FUEL INJECTION PUMP + Plunger seat DISASSEMBLY AND ASSEMBLY ASSEMBLY OF PLUNGER BLOCK ASSEMBLY art no, | Thckness weava0-0000 | 3.70 34140-0100 | 3.75 1341400200 | 3.80 241400300 | 3.85 raareo0200 | 3.90 t241400800 | 3.95 1241400800 | 400 3) Assemble washer on top of sleeve flange. 4) Set cam at bottom dead center, then tighten puts. 4% When tightening the nuts, insert adjusting shims on the right or left between the sleeve flange and pump housing, and tighten the nuts uniformly in turn. RED Lock nut: 4.25 + 0.25 kam | %* Assemble the adjusting shims after the ‘O-ring is inserted inside the housing, 2 Rack guide serew, rack cap 9. Upper cover GE Upper cover: 0.45 + 0.05 kam 10. gear FEI Drive goar: 6.5 + 0.6 kom 11, Bearing, driven gear 12. Bearing cover 13. Flyweight assembly GSE] Flyweight assembly: 65 + 0.5 kgm 14, Governor cover assembly 13-238 @ Sleeve fisnge 1 + Ong ; 2 At Sorins Piunaw serv} Daina 4 Oaivery ve der 61276 195-6 Plunger assembly Position sleeve flange and plunger assembly with straight pin, then secure with snap ring. Delivery valve assembly 1% Always replace the delivery valve gasket. xing, spring Coat two O-rings on outside of sleeve plunger with grease, Then assemble plunger, lower spring seat and plunger spring correctly. Always use new O-rings, Delivery valve assembly Tighten with socket wrench P. GRE Delivery valve holder Order Tightening torque (kgm) Ist time 1-12 2nd time 0 3rd time W-12 4th time 0 th time m-12 * Always use new O-rings end assemble from the {op of the holder. 155-4 SERIESFUEL INJECTION PUMP ASSEMBLY OF FUEL INJECTION PUMP ASSEMBLY OF PUMP BODY DISASSEMBLY AND ASSEMBLY er bear 1 2 Angst sen] 5 ‘ [oma “Governor |_[7 7: onto 0 “teeine PLS, 4D teeent_F-ponver nei a Sesring coer nm iH Dene grr 08 Parag [4 Feed pume ® Overflow Pipe 7 4 8 Frac Finger a i Froese tcc Fase Lpaer caver Wieaideeil n 2 B M4 Fea Beare |_[Fyweom |_[ Governor j From 8 we —1- Brive gen | —]_ comer aay Sve ay 6127F 135-3 Special tools i Part number Partname _[a'ty | m | 1543606800 | Crate paper 1 Nn | 1978287200 | Plate, measuring | 1 © | 157220-4140 | Measuring device | 1 P| 167914.0500 | Socket wrench 1 1 13-236 155-4 SERIESFUEL INJECTION PUMP. DISASSEMBLY AND ASSEMBLY 9, Break the tappet guid jet assembly into its parts by taking out drawing off roller pin, 10, Lay the disassembled parts in an orderly manner on the table, 13-234 155-4 SERIES oFUEL INJECTION PUMP DISASSEMBLY OF FEED PUMP 1. Removing three nuts securing the feed pump to Injection-pump housing allows the feed pump to be detached as 2 unit. 2. Remove dust cover enclosing the priming pump seetion of the feed pump. 3. Loosen the knurled screw on the bottom of filter, and take off the filter ‘The following three steps 4, 5 and 6 are to be carried out with the feed pump secured to the pump housing. 4. Remove priming pump, and take out valve spring and i check valve, 13-232 ® DISASSEMBLY AND ASSEMBLY 155-4 SERIESFUEL INJECTION PUMP 8. 1) Remove tension lever pin (supporting tension lever and guide lever} from governor cover. 2} Hold tension lever with fingertips and remove fram top of governor cover together with governor spring. 6. Guide lever 7. Control lever 8. Swivel lover 1} Remove snap ring on inside of governor cover. 2) Remove bushing from governor cover, then remove swivel lever, 9. Full load stopper bolt 10. taling sub spring + Clean all parts after disassembly and keep in a safe place, Be particularly careful whon handling precision parts such as plungers and delivery valves. Put to soak in a dish containing clean diesel o 13-230 ® DISASSEMBLY AND ASSEMBLY 155-4 SERIESFUEL INJECTION PUMP # Rotate the camshaft slowly to sot each cam at bottom dead center before starting to remove any part. 2) Loosen mounting nut slightly, then remove shim 10 prevent damage to O-ring. 3) Loosen mounting nuts slowly in turn to remove. 4) Remove washer. 5) Using extractor G, remove plunger block assembly from pump housing. * Remove the O-ring vertically to prevent it from being damaged. 6) Remove rack stopper. 12, Control rack 13, Tappet Remove tappet, ‘When removing the tappot from the top of the ‘pump, be careful not to drop the plunger seat which is fitted to the tappet. 14, Bearing cover 18. Center bearing Using hole wrench, remove two screw lugs of center bearing, 16. Camshaft 1) Remove two set screws of conter bearing, then using bracket H and extractor I, remove bearing cover. 2) Using wooden hammer, tap tip of camshaft from governor side, and remove camshaft together with center bearing. 3) Using extractor J, remove bearing from camshaft, 17. Governor housing 1) Loosen eight set screws, then remove governor housing, 2) Using extractor K, remove outer race of bearing, 13-228 a DISASSEMBLY AND ASSEMBLY 16127 160-9 185-4 SERIES.FUEL INJECTION PUMP 1. Timing gear Remove timing gear using extractor A. 2. Feed pump 3. Overflow pipe 4. Governor cover assembly 1) Using & screwdriver, remove seven bolts holding sgovernor cover, 2) Tap governor cover with plastic hammer to move slightly. Using a screwdriver, push down plate hold- ing link, then remove link from control rack. 3) Using narrow-nosed pliers, remove start spring from spring eve, 5. Flyweight assembly 1). Using socket wrench B, remove round nut holding flyweight ‘* When doing this, install Z-coupling € end use special spanner D to prevent the camshaft from rotating 2) Screw: extractor E into flyweight holder, and remove flyweight assembly from driven gear. 1 3-226 DISASSEMBLY AND ASSEMBLY 155-4 SERIESSTARTING ENGINE DISASSEMBLY AND ASSEMBLY ASSEMBLY OF 2G84 POWER TRAIN cure Tapection From A nsoe * ‘cover (chatenenafl From % Pinion shaft Pinion (* Weight holder * Weight tock ji) With the tock washer in place, temporarily assemble | the weight lock. Indicate the position at which the ! pinion shaft and weight lock are in alignment. li) Temporarily assemble the pinion and weight holder s0 that the stopper bolt holes are in alignment. iil) Install the pinion so that, when the weight holder is | stalled, the weight is caught on the are of the | weight lock, |) Install the return spring and return rod. Lock the i weight lock. 