Manuel Reparation Moteur

SERVICE MANUAL
199619-33100
for CHINA FORKLIFT TRUCK STD.
February 2010
Pub. No. 99619-33100
INTRODUCTION
This service manual describes the maintenance and adjustment procedures, and specifi-
cations for Mitsubishi diesel engines.
To maintain the performance of the engine for many years and to ensure safe operation,
it is important to use the engine correctly and conduct regular inspection and maintenance,
and it may also be necessary to take appropriate measures which involve in disassembly,
inspection, repair and assembly work 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.
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 Diesel Engine (standard model for land use).
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 basic size 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)
Rotation speed: 1 min-1 = 1 rpm
III
INTRODUCTION
Safety cautions
Fire and explosions
Keep flames away Watch out for fuel, oil and exhaust gas
Do not use flames near the engine (in leaks
the engine room). Spilled fuel, oil and If any fuel, oil or exhaust gas leakage is found, imme-
LLC may ignite and cause a fire. Wipe diately take corrective measures to stop it. Such leak-
off spilled fuel, oil and LLC immedi- ages, if left uncorrected, can cause fuel or engine oil to
ately and thoroughly. Spilled fuel, oil reach hot engine surfaces or hot exhaust gas to con-
and LLC may ignite and cause a fire. Store fuel and tact flammable materials, possibly leading to personal
engine oil in a well ventilated designated area. Make injury and/or damage to equipment.
sure that the fuel and engine oil container caps are
Use explosion-proof lighting apparatus
tightly closed.
When inspecting fuel, engine oil, coolant, battery elec-
Keep engine surrounding area tidy and trolyte, etc., use a flameproof light. An ordinary lighting
clean apparatus may ignite a gas and cause an explosion.
Do not leave combustible or explosive materials, such Prevent electrical wires from short-circuit-
as fuel, engine oil and LLC, near the engine. Such
ing
substances can cause fire or explosion. Thoroughly
Avoid inspecting or servicing the electrical system with
remove dust, dirt and other foreign materials which are
the ground cable connected to the battery. Otherwise,
accumulated on the engine and the area around the
a fire could result from short-circuiting. Be sure to dis-
engine. Such materials can cause fire or the engine to
connect the battery cable from the negative (-) termi-
overheat. In particular, clean the top surface of the bat-
nal before beginning work. Short-circuits, possibly
tery thoroughly. Dust can cause a short-circuit. Always
resulting in fire, may be caused by a loose terminal or
place the engine at a position at least 1 m [3.28 ft.]
damaged cable/wire. Inspect the terminals, cables and
away from buildings and other equipment to prevent
wires, and if any faulty parts are found, repair or
possible fire caused by engine heat.
replace prior to work.
Keep fire extinguishers and first-aid kit

handy
Keep fire extinguishers handy, and
become familiar with their usage.
Keep a first-aid kit at the designated
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,
contact points, and means of communication in case
of emergency.
IV
INTRODUCTION
Stay away from rotating and moving parts
Install protective covers on rotating parts Lockout and tagout

