0.0043 to 0.0079 in.]
Shim thickness Part No.

0.05 mm [0.0020 in.] 37507-12510
0.10 mm [0.0039 in.] 37507-12500
0.15 mm [0.0059 in.] 37507-12520
2.3 Cylinder liner - Install
Apply engine oil to the O-rings to prevent them from

twisting.
(1) Install the O-ring to the cylinder liner.
(2) Insert the shim for adjusting the cylinder liner flange
protrusion to the cylinder. O-ring
Apply
engine oil
O-ring
O-ring
Cylinder liner O-ring - Install

(3) Slowly insert the cylinder liner into the bore in the
crankcase. Using the cylinder liner installer, lightly tap
the cylinder liner until its flange rests snugly on the
seating surface of the crankcase. Then, give several
light taps on the liner to settle. Installer
Note: To check the O-ring installation, measure the round- Cylinder liner
ness of inside cylinder liner (O-ring installing position)

for the malfunctions.
Cylinder liner - Install
7-9
2.4 Cylinder liner flange protrusion - Measure (when installing cylinder liner)
(1) Remove the dust and stain on the crankcase and at the
Bolt Cylinder liner
top end to be measured of cylinder liner. P/N:37591-06300 flange protrusion
(2) Attach the liner holders on equally spaced 4 locations Tightening
torque
of the cylinder liner upper rim and tighten the bolts of
98 N·m
the holders evenly to contact the crankcase. {10 kgf·m}
[72 lbf·ft]
(3) Apply the dial gauge plunger to the top surface of the
crankcase, and zero the dial gauge.
(4) Measure the flange protrusion at four locations on the
top of the cylinder liner, and obtain the mean value. Liner pusher
P/N:37591-06200
(5) If the mean value of the protrusion is smaller than the
standard, insert a shim under the cylinder liner flange.
2.5 Cylinder liner inside diameter - Measure
Measure the inside diameter of the cylinder at three levels,
i.e., upper (position of No.1 compression ring when piston
Cylinder liner
is at top dead center), middle, and O-ring insertion portion,
in both directions parallel to and perpendicular to the piston
pin direction of the inside cylinder liner.
If the measured value exceeds the limit, replace the cylinder
liner with a new one, or repair the deformation.

ø170 mm 170.020 to 170.040 mm 170.500 mm
Inside diameter
[6.69 in.] [6.6937 to 6.6945 in.] [6.7126 in.]
0.02 mm
Roundness - -
[0.0008 in.] or less
Pin right angle
0.02 mm
Cylindricity - - Pin direction
[0.0008 in.] or less
[1.18 in.]
[3.94 in.]
30 mm
100 mm
[9.84 in.]
250 mm
Cylinder liner dimension measuring position
7-10
2.6 Piston and Connecting rod - Assemble

(1) Apply engine oil to the piston pin, and assemble the
A
piston and the connecting rod. The orientation of piston View A
and connecting rod is shown in the illustration. Piston weight
Note: The piston and piston pins are assembled to each other
with a clearance fit. However, the piston pins are more Camshaft
easily inserted into the pistons if the pistons are
&$0
Matching
warmed up with a heater or with hot water. marks
(2) Install the snap ring with ring pliers. Make sure the Direction mark
snap ring is fully inserted into the ring groove. (CAMЎ)
Part No.
Assembling direction of piston and connecting rod
Ring pliers
P/N:45191-08400
Piston and Connecting rod - Assemble

2.7 Piston ring - Install
Ring expander
P/N:37191-03200
Every piston ring has a top mark such as an "R" near
the end gap. Install all piston rings with this mark fac- Top mark
ing upward. No.1
compression ring
If the rings are installed upside down, it could cause
No.2
malfunctions such as excessive oil consumption or compression ring
engine seizing.
Oil ring
(1) Install the piston rings to the piston with a ring
Coil spring
expander.
(2) Install the oil ring with its end gap 180° away from the Piston and Piston ring - Install
joint of the coil spring, as shown in the illustration.
Coil spring joint
180°
Oil ring ends
Oil ring end gap and coil spring joint orientation
7-11
2.8 Rotating crankshaft

(1) Install two bolts in the flywheel mounting holes of the
crankshaft.
(2) Using the bolt, rotating the crankshaft with a bar.
M22 × 1.5 mm
Crankshaft
Rotating crankshaft
2.9 Piston installation - Prepare
(1) Rotate the crankshaft to the position that the connecting
rod big end does not hit the crankpin when installing
piston.
Crankpin Position that the connecting

rod big end does not hit the
crankpin
Position of crankpin - Adjust
(2) Clean the cylinder liner inner surface and the crankpin,
and apply engine oil to the cylinder liner.
Piston installation - Prepare

2.10 Upper connecting rod bearing - Install
Upper connecting
rod bearing
Do not apply engine oil to the back of the upper con- Lug groove
necting rod bearings.
Install the upper connecting rod bearing into the connecting
rod big end while aligning its lug with the lug groove, and
apply engine oil to the sliding surface. Make sure that the oil
hole of the bearing and the oil hole of the connecting rod are
aligned. Oil hole
Upper connecting rod bearing - Install
7-12
2.11 Piston - Install
Mark on the piston top

“CAM↓”
When installing the piston, install the eye bolt to the
threaded hole, and then lift the piston with chain
block. If lifting piston by hands, be careful of falling
&$0
down the piston. Take utmost care to insure that your
fingers are not damaged.
Camshaft side
Camshaft
(a) Make sure that the mark on the piston top points
Do not hit.
the camshaft side. Piston - Install (1)
(b) Checking through the inspection window on the
side of crankcase, make sure that the connecting No.1
Coil spring joint compression
rod does not come into contact with the piston ring ends
cooling nozzle when installing piston.
(c) To protect the oil ring from damage due to shock,
Piston pin
gently insert the piston.
(1) Insert the connecting rod into the cylinder liner, taking
care not to damage the cylinder liner, and slowly lower No.2
the piston to the upper surface of the crankcase. compression Oil ring ends
ring ends
(2) Apply engine oil to the piston rings.
Place the end gaps equally spaced each other, avoiding Piston - Install (2)
thrust and anti-thrust direction, and pin direction.
(3) Hold the piston with your hands on the compression
rings, and carefully insert the piston skirt into the cylin-
der liner. Compression
Note: Hold the oil ring to insert the stick to the piston pin ring
hole, not to pressurize to the oil ring.
Piston - Install (3)

(4) Revalidate that the piston ring end gaps are positioned
correctly.
Apply engine oil to the piston rings.
Apply engine oil to the inner surface of piston installer.
Check that the oil ring does not deviate from the
groove. Then, fasten the piston ring with the piston
Piston installer
installer. P/N:37191-07100
7-13
(5) Insert piston into cylinder liner and tap the piston head
with a soft-head hammer to install.
Note: Make sure that the piston is not caught in the cylinder
liner, or the connecting rod big end does not hit the
crank pin etc.
Use a soft hammer
handle

(6) Check that the upper connecting rod bearing shell is
positioned in place on the side face of the crankcase. If Check bearing position.
the bearing is out of alignment, push the bearing

upward with your hand to adjust.

(7) If the upper connecting rod bearing is off the connect-
ing rod big end, turn the crankshaft to make a space
between the connecting rod big end and crankpin.
Insert the connecting rod bearing along the crankpin,
aligning with the lug groove.
Upper connecting
rod bearing
7-14
2.12 Connecting rod cap - Install
Lower connecting
(a) Make sure that the matching numbers on the Connecting rod bolt rod bearing
connecting rod and the connecting rod cap are Lug groove
on the same side and in alignment. Thread
(b) Make sure that the mounting position of connect-
ing rod bolt with the identification mark.
Serration
(c) When installing the connecting rod caps, make
sure that dust, metal particles, etc. are not Connecting rod
Bolt seating
caught in the serrations, bolt seating surfaces cap
surface
and the bolt threads. Connecting rod cap - Install (1)
(1) Install the lower connecting rod bearing, aligning with
the lug groove of the connecting rod bearing cap.
(2) Apply engine oil to the connecting rod bolt threads and
seating surface, and the sliding surface of the lower
connecting rod bearing shell.
(3) Make sure that the matching numbers on the connecting
Identification mark
rod cap and the connecting rod are on the same side and “AU”: Top (short)
in alignment. Then, install the connecting rod cap to the
AU
connecting rod.
(4) Tighten the connecting rod bolt temporarily.
Note: Bolt identification mark
AL
"AU": Top (short)
"AL": Bottom (long)
Identification mark
“AL”: Bottom (long)
Connecting rod cap - Install (2)

(5) Keep the end play so that there is no deviations for the
connecting rod cap.
Note: It can be adjusted with inserting the connecting rod
gauge between two connecting rods to keep the mini-
mum standard end play.
Ensure the end play

with a connecting
rod gauge
P/N :37791-01500 (Thickness 0.5 mm [0.020 in.])

:37791-01600 (Thickness 0.6 mm [0.024 in.])
7-15
(6) Measure the connecting rod end play, and adjust the
Tightening torque
end play to the standard. ‫ۑ‬Bolt identification mark “AL”“AU”
(7) Tighten the connecting rod bolts to the specified torque. 637 ± 31.9 N·m {65 ± 3.25 kgf·m}
[470 ± 24 lbf·ft]
Then, loosen the connecting rod bolts completely and 2-time tightening method (Wet)
tighten them again to the specified torque.
Measure the end play again.
Note: When tightening the connecting rod bolts according to
the angle method, follow the sequence described be-
low.
(a)Tighten it with snug torque.
Bolt
Location identification Snug torque
mark
245 ± 12.3 N·m
Top AU
{25 ± 1.25 kgf·m} [180 ± 9 lbf·ft]
294 ± 14.7 N·m
Bottom AL
{30 ± 1.5 kgf·m} [217 ± 11 lbf·ft]
(b)Turn an additional 60 ± 3°(all bolts).

(c)Loosen all bolts, and then tighten them with the
angle method. (2-time tightening method)
2.13 Connecting rod end play - Measure
Measure the connecting rod end play (clearance between
connecting rod width and crankpin width).
Connecting rod
If the limit is exceeded, specify the causal parts, then
replace them with new ones.
Item Standard Limit

0.6 to 0.9 mm 1.4 mm
Connecting rod end play
[0.024 to 0.035 in.] [0.055 in.]
Connecting rod
end play
Connecting rod end play - Measure
7-16
2.14 Piston protrusion - Measure
Piston protrusion
Piston protrusion must always meet the standard, as
the amount of protrusion not only influences engine
performance, but it also prevents valve interference.
Measure the protrusion of each piston following the instruc-
tions below. If the measured value does not meet the stan-
dard, inspect the clearances between various parts involved.
(1) Bring the piston to top dead center.
(2) Apply the dial gauge plunger to the top surface of the
crankcase, and zero the dial gauge. Piston protrusion - Measure
(3) Move the dial gauge to the top of piston, measure the
Top clearance
maximum protrusion with rotating near top dead center.
Cylinder head Piston protrusion
Note: The crankshaft position that indicates the maximum gasket thickness Cylinder head
protrusion considered to be top dead center.
(4) Measure the protrusion at four points on the piston Cylinder liner
head, and calculate the mean value.
Note: The top clearance (clearance between the piston top Crank
case Cylinder liner Piston
and cylinder head) will be determined by the piston flange protrusion
protrusion, cylinder liner flange protrusion and cylin-
der head gasket thickness.
Top clearance
Top clearance = cylinder head gasket thickness + cyl-
inder liner flange protrusion - piston protrusion
Item Standard
0.03 to 0.63 mm
Piston protrusion
[0.0012 to 0.0248 in.]
0.11 to 0.20 mm
Cylinder liner flange protrusion
[0.0043 to 0.0079 in.]
1.77 to 1.83 mm
Thickness of cylinder head gasket
[0.0697 to 0.0720 in.]
1.25 to 2.00 mm
Top clearance
[0.0492 to 0.0787 in.]
7-17
3. Front equipment - Assemble

3.1 Coupling - Install
(1) Install the coupling with aligning the dowel pin on the
camshaft front end, and tighten the bolt.
(2) Install the oil seal and O-ring to the oil seal case, and
tighten the bolt. Oil seal
case
Note:(a) Apply the grease to the oil seal lip and the entire cir-
cumference of the O-ring.
(b) Install camshaft, then install the coupling, oil seal
and oil seal case.
Coupling
Oil seal
Coupling - Install
3.2 Front plate - Install
(1) Apply sealant (ThreeBond 1211) to the crankcase mat-
ing surface to the front plate, and attach the packing.
(2) Apply the same sealant (ThreeBond 1211) to the pack- Front plate
ing, and then install the front plate.

(3) Tighten the bolt to the specified torque.
(4) Check that the lower end of the front plate is flush with
the bottom surface of the crankcase. Cut off any excess
59 ± 5.9 N·m
packing neatly. {6 ± 0.6 kgf·m}
[43 ± 4.3 lbf·ft]
Front plate - Install

3.3 Front idler shaft - Install
(1) Install the front idler shaft to the crankcase.
108 ± 10.8 N·m

{11 ± 1.1 kgf·m}
[80 ± 8 lbf·ft]
Front idler shaft
Front idler shaft - Install

3.4 Front idler gear - Install
(1) Apply engine oil to the front idler gear shaft.
(2) Install the front idler gear.
(3) Install the thrust plate and tighten bolts to the specified Front idler gear
torque.
Thrust
plate
60 ± 3.0 N·m
{6.1 ± 0.31 kgf·m} [44 ± 2.2 lbf·ft]
Front idler gear - Install
7-18
3.5 Front idler gear backlash - Measure

Measure the backlash of the front idler gears by using one of
the following two methods; measure the gear play with the
dial gauge applied to a tooth flank on the pitch circle at a
right angle to the tooth axis, or measure the clearance
between gears by inserting a thickness gauge between the
gears at the tooth-to-tooth contacting area. If the limit is
exceeded, replace the gears with new ones. Front
idler gear
Item Standard Limit
0.11 to 0.28 mm 0.50 mm
Front idler gear backlash
[0.0043 to 0.0110 in.] [0.0197 in.]
3.6 Front idler gear end play - Measure
Measure the end play of the front idler gear. If the measure-
ment exceeds the limit, replace the thrust plate or rear idler Front
gear with a new one. idler gear
Item Standard Limit

Front idler gear 0.20 to 0.40 mm 0.6 mm
end play [0.0079 to 0.0157 in.] [0.024 in.]

3.7 Water pump bearing cover and Oil pump bearing cover - Install
(1) Install the oil seal to the water pump bearing cover.
Water pump
(2) Install the water pump bearing cover and oil pump bearing cover
bearing cover to the front plate.
108 ± 10.8 N·m
{11 ± 1.1 kgf·m}
[80 ± 8.0 lbf·ft]
Oil seal
Oil pump
bearing cover
Water pump bearing cover and Oil pump bearing
cover - Install
3.8 Water coupling - Install
(1) Apply the grease to the O-ring and O-ring groove.
(2) Install the water coupling of crankcase and gear case to
Apply grease
the crankcase, taking care not to damage the O-rings.
Apply grease
Water coupling - Install
7-19
3.9 Front gear case - Install

ing surface to the front gear case packing. Apply the Hoisting tool
same sealant (ThreeBond 1211) to the packing, and
then install the front gear case.
(2) Tighten the bolts evenly to the specified torque.
(3) Check that the lower end of the front gear case is flush
with the bottom surface of the crankcase. Cut off any
M12 : 59 ± 3.0 N·m
excess packing neatly. {6 ± 0.3 kgf·m}
[43 ± 2.2 lbf·ft]
M16 : 255 ± 12.8 N·m
{26 ± 1.3 kgf·m}
[188 ± 9.4 lbf·ft]
Front gear case - Install
3.10 Front oil seal - Install
Use the front seal installer assembly to install the front oil
Insert bolt
seal.
Guide flange
(1) Apply a clean engine oil evenly to the oil seal lip.
Insert
Note: Be sure to install the oil seal in the correct direction,
taking care not to damage the oil seal. Socket bolt
(2) Install the guide flange to the crankshaft front end, and Bolt
secure it with the insert bolts.
(3) Set the oil seal to the insert and install it to the guide Front seal installer
flange. assembly
Swing washer P/N:37591-05010
(4) Tighten the bolt attached to the guide flange to install
Front oil seal - Install (1)
the oil seal into the front cover.
(5) Loosen the socket bolt, remove the swing washer from
the bolt and pull out the insert. 15.5 mm [0.610 in.]
(6) Remove the insert bolt, and then remove the guide
Slinger
flange from the crankshaft.
Front seal installer
assembly
P/N:37591-05010
Oil seal
Front oil seal - Install (2)

3.11 Oil pump gear and Pump plate (for water pump and oil pump) - Install
(1) Install the bearing to the oil pump gear.
(2) Insert the oil pump gear into place. 59 ± 5.9 N·m Oil pump
gear
(3) Install the pump plate to the front case. {6 ± 0.6 kgf·m}
[43 ± 4.3 lbf·ft]
Pump plate
Oil pump gear and Pump plate (for water pump and oil
pump) - Install
7-20
3.12 Breather case - Install

Install the breather case to the front gear case.
Breather case
O-ring
Breather case - Install

3.13 Damper - Install
(1) Screw the guide bolts to the damper mounting hole of Stamping No stamping
crankshaft. Front damper
(2) Put in order of the spacer, rear damper, spacer, front
Rear damper
damper to the guide bolt, and install them with aligning
dowel pin. Dowel pin

Note: Check the installing position and direction of damper. Spacer
490 ± 24.5 N·m
{50 ± 2.5 kgf·m}
[361 ± 18 lbf·ft]
Damper - Install
3.14 Damper face and radial runouts - Measure
Measure the face and radial runouts of the damper.
If the measured value exceeds the standard, check the bolt
for looseness as well as the accumulation of foreign matter
on the mounting face.
Note: Do not measure on the stamping position.
Item Standard
Face runout 0.5 mm [0.020 in.] or less Face runout
Radial runout 0.5 mm [0.020 in.] or less
Radial runout