'v) Install the weight holder and weight. Check the ‘weight for proper function. * Cover i Install the cover without fal. | 13-224 185-4 SERIES @STARTING ENGINE DISASSEMBLY AND ASSEMBLY * Powertrain © Adjusting clutch ‘After mounting the transmission, if the clutch does not respond positively when the clutch lever is pulled to the operating position, insert the hand through the inspection window of the clutch chamber, pull the knob and adjust the clutch response by turning the adjusting ring. ‘After adjustment is eomploted, insert the ad- justing pin in the nearest adjusting pin hole in the pressure plate to stop the adjusting ring from turning. When the adjusting ring is turned clockwise the clutch response will become herd, while turning it counterclockwise will result in ‘a soft response. + Magnet Remove the clutch case cover and put No. 1 piston in the compression T.D.C. position. Leaving the ignition cable connected, clamp the magnet in a vice, then rotate the rotor shaft, lower the claw of the impulse and mount the magnet at the position where a spark appears between the ignition cable on the rear cover side and the vice (position where No. 1 cylinder points open}. ‘After mounting the magnet, adjust-the gap between the contact points and also the ignition timing. 13-222 @ Gap between contact points Loosen the adjusting screw, then move the arm until the maximum gap becomes 0.3 to 0.4 mm. Ignition timing Remove the rear cover of the magnet, then place 2 0.3 mm feeler gauge between the contact points and slowly rotate the engine until the feeler gauge is just able to be withdrawn (ignition timing = instant which points open}. If the indication on the ‘graduated scale of the flywhea! at this point in time is outside the range 5 to 10” past the compression T.D.C. position, loosen the magnet mounting bolt ‘and rotate the magnet proper until the indication, is within the range 5 to 10” past the compression T.D.C. position, © Turning the macnet clockwise will cause the ignition timing to advance, while turning coun: terclockwise will cause the timing to be re: tarded. The ignition timing can also be adjusted by removing the rear cover and turning the base plate of the interrupter. © If the above procedure is carried out, the ignition timing during operation of the machine will be 25° before the compression T.D.C. position. jon ~ disengagement engine speed Start the engine by meshing the pinion with the engine flywheel ring gear. Check to see that the pinion backs out of mesh at an engine speed of 400 to 450 rpm © To adjust, turn the adjustment screw in or out. {If the high pinion — disengagement engine speed ‘cannot be corrected with the adjustment serew, cut off one or two coils of spring and readjust the adjustment screw, 185-4 SERIESSTARTING ENGINE DISASSEMBLY AND ASSEMBLY ASSEMBLY OF STARTING ENGINE (2G84) Taare ‘Carturator Tamold fir cleaner 2684 Starting Copnectin robeas ‘crankshaft tpn Main meta Ting sear case * 3 Timing cer 6127F 139-1 13-220 155-4 SERIES. @‘TURBOCHARGER a 10. Blower housing SSE) Mounting bolts: 1.3 kam Turbine housing Because the turbine housing operates at red heat, it employs stainless steel nuts and bolts. Be careful not ‘to mix ordinary nuts and bolts with them. ‘Assomble the following components after applying head seizure prevention paint to the threaded parts thereof. 72+ Painting point '* Mounting nuts for connecting exhaust pipe and ‘urbine housing © Mounting nuts for connecting turbine housing and center housing Inspection After completely assembling the turbocharger, gently rotate the rotating part with the fingers and also push it backward and forward and left and right while rotating it in order to ensure that it does not strike any other parts. Subsequently measure the amount of play of the rotating part. 1) Total end play Move the rotor in the axial direction and ‘measure the clearance using a dial gauge. The clearance for a new assombly should be 0.05 to 0.09 mm. If the measured clesrance becomes greater than 0.19 mm, check the dimensions of the components related to the thrust bearing and replace any worn parts, e127P182 13-216 2 SASSEMBLY AND ASSEMBLY. Radial play Before installing the blower housing, measure the radial clearance at the boss on the shaft end, at the blower side. The clearance for the assembly should be 0.43 100.67 mm. Next, install the blower housing, then push the rotor in the radial direction with the tip of the finger and measure the clearance between the blower impeller and the blower housing using a thickness gauge. ‘The clearance for the assembly should be 0.10 10 0.15 mm. If it is lass than 0.05 mm, check the dimensions of the shaft bearing. As apposed to the case where an ordinary flat bearing is used, there are clearances between the rotor {and the floating bearing and also between the rotor end sleeve. Consequently, the overall clearance appears larger than in the case where 2 conventional shaft bearing is employed. Be sure to measure the clearances and to indicate ther as numerical values. 