after inspection/maintenance work Be sure to lockout and tagout before starting inspec-
Make sure the protective covers of tion and maintenance. Lockout and tagout are effec-
the engine are correctly installed. tive methods of cutting off machines and equipment
Repair any damaged or loosed cov- from energy sources. To accomplish the lockout/
ers. Never remove the protective cov- tagout, remove the starter switch key, set the battery
ers of rotating parts during operation. switch to OFF and attach a "Do Not Run" or similar
When the engine is coupled to the radiator or other caution tag to the starter switch. The starter switch key
equipment, install protective covers around the must be kept by the person who performs inspection
exposed connecting belt and coupling. and maintenance work.
Check work area for safety Be sure to stop the engine before inspec-
Before starting the engine, make sure that no one is tion and maintenance work.
near the engine and that tools are not left on or near Be sure to stop the engine before proceeding to
the engine. Verbally notify persons within the immedi- inspection and maintenance work. Never attempt to
ate area when starting the engine. When the starter make adjustments on the engine parts while the
device is posted with a warning sign saying "DO NOT engine is running. You can get caught in rotating parts
START-UP," never operate the engine. and seriously injured.
Stay away from moving parts while engine Always restore engine turning tools after
is running use
Keep away from the rotating parts Be sure to remove all turning tools used during inspec-
while engine is running. Do not leave tion and maintenance work. If the engine is started
any objects that may get caught in with a turning tool inserted or if the engine is started
rotating parts. If clothes or tools get under the turning condition, it can not only cause the
caught in rotating parts, it could result damage to the engine, but also lead to personal inju-
in serious injuries. ries.
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, always use a cor-
If the engine is installed in an rect wire rope capable of withstanding
enclosed area, and the exhaust gas is the engine weight. Attach the wire
ducted outside, ensure that there is rope to the lifting hangers provided on
no exhaust gas leak from duct joints. the engine using a correct sling. Dur-
Exhaust gas from the engine contains ing lifting process, keep the engine in
carbon monoxide and other harmful substances. a well-balanced position by taking the center of gravity
Operating the engine in an ill-ventilated area can proof the engine into consideration.
duce gas poisoning. The hangers equipped with the engine are designed
for lifting the engine only. In the case where the gener-
Protect ears from noise
ator, marine gear, etc. are installed to the engine,
make consideration so that additional weight will not
Wear ear plugs
affect the hangers of the engine.
Always wear ear plugs when entering
Keep the angle formed by slings attached to hangers
the machine room (engine room).
within 60°. If the angle exceeds this limit, excessive
Combustion sound and mechanical
load could be imposed on the hangers and this could
noise generated by the engine can
damage the hangers and result in a serious accident.
cause hearing problems.
When the wire rope comes into contact with the engine
directly, place a cloth or other soft pad to avoid dam-
age 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 is firmly secured. Climbing on the
engine may not only damage engine parts but also you
may fall down from the engine and get injured.
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 specified fuel, engine oil and long-life ately after operation
coolant (LLC) only. Do not touch any parts of the engine
Use the fuel, oil and LLC specified in this manual only, during or immediately after operation.
and handle them carefully. Use of any other fuel, oil or You can get burned. Before conduct-
LLC, or improper handling may cause various engine ing maintenance and inspection work,
problems and malfunctions. Obtain the Material Safety check the water temperature gauge to make sure that
Data Sheets (MSDS) issued by the fuel, oil and LLC the engine has cooled down.
suppliers, and follow the directions in the MSDSs for Do not open the radiator cap when the
proper handling. engine is hot
Handle LLC carefully Never open the radiator cap while the engine is run-
When handling LLC, always wear rubber gloves and a ning or immediately after the engine stops. Stop the
protective face mask. If LLC or cooling water contain- engine and give a sufficient time to allow the coolant to
ing LLC comes into contact with your skin or eyes, or if cool down before opening the cap. When opening the
it is swallowed, you would suffer from inflammation, radiator cap, slowly open the cap so as to release
irritation or poisoning. Should LLC be accidentally internal pressure. To prevent hot steam scalds, wear
swallowed, induce vomiting immediately and seek thick rubber gloves or cover the cap with a cloth. When
medical attention. Should LLC enter your eyes, flush closing the radiator cap, firmly tighten the cap. Do not
them immediately with plenty of water and seek medi- open the radiator cap during engine running or just
cal attention. If LLC splashes onto your skin or cloth- after the engine stops. Otherwise hot steam and cool-
ing, wash it away immediately with plenty of water. ant gush out and can cause scalds.
Keep flames away from LLC. The LLC can catch Refill coolant only after the coolant temper-
flames, causing a fire. Coolant containing LLC is a
ature dropped
hazardous material. Do not dispose of it in unauthor-
Do not add coolant immediately after the engine stops.
ized manner. Abide by the applicable law and regula-
Wait until the coolant temperature lowers sufficiently to
tions when discarding drained coolant.
avoid a risk of burns.
Proper disposal of waste oil, LLC and cool-
ant
Do not discharge waste engine oil, LLC and coolant
into sewerage, river, lake or other similar places. Such
a way of disposal is strictly prohibited by laws and reg-
ulations. Dispose of waste oil, LLC, coolant and other
environmentally hazardous waste in accordance with
the applicable law and regulations, or consult a Mit-
subishi dealer.
VII
INTRODUCTION
Service battery When abnormality occurs
Handle the battery correctly Stop overheated engine after cooling run
Never use flames or allow sparks to Even if the engine is about to overheat, do not stop the
generate near the battery. The bat- engine immediately. Abrupt stopping of an overheated
tery releases flammable hydrogen engine can cause the coolant temperature to rise,
gas and oxygen gas. Any flames resulting in seized engine parts. If the engine is about
or sparks in the vicinity could to overheat, run the engine at low idling speed (cooling
cause an explosion. operation), and stop the engine after the coolant tem-
Do not use the battery if its fluid level is below the perature lowers sufficiently.
lower limit line. Using such batteries could result in
Do not add coolant immediately after a sud-
an explosion.
Do not short the battery terminals with a tool or other den stop due to overheating
metal object. If the engine stops suddenly or if you have no choice
When disconnecting battery cables, always remove but stop the engine suddenly due to overheating, do
the cable from the negative (-) terminal first. When not add coolant immediately. If water is added immedi-
reconnecting the cables, always connect the positive ately, parts such as cylinder heads can be damaged
(+) terminal first. due to the sudden drop of temperature. Add coolant
Charge the battery in a well-ventilated area, with all gradually after the engine has completely cooled.
battery plugs removed.
Avoid immediate restart after abnormal
Make sure the cable clamps are securely installed on
the battery terminals. A loose cable clamp can stop
cause sparks that may result in an explosion. If the engine stops abnormally, do not restart the
Before servicing electrical components or conducting engine immediately. If the engine stops giving alarm
electric welding, set the battery switch to the [Open/ sound, inspect the engine and remedy the cause of
OFF] position or disconnect the cable from the nega- the problem before restarting. If the engine is kept
tive (-) battery terminal to cut off the electrical cur- operating in such condition, it can result in serious
rent. engine failure.
Electrolyte (battery fluid) contains dilute sulfuric acid.
Immediately stop the engine when engine
Careless handling of the battery can lead to the loss
of sight and/or skin burns. Also, do not swallow bat- oil pressure drops
tery fluid. If engine oil pressure drops dangerously low, stop the
Wear protective goggles and rubber gloves when engine immediately, and inspect the lubrication sys-
working with the battery (such as adding water or tem to locate the cause. Continuous engine operation
charging). with low oil pressure may cause bearings and other
If battery electrolyte is spilled onto the skin or cloth- parts to seize.
ing, immediately wash it away with lots of water. Use
Stop the engine immediately if belt is bro-
soap to thoroughly clean.
Battery fluid can make you blind if gotten into your ken
eyes. If it gets into the eyes, immediately flush it If the belt breaks, stop the engine immediately. Contin-
away with plenty of clean water, and seek immediate uous engine operation with the broken belt could
medical attention. cause the engine to overheat and thereby the coolant
If the battery fluid is accidentally swallowed, gargle to boil into steam, which may gush out from the
with plenty of water, then drink lots of water, and reserve tank or radiator, and you could get burned.
seek immediate medical attention.
VIII
INTRODUCTION
Other cautions
Never modify engine Warm-up the engine before use