3.15 Pointer - Install and Adjust
(1) Install the pointer to the front gear case.
(2) Rotate the crankshaft to bring top dead center of No. 1
cylinder. Align the stamped line of top dead center of
No. 1 cylinder on the periphery of damper with the Timing gear
case
pointer.
(3) Turn the flywheel so that its punch mark is positioned
at the same distance from the two punch marks stamped Flywheel
on the timing gear case. This position is considered to
be top dead center of No. 1 cylinder.
Note: For checking top dead center by the piston movement,
Top dead center of punch mark - Check
refer to "Piston protrusion - Measure" of "ASSEM-
BLY OF BASIC ENGINE".
7-21
4. Rear equipment - Assemble

4.1 Rear plate - Install
(1) Install the nozzle plate.
Nozzle plate
ing surface to the rear plate packing.
(3) Apply the same sealant (ThreeBond 1211) to the pack-
ing, and then install the rear plate.
Torque
(5) Check that the lower end of the rear plate is flush with M12 : 108 ± 5.4 N·m
{11 ± 0.55 kgf·m}
the bottom surface of the crankcase. Cut off any excess [80 ± 3.98 lbf·ft]
M16 : 255 ± 12.8 N·m
packing neatly. {26 ± 1.3 kgf·m}
[188 ± 9.4 lbf·ft]
Rear plate - Install
4.2 Rear idler shaft - Install
Fit the O-rings onto the rear idler shaft. Apply grease on the
O-ring. Rear plate
Adjust the rear idler shaft to the dowel pin, and install to the
Apply grease to O-ring
crankcase.
Rear idler shaft

Dowel pin
Rear idler shaft - Install
4.3 Camshaft - Install
Camshaft
Install the camshafts with support them with a protec-
tor such as a pad through the Crankcase window.
Thrust plate
Hitting the camshaft could cause damage to the cam-
shaft bushing. 59 ± 5.9 N·m
{6 ± 0.6 kgf·m}
(1) Apply engine oil to the inner surface of camshaft bush- [43 ± 4.3 lbf·ft]
ing.
(2) Apply the engine oil in the oil bore of camshaft, journal
and cam.
(3) Support the camshaft with protector, and insert the Camshaft - Install
camshaft gently to the crankcase.
(4) Install the thrust plate, and tighten the bolt to the speci-
fied torque.
(5) Make sure that each camshaft rotates freely.
7-22
4.4 Camshaft gear - Install

(1) Install each camshaft gear by aligning its hole with the
dowel pin on the camshaft. Camshaft gear
(3) Make sure that each camshaft rotates freely.
127 ± 6.4 N·m

{13 ± 0.65 kgf·m}
[94 ± 5 lbf·ft]
Camshaft gear
Camshaft gear - Install
4.5 Camshaft end play - Measure
Measure the camshaft end play. If the limit is exceeded,
specify the causal parts, then replace them with new ones. Camshaft gear
Item Standard Limit

0.10 to 0.25 mm 0.40 mm
Camshaft end play
[0.0039 to 0.0098 in.] [0.0157 in.]

4.6 Fuel injection pump accessory drive - Assemble
(1) Install the O-ring to the mounting surface of the fuel
injection pump accessory drive case. Apply a thin coat 108 ± 5.4 N·m {11 ± 0.55 kgf·m}
[80 ± 4.0 lbf·ft]
of ThreeBond 1212 to the flange.
(2) Install the fuel injection pump accessory drive to the
rear plate.
Fuel injection pump

accessory drive
Fuel injection pump accessory drive - Assemble
7-23
4.7 Idler gear - Install

(1) Rotate the crankshaft to bring the No. 1 at top dead cen-
ter. Camshaft gear
(2) Apply engine oil to the idler shaft. Rear idler gear
(3) Install the idler gear with matching mark.

(4) Install the thrust plate to the idler shaft.


/

5

(6) Ensure that the matching marks on the timing gears are
aligned as shown in the illustration.
Injection pump gear Injection pump gear
Crankshaft gear
Timing gear train
Thrust plate
392 ± 19.6 N·m
{40 ± 2.0 kgf·m}
[289 ± 14 lbf·ft]
Apply Molykote to threads.
Dowel pin
Apply Molykote on the
inner surface of rear
idler bushing
(whole surface).
Rear idler gear
Slinger
Idler gear - Install
4.8 Rear idler gear end play - Measure
Measure the end play of the rear idler gear. If the measure-
ment exceeds the limit, replace the thrust plate or rear idler
gear with a new one.
Item Standard Limit

0.3 to 0.6 mm 1.0 mm
Rear idler gear end play
[0.012 to 0.024 in.] [0.040 in.]

4.9 Timing gear backlash - Measure
Measure the backlash of the timing gears by using one of
the following two methods; measure the gear play with the Camshaft gear
dial gauge applied to a tooth flank on the pitch circle at a Injection
pump gear
right angle to the tooth axis, or measure the clearance
between gears by inserting a thickness gauge between the
gears at the tooth-to-tooth contacting area. If the limit is
exceeded, replace the gears with new ones.
Item Standard Limit

0.11 to 0.28 mm 0.50 mm Rear idler gear
Timing gear backlash
[0.0043 to 0.0110 in.] [0.0197 in.]
7-24
4.10 Timing gear case - Install
Be careful not to drop or hit the timing gear case.

Doing so may damage to the timing gear case and
lead to personnel injuries.
(1) Apply sealant (ThreeBond 1211) to the packing mount-
255 ± 12.8 N·m
ing surface of the rear plate, and install the packing.
{26 ± 1.3 kgf·m}
(2) Apply sealant (ThreeBond 1211) to the packing for the [188 ± 9.4 lbf·ft]
timing gear case mounting.
Timing gear case
(3) Attach a hoisting tool to the timing gear case, align it
with the dowel pin, and install the timing gear case. Timing gear case - Install
(5) Cut off neatly any excess packing from the bottom of
crankcase.
4.11 Rear idler shaft thrust collar - Install
(1) Apply grease to the rear idler thrust collars, and insert
the thrust collars to the timing gear case.
Make sure the "TOP" mark is located at the top. Install
Rear idler
the rear idler shaft thrust collar with the identification
shaft thrust collar
mark that marked when removing.
(2) Tighten the nut with the specified torque. Cover
(3) Install the cover to the timing gear case.
196 ± 9.8 N·m
{20 ± 1.0 kgf·m}
[145 ± 7 lbf·ft]
Rear idler shaft thrust collar - Install
7-25
4.12 Rear oil seal - Install

Use the rear seal installer assembly to install the rear oil
seal. Insert bolt
(1) Apply a clean engine oil evenly to the oil seal lip. Guide flange
Insert
Note: Be sure to install the oil seal in the correct direction, Swing washer
taking care not to damage the oil seal.
Rear seal installer Socket bolt
(2) Install the guide flange to the crankshaft rear end, and
assembly
secure it with the insert bolts. P/N:37791-06010 Bolt
(3) Set the oil seal to the insert and install it to the guide
flange.
(4) Tighten the bolt mounted on the guide flange to insert
Rear oil seal - Install (1)
the oil seal into the timing gear case.
(5) Loosen the socket bolt, remove the swing washer from 17.5 mm
Timing [0.6890 in.] Rear seal installer
the bolt and pull out the insert.
Gear case assembly
(6) Remove the insert bolt, and then remove the guide
Oil seal P/N:37791-06010
flange from the crankshaft.
Slinger
Rear oil seal - Install (2)

4.13 Flywheel - Install
Be careful not to drop or hit the flywheel. Doing so

Flywheel
may damage to the flywheel and lead to personnel
injuries.
(1) Check the mounting surfaces of flywheel and crank-
shaft for foreign matter or damage.
588 ± 29.4 N·m
(2) Attach a hoisting tool to the flywheel. {60 ± 3.0 kgf·m}
(3) Install the flywheel by aligning its holes with the dowel [434 ± 22 lbf·ft]
[Wet]
pins on the crankshaft.
(4) Apply engine oil to the threads and bolt seat surfaces, Flywheel - Install
then tighten the bolts to the specified torque.
4.14 Flywheel face and radial runouts - Measure
Measure the face and radial runouts of the flywheel.
If the measured value exceeds the standard, check the bolt
for looseness as well as the accumulation of foreign matter Face runout
measurement
on the mounting face.
Radial runout
measurement
Item Standard
Face runout 0.336 mm [0.0132 in.] or less
Radial runout 0.130 mm [0.0051 in.] or less
7-26
4.15 Governor drive - Install

(1) Install the O-ring to the governor drive.
Ｏ-ring
(2) Install the governor drive to the rear plate.
Governor drive
108 ± 5.4 N·m
{11 ± 0.55 kgf·m}
[80 ± 4.0 lbf·ft]
Governor drive - Install
7-27
5. Cylinder head and Valve mechanism - Assemble

5.1 Cylinder head - Assemble
Guide & seal installer Guide & seal installer
P/N:37191-11500 P/N:37591-12300
(a) Be careful when inserting the stem seal through Valve stem
the valve, as the edge of the valve can cause
Stem seal
damage to the lip of stem seal.
33.6 mm [1.323 in.]

34.3 mm [1.350 in.]
(b) Do not apply oil or liquid sealant to the fit of stem Valve guide
seal and valve guide.

(c) Always replace the stem seal with a new one Lower retainer
once it has been removed. Cylinder head

(1) Apply engine oil to the valve stem, then insert the valve Inlet side Exhaust side
onto the valve guide. Stem seal - Install
(2) Install the lower retainer to the valve guide on the Exhaust Inlet
exhaust side.
Valve cotter
(3) Insert the stem seal through the valve guide using a Valve cotter
Upper rotator
guide & seal installer. Valve rotator
Inner valve
Note: Press fit the valve stem seal with centering by the valve spring Valve spring
stem that is installed to the cylinder head. Outer valve
(4) Apply engine oil to the lip of stem seal. spring Stem seal
(5) Install the retainer, valve spring and rotator to the valve Lower retainer
guide, and then install the valve cotter with valve spring Stem seal
pusher.
Valve and Valve spring - Install
Note: Check the inlet parts and exhaust parts when installing.
Valve spring pusher
P/N:33591-04500
Apply engine oil.

Valve cotter - Install
(6) Tap the top of valve stem lightly several times with a
soft-head hammer to ensure that the valve spring and Valve stem head
valve cotters are properly installed and seated firmly.
Valve - Install
7-28
5.2 Valve sinkage - Measure

Measure the valve sinkage.
If the measurement exceeds the limit, replace the valve or
Seat width
valve seat with a new one. Always lap the valve and valve
seat after the valve or valve seat has been refaced or
replaced.
Item Standard Limit

Valve seat
-0.1 to 0.1 mm 1.0 mm Valve margin
Valve sinkage angle
[-0.004 to 0.004 in.] [0.040 in.] Valve sinkage

5.3 Tappet - Install
Coat the periphery of tappets with engine oil, insert them
into the tappet holes and place them gently on the cam-
shafts.
Apply engine oil.
Tappet - Install
5.4 Liquid gasket - Apply
(a) Do not apply liquid gasket more than necessary.

Doing so may cause deformation of O-rings. 10 mm
Do not apply
[0.39 in.]
When applying gasket to portions A and B, in liquid gasket
on this area.
particular, take utmost care since there is little
A
clearance to the O-rings. 5 to 8 mm
[0.20 to 0.32 in.]
(b) Do not apply liquid gasket to the bore. Doing so Liquid gasket:
ThreeBond 1211
may cause gas leakage. P/N:37594-01300
(1) Wipe off oil, grease and other stains from the cylinder Liquid gasket coating area
head gasket, the cylinder head bottom surface and the Liquid gasket coating area (head side)
crankcase upper surface.
(2) Apply a thin coat of liquid gasket to both sides of the 10 mm
[0.39 in.]
cylinder head gasket around the tappet holes and oil
passages. Beads of liquid gasket should be 5 to 8 mm Do not apply liquid gasket
[0.20 to 0.32 in.] from the cylinder head gasket outer on this area.
edge with a thickness of 0.2 to 0.5 mm [0.008 to 0.020

in.]. The particular applying ranges are as illustrated at B
Liquid gasket:
right. ThreeBond 1211
P/N:37594-01300
Note: After applying liquid gasket, install the cylinder head
Liquid gasket coating area
as soon as possible, as the gasket will be dried up read-
Liquid gasket coating area (crankcase side)
ily.
7-29
5.5 Cylinder head gasket - Install

(1) Wipe off oil, grease and other stains from the cylinder
head bottom surface and the crankcase upper surface.
(2) Install the cylinder head gasket that has been coated
with liquid gasket onto the crankcase with the dowel
pin and the hole in alignment.
Dowel pins
Cylinder head gasket - Install
5.6 Cylinder head assembly - Install
(1) Apply engine oil to the threads, bolt seat and washer
Eye nut
surface. P/N:37591-02400 Apply engine oil.
Note: Remove excess oil before installation.
(2) Install the eye nut to the stud bolt, then lift the cylinder
head assembly.
(3) Position the head properly by aligning the holes with
the dowel pins, and temporarily tighten the cylinder
head bolts while keeping the head slightly lifted.
Cylinder head assembly - Install

5.7 Cylinder head bolt - Tighten
The tightening of cylinder head bolts can be accomplished
Torque for 2-time tightening method:
in two ways, i.e., torque method and angle tightening 539 ± 27 N·m {55 ± 2.75 kgf·m}
[398 ± 20 lbf·ft] [Wet] 2
method.
Snug torque for 4
5.7.1 Torque tightening method angle tightening
method:
(1) Tighten the cylinder head bolt progressively in the 294 ± 14.7 N·m
sequence shown in the illustrated order. {30 ± 1.5 kg f·m} 5
[217 ± 11 lbf·ft] 6
(2) Loosen all bolts, then retighten them according to this
torque method. (2-time tightening method)
5.7.2 Angle tightening method 3
1
(1) Tighten the cylinder head bolts to the specified snug
Tightening sequence of cylinder head bolts
torque in the sequence shown in the illustrated order.
(2) Place the head bolt plate on the top of cylinder head.
Head bolt plate
(3) Add the mark to the cylinder head bolt.
P/N:37598-08900
(4) Tighten each bolt in the indicated sequence by turning
65±3°.
(5) Loosen all bolts, and then tighten them with the angle Apply engine oil.
method. (2-time tightening method)
Cylinder head bolt with angle method - Tighten
7-30
5.8 Rocker case - Install

(1) Apply grease to a new O-ring, then install the O-ring on
Connector
water outlet connector. mounting hole Connector
Snap ring groove
(2) Install the snap ring groove of water outlet connector to (deeper hole) mounting hole
the deeper connector mounting hole of rocker case, and
insert the water outlet connector fully.
Water outlet
(3) Install the rocker case by aligning its holes with the connector
dowel pins.
(5) Slide and insert the water outlet connector to next con- O-rings
Apply grease. Rocker case
nector mounting hole of rocker case.
Water outlet connector - Install
(6) Install the snap ring to the snap ring groove on the
water outlet connector. Slide the water outlet
connector to the next
connector hole.
108 ± 5.4 N·m

Water outlet Snap ring {11 ± 0.55 kgf·m}
スナップ
connector groove
リング溝 [80 ± 4 lbf·ft]
Rocker case - Install
5.9 Bridges and Bridge cap - Install
(1) Apply engine oil to the bridge guide.
(2) Install the bridge onto the bridge guide so that the Bridge cap
screw-fitted end of the bridge is positioned on the
exhaust manifold side.
(3) Apply engine oil in contact with the bridge, then install
the bridge cap. At this time, take care not to drop the
cap inside the crankcase through the push rod hole.
Apply engine
oil.
Bridges and Bridge cap - Install

5.10 Valve bridge and Adjusting screw - Adjust
Adjust the contact condition of the valve stem to contact
Hold the top of
bridge and bridge guide evenly and press down the both bridge by hand 55 ± 2.8 N·m
valve. {5.6 ± 0.28 kgf·m}
Tighten 10° [40.5 ± 2.07 lbf·ft]
(1) Loosen the adjusting screw to protrude 6 to 7 mm [0.23
to 0.27 in.] from top of nut.
Contact
(2) Hold the top of bridge by hands, and contact the top of surface of
valve stem on the other side of adjusting screw and valve
bridge and
bridge end. valve
(3) Turn the adjusting screw slowly until the screw con-
tacts the top of valve stem. Then, turn the screw further,
Valve bridge and Adjusting screw - Adjust
at angle of 10° from the position, and tighten the lock
nut to the specified torque.
7-31
5.11 Clearance between the bottom surface of valve bridge and the top surface of valve rotator - Inspect
Hold the top of bridge

by hand
Keep the standard clearance between valve bridge Valve bridge Bridge cap Clearance between
and valve rotator. If the clearance deviates from the the bottom surface
standard, the valve cotter is removed or damaged. Valve rotator of valve bridge and
the top surface of
Hold the valve bridge by hand to contact the top end of valve rotator
valve stem. Then, inspect the clearance between the bottom

surface of valve bridge and the top surface of valve rotator.
If the measured clearance deviates from the standard, spec-
ify the causal parts, then replace them with new ones.
Clearance between the bottom surface of valve bridge
Item Standard and the top surface of valve rotator - Inspect
Clearance between the bottom
surface of valve bridge and the top 2.1 mm [0.083 in.]
surface of valve rotator
5.12 Rocker shaft assembly - Install