155-4 SERIES‘TURBOCHARGER DISASSEMBLY AND ASSEMBLY 10. Nozzle ‘The nozzle and turbine nozzle plate are shrink fit Accordingly, place a piace of wood against the end of the nozzle from the gas outlet side, then tightly tap the wood and remove the nozzle. The respective positions of the spring pin and claw are predeter. mined. 11, Rotor an’y Stand up the center housing and extract the rotor ass'y in the horizontal direction. Because the float: ing metal will come away with the rotor ass'y, take ‘out the rotor shaft first in order to prevent damaging the bearing, The shield plate is fixed by imeane of a snap ring. 2, Shield plate Remove the snap ring and take out the shield plate, 13, Floating metal * Sleeve Because the sleeve is shrink fit, place @ piece of wood against the end of the sleeve and lightly tap it to extract the sleeve, 61277137 13-214 Seal ring If the rings on both the turbine and blower sides wear significantly and have large clearances, replace ‘them using pliers, being careful not to damage the grooves. 155-4 SERIESTURBOCHARGER DISASSEMBLY AND ASSEMBLY 10, Housing 1), Carefully install blower housing (4) and turbine housing (8) in such @ way that the impeller is aot damaged ATX Apply liquid gasket LG-2 to the mating faces of turbine housing (3) and biower housing (4). ADS Whon installing the turbine housing, ap- ply liquid gasket 16-3 to the mounting flange face on the center housing side. 11. Clamp Install clamps (1) and (2). GE) Bolt: 0.9540.05 kam 12, Rotor inspection 1) Turn the rotor with the fingers and ensure that the impeller rotates smoothly. Also, push the rotor backward and forwerd and left and right while turning it and ensure that the impeller does not strike the housing. 2) Measure the clearance between the blower housing ‘and the blowar impeller using a thickness gauge. KTR100: 0.15 mm min, KTR130; 0.20 mm min. gi27P ial) | 13-212 155-4 SERIES ©TURBOCHARGER DISASSEMBLY AND ASSEMBLY 5. Thrust esting < : ‘Mount thrust bearing (10). wo 7 0 © Apnly oil to Both ofthe surfaces with which the eds thrust collar comes into contac. © Make sure that the collar and spacer do not move, 6127P 167 6. Cover 1) Align the match mark on the shaft with the match mark on collar (8), then install the cover and | colle. | 2) Apply These Bond No. 4 st the points on the | ‘cover corresponding to the locations of the extrac: tion bolt holes. slingor into the insert (16), 4% Ensure that the gap in the seal ring is on the oil filler side of the center housing. Align the match mark on the shaft with the match mark. cn the slinger, and also ensure that the collar and spacer do not move, 7. Stinger 7 1) Insert @ seal ring into slinger (17) and fit the i | 2). Fit O-ring (18) on insert (16). / / ei27PI72 3) Apply Three Bond No, 4 to both faces of the lock washer, | 4) Bolt the thrust bearing, cover and insert together. | | * During the above operation, be careful to avoid moving the center housing in order to lensure that the match marks do not get aut of line. Sw Bolt: 1.2540.25 kam 5) Bend the lock washer. ! 13-210 155-4 SERIES‘TURBOCHARGER 12, Nozzle (KTR130) Using the insert mounting bolts, extract nozzle (19) \which is fitted on the turbine housing. hy 2 13-208 DISASSEMBLY AND ASSEMBLY 155-4 SERIESTURBOCHARGER DISASSEMBLY AND ASSEMBLY 4. ‘Cover Extract cover (8). 6 Collar Extract collar (9). 6 Thrust bearing Extract thrust bearing (10). 7. Spacer and thrust collar Extract spacer and thrust collar (11). 13-206 siz7P 166 6127167 6127168 155-4 SERIESWATER PUMP. 2) 3) vi) Apply Film Bonding to the counter bore. During this operation, be careful not to soil the Film Bonding with dirt, oil, humidity, fingerprints or dust. Do not use film bonding which is more than six months old. vii) Remove the backing strip from the Film Bonding. vill) Place @ floating seat on the counter bore to which the check mark has been applied, then rotate the seat and coat its entire periphery with adh ix) Place @ 6.8 kg weight on the floating seat and bond the floating seat to the counter bore by leaving it for 65 minutes in an ‘oven at a temperature of 174 to 179°C. Select the temperature and time carefully in order to ensure complete bonding, Exposed edges of film will change color from yellow to rust brown. '$4D155-4 (Engine serial No.50133 and up) ‘$6D185-4 (D150A-1,0155A,S-1 Engine serial No.60133 and up} i) Lightly apply water soluble lubricant (toi- let soap, etc.) to the inside surface of the rubber of the seat ast'y Ui) Fit the seat ass'y onto the shaft in such a way that the carbon face of the pump seal ‘comes into contact with the abrasive face Of the ceramic of the seat as'y iii) Press fit the impeller. \—— ceramic Set es'y 6127F136 $6D155-4 (0365.1) (Engine serial No.10011 ~ 19999) SAGD156-4 (Engine serial No.20338 and up) 1) Apply @ thin coat of water soluble lubri- cant (such as toilet soap) to the periphery Of the rubber of the seat assembly, 13-204 @ DISASSEMBLY AND ASSEMBLY {i Fit the seat assembly to the impeller ‘* Push in the assembly with force, taking care not to cause the seat to rise or fall Falling of seat: 0.1 mm or less Rubber ving / Cceramie (Wo.10011 ~ 183131 Refractory metal (No.15314 ancup) = 6127F 136-1 Til) Wipe the sealing surface of the seat with a ‘loth soaked in methyl ethyl ketone to emove oil, grease and dust. 4) Ciean the tapered surfaces. Fit the tapered sur- face of the impeller to that of the shaft. 