(1) Install the spacer to the rocker shaft, and mount the
147 ± 7.4 N·m Spacer
rocker arms on both sides. {15 ± 0.75 kgf·m}
Oil passage
[108 ± 5.46 lbf·ft]
(2) Align the pin hole of the rocker shaft with the position-
Positioning
ing pin, and install the rocker shaft assembly to the pin
rocker case.
Rocker shaft
Rocker case Oil passage (clearance)
Rocker shaft assembly - Install
7-32
5.13 Valve clearance - Inspect and Adjust

Adjust the valve clearance. The valve clearance should be
adjusted when the engine is cold.
Note:(a) The inlet valves are on the left side and the exhaust
valves are on the right side when the cylinder head
is viewed from the camshaft gear side.
(b) The valve clearance standard values are indicated
VALVE CLEARANCE (COLD)
on the caution plate on the No. 1 cylinder rocker INLET
0.6 mm EXHAUST 0.8 mm
cover. F I R I N G O R D E R
1-9-6-14-2-10-4-12-8-16-3-11-7-15-5-13
FUEL INJECTION TIMING °
BTDC
CON-ROD RANK
Item Standard
Inlet 0.6 mm [0.024 in.] Caution plate
Valve clearance
Exhaust 0.8 mm [0.032 in.]
(1) Check the valve clearance on all cylinders in the same

1 8
sequence as the firing order. On each cylinder, place the
piston at compression top dead center stroke before
checking the valve clearance. Turn the crankshaft in the
normal direction to bring the piston of the next cylinder
Check for compression
to top dead center. top dead center
(2) On each cylinder, the piston is at compression top dead
Firing order
center when the corresponding cylinder number Cylinder number:1-9-6-14-2-10-4-12-8-16-3-11-7-15-5-13
stamped on the damper is aligned with the pointer. Nei- No. 1 cylinder compression top dead center - Check
ther the inlet valve nor the exhaust valve should be
lifted off its seat by the push rod.
(3) Insert a thickness gauge between the rocker arm and
bridge cap. Tighten or loosen the adjusting screw while
measuring the clearance with a thickness gauge of
appropriate thickness.
(4) After adjustment, tighten the lock nut firmly to the
specified torque. Then, check the clearance again.
64 ± 3.2 N·m
{6.5 ± 0.33 kgf·m}
[47 ± 2.4 lbf·ft]
Valve clearance - Adjust
5.14 Fuel injection timing - Check and Adjust
5.14.1 Specified value of fuel injection timing - Check
The fuel injection timing varies with the engine output,
speed and fuel gas specifications. Be sure to check the fuel
injection timing according to the plate attached on the No. 1
rocker cover.
VALVE CLEARANCE (COLD)

INLET
0.6 mm EXHAUST 0.8 mm
F I R I N G O R D E R
1-9-6-14-2-10-4-12-8-16-3-11-7-15-5-13
FUEL INJECTION TIMING °
BTDC
CON-ROD RANK
Specified value of fuel injection timing - Check
7-33
5.14.2 Fuel injection timing - Check

(1) Rotate the crankshaft in the normal direction, stop
rotating in cylinder No. 1 to 30° before compression top 1 8
dead center.
(2) Make sure that the valve clearance of No. 1 cylinder
within the standard and press down the valve, then
determine compression top dead center. Check for compression
Check that the "0" stamped line of fuel injection pump top dead center
flywheel indicates near the pointer.
(3) Align the specified mark for fuel injection timing to the
Positioning compression top dead center of No. 1
pointer with turning crankshaft to the normal direction
cylinder
progressively.
When the "0" stamped line of fuel injection pump fly-
Pointer
wheel aligns with the pointer, the specified fuel injec-
tion timing would be set.
If misaligned the "0" stamped line with the pointer,
align the fuel injection timing.
Note: For the left fuel injection pump, turn the crankshaft in
No.9 cylinder to before compression top dead center,
and then follow a procedure described above.
Line mark on the flywheel
Fuel injection timing - Check
5.14.3 Fuel injection timing - Adjust

Line mark
on the flywheel
progressively.
(2) Loosen the bolt (long) for driving coupling, and rotate
the fuel injection pump only. Adjust the "0" stamped Pointer
line to the pointer, then tighten the bolt (long).
(3) Rotate the crankshaft to the inverse direction by 118 ± 5 N·m
approx. 20°. {12 ± 0.5 kgf·m}
[87 ± 3.6 lbf·ft]
Fuel injection timing - Adjust
progressively again.
Check that the "0" stamped line of fuel injection pump
flywheel aligns with the pointer.
Repeat the step (2) if misaligned.
7-34
5.15 Valve timing - Inspect

The valve timing will be set in the specified range if each
gear is assembled according to the matching marks and
adjust the valve timing. Checking valve timing is as follows.
5.15.1 Valve timing when valve clearance is 0 mm

Top dead center
(1) Check that the valve clearance is adjusted to the stan- 45㺽 63㺽
dard. Exhaust Inlet valve
valve close open
(2) Insert the thickness gauge as the same thickness of
Rotational
valve clearance standard values between bridge cap and direction
rocker arm. (valve clearance 0 mm)
(3) Turn the crankshaft to the normal direction progres-
sively. Check that the opening valve and closing valve Exhaust
valve open 53㺽 35㺽 Inlet valve
position. close
(4) Check that the angle is matched with the illustration. Bottom dead center
Valve timing when valve clearance is 0 mm
Rocker arm
Standard value
of valve clearance
Bridge cap Thickness gauge

Valve clearance 0 mm
5.15.2 Valve timing when valve clearance is 2 mm
Top dead center
[0.08 in.] 25㺽 Inlet valve
Exhaust 7㺽
Adjust the clearance to 2.5 mm [0.098 in.] with inspecting open
valve close
certainly in the position that varies the valve motion.
Rotational
(1) With a 0.5 mm [0.020 in.] thickness gauge inserted direction
between the bridge cap and the rocker arm. (Valve
clearance 2 mm [0.08 in.])
(2) Turn the crankshaft to the normal direction progres- Exhaust Inlet valve
valve open 21㺽 3㺽
sively. Check that the opening valve and closing valve close
position. Bottom dead center
Valve timing when valve clearance is 2 mm [0.08 in.]
(3) Check that the angle is matched with the illustration.
(4) Adjust the normal valve clearance. Rocker arm
Valve clearance
2 mm [0.08 in.]
0.5 mm
[0.020 in.]
Bridge cap Thickness gauge

Valve clearance 2 mm [0.08 in.]
7-35
5.16 Fuel injection nozzle assembly - Install
98 ± 4.9 N·m Spherical side down

{10 ± 0.5 kgf·m}
The fuel inlet connector must be used only for the [72 ± 3.6 lbf·ft]
installed fuel injection pump. O-ring
Nozzle gland
(apply grease)
(1) Remove the fuel inlet connector from fuel injection
nozzle assembly. Gasket
(apply grease)
(2) Install the 3 O-rings to the fuel injection nozzle, and
69 ± 5 N·m
apply a grease to its surface. {7 ± 0.5 kgf·m}
(3) Apply a thin coat of grease to the gasket and install it to [50 ± 3.6 lbf·ft]
Fuel inlet connector
the fuel injection nozzle.
(4) While checking the center of the connector mounting Fuel injection nozzle - Install
hole, insert and tighten temporary the fuel injection
nozzle assembly into the cylinder head.
(5) Tighten the nut to the specified torque, and secure the
nozzle gland.
(6) Install the sleeve to the clearance between inlet connec-
tor and cylinder head.
(7) Tighten the fuel inlet connector to the specified torque.
(8) Install the sleeve securely, and fix it with band.
Note: Be sure to install the gasket when installing the fuel in-
jection nozzle assembly.
7-36
1. Fuel system - Remove and Inspect........................................................................ 8-3
1.1 Fuel injection pipe and Fuel leak-off pipe - Remove and Inspect ............................................. 8-3
1.2 Fuel filter and Fuel pipe - Remove and Inspect ........................................................................ 8-4
1.3 Stop solenoid - Remove and Inspect........................................................................................ 8-5
1.4 Fuel control link - Remove and Inspect .................................................................................... 8-6
1.5 Fuel injection pump - Remove and Inspect .............................................................................. 8-7
2. Fuel system - Disassemble and Inspect................................................................ 8-8
2.1 Fuel filter (paper element) - Disassemble and Inspect ............................................................. 8-8
2.2 Fuel injection nozzle - Disassemble and Inspect.................................................................... 8-10
2.3 Fuel injection nozzle - Inspect and Adjust .............................................................................. 8-11
2.4 Fuel injection nozzle - Assemble ............................................................................................ 8-14
2.5 Fuel injection pump accessory drive - Disassemble and Inspect ........................................... 8-15
2.6 Outside diameter and inside diameter of accessory drive bearing fit - Inspect ...................... 8-16
2.7 Fuel injection pump accessory drive - Assemble.................................................................... 8-17
2.8 Governor drive - Disassemble and Inspect............................................................................. 8-18
2.9 Outside diameter and inside diameter of bearing fit ............................................................... 8-19
2.10 Governor drive - Assemble ..................................................................................................... 8-20
3. Fuel system - Install .............................................................................................. 8-21
3.1 Fuel injection pump - Install .................................................................................................... 8-21
3.2 Fuel control link - Install .......................................................................................................... 8-25
3.3 Stop solenoid - Install ............................................................................................................. 8-29
3.4 Fuel filter and Fuel pipe - Install.............................................................................................. 8-31
3.5 Fuel injection pipe and Fuel leak-off pipe - Install................................................................... 8-32
8-1
1. Fuel system - Remove and Inspect

1.1 Fuel injection pipe and Fuel leak-off pipe - Remove and Inspect
Replace
1
4
1
Replace
A 11
5 3
C
Replace
3 Replace
Left cylinder head
Replace Replace
Right
cylinder head 8
Replace
8
A Front Left fuel
injection pump
Right fuel injection pump
2
Replace B
9
B 6
Replace
10
7 C
11
1
Fuel injection pipe and Fuel leak-off pipe - Remove and Inspect
Removing sequence
1 Leak-off pipe 7 Left leak-off pipe
2 Right leak-off pipe 8 Left leak-off pipe
3 Right leak-off pipe 9 Clamp
4 Clamp 10 No.9 to 16 fuel injection pipe (double pipe)
5 No.1 to 8 fuel injection pipe (double pipe) 11 Leak-off connector
6 Left leak-off pipe
Cover the openings on the fuel injection pipe, nozzle inlet connector and fuel injection pipe to prevent dust from
entering the fuel system.
8-3
1.2 Fuel filter and Fuel pipe - Remove and Inspect
Replace
11 12 Front
14
11
15
Replace 16
13 6
7 B
5
Replace Left
Replace Replace
A
B
8 10
4
Right
9
Replace A
3
2
1 Replace
Fuel filter and Fuel pipe - Remove and Inspect

Removing sequence
1 Fuel pipe 7 Pipe stay 12 Left fuel pipe
2 Clamp 8 Left fuel pipe 13 Left fuel pipe
3 Right fuel pipe 9 Left fuel pipe 14 Fuel filter assembly
4 Right fuel pipe 10 Connector 15 Fuel filter bracket
5 Fuel filter assembly 11 Clamp 16 Pipe stay
6 Fuel filter bracket
8-4
1.3 Stop solenoid - Remove and Inspect
Control
shaft
6 5
4
3
2
8
7
Stop solenoid - Remove and Inspect

Removing sequence
1 Link 4 Ball bearing 7 Stop solenoid
2 End plate 5 Stop lever 8 Bracket
3 Snap ring 6 Follower
8-5
1.4 Fuel control link - Remove and Inspect
Looseness, wear
Looseness, wear
3
2
Replace
B 4
A 15
5 Fatigue, deformation
7 Replace
B
12
6 A
1
13
14
Looseness, wear
Looseness, wear
11 10
8
Looseness, wear
9
Fuel control link - Remove and Inspect

Removing sequence
1 Left link 6 Left lever 11 Right lever
2 Left link 7 Bearing cover 12 Bearing cover
3 Left link 8 Right link 13 Control shaft
4 Left lever 9 Right link 14 Pipe
5 Stop lever 10 Right lever 15 Governor actuator
8-6
1.5 Fuel injection pump - Remove and Inspect
3
4
Fuel injection pump - Remove and Inspect

Removing sequence
1 Coupling cover 4 Fuel injection pump (Approx. 68 kg [149 lb.])
2 Cover stay 5 Shim (check the installing position)
3 Stay 6 Bracket
8-7
2. Fuel system - Disassemble and Inspect

2.1 Fuel filter (paper element) - Disassemble and Inspect
Replace Air vent plug

9 ± 1 N·m
{0.9 ± 0.1 kgf·m} [6.5 ± 0.7 lbf·ft]
Filter wrench
Crack, damage Use the filter wrench
to dismount the fuel filter.
(Use only when dismounting)
5
4 2
Replace
1
3
Dent
Replace : every 1000 hours
Fuel filter (paper element) - Disassemble and Inspect

1 Fuel filter cartridge 3 Cover 5 Fuel filter bracket
2 Pin 4 Cock
8-8
2.1.1 Fuel filter cartridge - Install
(a) Check that there is no flame when handling fuel.

(b) Wipe any split fuel to prevent a fire.
(c) Do not use the fuel filter cartridge that has damaged with its case. Such damages and leakages in operation
can cause possibly resulting in fire.
(a) Do not use a filter wrench. Tighten with your hand when installing the fuel filter cartridge.
(b) Be careful not to dent or damage the surface of the fuel filter cartridge.
(1) Clean the mounting surface of the fuel filter cartridge.
(2) Apply clean fuel on the fuel filter gasket.
(3) When the fuel filter gasket contacts the base, tighten the cartridge by 3/4 to 1 turn by hand.
(4) Confirm that there is no fuel leakage after starting the engine.
Note: The fuel filter cartridge should be installed just before the engine is started.
After installing, bleed the fuel system.
8-9
2.2 Fuel injection nozzle - Disassemble and Inspect

Fuel injection start pressure - Inspect
Fuel injection nozzle spray - Inspect
Replace
10 2
Replace Replace
9
3
Fatigue, damage
Wear of needle valve and contact surface
7
Carbon deposit
Nozzle hole clogged, needle valve fixing
6
5
Replace
4
Fuel injection nozzle - Disassemble and Inspect

1 Set screw, sealing washer 6 Nozzle tip
2 Cap nut, sealing washer 7 Spacer
3 Adjusting screw 8 Push rod, nozzle spring, spring seat
4 O-ring 9 O-ring
5 Retaining nut 10 Nozzle holder
8-10
2.3 Fuel injection nozzle - Inspect and Adjust

2.3.1 Fuel injection start pressure - Inspect and
Adjust
Nozzle tester
Never touch the fuel injection nozzle tip during noz- P/N:83091-03301
zle injection test.
(1) Install the fuel injection nozzle onto the nozzle tester.
(2) Push down the handle at a speed of once a second and
measure the pressure when injection starts. If it is out of
the standard, adjust it to the standard.
(3) To adjust the injection start pressure, remove the set Fuel injection start pressure - Inspect
screw on the nozzle holder, loosen the cap nut and turn
the adjusting screw with a driver. Set screw
(4) After adjustment, tighten the cap nut and set screw to 39 ± 5 N·m
{4 ± 0.5 kgf·m}
the specified torque. [28 ± 3.6 lbf·ft]
(5) After tightening the set screw, inspect if the injection
Large
start pressure is within the standard again. Small pressure
pressure
Item Nominal Standard Cap nut
34.32 to 34.81 MPa 73.5 ± 4.5 N·m
34.32 MPa {7.5 ± 0.5 kgf·m}
Fuel injection {350 to 355 kgf/cm2}
{350 kgf/cm2} [54 ± 3.3 lbf·ft]
start pressure [4978 to 5049 psi]
[4978 psi]
(When new nozzle is measured) Fuel injection start pressure - Adjust
2.3.2 Fuel injection nozzle spray - Inspect

When adjusting for nozzle opening pressure using the noz-
zle tester, inspect for nozzle hole condition and fuel spray Good Defective spray patterns
pattern. If spray condition is faulty, clean or replace the noz-
zle tip.
Checking points of fuel spray are as follows:
Inject straight.
Fuel is injected in a spray of fine droplets. Large After Inter- Whirling
angle dribble mittent spray
Fuel is injected without after-dribbling. spray spray
Fuel injection nozzle spray - Inspect
8-11
2.3.3 Nozzle tip - Clean and Replace
Be careful not to hit the nozzle tip.
(1) First, remove the cap nut because the spring pressure is
applied to the nozzle tip.
(2) Loosen the adjusting screw with screwdriver to the Loosen the
adjusting screw
degree that you can lightly turn it by hand.
Loosen the adjusting screw

(3) Remove the retaining nut.
(4) Remove the nozzle tip.
Nozzle tip
Retaining nut
Nozzle tip - Remove
(5) Clean the needle valve and body of the nozzle tip.
When cleaning the needle valve and nozzle tip body,
use clean wash oil. Assemble the needle valve and body
in clean diesel fuel after cleaning.
Note: The needle valve and body are precision parts. Handle
them carefully, and do not change the combination of
Needle valve
the valve and body.
Body
(6) Tighten the nozzle tip tightening retainer nut to the
specified torque.
(7) If the spray pattern is still faulty after cleaning and Nozzle tip - Clean
adjusting, change the nozzle tip with a new one.
New nozzle tips are coated with anti-corrosive agent to
prevent from rusting. At first, wash it off in wash oil.
Then wash it again with clean diesel fuel before instal-
lation.
2.3.4 Squareness, free length, and parallelism of
nozzle spring - Measure
Squareness
Measure the squareness, free length and parallelism for top
and bottom surface of nozzle spring. Square
Item Standard
Free length 30 mm [1.18 in.]
Squareness Less than 0.6 mm [0.024 in.] Free length
Parallelism for top and bottom surface Less than 0.1 mm [0.004 in.]
Squareness, free length, and parallelism of

nozzle spring - Measure
8-12
2.3.5 Push rod - Inspect

Inspect the push rod visually. If its spring seat wears Check for spring seat
uneven wears
unevenly, or its needle valve contact surface wears remark-
ably, or the cavitation occurs on its tapered parts, replace the
push rod with a new one.
Needle valve contact

surface wears Check for cavitation
Push rod - Inspect

2.3.6 Spacer - Inspect
High pressure
Inspect the spacer visually. If its needle valve contact sur-
seal surface
face and high pressure seal surface wear remarkably, replace
the spacer with a new one.
High pressure
seal surface
Needle valve contact surface
Ǿ6 mm [0.24 in.]
Spacer - Inspect
8-13
2.4 Fuel injection nozzle - Assemble
39 ± 5 N·m Never hit with a hammer when

{4 ± 0.5 kgf·m} mounting onto the cylinder head.
[28 ± 3.6 lbf·ft]
73.5 ± 4.5 N·m Apply engine oil on the upper and

{7.5 ± 0.5 kgf·m} lower surfaces of the sealing washer.
[54 ± 3.6 lbf·ft]
186.5 ± 9.5 N·m

{19 ± 1 kgf·m}
[137 ± 7 lbf·ft]
Fuel injection nozzle - Assemble
Be sure to tighten the retaining nut to the specified torque. Excessive tightening torque on the retaining nut can
hinder smooth movement of the needle and result in abnormal exhaust smoke or needle sticking.
Note: When putting the nozzle tip in the nozzle holder, make sure that the tip locating pin enters its hole in the holder.
8-14
2.5 Fuel injection pump accessory drive - Disassemble and Inspect
Deformation, wear on the lip
Wear, damage
Rotation
9
Wear, damage
Rotation 8
6
Flaking, wear
5
7
4
2 3
1
Fuel injection pump accessory drive - Disassemble and Inspect

1 Nut 4 Snap ring 7 Bearing
2 Washer 5 Drive shaft 8 Bearing
3 Fuel injection pump gear 6 Drive case 9 Oil seal
8-15
2.6 Outside diameter and inside diameter of accessory drive bearing fit - Inspect
(1) Turn the bearing and if the turning is not smooth,
replace the bearing with a new one. Fuel injection pump gear
(2) Inspect the fit of drive shaft and bearing. If heavy wear
is found, replace them with new one.
(3) Inspect the fit of drive case and bearing. If heavy wear
is found, replace them with new one. Socket
(4) Inspect the driveshaft and oil seal, and if any defect is P/N:58309-73100
found, replace them with new one.

ø90 mm 89.987 to 90.022 mm Fuel injection pump gear - Remove
Inside diameter of [3.54 in.] [3.5428 to 3.5442 in.]
case bearing fit ø100 mm 99.987 to 100.022 mm
[3.94 in.] [3.9365 to 3.9379 in.]
ø90 mm 89.985 to 90.000 mm
Small
Outside [3.54 in.] [3.5427 to 3.5433 in.]
diameter ø100 mm 99.985 to 100.000 mm
Large
[3.94 in.] [3.9364 to 3.9370 in.]
Bearing
ø45 mm 44.988 to 45.000 mm
Small
Inside [1.77 in.] [1.7712 to 1.7717 in.]
diameter ø50 mm 49.988 to 50.000 mm
Large
[1.97 in.] [1.9680 to 1.9685 in.]
ø45 mm 45.002 to 45.013 mm
Outside diameter of [1.77 in.] [1.7717 to 1.7722 in.]
drive shaft bearing fit ø50 mm 50.002 to 50.013 mm
[1.97 in.] [1.9686 to 1.9690 in.]
8-16
2.7 Fuel injection pump accessory drive - Assemble
490 ± 24.5 N·m

{50 ± 2.5 kgf·m}
[361 ± 18 lbf·ft]
Apply engine oil on the lip
Apply engine oil
Fuel injection pump accessory drive - Assemble
8-17
2.8 Governor drive - Disassemble and Inspect
Damage, wear 7
Wear
8
9 Wear, rotation
Replace
10
2
3
4
Defect of spline, wear
1
Wear, rotation
Governor drive - Disassemble and Inspect

1 Snap ring 5 Sealing cap 9 Bearing
2 Drive gear, drive shaft 6 Bolt, washer 10 Drive case
3 Snap ring 7 Idler gear, idler shaft
4 Bearing 8 Snap ring
Note: Do not disassemble the drive gear, drive shaft, idler gear and idler shaft unless it is necessary.
8-18
2.9 Outside diameter and inside diameter of bearing fit

Turn the bearing and if the turning is not smooth, replace the
bearing with a new one.
Inspect the fit of drive shaft, idler shaft and bearing. If
heavy wear is found, replace them with new one.
Inspect the fit of drive case and bearing. If heavy wear is
found, replace them with new one.

Inside diameter of driving shaft ø 52 mm 51.988 to 52.018 mm
case bearing fit [2.05 in.] [2.0468 to 2.0479 in.]
Outside ø 52 mm 51.987 to 52.000 mm
diameter [2.05 in.] [2.0467 to 2.0472 in.]
Drive shaft bearing
Inside ø25 mm 24.990 to 25.000 mm
diameter [0.9843 in.] [0.9839 to 0.9843 in.]
Outside diameter of drive shaft ø25 mm 25.002 to 25.011 mm
bearing fit [0.9843 in.] [0.9843 to 0.9847 in.]
Inside diameter of idler shaft ø47 mm 46.989 to 47.014 mm
case bearing fit [1.85 in.] [1.8500 to 1.8509 in.]
Outside ø47 mm 46.986 to 47.000 mm
diameter [1.85 in.] [1.8498 to 1.8504 in.]
Idler shaft bearing
Inside ø20 mm 19.990 to 20.000 mm
diameter [0.78 in.] [0.7870 to 0.7874 in.]
Outside diameter of idler shaft ø20 mm 20.002 to 20.011 mm
bearing fit [0.78 in.] [0.7875 to 0.7878 in.]
8-19
2.10 Governor drive - Assemble
Shrinkage fit at
200°C [392°F] or less
Backlash
0.12 to 0.18 mm
[0.0047 to 0.0071 in.]
Shrinkage fit at
200°C [392°F] or less
108 ± 5.4 N·m
{11 ± 0.55 kgf·m}
[80 ± 4.0 lbf·ft]
Governor drive - Assemble
8-20
3. Fuel system - Install

3.1 Fuel injection pump - Install
108 ± 5.4 N·m

{11 ± 0.55 kgf·m}
[80 ± 4 lbf·ft]
118 ± 5 N·m
{12 ± 0.5 kgf·m}
[87 ± 3.6 lbf·ft]
108 ± 5.4 N·m

{11 ± 0.55 kgf·m}
[80 ± 4 lbf·ft]
108 ± 5.4 N·m

{11 ± 0.55 kgf·m}
[80 ± 4 lbf·ft]
Fuel injection pump - Install
8-21
3.1.1 Checking before installing fuel injection pump

Pointer
Check the installing position of driving coupling. If the "0" stamped line
of flywheel
driving coupling is installed in reverse, the fuel injec-
tion timing is not aligned.
(1) Turn the crankshaft. Align with the No.1 compression

top dead center when installing right bank fuel injection
pump, and align with the No. 9 compression top dead
center when installing left bank fuel injection pump.
(2) Remove the temporary installed driving coupling and Aligning pointer with mark
laminated plate set of the driving coupling side on the
fuel injection pump assembly, then install them to the
Fuel injection pump accessory drive
accessory driving shaft through the woodruff key. Insert
the driving coupling to the drive case side as possible,
Driving coupling
loosen the tightening bolt.
(3) Align the "0" stamped line of fuel injection pump fly-
wheel with the pointer. (the injection start timing of cyl- Shaft tightening bolt
inder No. 1 and No. 9)
/DPLQDWHGSODWHVHW
Laminated plate set
Driving coupling - Install
(4) Check that the position between stamped characters of
Ap
camshaft and key groove of coupling is shown in the
pr
ox
illustration. Stamped characters
.1
for camshaft
70
°
/
Coupling key groove

Assembling position of the fuel injection pump
camshaft and driving coupling of the left bank
(from the rear (driving side))
0°
.1
ox
pr
Ap
Coupling key groove
Stamped characters
for camshaft
Assembling position of the fuel injection pump
camshaft and driving coupling of the right bank
(from the rear (driving side))
8-22
3.1.2 Fuel injection pump - Install
(a) Install and assemble new shim of the same thickness (t=0.25 mm [0.0098 in.]) as removed shim on the fuel
injection pump installing surface of right bank bracket. (A shim is not installed on the left bank bracket.)
(b) First, tighten the bolt (long) to connect the driving coupling and laminated plate to the specified torque, and
then loosen it. Then, tighten it to the specified torque. (2-time tightening method)
(c) Wash the bolt, bushing and washer before using. The foreign materials on the contact surface of driving cou-
pling and laminated plate can cause slipping or damaging.
(d) After tightening each coupling, retighten the coupling if the laminated plate is distorted.
(1) Install new shim of the same thickness (t=0.25 mm
Washer Nut
[0.0098 in.]) as removed shim on the fuel injection Bushing (Do not apply oil.) 118 ± 5 N·m
{12 ± 0.5 kgf·m}
pump installing surface of right bank bracket. [87 ± 3.6 lbf·ft]
Note: A shim is not installed on the left bank bracket. 2-time tightening
method
(2) Lift the fuel injection pump. Lift down the fuel injec-
tion pump gently, install the fuel injection pump with Bolt (long)
aligning the dowel pin of bracket.

Washer
Note: Check that the shim is installed firmly when installing (Do not apply oil.)
bolts.
(3) Connect the laminated plate and driving coupling, and Laminated plate
then tighten the bolt temporarily.
Check that the "0" stamped line of fuel injection pump
flywheel with the No. 1 and 9 compression top dead Drive coupling
center indicates near the pointer.
Note: Check the installation and direction of bushing and
washer when installing the each coupling connecting
bolt. Bolt (short)
118 ± 5 N·m
(4) Adjust the clearance between the driving coupling and {12 ± 0.5 kgf·m}
flywheel to the standard. [87 ± 3.6 lbf·ft]
For the adjusting procedures, refer to "Clearance Driving coupling and Laminated plate - Connect
between fuel injection pump flywheel and driving cou-
Inserting points for shim (6 points)
pling - Adjust" of "FUEL SYSTEM".
(5) Tighten all bolt and nut that installed temporary to each
coupling to the specified torque.
(6) Check the clearance between each couplings and the
tightening condition for each bolt and nut.
108 ± 5.4 N·m

(View from the top of bracket) {11 ± 0.55 kgf·m}
[80 ± 4 lbf·ft]
Inserting position of shim
8-23
(7) Install the stay between the fuel injection pump case
and crankcase.
(8) Refill engine oil to the intake hole on the oil drain pipe
of cam chamber.
(9) Install the oil pipe and fuel pipe.
Refill the engine oil to the

intake hole on the oil drain pipe.
Engine oil - Refill
3.1.3 Clearance between fuel injection pump flywheel
Clearance
and driving coupling - Adjust 49 ± 0.25 mm 172 ± 5 N·m
[1.93 ± 0.0098 in.] {17.5 ± 0.5 kgf·m}
Set the clearance between the fuel injection pump flywheel [126.6 ± 3.6 lbf·ft]
and the driving coupling using the fuel injection pump cou-
pling gauge as follows:
(1) Insert the GO side of the gauge into the clearance
between the fuel injection pump flywheel and the driv-
ing coupling. GO
Fuel injection pump
(2) Tighten the bolt to the specified torque. coupling gauge
P/N:37591-06100
(3) Verify that the NO GO side of the gauge cannot be
NO GO
Clearance between fuel injection pump flywheel and

inserted in the clearance while the GO side can be
driving coupling - Adjust
inserted. In this state, the clearance between the fuel
injection pump flywheel and the driving coupling
should be the set value.
(4) If the set value cannot be achieved by inserting the
gauge, loosen the bolt, and set the clearance all over
again.
8-24
3.2 Fuel control link - Install
Looseness, wear
Looseness, wear
Replace
A B
Fatigue, deformation
Replace
B
Looseness, wear
Looseness, wear
Looseness, wear
Fuel control link - Install
8-25
3.2.1 Control shaft - Install
Cover Control shaft
O-Ring
Stop lever
Pipe
Engine left Engine right
Control shaft - Install

(1) Insert the pipe that installed O-ring to the timing gear case.
(2) Insert the control shaft to the pipe.
(3) Press-fit the bearing to the both ends of control shaft, and install the bearing cover.
(4) Tap the either side of control shaft with plastic hammer.
(5) Turn the control shaft with hands, check that it turns smoothly.
3.2.2 Control link lever - Install
(1) Install the link lever of both banks (stamped mark: L and R) with ball bearing, snap ring and end plate to the stay.
(2) Temporary install the link lever with serration hole to the right end of control shaft.
(3) Temporary install the link lever to connect the governor with the ball bearing, snap ring and end plate to the left end of con-
trol shaft.
(4) Assemble the serration to move the throttle lever at 20° when the governor output shaft is at 0 (no injection position).
8-26
3.2.3 Fuel control link - Install and Adjust
Fixed length control link

(239 mm [9.41 in.])
Control link lever

Control shaft lever
65 ± 0.7 mm
[2.56
65 ± ±0.7
0.028
mmin.]
Distance from the end of fuel

injection pump to the end of rack:
68 ± 0.5 mm [2.68 ± 0.019 in.]
Rack ࡜࠶ࠢ‫ޟ‬
࡜࠶ࠢ‫ޟ‬0‫ޠ‬㧦
"0": 66 mm‫ޠ‬㧦66
[2.60
66 in.]
mm
Play: ㆆ߮㊂㧦⚂ 2mm
approx. 2 mm [0.08 in.]
Link on the right bank
OP
Distance from the end of fuel injection pump ST Stop lever
to the end of rack:
68 ± 0.5 mm [2.68 ± 0.019 in.] Flexible length Flexible length
Rack "0": 66 mm [2.60 in.] control link control link
Play: approx. 2 mm [0.08 in.]
Throttle lever
239 ± 1.5 mm [9.41 ± 0.059 in.]

20°
Fuel injection Rack control lever PSG

pump rack
65 ± 0.7 mm [2.56 ± 0.028 in.]
Link on the left bank
8-27
(1) Adjust the link between the fuel injection pump rack
and rack control lever to 65 ± 0.7 mm [2.56 ± 0.028
in.], and install the fuel control link to the left and right
bank.
Fixed length control link for the right bank
(2) Install the fixed length control link for the right bank
(239 mm [9.41 in.]) between the control link lever and
control shaft lever.
(3) Set the extendable control link for the left bank to the Welding
239 mm [9.41 in.], and installed it temporary, then Extendable control link for the left bank Right-hand
Left-hand thread thread
assemble it to the stop lever with serration hole.
Check that the fuel injection pump rack of both banks
are at the no-injection position, then install the stop
Make the screw engagement margin even.
lever with the spacer and cancel spring to the serration
Control link for right and left banks
of control shaft.
Note: Screw evenly.
(4) Adjust the flexible length control link for the left bank
to become same displacement of fuel injection pump
rack for both banks.
(5) Install the flexible length control link between the con-
trol shaft lever and throttle lever.
Adjust the distance to be 68 mm [2.68 in.] from the end
of fuel injection pump to the end of rack when the gov-
ernor output shaft is at 0 (no injection position).
Note: Screw evenly for the flexible length link thread, and
the screw must be screwed 8 mm [0.32 in.] or more.
(6) Check that the distance between the end of fuel injec-
tion pump and fuel injection pump rack is 66 mm [2.60
in.] and the play is 2 mm [0.08 in.] when the stop lever
is maximally pulled to the stop side.
8-28
3.3 Stop solenoid - Install
Control
shaft
shuft
Stop solenoid - Install
8-29
3.3.1 Stop solenoid (RUN OFF type) - Adjust
Stop solenoid OFF: 0.5 to 1.0 mm

Flexible length [0.020 to 0.039 in.]
control link
ON
FULL
STOP
Stop solenoid ON: 68 to 69 mm

[2.6772
[2.68 to 2.7165
to 2.72 in.] in.]
Looseness: approx. 2 to 3 mm
[0.08 to 0.12 in.]
Section A-A
Stop solenoid (RUN OFF type) - Adjust
(1) Pull the stop solenoid manually to turn the stop solenoid on.
(2) Adjust the flexible length control link to be 68 to 69 mm [2.68 to 2.72 in.] for the distance between the end of the fuel
injection pump and the control rack.
(3) Turn off the stop solenoid (stretched).
(4) Make adjustment so that the gap between the follower on the lever and the stop lever is 0.5 to 1.0 mm [0.020 to 0.039 in.]
with the flexible length control link.
Note:(a) Keep the play for 2 to 3 mm [0.08 to 0.12 in.] when the stop solenoid is turned on.
(b) Screw evenly for the flexible control link thread, and the screw must be screwed 8 mm [0.32 in.] or more.
3.3.2 Stop solenoid operation - Check (when running engine)
(1) Turn the stop solenoid off.
(2) Run the engine in idling.
(3) Turn the stop solenoid on.
(4) Check that the engine is stopped completely and the distance from the end of fuel injection pump to front of control rack is
68 to 69 mm [2.68 to 2.72 in.].
Note:(a) If the distance from the end of fuel injection pump to front of control rack is 70 mm [2.76 in.] (the play is 5 mm [0.20
in.]) or more, the engine may not be stopped.
(b) If the distance from the end of fuel injection pump to front of control rack is 66 mm [2.60 in.] (the stopper is contacted),
the fuel injection pump rack could be damaged.
8-30
3.4 Fuel filter and Fuel pipe - Install
Replace
Front
Replace
B
Left side
Replace
Replace Replace
A
Right side
A
Replace
Replace
Replace
Fuel filter and Fuel pipe - Install
8-31
3.5 Fuel injection pipe and Fuel leak-off pipe - Install
Replace
Replace
C
Replace
Replace
Left cylinder head