5). Tighten the nut, % Apply light taps to the periphery of the impeller with a mallot and confirm that the tightening torque dovs not decrease, Impeller lock nut; 7.75 £0.25 kam 6) Bend the tongue on the lockplete. Cover Inlet connection {In order to provent water leakage, apply Three Bond No. 4 to the threaded part of the stud body, then screw in the stud. ‘After assembling the inlet connection, put the gear into manual, then rotate it to check that it turns smoothly. 155-4 SERIESWATER PUMP DISASSEMBLY OF WATER PUMP ey DISASSEMBLY AND ASSEMBLY 5 ‘ ara ager pu iene Sie Oia wager Cover © sap1s6-4 'S6D166-4 (D150A,D155A,S-1) Inlet connection © S6D155-4 (0355-1) Impelier and floating seat © S4D155-4 S6D155-1 (D155A,0155A,5-1) (0355-1: Engine serial No.10011 ~ 10100) Using extraction taps (8 mm, P = 1.25), extract the impeller and floating seat by means of a puller. © s6p186-4 {D355A-1: Engine serial No.10101 and up) ‘SAGD185-4 (Engine serial No.20338 and up} Romove the lock nut, then, using extraction taps (B mm, P= 1.25), extract the impeller and floating seat by means of a puller. Shatt assy When extracting the shaft ass'y, be careful not to damage the oil seal and water seal. Oil seat After disassembling the water pump ass'y, replace it with a new one. Water seal After disassembling the water seal, replace it with a 13-202 @ 185-4 SERIESGENERAL ASSEMBLY 55. Starting motor 1). Fit an O-ring to starting motor (2), then lift up the starting motor and mount it on the flywheel housing. G3) Starting motor mounting bolt: 27.544 kam =D Bracket mounting bolt Block side: 11 1.5kgm Starting motor side: 6 + 1.5 kgm 21 Install bracket (1). ‘% If there is @ clearance between bracket and starting motor, fit the shim. %* Note that the bracket mounting bolts on the starting motor side ate fine thread bolts 56. Filter bracket Install filter bracket (1). 57. Corrosion resistor 1) Mount corrosion resistor (1) on filter bracket (2). 2) Connect up the water pump by-pass tube to ‘corrosion resistor inlet hose (3), then fit clamp (4). 3) Connect outlet hose (5) to cylinder block return valve (6), 58. Bypas filter 1) Mount by-pass filter (7) on filter bracket (2) using ‘mounting bands (8) and (9). 2) Connect up the by-pass filter outlet hose to the cylinder block, and connect inlet hose (10) to the engine oil cooler. 13-132 DISASSEMBLY AND ASSEMBLY 155-4 SERIESGENERAL ASSEMBLY 47. Exhaust manifold S3=) Mounting bolt: 1121.5 kam ‘* Fit the ring to prevent a gas escape. 48, Turbocharger 49, Muffler 1) Lift up muffler (1), turbocharger (2) and exhaust manifold (3) as a single assembly, then insest @ gasket between the cylinder head and the exhaust ‘manifold, and mount the assembly on the cylinder heed. Subsequently, lock the mounting bolts with lock plates (4). %* Use 125 mm bolts (six bolts) 10 clamp the heat shield (5) end 110 mm bolts (twelve bolts) for the other parts of the oxhaust manifole. * Confirm that the step between the exhaust manifold conter and muffler mounting bracket does not exceed 0,1 mm. If the step is too large, adjust the muffler mounting bracket posi- tion with shims, 2). Install muffter drain tube (6) and clamp it using a clamp. 50. Turbocharger lubricating tube 1). Fit a gasket to the flange end face of turbocharger lubricating inlet hose (1) and connect the hose té the turbocharger. 2). Fit an O-ring to the cylinder block connecting side of outlet tube (2), then fit a gasket to the end face of the turbocharger connecting flange and install the outlet tube. Make sure that every pipe is free from twisting ‘caused by immoderate force. 51. Intake connector Fit an O-ring to the turbocharger insertion part of intake connector (1), apply grease (G2-LI) to the intake connector then insert the intake connector and ten up the bolt securing it to the intake manifold * Be careful riot to bite into the O-ring when ng the intake connector. 13-130, ® DISASSEMBLY AND ASSEMBLY 155-4 SERIES.genematasseuety sassy ann asenaty 38. Injection pipe 1) Wrap sealing tape around the nipple of cam lubricating pipe (1) and mount the pipe on the cylinder biock. % Note that the nipples fitted with nozzles ar cam lubricating (total of 12 nipples on lower side) nipples. 2). install injection pipe (2) on the rocker housing and injection pump. FE Injection pipe sleeve nut: 2.440.1 kam 3) Install cam lubricating pipes (1) (six pipes) on the cylinder block. S=M=1 Cam lubricating pipe sleeve nut: 2440.1 kgm 4) Install lubricating pipe (3) on the cylinder block and injection pump. s 39. Oil filler Fit @ gasket to the flange end face of oil filler (3) and install the oil filler on the eylinder block 40. Lubricating pipe Instals lubricating pipe (2) on the injection pump and the oil filler flange, and fix it in position using clamp ay. aul. Breather tube Connect breather tube (2) to breathor (6), then tighten up hose clamp (3) and install tube clamp (4. * 42. Intake manifold | Fit a gesket 10 intake manifold (1) and mount the intake manifold in the cylinder head, EE Intake manifold mounting bolts: 6.52 1 kgm 195-4 SERIES\SSEMBLY AND ASSEMBLY ‘Adjust the valve clearance