Right
cylinder Replace Replace
head
Replace
A
Front Left fuel
injection pump
Right fuel injection pump
Replace B
B
Replace
C
Fuel injection pipe and Fuel leak-off pipe - Install
8-32
1. Lubrication system - Remove and Inspect............................................................ 9-3
1.1 Oil pipe and Right oil cooler - Remove and Inspect.................................................................. 9-3
1.2 Oil pump, Oil filter, Oil pan and Left oil cooler - Remove and Inspect ...................................... 9-4
1.3 Bypass oil filter - Remove and Inspect ..................................................................................... 9-5
1.4 Breather and Oil filler - Remove and Inspect............................................................................ 9-6
1.5 Governor oil filter - Remove and Inspect .................................................................................. 9-7
2. Lubrication system - Disassemble, Inspect and Assemble................................. 9-8
2.1 Oil pump and Safety valve - Disassemble and Inspect ............................................................ 9-8
2.2 Oil pump and Safety valve - Inspect ......................................................................................... 9-9
2.3 Oil pump and Safety valve - Assemble................................................................................... 9-11
2.4 Oil filter, Relief valve and Left oil cooler - Disassemble and Inspect ...................................... 9-12
2.5 Oil filter - Inspect..................................................................................................................... 9-13
2.6 Relief valve opening pressure - Measure ............................................................................... 9-13
2.7 Relief valve - Inspect .............................................................................................................. 9-13
2.8 Oil cooler - Inspect.................................................................................................................. 9-13
2.9 Oil thermostat - Inspect........................................................................................................... 9-14
2.10 Oil cooler, Oil filter and Relief valve - Assemble..................................................................... 9-14
2.11 Oil filter cartridge - Install ........................................................................................................ 9-15
2.12 Right oil cooler - Disassemble and Inspect............................................................................. 9-16
2.13 Right oil cooler and oil thermostat - Inspect............................................................................ 9-16
2.14 Right oil cooler - Assemble ..................................................................................................... 9-16
2.15 Governor oil filter - Disassemble and Inspect ......................................................................... 9-17
2.16 Governor oil filter - Assemble ................................................................................................. 9-18
3. Lubrication system - Install .................................................................................. 9-19
3.1 Governor oil filter - Install........................................................................................................ 9-19
3.2 Breather and Oil filler - Install ................................................................................................. 9-20
3.3 Bypass oil filter - Install ........................................................................................................... 9-21
3.4 Oil pump, Oil filter, Oil pan and Left oil cooler - Install............................................................ 9-22
3.5 Oil pipe, Right oil cooler - Install ............................................................................................. 9-23
9-1
1. Lubrication system - Remove and Inspect

1.1 Oil pipe and Right oil cooler - Remove and Inspect
4
Replace: O-ring
Oil filter Packing
Sealing washer
Accessory drive Front

3 Crankcase
A
7
B
6
7
Oil cooler
9
A Oil pan
11 8
Crankcase 2
10 5
B 5
11 1
10 Accessory drive
Oil pipe and Right oil cooler - Remove and Inspect

Removing sequence
1 Right drain pipe 5 Oil pipe 9 Left oil pipe
2 Right oil pipe 6 Right oil cooler (approx. 21 kg [46.3 lb.]) 10 Oil drain connector
3 Left drain pipe 7 Oil pipe 11 Turbocharger bracket
4 Left oil pipe 8 Right oil pipe
9-3
1.2 Oil pump, Oil filter, Oil pan and Left oil cooler - Remove and Inspect
Replace
Replace 8
10
Replace 9
Replace
7
Clogged
12
Replace
Replace
Replace
6
Replace
3 Replace
Replace 1
Damage, crack Replace Replace

11
Oil pump, Oil filter, Oil pan and Left oil cooler - Remove and Inspect
Removing sequence
1 Bypass drain pipe 5 Oil pipe 9 Connector
2 Connector 6 Oil filter assembly, left oil cooler 10 Oil pump (Approx. 26 kg [57 lb.])
3 Oil pipe (Approx. 40 kg [88 lb.]) 11 Oil pump (Approx. 190 kg [418 lb.])
4 Oil pipe 7 Stay 12 Oil strainer assembly
8 Oil pipe
9-4
1.3 Bypass oil filter - Remove and Inspect
Cam room cover

5
Replace
3
Replace
Bypass oil filter - Remove and Inspect

Removing sequence
1 Bypass oil filter 4 Bracket
2 Oil inlet pipe 5 Stay
3 Oil outlet pipe
9-5
1.4 Breather and Oil filler - Remove and Inspect
Replace
Replace
Replace
3
Replace
4
5
Replace
Breather and Oil filler - Remove and Inspect

Removing sequence
1 Front breather 4 Oil level gauge guide
2 Cover 5 Oil filler cap
3 Oil level gauge 6 Oil filler
9-6
1.5 Governor oil filter - Remove and Inspect
Replace
Replace
To governor drive case

4
5
To turbocharger oil pipe Replace
To timing gear case
Replace
6
Governor oil filter - Remove and Inspect

Removing sequence
1 Oil pipe 4 Governor oil filter
2 Air purge pipe 5 Bracket
3 Oil pipe 6 Drain pipe
9-7
2. Lubrication system - Disassemble, Inspect and Assemble

2.1 Oil pump and Safety valve - Disassemble and Inspect
Fatigue, damage, wear
Damage, crack
Replace
Replace
Damage on the spline, wear
Damage, wear
6
Contact, flaking,
wear
5
4
Damage, wear
Replace
1
Replace
Damage, crack
Oil pump and Safety valve - Disassemble and Inspect

1 Oil pump cover 3 Drive gear 5 Driven gear
2 Safety valve assembly 4 Driven gear 6 Oil pump case
9-8
2.2 Oil pump and Safety valve - Inspect

2.2.1 Drive gear and driven gear backlash - Measure
Measure the drive gear and driven gear backlash. If the limit
is exceeded, replace the gears with new ones.
Item Standard Limit

Drive gear and 0.100 to 0.200 mm 0.400 mm
driven gear backlash [0.0039 to 0.0079 in.] [0.0157 in.]
2.2.2 Clearance between gears and case - Measure

Measure the clearance between gear teeth and case bore. If
the limit is exceeded, replace gears or case with a new one.
Item Standard Limit

Clearance between 0.100 to 0.148 mm 0.350 mm
gear teeth and case bore [0.0039 to 0.0058 in.] [0.0138 in.]
Clearance between gears and case - Measure

2.2.3 End clearance between gears and case - Mea-
sure
Measure the end clearance between gear width and case
depth. If the limit is exceeded, replace gears or case with a
new one.
Item Standard Limit

Clearance between gear 0.040 to 0.116 mm 0.210 mm
width and case depth [0.0016 to 0.0046 in.] [0.0083 in.]
End clearance between gears and case - Measure

2.2.4 Drive and driven gear shaft outside diameters
and Bushing inside diameter - Measure
(1) Inspect the gear teeth. If any defects are found, replace
the gear with a new one.
(2) Measure the drive and driven gear shaft outside diame-
ters and the bushing inside diameter. If any of the gear
and bushing combination exceeds the limit, replace it
with the new set of such parts.
Nomi-
Item Standard Limit
nal
Drive shaft 29.887 to 29.900 mm 29.840 mm
outside diameter [1.1767 to 1.1772 in.] [1.1748 in.]
Driven shaft ø30 29.947 to 29.960 mm 29.920 mm
outside diameter [1.18] [1.1790 to 1.1795 in.] [1.1780 in.]
Bushing 30.000 to 30.021 mm 30.055 mm
inside diameter [1.1811 to 1.1819 in.] [1.1833 in.]
9-9
2.2.5 Oil pump safety valve - Inspect

Stopper Valve
Valve spring
Item Standard
1.3 ± 0.13 MPa
Safety valve opening pressure
{13 ± 1.3 kgf/cm2} [189 ± 19 psi]
(1) Inspect oil pump safety valve spring for settling and
O-ring
damage. If significant settling, wear, or damage is
found, or if the distortion exceeds the limit, replace it
with a new one.
Item Standard Limit Safety valve - Inspect

65.8 mm [2.591 in.]/ 65.8 mm [2.591 in.]/
Safety valve spring
359 N {36.6 kgf} 314 N {32.0 kgf}
Set length/load
[80.7 lbf] [70.6 lbf]
Free length of 78 mm
-
safety valve spring [3.07 in.]
(2) Inspect the valve and stopper. If significant wear or

malfunction for sliding part are found, replace them
with new ones.
9-10
2.3 Oil pump and Safety valve - Assemble
33 ± 3.3 N·m 88 ± 10 N·m

{3.4 ± 0.34 kgf·m} {9 ± 1.0 kgf·m}
[25 ± 2.5 lbf·ft] [65 ± 7.4 lbf·ft]
Apply engine oil

to O-ring.
74 ± 10 N·m
{7.5 ± 1.0 kgf·m}
[54 ± 7.4 lbf·ft]
Apply ThreeBond No.1215 to the

cover and case.
Oil pump and Safety valve - Assemble
Note: Apply engine oil to the individual parts when assembling. Apply a thick coat of engine oil to the threads and seating sur-
faces of the nuts and bolts before tightening them.
9-11
2.4 Oil filter, Relief valve and Left oil cooler - Disassemble and Inspect
4
Clogged,
rupture, crack
Replace
2
Crack, deformation 3
Replace
Replace
2
Crack, deformation
1
Replace Replace
Replace 1
3
5
Fatigue,
breakage and wear
Replace 1
9 Replace
Aging, wear, crack
8
Wear, crack
7
Replace 12
6
11
10
Replace: Every 250 hours

1
Oil filter, Relief valve and Left oil cooler - Disassemble and Inspect
1 Full-flow oil filter 7 Oil thermostat
2 Oil filter bracket (Approx. 15 kg [33 lb.]) 8 Thermostat seal
3 Adapter assembly 9 Body
4 Oil cooler element 10 Cover
5 Relief valve assembly 11 Cover
6 Connector 12 Drain cock
9-12
2.5 Oil filter - Inspect

When replacing the oil filter, sample the oil (500 ml [0.13
U.S. gal.]) and check for metal and other particles. If metal
or other particles are found, cut and unfold the element, and
inspect the color and shape of metal particles trapped in the
element to identify the cause.
Oil filter - Inspect

2.6 Relief valve opening pressure - Measure
(1) Remove the taper plug (R1/8) on the upper surface of
the oil filter bracket, and set a pressure gauge.
Pressure gauge
(2) Conduct a warm-up operation until the oil temperature
Taper plug
reaches 70 to 90 °C [158 to 194 °F]. R1/8
(3) Measure the oil pressure at idle and maximum speed
respectively.
Note: When the oil temperature is low, the oil pressure may
rise above the set pressure, but it returns to the set pres-
sure as the oil temperature rises.
Item Standard Relief valve opening pressure - Measure

0.51 ± 0.02 MPa
Relief valve opening pressure
{5.2 ± 0.2 kgf/cm2} [74 ± 3 psi]
2.7 Relief valve - Inspect

(1) Inspect the relief valve spring for settling and damage.
If significant settling, wear, or damage is found, replace Valve
it with a new one.

Spring
Item Standard
Free length of relief valve spring 188 mm [7.40 in.]
(2) Inspect the valve. If significant wear or malfunction for

sliding part are found, replace it with a new one.
Relief valve - Inspect

2.8 Oil cooler - Inspect
Check oil passages in the element by blowing through them
Air
with compressed air of 1.5 MPa {15 kgf/cm²} [217 psi] for Check for leakage,
damage, crack
damage and cracks.
If any leakage or damage is found, replace the element with
a new one.
Oil cooler - Inspect

9-13
2.9 Oil thermostat - Inspect

2.9.1 Oil thermostat seal - Inspect
(1) Inspect the oil thermostat seal for deterioration and Thermostat seal
cracks. If defects are found, replace the seal with a new
one. Installing direction
(2) Refer to the illustration for the correct direction of seal

installation.
Thermostat
Oil thermostat seal - Install

2.9.2 Oil thermostat operation - Inspect
Water (stir with bar)

Be very careful of hot water and flames.
It may cause burns and fire.
(1) Immerse the oil thermostat in a container filled with

water.
(2) Heat the water while measuring the water temperature.
Record the temperature when the valve starts to open,
and when the valve lift is about equal to the standard
value in the table below. If the temperatures are not Oil thermostat operation - Inspect
within the standard range, replace the thermostat with a
new one.
Note:(a) Stir the water to maintain even temperatures during
the test.
(b) At assembly, confirm the valve opening tempera-
ture stamped on its mounting flange.
Item Standard
80 to 84°C
[176 to 183.2°F]
Temperature at which valve lift becomes 95°C
11 mm [0.43 in.] or more [203°F]
2.10 Oil cooler, Oil filter and Relief valve - Assemble

To assemble, follow the disassembly sequence in reverse.
Thoroughly clean oil passages using an oil wash, and dry
the cleaned parts with compressed air.
9-14
2.11 Oil filter cartridge - Install
(a) Do not use a filter wrench. Tighten with your

hand when installing the oil filter cartridge.
(b) Be careful not to dent or scratch the surface of
the oil filter cartridge.
(1) Clean the mounting surface of the oil filter cartridge.
(2) Apply clean engine oil on the oil filter gasket.
(3) When the oil filter gasket contacts the base, tighten the
cartridge by 3/4 to 1 turn by hand.
(4) Confirm that there is no fuel leakage after starting the
engine.
Note: The oil filter cartridge should be installed just before
the engine is started.
9-15
2.12 Right oil cooler - Disassemble and Inspect
4
Aging, wear, crack
Clogged, rupture,
crack
Replace 5
2
Replace Replace
Replace
Wear, crack
Replace
1
Replace
3
Crack, deformation
Replace
Replace
Right oil cooler - Disassemble and Inspect

1 Connector 3 Oil cooler cover 5 Thermostat seal
2 Oil thermostat 4 Oil cooler element
2.13 Right oil cooler and oil thermostat - Inspect
Inspect the right oil cooler and oil thermostat in the same manner as the left oil cooler and oil thermostat.
Replace defective parts if any.
2.14 Right oil cooler - Assemble
Thoroughly clean oil passages using an oil wash, and dry the cleaned parts with compressed air.
9-16
2.15 Governor oil filter - Disassemble and Inspect
3
6
Replace
Clogged, crack
Governor oil filter - Disassemble and Inspect

1 Center bolt 3 Spring seat 5 Case
2 Element 4 Spring 6 Cover
9-17
2.16 Governor oil filter - Assemble
9.8 ± 1.96 N·m

{1 ± 0.2 kgf·m} [7 ± 1.5 lbf·ft]
Replace
Clogged, crack
9.8 ± 1.96 N·m

{1 ± 0.2 kgf·m} [7 ± 1.5 lbf·ft] 34.3 ± 6.86 N·m
{3.5 ± 0.7 kgf·m} [25.3 ± 5.0 lbf·ft]
Governor oil filter - Assemble
9-18
3. Lubrication system - Install

3.1 Governor oil filter - Install
Replace
Replace
To governor drive case
Replace
To turbocharger oil pipe
To timing gear case
Replace
Governor oil filter - Install
9-19
3.2 Breather and Oil filler - Install
Replace
Replace
Replace
Replace
Replace
Breather and Oil filler - Install
9-20
3.3 Bypass oil filter - Install
Cam room cover
Replace
Replace
Bypass oil filter - Install
9-21
3.4 Oil pump, Oil filter, Oil pan and Left oil cooler - Install
Replace
Replace
Replace
Replace
108 ± 10.8 N·m

{11 ± 1.1 kgf·m} Clogged
[80 ± 8.0 lbf·ft]
Replace
Replace
Apply sealant (Heldite) Replace
to both surfaces of the
oil pan packing along
its parting line.
Replace
Replace
Replace
59 ± 5.9 N·m
{6 ± 0.6 kgf·m}
[43 ± 4.3 lbf·ft]
Damage, crack Replace Replace
Oil pump, Oil filter, Oil pan and Left oil cooler - Install
9-22
3.5 Oil pipe, Right oil cooler - Install
Replace: O-ring
Oil filter ‫ޓޓޓ‬Packing
‫ޓޓޓ‬Sealing washer
Front
Accessory drive
Crankcase
Oil cooler
A Oil pan
Crankcase
B
Accessory drive
Oil pipe, Right oil cooler - Install
9-23
1. Cooling system - Remove and Inspect................................................................ 10-3
1.1 Water pipe - Remove and Inspect .......................................................................................... 10-3
1.2 Thermostat case and Water pipe - Remove and Inspect ....................................................... 10-4
1.3 Water pump - Remove............................................................................................................ 10-5
2. Cooling system - Disassemble, Inspect and Assemble..................................... 10-6
2.1 Thermostat - Disassemble and Inspect .................................................................................. 10-6
2.2 Thermostat - Inspect............................................................................................................... 10-7
2.3 Water pump - Disassemble and Inspect................................................................................. 10-8
2.4 Water pump - Inspect ........................................................................................................... 10-10
2.5 Water pump - Assemble ....................................................................................................... 10-11
3. Cooling system - Install ...................................................................................... 10-14
3.1 Water pipe - Install................................................................................................................ 10-14
3.2 Thermostat case and Water pipe - Install ............................................................................. 10-15
3.3 Water pump - Install.............................................................................................................. 10-15
10-1
1. Cooling system - Remove and Inspect

1.1 Water pipe - Remove and Inspect
Replace
Aircooler
Ai rcooler
Replace
Crankcase Replace
Timing
gear case
4
2
6
Outlet
3
Replace
IInlet
Water pipe - Remove and Inspect

Removing sequence
1 Water pipe 4 Water pipe
2 Cock 5 Drain pipe
3 Tube 6 Drain pipe
7 Water pipe
10-3
1.2 Thermostat case and Water pipe - Remove and Inspect
Replace
Replace
5 6
Replace
4
2
Replace 7
1
3
Replace
10
8
11
Thermostat case and Water pipe - Remove and Inspect

Removing sequence
1 Coupling 6 Bracket
2 Bypass water pipe 7 Bracket
3 Bypass water pipe 8 Nut
4 Left thermostat case 9 Pulley (for alternator driving)
5 Right thermostat case 10 Key
11 Water pump (approx. 40 kg [88 lb.])
10-4
1.3 Water pump - Remove

Remove the nuts using the socket.
Socket
P/N:58309-73100
Water pump - Remove
10-5
2. Cooling system - Disassemble, Inspect and Assemble

2.1 Thermostat - Disassemble and Inspect
3
4
Aging, wear, crack
5
Replace
Wear, crack
Thermostat - Disassemble and Inspect

1 Thermostat cover 3 Snap ring 5 Thermostat seal
2 Packing 4 Thermostat 6 Thermostat case
10-6
2.2 Thermostat - Inspect

2.2.1 Thermostat seal - Inspect
(1) Inspect the thermostat seal for deterioration and cracks. Thermostat seal
If defects are found, replace the seal with a new one.
(2) Refer to the illustration for the correct direction of seal
Installing direction
installation.
Thermostat
Thermostat seal - Install

2.2.2 Thermostat operation - Inspect
Water (stir with bar)

Be very careful of hot water and flames.
It may cause burns and fire.
(1) Immerse the thermostat in a container filled with water.

(2) Heat the water while measuring the water temperature.
Record the temperature when the valve starts to open,
and when the valve lift is about equal to the standard
value in the table below. If the temperatures are not
within the standard range, replace the thermostat with a Thermostat operation - Inspect
new one.
Note:(a) Stir the water to maintain even temperatures during
the test.
(b) At assembly, confirm the valve opening tempera-
ture stamped on its mounting flange.
Item Standard
69 to 73°C
[156.2 to 163.4°F]
Temperature at which valve lift becomes 85°C
9 mm [0.35 in.] or more [185°F]
10-7
2.3 Water pump - Disassemble and Inspect
14
15
Rotation
16
10
Replace
11
Flaking, wear
8 1
2
9
3
6
Replace 4
7
5 12
13
Rotation
17 Replace
Corrosion, damage
Replace
18 Replace
Corrosion, crack, damage
Replace
Water pump - Disassemble and Inspect

1 Snap ring 7 O-ring 13 Unit seal
2 Cover 8 Water pump gear 14 Oil seal
3 O-ring 9 Bearing 15 Snap ring
4 Impeller 10 Snap ring 16 Bearing
5 Nut 11 Water pump shaft 17 Oil pump (Approx. 21 kg [46 lb.])
6 Oil seal sleeve 12 Ring 18 O-ring
10-8
2.3.1 Water pump mounted on engine - Inspect

With fingers, touch the drain port at the center of the water
pump case bottom. If it is wet with water, the unit seal is
defective.
Water pump mounted on engine - Inspect

2.3.2 Impeller - Remove
(1) Remove the snap ring that holds the cover using water Water pump pliers
P/N:37591-03100
pump pliers, and remove the cover.
Cover
Snap ring
Water pump cover - Remove
(2) Remove the impeller with the impeller remover.
Impeller remover P/N:37591-03200
(Remover plate) Impeller
(Jack-bolt)
Shaft
Impeller - Remove
10-9
2.3.3 Water pump shaft - Remove

(1) Remove the oil seal sleeve. Gear puller
(2) Remove the gear and ball bearing together using the
gear puller.
(3) Remove the snap ring from the water pump impeller
ball bearing.
(4) Insert the two half rings of the ring remover between
the unit seal ring and the water pump case as shown in
the illustration.
(5) Install the outer ring not to remove the half ring.
Water pump gear - Remove
(6) Push the impeller end of water pump shaft with hand
press, remove the unit seal ring and shaft.
Ring remover Press
P/N:37791-03400 Unit seal ring
(Half ring)
(Outer ring)
Water pump
case
Water pump shaft - Remove

2.4 Water pump - Inspect
Measure the outside diameter and inside diameter of the
water pump case, shaft bearing fit and bearing. If any of the
measurements is out of the standard, replace the part with a
new one.

ø120 mm 119.987 to 120.022 mm
Inside Pump case
[4.72 in.] [4.7239 to 4.7253 in.]
diameter of
bearing fit Bearing cover ø110 mm 110.005 to 110.040 mm
[4.33 in.] [4.3309 to 4.3323 in.]
Outside ø120 mm 119.985 to 120.000 mm
diameter [4.72 in.] [4.7238 to 4.7244 in.]
Large
Inside ø55 mm 54.985 to 55.000 mm
diameter [2.17 in.] [2.1648 to 2.1654 in.]
Bearing
Outside ø110 mm 109.985 to 110.000 mm
diameter [4.33 in.] [4.3301 to 4.3307 in.]
Small
Inside ø50 mm 49.988 to 50.000 mm
diameter [1.97 in.] [1.9680 to 1.9685 in.]
ø55 mm 55.011 to 55.024 mm
Outside diameter of [2.17 in.] [2.1658 to 2.1663 in.]
shaft bearing fit ø50 mm 50.011 to 50.024 mm
[1.97 in.] [1.9686 to 1.9694 in.]
1.04 mm 0.58 to 1.50 mm
Clearance of front impeller
[0.0409 in.] [0.0228 to 0.0591 in.]
10-10
2.5 Water pump - Assemble
Replace
Front plate
Bearing case
Oil seal
392 ± 19.6 N·m
{40 ± 2.0 kgf·m}
[289 ± 14 lbf·ft]
Replace Install the oil seal sleeve

to turn the chamfered
side of oil seal sleeve
at the pulley.
Replace
Apply LLC to the outer circumference

of floating seat and sliding surface when
press-fitting the unit seal (rotating side)
Apply LLC. to the ring.
Apply sealant (ThreeBond 1102) to the
outer circumference of unit seal
(fixing side)
Unit seal (rotating side) Apply engine oil to the oil seal lip,
and fit it with the end of case face.
Unit seal (fixing side)
Apply sealant.
Water pump - Assemble
10-11
2.5.1 Oil seal - Install

(1) Using installer, install the oil seal, making sure that oil
seal surface is flush with the water pump case face.
(2) Be sure to coat the oil seal lip with engine oil.
Apply engine oil.
Oil seal - Install

2.5.2 Unit seal (fixing side) - Install
Unit seal installer
(1) Apply sealant (ThreeBond 1102) to the circumference P/N:37191-06300
of the unit seal (fixing side).
(2) Insert the unit seal into the water pump case using a unit
seal installer.
Note: Always replace the unit seal with a new one when it
has been removed from the water pump case once.
Apply sealant.
Unit seal - Install
2.5.3 Water pump shaft - Install
Water pump shaft

Do not damage the water pump shaft with the oil seal with ball bearing
and unit seal (fixing side) when press-fitting the water
pump shaft.
(1) Press-fit the impeller ball bearing to the water pump

shaft.
(2) Press-fit the water pump shaft to the pump case gently
until the end of ball bearing contacts the pump case.
(3) Install the snap ring to the groove firmly. Water pump shaft - Install
2.5.4 Unit seal ring and Unit seal (rotating side) -

Press-fit
Install
(1) Install the unit seal (rotating side) to the unit seal ring. Shaft
(2) Apply LLC to the unit seal (rotating side). 80 ± 0.15 mm

(3) Press in the unit seal ring with unit seal floating seat [3.1496 ± 0.0059 in.] Ring installer
slowly to the specified position using the ring installer P/N:37791-03300
(special tool) and a press. Unit seal ring
Unit seal
(rotating side)
Unit seal ring and Unit seal (rotating side) - Install
10-12
2.5.5 Pulley side ball bearing - Install

(1) Insert the gear into the shaft by aligning the key.
(2) Press-fit the ball bearing on the pulley nut side with a
press.
Press-fit
Pulley side ball bearing - Install

2.5.6 water pump impeller - Press-fit
Flush
Press-fit the water pump impeller with a press. Press in the
water pump impeller to the impeller's boss end face is flush Impeller
with the pump shaft end. Press-fit
Shaft
water pump impeller - Press-fit

2.5.7 Oil seal sleeve - Install
(1) Insert the O-ring to the oil seal sleeve.
(2) Insert the chamfering of sleeve outer surface to the Chamfering
pump shaft with facing outside (pulley side). O-ring
Oil seal sleeve
Oil seal sleeve - Install
10-13
3. Cooling system - Install

3.1 Water pipe - Install
Replace
Aircooler
エアクーラ
Replace
Crankcase Replace
Timing
gear case
Outlet
Replace
Inlet
Water pipe - Install
10-14
3.2 Thermostat case and Water pipe - Install
Replace
Replace
Replace
Replace
Replace
392 ± 19.6 N·m

{40 ± 2.0 kgf·m}
[289 ± 14 lbf·ft]
108 ± 10.8 N·m

{11 ± 1.1 kgf·m}
[80 ± 8 lbf·ft]
Thermostat case and Water pipe - Install

3.3 Water pump - Install
Tighten the nut to the specified torque using a socket
wrench.
Socket
P/N:58309-73100
Water pump - Install
10-15
1. Inlet and exhaust systems - Remove and Inspect.............................................. 11-3
1.1 Air duct and Intercooler - Remove and Inspect ...................................................................... 11-3
1.2 Exhaust pipe - Remove and Inspect....................................................................................... 11-4
1.3 Exhaust manifold - Remove and Inspect ................................................................................ 11-5
2. Inlet and exhaust systems - Disassemble, Inspect and Assemble................... 11-6
2.1 Intercooler - Disassemble, Inspect and Assemble.................................................................. 11-6
2.2 Pre-cleaner - Clean................................................................................................................. 11-7
3. Inlet and exhaust systems - Install ...................................................................... 11-8
3.1 Exhaust manifold - Install........................................................................................................ 11-8
3.2 Exhaust pipe - Install .............................................................................................................. 11-9
3.3 Air duct and Intercooler - Install ............................................................................................ 11-10
11-1
1. Inlet and exhaust systems - Remove and Inspect

1.1 Air duct and Intercooler - Remove and Inspect
Replace
Turbocharger
2 Replace 1
3 Replace
Turbocharger 4
3
Replace
1
3
Turbocharger
5
Replace Replace
2
6 3
Turbocharger
Replace
Air duct and Intercooler - Remove and Inspect

Removing sequence
1 Upper air duct 4 Air duct
2 Lower air duct 5 Air duct
3 Connector 6 Duct stay
7 Intercooler
11-3
1.2 Exhaust pipe - Remove and Inspect
2
Crack, damage, deformation
4 1
B
5 Replace
Replace B
4
B 3
7 Replace
5
Replace
3 4
Replace
5
5
3
3 A
1 Replace
4
A Replace
2
A
Replace
8
Exhaust pipe - Remove and Inspect

Removing sequence
1 Silencer assembly 5 Exhaust joint
2 Silencer cover 6 Exhaust cover
3 V clamp 7 Exhaust manifold (Approx. 50 kg [110 lb.])
4 Turbocharger (Approx. 25 kg [55 lb.]) 8 Bracket
11-4
1.3 Exhaust manifold - Remove and Inspect
1
3
Crack, damage,
deformation
Replace: gasket
Exhaust manifold - Remove and Inspect

Removing sequence
1 V-clamp 2 Flexible joint 3 Exhaust manifold
11-5
2. Inlet and exhaust systems - Disassemble, Inspect and Assemble

2.1 Intercooler - Disassemble, Inspect and Assemble
The clearance between

the element and plate
must be sealed with
KE45-W (Shin-Etsu
1 Chemical Co., ltd.)
Replace or equivalent silicon
sealant. (two points)
Replace
Replace
The clearance between
the element and plate
must be sealed
2 with KE45-W (Shin-Etsu
Replace Chemical Co., ltd.)
or equivalent silicon
6 sealant. (two points)
3
Replace
4
Replace
Replace
6
7
Intercooler - Disassemble, Inspect and Assemble

1 Intercooler cover 5 Intercooler (Approx. 50 kg [110 lb.])
2 Intercooler (Approx. 50 kg [110 lb.]) 6 Plate
3 Plate 7 Spacer
4 Intercooler case
11-6
2.1.1 Intercooler - Inspect
Handle it with care since the water intercooler is dif-

ferent from sea water intercooler for its material and
design.
2.1.2 Intercooler - Clean
Blow compressed air (at a pressure of 0.29 to 0.49 MPa {3
to 5 kgf/cm2} [43 to 71 psi] or less) through the air cooler in
the opposite direction to the normal air flow to remove the
Compressed air
accumulation of dust and dirt. Then, inspect for corrosion
and cracks.
Intake
Intercooler - Clean
2.1.3 Intercooler - Inspect for leakage

Immerse the intercooler in water. In this condition, feed
compressed air (at a pressure of 0.39 MPa {4 kgf/cm2} [57
psi]) through the coolant passage to check for air leakage.
Air leak
Intercooler - Inspect for leakage

2.1.4 Intercooler - Assemble
The clearance between the element and plate must be sealed
with KE45-W (Shin-Etsu Chemical Co., ltd.) or equivalent
silicon sealant.
2.2 Pre-cleaner - Clean

(1) Remove the pre-cleaner from the silencer, wash the pre-
cleaner with neutral detergent. Mild
detergent
(2) Rinse the pre-cleaner with freshwater.
(3) Dry pre-cleaner, then install it to the silencer.
Note: If breakage is found, replace it with new one. Water
(Wash) (Rinse)
Install
(Dry)
Pre-cleaner - Clean
11-7
3. Inlet and exhaust systems - Install

3.1 Exhaust manifold - Install
Crack, damage,
deformation
Exhaust manifold coupling tightening torque

: 9 ± 0.45 N·m {0.9 ± 0.05 kgf·m} [6.5 ± 0.36 lbf·ft]
Replace: gasket
Exhaust manifold - Install
Check that the centers of exhaust manifold and coupling are aligned when installing. The misalignment of exhaust manifold
and coupling causes gas leakage.
Attach the exhaust gasket such that the side having letters "MANIFOLD" stamped is oriented to the exhaust manifold.
3.1.1 Exhaust manifold coupling - Tighten
Do not distort the exhaust manifold coupling.
(1) Apply Molykote or equivalent to the bolt.

(2) Tighten the nut with the specified torque.
(3) Vibrate the circumference of exhaust manifold coupling, and attach firmly the mating surfaces of the exhaust manifold to
the tapered face of exhaust manifold coupling.
(4) Tighten the nut with the specified torque.
(5) Vibrate the circumference of V-clamp again, and check the torque.
11-8
3.2 Exhaust pipe - Install
Crack, damage,
deformation
Replace
Replace B
Crack, damage,
B deformation
Replace
Replace Crack, damage,

deformation
Crack, damage, Replace

deformation
A
Replace
A Replace
A
Replace
Crack, damage, V-clamp tightening torque:
deformation 9 ± 0.45 N·m
{0.9 ± 0.045 kgf·m} [6.5 ± 0.33 lbf·ft]
Exhaust pipe - Install
Check that the centers of bracket, exhaust pipe and exhaust joint are aligned when installing. The misalignment of bracket,
exhaust pipe and exhaust joint causes gas leakage.
11-9
3.3 Air duct and Intercooler - Install
Replace
Turbocharger
Replace
Replace
Turbocharger
Replace
Turbocharger
Replace Replace
Turbocharger
Replace
44 ± 4.4 N·m
{4.5 ± 0.45 kgf·m} [32.45 ± 3.25 lbf·ft]
Air duct and Intercooler - Install
11-10
1. Electrical system - Remove and Inspect ............................................................. 12-3
1.1 Starter - Remove and Inspect................................................................................................. 12-3
1.2 Inspection before removal of alternator .................................................................................. 12-3
1.3 Alternator - Remove and Inspect ............................................................................................ 12-4
2. Electrical system - Disassemble, Inspect and Assemble .................................. 12-5
2.1 Starter - Disassemble and Inspect.......................................................................................... 12-5
2.2 Starter - Inspect and Repair.................................................................................................... 12-8
2.3 Starter - Assemble ................................................................................................................ 12-14
2.4 Alternator - Disassemble and Inspect................................................................................... 12-18
2.5 Alternator - Inspect and Repair............................................................................................. 12-21
2.6 Alternator - Assemble ........................................................................................................... 12-23
3. Electrical system - Install.................................................................................... 12-26
3.1 Alternator - Install.................................................................................................................. 12-26
3.2 Starter - Install ...................................................................................................................... 12-26
12-1
1. Electrical system - Remove and Inspect

1.1 Starter - Remove and Inspect
(1) Disconnect the harness.
(2) Remove the starter.
Starter
(Approx. 19 kg [42 lb.])
Starter - Remove and Inspect
1.2 Inspection before removal of alternator
1.2.1 Alternator operation - Inspect
Locate the cause of faulty charging from the malfunctions
described below. Do not remove the alternator for inspec-
tion and repair unless inspection cannot be performed with
the alternator installed on the engine.
Adjusted value of voltage regulator is high.