according to the follow: ing procedure, + Ignition sequence: SAD1854: 1-2-4—3 SeD155-4. Siopoga) 189-6 -2-4 * Valve clearance {i atmosphere}: $4D155-4 Engine serial No.10287 ~ 50156 S6DI5E-4 Engine serial No.10011 ~ 11745, Intake valve 0.3 mm Exhaust valve 0.3 men ‘SAD185-4 Engine serial No.60187 and up ‘S6D155-4 Engine serial No.11746 and up SAGDI65-4 Intake valve 0.4 mm Exhaust valve 0,6 mim 1D. “Align the embossed fine afound the:periphery ‘of the damper (Iront end of,erankshaft) with the pointer. ii) Chock that theres @ clearance between rocker lever (17) and compression release shaft (14) Serew in adjusting screw (15) until feeler gauge TB moves sluggishly. . oe iv) Tighten up lock rut (16). = GES “Lock nut: 6.981.0 kai a _Repeat stops i) to iv) for each cylinder. ‘ ‘Botate’ compression release shaft (14) and ‘Fhourethat.the intake push rod rises up. . i ad Fuel pipe “ jostle pe (3). ‘GED Fuel pipe sleeve nut: 4.25 ¥ 0.25 kgim “f Tighten the pipe of nozzle side then’ tighten ity rocker arm side. : 4 ©. If there is no abnormality, install the pipe on th same cylinder. 31. Spill pipe Fit gaskets and. joint bolts to spill pipes.(2) and (1), ‘then mount the spill pipes on the rocker housing and fit the clamp bolts. I SHillpipe joint bolts; 240.5 kgm 32. Rocker housing cover Apply liquid gasket (LG-1) to the mounting faces of rocks housing covers (1), (2) and (3), then fit gaskets anid install the covers on the rocker housing. Rocker housing cover mounting bolts: |» 32820.25 kgm 155-4 SERIES.GENERAL ASSEMBLY 3) Fit sling bolts @ (12 mm, P = 1.75) to cylinder head ass'y (12), then lift up the assembly and mount iton the cylinder block. * Apply engine oil (EO10-CD) to the threads of the mounting bolts and.also the washers, =I Cylinder head mounting bolts + Tighten up in the sequence (1) to (10) indicated in the diagram, Units kgm Sequence, | Target ange st pass 7 255-325 zapas | aa 40.5-475 3rd pass 55 557555 Nozzle holder ‘% Tighten them taking a balance mutually, ‘Zuw] Mounting bolt: 3.25 +0.25 kam, 28. Tappet, push rod and crosshead 1) Apply engine oil (EO10-CD) to tappets (1), then 7 mount the tappets on cylinder head (2) and insert ay push rod (3). 2) Install crosshead (4) and adjust it according to the procedure below. 1} Loosen lock nut {5) and return adjusting serew (6), ii) Using the fingers, lightly holt down the surface which comes into contact with the rocker arm of crosshead (4), then support the crosshead with the valve stems on the push ‘od side in contact with it. {ii} Screw in adjusting screw (6) until the cross- head comes into contact with the valve stems ; (on the other side, then serew in the screw by a further 29° (30° if the crosshead of guide is not new). |v) Tighten up tock nut (5), SHED Lock nut: 4,020.4 kgm 13-124 DISASSEMBLY AND ASSEMBLY 6127F 199 155.4 SERIESGENERAL ASSEMBLY 25, Flywheel 1) Fit sling bolts D (12 mm, P = 1.7) to flywheel (1), then ‘aise the flywheel and mount it on the ’ flywheel housing after engaging the respective ‘eats, and lock the mounting bolts with lock plates 4 2). ‘ G3) Flywheel mounting bolt: 6342 kam 2) Using dial gauge @, measure the radial and face Mh? ow of fates i] med tyne tousog Sena Red nunou—0.35 mms Fosnecelteansaneue Oil pan 1) Before installing the oil pan, measure the differ- ‘ence in height between the mounting face of the ~ cll pan and timing gear case (1), gear case cover {2), flywheel housing (3) and cylinder block (4), respectively using depth gauge (D). Repair limit: 0.15 mm 2) Apply liquid gasket {LG-1) to oil pan (6), then fit 4a gasket to the oil pan, raise it and mount it on the cylinder block. GHZ) Oil pan tightoning bolt: 6.5 1 kam + Note thet the oll pan mounting bolts are of ‘two different lengths, 30 mm (14 bolts) and 35 mm (measured from head bottom face). =) Oil pan drain plug: 155425 kgm Se Oil drain plug: 8521.5 kom wy DISASSEMBLY AND ASSEMBLY 1554 SERIESGENERAL ASSEMBLY 22. Rear seal 1) Drive the rear seal into rear seal cage (1) using tool Y. 2) Apply grease (G2-LI) on the seal lip surface. 3) Fit an Orting to roar seal cage (1), then mount to flywheel housing (2) and lock the mounting bolts with lock plates (3). 4% Be careful not to damage on the seal lip surface, %* Bend lock plates securely. 23. Steering pump gear 41). Fit‘an Oring to the flywheel mounting face of bearing cago (1), then mount it to flywheel housing (2) from the eylinder block si 2}. Install steering pump gear (3) on the drive shatt, then lock the mounting bolts with lock plates (4). + Bend lock plates securely DISASSEMBLY AND ASSEMBLY 61277139 155-4 SERIESGENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY 17, Damper flange 1) Fit the key on the crankshaft, then mount damper flange (1) on the crankshaft after aligning the key groove of the flange with the key on the crank- shaft. 2) Mount holder (2) using mounting bolts (3). GH Holder mounting bolts: 16 + tkam * Indicator plate (S4D 185-4} Position the No.1 cylinder piston at TDC on the com- pression stroke and align the 1.4 TOP mark on the indicator plate with the pointer. 18. Damper Mount damper (1) and lock the mounting bolts using lock plate (2). + Position the No.1 eyiinder piston at TDC on the compression sirgke and align the 1.6 TOP mark on the damper withthe pointer + Aftor installation, check the damper for face runout and radial runout Damper face runout and radial runout: Within 0.25 mm GE Damper mounting bolts: 17 4 1kg.m 19. Accessory pulley ass'y 1) When repiacing the bushing of cover (1), drive in ‘the new bushing using tool X. 2) Apply engine oil (EO10-CD) to the inside surface ‘of the bushing, then fit the thrust washer to shaft {2) and install cover (1). 