Overcharge
Faulty battery.
Adjusted value of voltage relay is low.
Faulty alternator output.
Over discharge Electric power consumption is extremely high.
Special load is used.
Faulty wiring.
1.2.2 Handling precaution

Improper handling could cause damage or failure to the
alternator.
(1) Connect battery cables correctly. The B terminal is (+)
and the E terminal is (-).
(2) Do not use any high voltage tester such as a megger.
(3) Do not disconnect lead wire from B terminal of the
alternator while the engine is running.
(4) Battery voltage is constantly applied to B terminal of
the alternator. Do not ground at this terminal.
(5) Do not short circuit or ground at L terminal. (For a
built-in IC regulator type)
(6) When a steam cleaner is used, do not allow the steam to
come into contact with the alternator.
12-3
1.3 Alternator - Remove and Inspect
Front
Rotation
4
5
Front gear case
Deterioration
Alternator - Remove and Inspect

Removing sequence
1 Connector 4 Adjusting rod 6 Alternator
2 Rear belt cover 5 Belt 7 Alternator bracket
3 Front belt cover
12-4
2. Electrical system - Disassemble, Inspect and Assemble

2.1 Starter - Disassemble and Inspect
8
2
Brush dust deposit, uneven wear,

brush movement inside the holder
Rotation 1
10
11
Wear, damage
Wear 7 5 3
4
9
Rotation
Wear, damage Rough surface, seizure,

stepped wear
Open circuit,ground
Starter - Disassemble and Inspect

1 Safety relay 5 Yoke assembly 9 Front bracket
2 Magnetic switch assembly 6 Armature assembly 10 Pinion case
3 Rear bracket 7 Center bracket 11 Pinion clutch assembly
4 Brush holder assembly 8 Lever assembly
12-5
2.1.1 Safety relay and Magnetic switch - Remove

Magnetic switch
(1) Remove a safety relay.
assembly
(2) Disconnect the lead wire, and remove the magnetic
switch.
Lead wire
Safety relay and Magnetic switch - Remove

2.1.2 Rear bracket - Remove
(1) Remove through bolts and screws of brush holder.
(2) Remove the rear bracket. Rear bracket
Rear bracket - Remove

2.1.3 Armature and Yoke assembly - Remove
(1) Remove the brush from the brush holder assembly.
(2) Remove the yoke from the center bracket.
Armature
Yoke assembly
Brush and Yoke assembly - Remove

(3) Remove the armature assembly.
Armature assembly
Armature assembly - Remove
12-6
2.1.4 Center bracket - Remove

Remove the center bracket. Center bracket
Hexagonal wrench
Center bracket - Remove

2.1.5 Lever assembly - Remove
Remove the lever pin, the inner housing, and the shift lever Lever assembly mounting
bolt, nut
from the pinion case.
Lever assembly - Remove

2.1.6 Pinion set - Remove
Unit: mm [in.]
(1) Remove the pinion stopper with a tool. Pipe
(2) Remove the overrunning clutch from the pinion shaft. ø 24
[0.94]
(3) Measure the diameter of pinion shaft at bearing fitting
ø 19.1
face. If the limit is exceeded, replace the faulty pinion [0.752]
shaft with a new one. Pinion shaft

Rear shaft ø 30 mm 30.002 to 30.011 mm
- Overrunning clutch
outside diameter [1.18 in.] [1.1812 to 1.1815 in.]
Front shaft ø 19 mm 18.90 to 18.94 mm
- Overrunning clutch - Remove
outside diameter [0.75 in.] [0.7441 to 0.7457 in.]
Front shaft ø 19 mm 19.000 to 19.033 mm
- Bolt 20 mm [0.79 in.]
receiver [0.75 in.] [0.7480 to 0.7493 in.] Press
M5 × 0.8 t = 7 mm
ø 19 mm 19.000 to 19.033 mm
Pinion - - 40 mm [0.28 in.]
[0.75 in.] [0.7480 to 0.7493 in.]
37 mm [1.46 in.]
Clearance 10 mm
0.25 mm [0.39 in.]
between bearing - -
120 mm [4.72 in.]
[0.0098 in.]
and shaft
Note: To remove the shaft bearing for replacement, use a

bearing puller as shown in the drawing.
M5 × 0.8
Bearer
Pinion shaft bearing puller
12-7
2.2 Starter - Inspect and Repair

2.2.1 Conduction of magnetic switch coil - Inspect
(1) Check the conduction between M terminal and C termi- Terminal M
nal. If isolated, replace the magnetic switch with a new
one.
Tester
Terminal C
Conduction between M terminal and C terminal -

Inspect
(2) Check the conduction between M terminal and the case.
If isolated, replace the magnetic switch with a new one. Case
Tester
Terminal M
Conduction between M terminal and the case - Inspect

(3) Check that the M terminal and the B terminal are iso-
lated. If electricity is conducted, replace the magnetic Terminal M
switch with a new one.
Tester
Terminal B
Insulation between M terminal and B terminal - Inspect
2.2.2 Conduction between magnetic switch coil, M
Tester
terminal and B terminal (touching the contact
point)
(1) Press the plunger until the contact point touches. Terminal M Plunger
(2) Check the conduction between the M terminal and the
B terminal. If defective, replace the magnetic switch
with a new one.
Terminal B
Conduction between M terminal and B terminal

(touching the contact point) - Inspect
12-8
2.2.3 Magnetic switch contact points - Inspect

Contact point
(a) Do not conduct an operation test with a dis-
mounted magnetic switch unit.
(b) Always turn the starter switch to ON before mea-
suring the voltage, then turn it to OFF after mea-
suring. If the starter switch is turned to OFF
during voltage measurement, the battery voltage
is directly applied to the voltmeter, and this can Measure voltage drop between terminals B and M.
damage the voltmeter.
Magnetic switch contact points - Inspect
Measure the load current of starter. If the voltage drop
between terminals B and M exceeds the limit, repair or
replace the contact point.
Item Limit
Voltage drop between terminals B and M
0.3 V
(load current 100 A)
2.2.4 Brush for wear - Inspect

Measure the length of the brushes.
If it is less than the limit, replace the brush holder assembly
and brush assembly with new ones.
Limit
Item Standard Limit Standard
Brush length 22 to 23 mm [0.87 to 0.91 in.] 13 mm [0.51 in.]
Brush for wear - Inspect

2.2.5 Brush spring load - Measure
Using a new brush, measure the spring load at which the
spring lifts from the brush. If it is less than the limit, replace
the spring with a new one.
Item Standard Limit

Brush spring load 44.1 N 40.2 N
(With brush installed) {4.5 kgf} [9.9 lbf] {4.1 kgf} [9.0 lbf]
2.2.6 Yoke assembly for conduction - Inspect

(1) Check for conduction between the M terminal of the Brush lead wire
Terminal M
field coil and the lead wire for the brush. If isolated,
replace the yoke assembly with a new one. Yoke
(2) Check that there is no continuity between field coil and
yoke. If electricity is conducted, replace the yoke
assembly coil with a new one.
(3) Check that the yoke body and the brush are isolated. If
electricity is conducted, replace the yoke assembly with
a new one.
Yoke assembly for conduction - Inspect
12-9
2.2.7 Bearing - Inspect

Rotate the bearing outer race with your hand, and confirm Bearing
whether it turns smoothly.
Bearing - Inspect
2.2.8 Armature shaft bearing fitting face - Measure
Measure the diameter of armature shaft at bearing fitting
face. If the measured value is less than the limit, replace the
armature with a new one.
Item Standard Limit

Outside diameter of ø20 mm 20.002 to 20.011 mm
front armature shaft bearing [0.79 in.] [0.7875 to 0.7878 in.]
Outside diameter of ø10 mm 10.001 to 10.007 mm
rear armature shaft bearing [0.39 in.] [0.3937 to 0.3940 in.]
2.2.9 Armature shaft runout - Measure

Using a dial gauge, measure the shaft runout. If the runout
exceeds the standard, repair or replace the armature. Armature shaft
Item Standard Remarks

Armature shaft runout 0.04 mm [0.0016 in.] TIR
Armature shaft runout - Measure

2.2.10 Commutator outside diameter - Measure
Measure the commutator outside diameter. If the measured
value is less than the limit, replace the armature with a new Ou
tsi
one. de
dia
m
et
Item Nominal Limit er
Commutator outside diameter ø43 mm [1.69 in.] 42 mm [1.65 in.]
Commutator outside diameter - Measure
12-10
2.2.11 Commutator runout - Measure

(1) Inspect the commutator surface. If the surface is rough,
polish it using a 400 to 600 grit sandpaper.
Polish using
(2) Measure the commutator runout with a dial gauge.
400 - 600 grid sandpaper
If the measured value exceeds the limit, replace the
armature with a new one.

0.06 mm 0.1 mm
Commutator runout TIR
[0.0024 in.] [0.004 in.]
Commutator surface - Polish

2.2.12 Undercut depth - Measure
Measure the depth of undercutting between the commutator
segments. If the measured value is less than the limit, repair Insufficient recutting
or replace the commutator. Defective
(need recutting) Good
Item Standard Limit
0.7 to 0.9 mm
0.7 to 0.9 mm 0.2 mm
Undercut depth [0.028 to 0.035 in.]
[0.028 to 0.035 in.] [0.008 in.]
Undercut depth - Measure

2.2.13 Front bracket - Inspect
If ball bearing does not turn smoothly or the abnormal noise
is generated, replace the front bracket with a new one.
12-11
2.2.14 Armature coil - Inspect

(1) Inspect the armature coil using a growler tester.
Iron plate
Put the armature on the growler tester, attach the iron
plate (e.g. teeth of a saw) at the core of armature. Hold
the iron plate, and rotate the armature with hands. If the
coil is shorted, the iron plate is sucked on that position. Growler tester
If the coil is shorted, replace the armature with a new
one.
Armature coil for short circuit - Inspect

(2) Check that the commutator and the shaft (core) are iso-
lated. If electricity is conducted, replace the armature
with a new one.
Commutator and shaft (core) for insulation - Inspect

(3) Check for conduction between segments in various
combinations. If isolated, replace the armature with a
new one.
Conduction between segments - Inspect

2.2.15 Overrunning clutch - Inspect
Do not clean the overrunning clutch in an oil wash Check that pinion freely rotates.
since grease is applied inside.
Make sure that, when attempting to turn the overrunning

clutch, it locks in one direction and rotates smoothly in the
opposite direction.
Overrunning clutch - Inspect

2.2.16 Pinion - Inspect
Inspect worn or damage for the pinion. If malfunction is
observed, replace the pinion with a new one.
12-12
2.2.17 Starter gear - Inspect

Inspect each starter gear. If it worn or damaged, replace the
gear with a new one.
2.2.18 Safety relay - Inspect
When connecting the battery, be sure to connect the Switch1

B S
battery in correct polarity. R Switch2
(+)
Constant-
Battery
Connect the safety relay as shown, and check the starter and voltage
battery
safety relay operations. (-) (+)
(-)
(1) Turn on the switch 1 and check if the starter operates Connected to the
(rotates). Terminal for safety starter body
relay earth (E)
(2) When turning on the switch 2 and the voltage (11 to 13
V) is supplied, make sure the starter stops. Safety relay - Inspect
12-13
2.3 Starter - Assemble
3.2 ± 0.4 N·m 17.7 ± 1.9 N·m

{0.33 ± 0.04 kgf·m} {1.8 ± 0.19 kgf·m}
4.5 ± 0.6 N·m [2.4 ± 0.3 lbf·ft] [13.0 ± 1.4 lbf·ft]
{0.46 ± 0.06 kgf·m}
[3.3 ± 0.4 lbf·ft]
22.6 ± 2.9 N·m
{2.3 ± 0.3 kgf·m}
22.6 ± 2.9 N·m [16.6 ± 2.1 lbf·ft]
10.9 ± 1.4 N·m {2.3 ± 0.3 kgf·m}
{1.1 ± 0.14 kgf·m} [16.6 ± 2.1 lbf·ft]
[8.0 ± 1.0 lbf·ft]
4.2 ± 0.3 N·m
{0.43 ± 0.03 kgf·m}
[3.1 ± 0.2 lbf·ft]
4.5 ± 0.6 N·m

{0.46 ± 0.06 kgf·m}
[3.3 ± 0.4 lbf·ft]
14 ± 1.7 N·m
{1.4 ± 0.17 kgf·m}
[10.3 ± 1.2 lbf·ft]
5.85 ± 0.75 N·m 8.7 ± 1.1 N·m
{0.6 ± 0.07 kgf·m} {0.9 ± 0.11 kgf·m}
[4.3 ± 0.55 lbf·ft] [6.4 ± 0.8 lbf·ft] 3.2 ± 0.4 N·m
{0.33 ± 0.04 kgf·m}
[2.4 ± 0.3 lbf·ft]
Starter - Assemble
12-14
2.3.1 Pinion shaft - Assemble

Assemble the center bracket, pinion clutch assembly and
pinion stopper to the pinion shaft, and insert the shaft in
position by tapping it with a soft-head mallet.
Pinion shaft - Assemble

2.3.2 Lever and Pinion shaft - Assemble
(1) Install the shift lever and pinion shaft to the front Pinion shaft
bracket while aligning the mark on the shift lever with Shift lever
the mark on the bracket.
(2) Apply the internal gear of the pinion shaft with a liberal
amount of Nikko Grease R. Pinion case
Lever and Pinion shaft - Assemble
12-15
2.3.3 Armature, Yoke, Brush and Brush holder -

Install
(1) Align the knock pin with the center bracket and assem-
ble the armature to the yoke. Armature
(2) Install the brush holder and brushes. Yoke assembly
Armature and Yoke - Install
Brush holder
Brush holder and Brush - Install

Note: Install the positive (+) and negative (-) brushes as
shown in the illustration on the right.
Positive (+) brush Negative (-) brush
Positive (+) and negative (-) brushes - Assemble

2.3.4 Armature end play - Measure
Measure the armature end play. If the measured value does
not meet the standard, adjust the end play at the rear.
Item Standard
Armature end play 0.2 to 0.7 mm [0.008 to 0.028 in.]
Armature end play
12-16
2.3.5 Pinion shaft end play - Measure

Measure the pinion shaft end play. If the measurement is out
of standard, adjust the end play at the internal gear side.
Item Standard
Pinion shaft end play 0.2 to 0.8 mm [0.008 to 0.032 in.]
Pinion shaft end play

2.3.6 Rear bracket - Install
Assemble the rear bracket to the yoke with the matching Rear bracket
marks. Tighten the brush holder with bolts and then install it
with the through bolts.
Rear bracket - Install

2.3.7 Magnetic switch - Install
(1) Install the magnetic switch and tighten the screws. Magnetic switch
(2) Connect the lead to the terminal M and tighten it with
the fixing nut.
Magnetic switch - Install

2.3.8 Safety relay - Install
(1) Tighten the lead wire.
(2) Install the safety relay.
2.3.9 Pinion gear retraction length - Measure

Apply a voltage of 24 V between terminals B and C. Con-
1.5 to 5.0 mm
nect the lead wire and supply a current between terminals B [0.0591 to 0.197 in.]
and M (for less than 1 second). After the pinion is moved,
push the pinion gear and measure the pinion gear retraction
length. If the measured value is not within the standard
range, adjust the length using the adjust screw of the mag-
netic switch.
Pinion gear retraction length - Measure
12-17
2.4 Alternator - Disassemble and Inspect
5 Rotation
Stain, damage, seizure
4 Crack,
Crack, damage damage
Rotation 8
3
11
10
Short circuit, 12
open circuit
9
7
6 Breaking, ground
Alternator - Disassemble and Inspect

1 Washer, nut 5 Rotor assembly 9 Regulator assembly
2 Pulley, fan 6 Field coil 10 Rectifier assembly
3 Through bolt 7 Stator coil 11 Terminal set
4 Front bracket assembly 8 Rear bracket 12 Connector set
12-18
2.4.1 Stator and Front bracket - Remove

Stator
(a) Disassemble the alternator only when repair
becomes necessary.
(b) Use care not to insert the screwdriver too deep,
or its tip may damage the stator.
(1) Remove through bolts.