3) Fit an O-ring to drive shatt ass'y (3), then engage the gear with the gear case cover and install the ear. 4% Orient the thrust washer so that its oil groove is facing the gear side. Za) Drive shaft ass'y mounting bolts: 3.7 40.6 kg. 1277134 155-4 SERIES< GENERAL ASSEMBLY pe DISASSEMBLY AND ASSEMBLY F418, camshatt Apply oil {EO30-CD) to camshaft (1), then insert the camshaft from the timing gear case side, align the ‘mounting bolt holes and fit the mounting bolt from gear holes (2). % Align the match marks of idle gear (3) and camshaft gear (1). Goa] Camshaft: 3.720.6 kam 44, Timer 1) Fit the key into the injection drive shaft and install timer (1) after aligning the mateh mark of the goar with the key groove, 2). Install special too! U and tighten up the timer ‘mounting nu oan Ti e mounting puts 17 kgm 3) Measure the backlash and end play of each gear using dial gauge ©. 6127F 130 i Unit: mn hem End play | Bockiaeh 4] Cam gear 0.19-0.25 | 0.14~0.32 Fuol injection pump dive : . 2| Fusl 0.03-0.17 | 0.12~0.38 3] crank gee gp. ona~o27] = “ 4] Olt pump ie gear 003~0,17,| 008-938 cg 5| 0 pump gear 0.04~0.10 | 0.05~0.20 ooso31 155-4 SERIESGENERAL ASSEMBLY 5. Gear lubricating nozzle Install gear lubricating nozzle (1}, noting the position of the hole. ‘# The hole position, must be 30° left under. Ale gear shaft 1) Install shaft of the main idle gear with the UP ‘mark facing upwards, then tock the mounting bolt with lock washer (4), 2). Install shaft (3) of the pump idle gear and lock the ‘mounting bolt with lock washer (2) ‘Tirming gear case 1) When replacing the bushing of the accessory drive ‘gear shaft, use tool O. 2) If blind plug (1) is removed, apply liquid gasket {LG-1) to the periphery of the plug and install it using tool K. 3) Apply tiquid gasket (LG-1) to the face of timing gear case (2) which is in contact with the cylinder block, then fit a gasket and grommet, raise the timing gear case and install it on. the cylinder block Zsa) Timing gear case mounting bolts: 27 kam DISASSEMBLY AND ASSEMBLY 186-4 SERIES.GENERAL ASSEMBLY 2 3) 4 5) 6) ” 8) ii) Put the piston and connecting rod together. © Position the part number stamp inside the piston and the part number embossed on the connecting rod on the same side. After ‘making sure that the number stamped on ‘the piston and connecting rod togeth ‘When the piston is replaced or when ‘the piston lacks the piston No. stamp, stamp the cylinder No. on the piston ‘at the position shown in the figure. If there is any difficulty in installing piston pin (3), immerse the piston in hot water. iii) Fit smap ring (4) to fix the piston pin in position. Align thé projection of the upper bearing of the ‘connecting rod with the notch on the connec fod, then install the bearing on the connecting rod. Fita reamer bolt in the connecting rod. After making sure that all ring gaps are positioned properly, set the assembly in the piston holder “P”, Put the crankshaft of the cylinder to be fitted in the B.D.C, position, then apply engine oil {E030-CD) to the bearing face of the connecting ‘od and the inside of the cylinder, Orient the connecting rod so that the embossed characters face towards the front of the engine (so ‘that the stamped mark faces the cam side} then insert connecting rod ass'y from the head sid Insert the piston ring part into the eylinder liner, then push it home with a wooden rod or the like. Align the projecting part of the lower bearing with ‘the notch on the connecting rod cap and install the bearing on the connecting rod cap. Sub- sequently, mount connecting rod cap (6) onto the connecting rod after aligning the respective stamped marks. ax 1198 DISASSEMBLY AND ASSEMBLY er27P 112 ‘Stamp position for Pert number stamp, cylinder number Front of engine Al B127F 129-1 6127F 128, a berz7er1a 165-4 SERIESGENERAL ASSEMBLY 4) 5) 6) n a 9 Fit upper thrust metal (8) to the No. 5 shaft bearing with the oll groove facing outwards, Align the projection of the lower bearing with the notch on cap (9) of the main metal, then fit the bearings together. ‘Apply engine cil (EO30-CD) to the journal face of the crankshaft, then align the embossed mark on the cylinder block and install the bearing cep on the cylinder block. Apply engine oil (EO30-CD) to the threaded part cof mounting bolts (10) and washers of the main ‘metal cap, then screw in the bolts alternately to {it the cap completely. + Because the lower thrust metal fi the No, 5 main metal cap, install the cap so that the oil groove is facing outwards. Tighten up bolts (10) in the following sequence, * Tighten up the bolts sequentially from the ‘center outwards, then gradually apply the final torque in the following steps. G5) Main metal cap mounting bolts kam Sequence | Target Range st poss aa | gona 2ndoos | 61 0-62 Slocken oft completa, athpas | 185 1816 3rd pose o Sth pas | 20 28-40 6th pass 5 s0~st Th pass ™ 70-78 After tightening up the bolts, measure the rotating torque of the crank. Standard value: 2.8 kg.m max. 13-110 @ DISASSEMBLY AND ASSEMBLY e127P198 165-4 SERIESGENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY 3), Prossit cylinder liner (1) to cylinder block using liner drive L, | 4) After press-ftting the cylinder liner, meature the | amount of protrusion using aia! gauge @. 1f the Oring pushes up the liner, fit plate @ to clamp the liner before taking measurements Standard values: Cylinder liner protrusion: 0.1 to.0,16mm. Difference in projection between cylinders: ie 0.06mm max, creme Liahie 2 Crankshaft 1) When replacing the rear sleeve, front sleeve and gear of the crankshaft, do so according to the following procedure. i) Grind @ groove into front sleeve (1), then apply 2 chisel to this groove and knock off the sleeve by tapping the chisel with a hammer. li) Extract gear (2) using a gear puller. lil) Grind a groove into rear sleeve (3), then apply 4 chisel to this groove and knock off the { sleeve by tapping the chisel with a hammer. iv) Drive on geer (2) using tool N. e127 102 13-108 155-4 SERIESGENERAL ASSEMBLY Cylinder tiner For the engines using O-rings for all three liner seal rings, replace the liners with ones of the clevis soal ype. For the engines with clovis seal type liners, the diameter of the liner head flange determine the combination of cylinder block, cylinder liners, cylinder head and gasket. Do not confuse the replacement parts. Combination of parts: eS] Fie or Griniersoak | eravananie | Fomeizrawiny Grinmrines | eraeatazia | Fomerzeavze Crinertes | Upworari? | RomerzriTaiia ‘© "Be sure to replace the liner O-rings whenever the liner is removed, © Install the O-rings and the clevis seal as illustrated below. Method of installing liner O-rings and clevis seals 1) Confirm that the O-ring grooves in the liner are not rough because of rust or pitting. {if rough, there is @ possibility of water leakage, Replace the liner.) 2} Apply SAE3O engine oil to the seal rings and ring grooves, 3) When installing the clovis seal, press its periphery so that the seal fits in the upper portion of the groove to prevent corrosion. 13-107-1 @ Cylinder ner DISASSEMBLY AND ASSEMBLY Clovis set Black (tie eubber) Brick-red (allcone rubber) 6127F 126-3 195-4 SERIES1 GENERAL ASSEMBLY SPECIAL TOOLS DISASSEMBLY AND ASSEMBLY Part No. Part name 79050-2000 | Engine rep. stand body | 790-901-1150 | Engine repair stand bracket 798-102-2101 | Spring pusher 795-226-1600 | Piston ring tool ij 795-100-1361 | Hunger 795-225-1300 | Push tool 795-100-2780 | Plate 790-101-5821 | Grip 796-100-2600 | Push tool kit 795-226-1510 | Liner driver 796-100-1280 | Sleeve driver 795-100-1281 | Sleeve driver 790-101-5221 | Grip 795-100-1471 | Piston holder 790-101-5080 | Piete 795-102-2402 | Push tool 790-101-5221 | Grip 1 1 795-102-2302 | Push tool 1 790-101-5021 | Grip af ia 795-100-1163 | Timer installer 1 795-100-1131 | Push toot 1 798-100-1120 | Seal guide 1 795-525-1310 | Push tool 1 795-101-5021 | Grip 1 795-102-1821 | Seal driver 1 796-101-8221 | Grip 1 795-502-1121 | Holder 1 795-126-1320 | Feller gauge 1 185-4 SERIESGENERAL ASSEMBLY trom A, DISASSEMBLY AND ASSEMBLY from & from © 5 4 8 ® » w a —— ® oes F Rocker Rossi ‘from housing a cover s ‘Shill pipe oe P ; _ tome # » « a Ll oe Ba oo 13-104 1954 SERIESGENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY a ENGINE ASSEMBLY 155 series eylinger Blose orssa-n) 13-102 Tale gor shate 0 fete gear 4 é Gear ub, Timing pozele Gear ee n nie ave Pision 1 Piping oll pump oH a ‘camanate 4 155-4 SERIESGENERAL DISASSEMBLY DISASSEMBLY AND ASSEMBLY ‘56. Piston and connecting rod ast'y 1) Check the No. embossed on the cap of the connecting rod. (Check that the cap No. and cylinder No. agroe with each other and that the embossed mark is on the cam side.) + If there is no mark, emboss mark before sdismounting the cap. 2) Rotate the clutch shaft so that the piston to be remove falls to the B.0.C. position. 9) Remove carbon deposits from the upper wall of the liner using fine sandpaper, etc. 4) Remove nut {2) of connecting rod cap (1). 5) Remove connecting rod cap (1) together with the connecting rod bearing while tapping it lightly ‘with 2 plastic hammer to prevent damaging the thread of the connecting rod bolt. 6) Extract the piston and connecting rod ass'y from the oil pan side using a wooden rod or the like, During this operation, support the piston at the cylinder head side to prevont damaging the inside of the cylinder liner ‘Temporarily fit the connecting rod and cap ‘together and place it alongside the bearing so 2 to ensure that these parts are assembled together correctly. 71 Disassombling piston and connecting rod as'y i) Remove the snap ring. iil Hold connecting rod (3) in the hand, then ‘extract piston pin (4) and disconnect the connecting rod and piston from each other iil) Retain the other piston pin and remove the snap ring 6127P080 IW) Using piston ring tool F, remove piston ring | (5). i %* Arrange the piston, connecting rod, | bearing, piston ring and piston pin of each cylinder No, together. ei27e091 13-024 155-4 SERIESGENERAL DISASSEMBLY 46. Camshaft Remove mounting bolt (2) from the hole in cam gear (1), then remove the camshaft and cam gear (1) while rotating ther. (is) Comshate: 25 ko 47. Adler gear 1) Push up lock plate {1} and remove the mounting bolt, then remove holder (2) and dismount main Idle goarass'y (3). 