(2) Insert the tip of a flat-blade screwdriver between the Front bracket
stator and front bracket, and wrench them.
Stator and Front bracket - Remove
2.4.2 Field coil - Remove
(a) When removing the field coil, be sure to observe

the removal order of screws. Otherwise, the out- Screw B
let lines of the field coil will be damaged.
(b) If all the screws are removed, the coil will fall
with its own weight. Be careful not to fall the coil.
(c) When removing the field coil, the outlet side of
the coil may be caught with the stator. Do not
Screw A
pull the coil forcibly.
Field coil - Remove
(1) Remove screw A.
(2) Remove screw B.
(3) Remove the field coil.
2.4.3 Pulley - Remove

Pulley assembly
When holding a rotor with a vice, be sure to hold at

the base of claw with a vice. Holding the tip of the Front bracket
claw can cause malfunctions.
(1) Attach the cloth to the rotor and fix it to the vise.
(2) Remove the pulley nut, and then pull out the pulley.
Rotor
Pulley - Remove
2.4.4 Rear bearing - Remove
Remove the rear bearing from the rotor with the bearing Rear bearing
puller.
Rotor
Rear bearing - Remove
12-19
2.4.5 Front bearing - Remove

Remove screws, and then remove the bearing retainer and Front bracket
front bearing from front bracket.
Front bearing
Front bearing - Remove

2.4.6 Stator - Remove
Lead wire Stator
The solder must be removed in a short time. If heat
Rectifier
from the soldering iron is applied for a long time
period, the diode will be damaged.
Melt the solder of stator and rectifier, and remove the stator
from the rectifier.
Stator - Remove
2.4.7 Regulator assembly - Remove
(1) Remove the screws from the regulator assembly. Rear bracket
(2) Remove the regulator assembly. Nut
Rectifier
Mould
Regulator assembly
Regulator assembly - Remove

2.4.8 Rectifier assembly - Remove
(1) Remove the screws and nuts from the rectifier.
(2) Remove the rectifier assembly.
12-20
2.5 Alternator - Inspect and Repair

2.5.1 Stator - Inspect
(1) Conduction between lead wires - Check
Check that electricity is conducted between a pair of
lead wires. If isolated, replace the stator with a new
one.
Conduction between lead wires - Check

(2) Insulation between lead wire and core - Inspect
Check that each lead wire and the stator core are iso-
lated. If electricity is conducted, replace the stator with
a new one.
Insulation between lead wire and core - Inspect

2.5.2 Rectifier - Inspect
Test the resistance and insulation of each of the diodes with
an analog tester. D
If inspected result does not match the below table, replace D F
Diode (+)
the rectifier with a new one.
A
B F
Polarity of tester
Condition C
Negative (-) Positive (+)
E Conducted A B E C Diode (-)
A,B,C
D Isolated E
E Isolated
A,B,C Rectifier - Inspect
D Conducted
Note: A,B,C:Stator coil lead wire connection part

D,E:Heatsink
F:Regulator connection part
12-21
2.5.3 Field coil - Inspect

Measure resistance between the terminals of the field coil. If Field coil
the measurement is not within the tolerance, replace the
field coil with a new one.
Item Standard
Field coil resistance (20 °C [68 °F]) 7.3 to 8.5 ohm
Field coil - Inspect
12-22
2.6 Alternator - Assemble
5.4 ± 1.5 N·m

Rotor {0.6 ± 0.1 kgf·m}
Rectifier [4.0 ± 1.1 lbf·ft]
3.9 ± 1 N·m
{0.4 ± 0.1 kgf·m} 147 ± 15 N·m
[2.9 ± 0.7 lbf·ft] {15 ± 1.5 kgf·m}
[108 ± 11 lbf·ft]
6.9 ± 0.9 N·m

{0.7 ± 0.09 kgf·m}
[5.0 ± 0.7 lbf·ft]
3.9 ± 1 N·m Stator Pulley

{0.4 ± 0.1 kgf·m}
[2.9 ± 0.7 lbf·ft] 3.9 ± 1 N·m
Coil
{0.4 ± 0.1 kgf·m}
E terminal bolt [2.9 ± 0.7 lbf·ft]
Rear bracket
Front bracket
Insulator
2.8 ± 0.35 N·m

{0.28 ± 0.03 kgf·m}
[2.0 ± 0.25 lbf·ft]
3.9 ± 1 N·m
{0.4 ± 0.1 kgf·m}
[2.9 ± 0.7 lbf·ft] Insulator
Alternator - Assemble
12-23
2.6.1 Rectifier assembly and regulator assembly -

Install Rear bracket
Install the rectifier assembly and regulator assembly to the Nut
rear bracket.
Rectifier
Mould
Regulator assembly
Rectifier assembly and regulator assembly - Install

2.6.2 Stator - Install
Lead wire Stator
Solder must be applied for a short period of time. If
Rectifier
heat from the soldering iron is applied for a long time
period, the diode will be damaged.
(1) Install the stator.

(2) Solder the lead wire of stator to the rectifier.
Stator - Install
2.6.3 Front bearing - Install
(1) Install the front bearing to the front bracket. Front bracket
(2) Secure the bearing retainer with the screw.
Front bearing
Front bearing - Install

2.6.4 Rear bearing - Install
Install the rear bearing to the rotor. Rear bearing
Rotor
Rear bearing - Install
12-24
2.6.5 Pulley - Install

Pulley assembly
(1) Insert the rotor to the front bracket.
(2) Attach the cloth to the rotor and fix it to the vise.
(3) Install spacer and pulley, and fix them with nut. Front bracket
Rotor
Pulley - Install
2.6.6 Rear bracket assembly and Front bracket
assembly - Assemble Front bracket Stator
Assemble the front bracket, stator, and rear bracket. Fix
them with the through bolt.
Rear bracket
Rear bracket assembly and Front bracket assembly

- Assemble
12-25
3. Electrical system - Install

3.1 Alternator - Install
Front
46 ± 8 N·m
{4.7 ± 0.8 kgf·m}
[34 ± 5 lbf·ft]
Rotation
Front gear case

Deterioration
Alternator - Install
3.2 Starter - Install

(1) Engage the flywheel ring gear and pinion gear, and
install the starter to the timing gear case.
(2) Tighten the starter mounting bolts to the specified
torque.
(3) Install the harness.
59 ± 5.9 N·m
{6 ± 0.6 kgf·m}
[43 ± 4.3 lbf·ft]
Starter
Starter - Install
12-26
1. Engine - Adjust ...................................................................................................... 13-3
1.1 Using turning gear .................................................................................................................. 13-3
1.2 Valve bridge and Adjusting screw - Check ............................................................................. 13-4
1.3 Valve clearance - Inspect ....................................................................................................... 13-4
1.4 Fuel injection timing - Check................................................................................................... 13-4
1.5 Fuel system - Bleed air ........................................................................................................... 13-4
1.6 Belt tension - Inspect and Adjust ............................................................................................ 13-6
2. Break-in operation ................................................................................................. 13-7
2.1 Preparation before starting engine ......................................................................................... 13-7
2.2 Starting up .............................................................................................................................. 13-7
2.3 Break-in operation .................................................................................................................. 13-7
3. Test and Adjustment for engine........................................................................... 13-9
3.1 Performance test .................................................................................................................... 13-9
3.2 Exhaust air performance test.................................................................................................. 13-9
3.3 Governor performance test..................................................................................................... 13-9
3.4 Protected operation, emergency stop test .............................................................................. 13-9
3.5 Setting of maximum fuel injection volume .............................................................................. 13-9
3.6 Sealing.................................................................................................................................... 13-9
13-1
1. Engine - Adjust
1.1 Using turning gear
Make sure that the turning gear is at the original position when the engine is started. If the engine is started while
the turning gear is depressed, it will cause not only damage the gear but could result in personal injuries.
(1) Loosen two bolts, and remove the plate from the slot of
the shaft.
Shaft
Bolt
Bolt Plate
Using turning gear (when driving)

(2) Then push in the shaft until it engages with the ring
gear.
Using turning gear (when pushed)

(3) Using the socket and ratchet handle, turn the shaft.
(4) After completing the turn, pull out the shaft, insert the
Socket
plate into the slot of the shaft, then tighten the bolts.
Pushing the ratchet down turns the shaft in the nor-

mal direction.
Ratchet handle
Using turning gear (when turning)
13-3
1.2 Valve bridge and Adjusting screw - Check

Check the valve bridge and adjusting screw. If unadjusted,
adjust them.
For the adjusting procedures, refer to "Valve bridge and
Adjusting screw - Adjust" of "ASSEMBLY OF BASIC
ENGINE".
1.3 Valve clearance - Inspect
Inspect the valve clearance.
If the valve clearance is out of standard, adjust it to the stan-
dard value.
For the adjusting procedures, refer to "Valve clearance -
Inspect and Adjust" of "ASSEMBLY OF BASIC
ENGINE".
1.4 Fuel injection timing - Check
Check the fuel injection timing.
If the fuel injection timing is out of standard, adjust it to the
standard value.
For the adjusting procedures, refer to "Fuel injection timing
- Check and Adjust" of "ASSEMBLY OF BASIC
ENGINE".
1.5 Fuel system - Bleed air
(a) Wipe off fuel spilled from the air vent plug thor- [Unlock] [Priming] [Lock]
oughly. This can cause a fire.
Turn left Move up
(b) After bleeding air, be sure to lock priming pump and down Hold and
cap. If the lock is insufficient, it could cause dam- turn right
age to the priming pump and result in fire due

fuel leaks.
To bleed air from the fuel system, while feeding fuel with
the priming pump, start at the place nearest to the fuel tank
as follows: water separator → fuel filter → injection pump. Priming pump - Operate
1.5.1 Fuel filter - Bleed air

Air vent plug
9 ± 1 N·m Switching cock
{0.9 ± 0.1 kgf·m}
If the air vent plugs, nuts of bracket and sealing [6.5 ± 0.7 lbf·ft] ( Operating position )
washers are defective, replace them with new ones.
(1) Loosen the air vent plugs for the fuel filter. (approx. 1.5 Pin B A Pin
turns)
Right filter
(2) Feed fuel with moving the priming pump up and down. Left filter
Switching cock
(3) When fuel flowing from the vent holes no longer con-
A:Air vent position of left filter
tains air bubbles, tighten the air vent plugs to the speci- B:Air vent position of right filter
fied torque. Fuel filter - Bleed air
13-4
1.5.2 Fuel injection pump - Bleed air

(1) Loosen the air vent plugs for the fuel injection pump.
(approx. 1.5 turns)
(2) Feed fuel with moving the priming pump up and down.
Air vent plug
(3) When fuel flowing from the vent holes no longer con- 15 ± 2 N·m

tains air bubbles, tighten the air vent plugs. Before {1.5 ± 0.2 kgf·m}
[11 ± 1.4 lbf·ft]
tightening the last air vent plug, lock the priming pump
cap by turning it clockwise while pushing it down.
Priming pump
Note:(a) If all the vent plugs are tightened before the priming cap
pump cap is locked, fuel pressure acts on the feed
Fuel injection pump - Bleed air
pump, making it hard to press. The operation condi-
tion of the check valve can be checked because it
stabilizes by pressure to open the check valve.
(b) Wipe off fuel spilled from the air vent plug thor-
oughly.
1.5.3 Priming pump cap - Lock

Position where 90 ± 10°
hand-tightening
If the priming pump cap is not locked enough, the becomes suddenly Priming pump
heavy
screw inside would wear by the vibration of the
engine, causing the priming pump cap to shoot out
and the fuel to leak.
If it is too tight, on the other hand, the head of the
priming pump would break. Make sure to tighten at
the correct angle.
Priming pump cap - Lock

Check that there are no deformation or damage for
the head packing of the priming pump. If any defect
is found, replace the priming pump with a new one. Head packing
(1) Tighten the priming pump cap fully by hand, and mark
the priming pump cap in this position.
(2) Tighten an additional 90 ± 10° with a wrench.
(3) Check the installing condition of head packing. If any
defect is found, replace the priming pump with a new
one.
Priming pump cap packing
13-5
1.6 Belt tension - Inspect and Adjust
If the damages such as cuts or surface separations are found during inspection, replace the belt with a new one.
Keep oil and grease away from the belt. They may cause the belt to slip and shorten the service life.
Excessive belt tension can cause rapid wear of the alternator bearing and shorten the service life of the belt.
Adjust the belt tension accurately by following the procedures.
1.6.1 Belt - Inspect

(1) Inspect the belt visually for separation or damage. If any defects are found, replace the belt with a new one.
(2) Inspect the deflection of V-belt.
Inspect the V-belt deflection by pressing it with approx. 98 to 147 N {10 to 15 kgf} [22 to 33 lbf] force at the center of its
span. The belt deflection should be 10 to 15 mm [0.39 to 0.59 in.].
If the deflection is out of standard, adjust the belt tension.
1.6.2 Belt tension (alternator side) - Adjust
(1) Remove the belt cover. 10 to 15 mm
(2) Loosen all bolts on each alternator. [0.39 to 0.59 in]
(3) Turn the adjusting rod and adjust the belt tension.
(4) Tighten all bolt on each alternator.
(5) Install the belt cover.
Lock nut
(Left-hand thread)
Adjusting bolt
Mounting Lock nut
bolt (Left-hand thread)
Belt tension (alternator side) - Adjust
13-6
2. Break-in operation
2.1 Preparation before starting engine
Check the levels of fuel, engine oil, and coolant, and also bleed the fuel system and cooling system.
Inspect the link from the governor output lever to fuel injection pump rack. Check that the fuel control rack is at the no-injec-
tion position and the control rack is "0" with pulling the stop lever.
Check the wiring for the electrical system (sensor, meter alarm panel, starter, alternator, stop solenoid, governor controller,
battery), then check that there is no defect to turn off the controller main switch.
Set the governor controller to run at low idling speed (cooling operation) after starting.
Operate the stop solenoid, and check that the fuel injection pump rack moves to the specified position.
Attach the pressure gauge, thermometer and flowmeter.
2.2 Starting up
(1) While pulling the stop lever, rotate the crankshaft for two or three times (quiescent time: 1 minute or more) by approx. 10
seconds to turn on the starter. Circulate engine oil to each engine parts.
Check that there are no defect such as abnormal noise or rotational fluctuation.
(2) Start engine with standard operation.
Check to run at low idling speed (cooling operation) after starting.
(3) Check that the oil pressure is increased and coolant is circulated.
(4) Check that any leakage of oil, coolant, fuel and gas (air), abnormal noise and abnormal vibration must not be found.
(5) Check that the engine runs at low idling speed (cooling operation), then turn OFF the key switch. Check that the engine
stops.
2.3 Break-in operation
If an abnormal condition occurs during engine operation, make sure an emergency stop can be activated.
2.3.1 Load in the break-in operation and operation

time
Progressively, increase the load during break-in operation.
The following times indicated in the chart below show the minimum times required for the engine to operate reliably.
Break-in operation
Loading Time
Engine speed (min-1)
factor (min)
1 Low rotation speed 600 to 900 No-load 20
Medium rotation
2 1000 to 1200 No-load 10
speed
3 High rotation speed 1400 to rated speed No-load 10
Equivalent to
4 25 % 20
output 25 %
Engine speed Equivalent
5 50 % 20
in partial load to output 50 %
Equivalent
6 75 % 30
to output 75 %
7 Rated speed 100 % 20
13-7
2.3.2 Inspecting engine condition after starting up

During the break-in operation, take care the followings and make sure no abnormalities are found.
Oil pressure, oil temperature Exhaust temperature
Coolant level, water level Variant of left and right bank
Any leakage of oil, coolant fuel, and gas (air) Blow-by gas (level and color)
Noise, vibration Rotational fluctuation
Intake air pressure, intake air temperature Face and radial runouts of rotating parts
Exhaust color, odor Indication and operation of meter and alarm
2.3.3 Inspection and adjustment after break-in operation
Valve clearance Belt tension
Fuel injection timing Inspect and repair for defects such as oil leakage
Additional tightening of exterior bolt and nut
13-8
3. Test and Adjustment for engine
(a) Test, adjustment and sealing for engine must be done at the appointed maintenance factories.
If seal for engine at maintenance factory except for specified one, request the presence of specified mainte-
nance factory's staff for test, adjustment and sealing.
(b) The warm-up operation is performed and the temperature of water and oil is stabled, then perform engine per-
formance confirmation and adjustment.
When the break-in operation completes, and the normal operation can be performed. Then, perform engine performance confir-
mation and adjustment.
Note the test result with referring the data when the engine is shipped.
3.1 Performance test
Fuel consumption rate, temperature, pressure, density of
exhaust air
3.2 Exhaust air performance test
Analysis
3.3 Governor performance test
Setting for minimum no-load speed
Setting for maximum no-load speed
Application of load, interrupting test
Rate of variability, hunting, rotational fluctuation
Other setting conditions of governor controller
3.4 Protected operation, emergency stop test
Oil pressure reduction, water temperature increase, over-
speed
3.5 Setting of maximum fuel injection volume
(1) Apply rated (maximum) load with removing the rack
Increase Spring case
set cap of fuel injection pump rack (front). the fuel injection
(2) Secure the nut at the position that the double nut at the volume
rack end contacts spring case end.
The rack position in maximum load
The position that the fuel injection pump rack is 0

Setting of maximum fuel injection volume
3.6 Sealing
All performance confirmation and adjustment are completed, stop engine, then seal the specified parts between governor actua-
tor and fuel injection pump rack.
13-9
September 2009 SERVICE MANUAL Pub. No. 99406-13200
Printed in Japan Pub. No. 99406-13200

SERVICE MANUAL GUIDE

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SERVICE MANUAL GUIDE

Uploaded by

Copyright:

Available Formats

SERVICE MANUAL

for MHI Equipment Europe B.V.

How to use this manual

Terms used in this manual

Stay clear of all rotating and moving parts

Install protective covers on rotating parts Lockout and tagout

Be careful of exhaust fume poi- Be careful of falling down

Do not climb onto the engine

Always prepare stable scaffold

Be careful when handling fuel, en- Be careful of burns

Be careful of burns when changing oil

Service battery When abnormality occurs

Never modify engine Never break seals

operation Do not touch high pressure injection fuel

About warning labels

Maintenance of warning labels

Tips on disassembling and assembling

Chapter 2 SERVICE DATA

Chapter 3 SERVICE TOOLS

Chapter 4 OVERHAUL INSTRUCTIONS

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

Chapter 7 ASSEMBLY OF BASIC ENGINE

Chapter 9 LUBRICATION SYSTEM

Chapter 10 COOLING SYSTEM

Chapter 11 INLET AND EXHAUST SYSTEMS

Chapter 12 ELECTRICAL SYSTEM

Chapter 13 ADJUSTMENT AND OPERATION

Engine front view

Silencer and pre-cleaner

Engine rear view

Fuel injection pump

Front hanger Governor oil filter

Bypass oil filter

Fuel feed pump

Engine left view

Fuel injection pump

Stop solenoid Alternator

Water drain cock

Engine coolant inlet

Engine right view

2. System flow diagrams

Fuel leak-off pipe

Fuel injection pump

Fuel feed pump

Fuel injection pipe To right side of engine

From right side of engine

Outline of fuel system

2.2 Outline of lubrication system

Camshaft Piston Rocker shaft

Main gallery Turbocharger

Oil cooler Piston cooling nozzle

Outline of lubrication system

2.3 Outline of cooling system

Water pump Oil cooler Water jacket

Engine coolant Intercooler

Outline of cooling system

2.4 Outline of inlet and exhaust system

Intake air Exhaust pipe

From pre-cleaner From pre-cleaner

Outline of inlet and exhaust system

3. The contents of plate and label

Chapter 2 SERVICE DATA