2) Push up lock plate (4) and remove the mounting bolt, then remove holder (5) and dismount pump idle gear (6). ‘gear case Fit sling bolts @ (14 mm, P = 1.75) to timing gear case (1) and lift it up, then remove mounting bolts (2) and the two mounting bolts connecting the gear case to the oil pan, and clismount the gear case. Timing gear case: 49 kg 49. Oil pan Remove the mounting bolts of oil pan (1) and lift out the oil pen. Cig) Open: 65 ke 13-022 DISASSEMBLY AND ASSEMBLY 185-4 SERIESGENERAL DISASSEMBLY 41. Spill pipe Flemove spill pipes (1) and (2). 42. Fuel pipe Remove fuel pipe (3) 43. Rocker housing 1) Dismount rocker housings (1), (2) and (3). ¥ Take care not to lose joints (4) end (5) of the compression release shaft, 2). Disassembling rocker housing 1) Compression ralease shaft When extracting compression release shaft (6), first remove the stopper bolt from part (7). ii) Rocker arm ‘© Remove left and right blind plugs (8). '* Remove'stopper bolt (3). © Extract rocker arm shaft (10), then remove rocker arm (11), spring (12) and collar (13). 13-020 DISASSEMBLY AND ASSEMBLY 6127 125, 155-4 SERIESGENERAL DISASSEMBLY 36. Damper flange 1) Remove bolt (1) and then dismount holder (2). 2) Fit bolt (1), then install puller € and remove damper flange (3). 36. Gear case cover Remove the crankshaft key, then suspend gear case | cover (1), remove mounting bolts {2} and (3) and remove the cover. [Cig] Gear case cover: 71 kg 37. Timer 1) Remove nut (1) and take out the shaft key. 13-018 DISASSEMBLY AND ASSEMBLY 6127P086 155-4 SERIESGENERAL DISASSEMBLY 29, Rear seal Push up lock plate (1) and remove the mounting bole, then extract rear seal {2} using extraction bolts (10 rom, P= 1.8). 90, P.T.O. and flywheel housing as'y i 1) Fit sting bolts D (14 mm, P = 1.75) and @ (16 mm, P = 2.0) to the P-T-O. and flywheel housing and temporarily suspend it 2) Remove mounting bolts (1) and (2) from the flywheel housing and dismount P.T.0. and ‘ly wheel housing (3), [is P-7.0. and flywheel housing: 294 kg 31. Tension pulley 1) Loosen adjusting nut (2) of tension spring (1), then remove bracket (3) and spring (1). Because tension pulley {4} will fatl down, be careful not to get hands caught. 2). Dismount tension pulley (41. 13-016 DISASSEMBLY AND ASSEMBLY 165-4 SERIESGENERAL DISASSEMBLY 21. Injection pipe 1} Remove the six cam lubricating tubes (1) and also remove the nipples at the eylinder block side. + Note that the nipples fitted with nozzles are for lubricating the cam (bottom side, total 12). 2) Disconnect injection pipe (2) from the connecting part of the rocker housing and injection pump. 22, Oil level gauge guide Remove oil level gauge guide (1). 23, Injection pump Remove mounting bolts (2) and (3), then dismount Injection pump ass'y (4) together with bracket (5) % Check that there are match marks on the mount: ing part. If there are none, mark them on the mounting part. (Cie) Iniection pump ass'y: 35 kg 24, Fullflow filter Dismount full-flow filter (1) after removing the mount: ing bolts of bracket (2) 25, Filtor brackot ismount bracket (2). 26. Flywheel 41) Push up the lock of lock plate (1) and remove the bolt. ' 13-014 @ DISASSEMBLY AND ASSEMBLY 185-4 SERIESGENERAL DISASSEMBLY DISASSEMBLY AND ASSEMBLY 2). Lift up muffler (2), turbocharger {3} and exhaust manifold (4), then remove the mounting bolts of the exhaust manifold and remove (2), (3) and (8) as an assembly. oe ag) Muller, urbocharge, exhaust ma 121 kg 13. Engine oil cooter 1) Remove the mounting bolts of engine oil cooler (1) and dismount the oil cooler. 2) Remove return cock (2) of the corrosion resistor. 14, Setting engine ropair stand 1) Fit bracket A of the engine repair stand using threaded holes for mounting the oil cooler. 2). Lift up engine ass'y {1} and set it on engine repair stand A, 8127P039 | 13-012 155-4 SERIES.GENERAL DISASSEMBLY DISASSEMBLY AND ASSEMBLY % 4. Stating motor 1) Remove bracket (1). 2 tow thet the two muting Hos for he brctet onthe saring motor side ae fine vate 21 Ramee the mounting bls of the starting moter sna cut starting moter (2) Ta Starting motor 509 5. Alternator 1) Remove V-belt cover (1) 2) Remove adjusting bolts (2), thon loosen support bolts (3), push alternator (4) to the engine side and remove V-belt (5). 3] Remove support bolts (3) and dismount alternator a. 6. Alternator drive shaft 1) Remove mounting bolts of bracket (1) and the |, 9#at cate, then dismount alternator drive shaft (2). 2) Remove bracket (1). CBP) Dive soit 2540 13-010, 155-4 SERIESGENERAL DISASSEMBLY DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS Port No, Part name 76003-2000 | Eine er and man 7 78001-1150 | Engine repair stand bracket 1 720-101-2600 | Gear pull 796-102:2201 | Flange puller 1 796-100-1181 | Timer remover 1 795:1022101 | Spring pusher 1 796-225-1600 | Piston rng too! 1 796-102-1100 | Liner puller 1 Preparation work © Set engine ass'y[1) on engine stan« 61279021 © Dismount engine-related parts 1) Dismount accelerator rod (2) together with bracket (3), 2) Dismount compression release rod (4). 3). Disconnect tube (5) of the intake air heater and tube (6) of the engine oil pressure gauge. 4) Disconnect wiring {7) and (8) from the alternator and starting motor, respectively, 13-008 185-4 SERIES ®GENERAL DISASSEMBLY DISASSEMBLY AND ASSEMBLY trom 8 from " from 0 Roar PETES Rooker hous eae so Ase housing [Fear Tae 6 trom € chore Fuet pine 5 Babe tram F a fp, @ ate gear from H pump. Evia ae'y from! from K trom L 13-006 155-4 SERIESRAL DISASSEMBLY DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY OF ENGINE ASSEMBLY ‘Starting 5 ‘Alvernator 185 seg toiesay” Altoenstor Grin aa 4 mutter 13-004 From A, Steering ump gear 155-4 SERIES.