Unauthorized modification of the engine will void the After starting the engine, run the engine at low idling
warranty even if the warranty period has not expired. speeds for 5 to 10 minutes for warming-up. Start the
Modification of the engine may not only damage the work after this operation is completed. Warm-up oper-
engine but also could lead to personal injuries. ation circulates the lubricant through the engine.
Work clothing and protective gear Therefore, individual engine parts are well lubricated
before they are subjected to heavy loads. Warm-up
Wear a hardhat, face shield, safety shoes, dust mask,
operation circulates lubricants in the engine and con-
gloves and other protective gear as needed. When
tributes to a longer service life and economical opera-
using compressed air, wear safety goggles, a hardhat,
tion. Do not conduct warm-up operation for a longer
gloves and other necessary protective gear. Works
time than necessary. Prolonged warm-up operation
without wearing proper protective gear could result in
causes carbon build-up in the cylinders that leads to
serious injuries.
incomplete combustion.
Never break the seals
Never operate the engine in an overloaded
To ensure proper engine operation, the fuel control
link is provided with seals that protect the fuel injection condition
volume and rotation speed settings against tampering. If the engine shows an overloaded condition such as
If these seals are broken and the settings are black exhaust smoke, reduce the load immediately to
changed, the proper operation of the engine will no operate the engine at an appropriate output and load.
longer be guaranteed, and the following problems will Overloading causes not only high fuel consumption
occur. but also excessive carbon deposits inside the engine.

Rapid wear of moving and rotating parts Carbon deposits cause various problems and will
Engine troubles such as damage and seizure of shorten the service life of the engine.
engine parts Conduct cooling operation before stopping
Drastic increase of fuel and lubricating oil consump-
the engine
tion
Before stopping the engine, idle the engine for 5 to 6
Degradation of engine performance due to improper
minutes to cool down. Stopping the engine immedi-
balance between fuel injection volume and governor
ately after high-load operation will cause engine parts
operation or overrunning of the engine which could
result in a serious accident to heat up and shorten the service life of the engine.
During cooling operation, check the engine for abnor-
Break-in the engine
malities.
To break in new engines or overhauled engines, oper-
ate the engine at a speed lower than the rated speed Protection of the engine against water entry
in a light load condition during the first 50 hours of Do not allow rainwater, etc. to enter the engine
operation. Operating a new engines or overhauled through the air inlet or exhaust openings. Do not wash
engines in a severe condition during the break-in the engine while it is in operation. Cleaning fluid
period shortens the service life of the engine. (water) can be sucked into the engine. Starting the
engine with water inside the combustion chambers
can cause the water hammer action which may result
in internal engine damage and serious accidents.
IX
INTRODUCTION
Properly maintain the air cleaner Do not turn off the battery switch during
The major cause of abnormal wear on engine parts is operation
foreign materials from intake air. Worn parts produce Do not turn off battery switch during operation. If the
many problems such as an increase of oil consump- battery switch is turned OFF when the engine is run-
tion, decrease of output and starting difficulties. For ning, not only various meters will stop working but also
effective removal of dust from intake air, maintain the the alternator may have its diode and transistor deteri-
air cleaner according to the following instructions. orated.
Do not maintain the air cleaner while the engine is
Cautionary instructions for transporting the
operating. Operating the engine without the air
engine
cleaner can suck particles of foreign matter into the
engine and could result in serious accidents. When transporting the engine on a truck, consider the
Remove the air cleaner slowly to prevent dust accu- engine weight, width and height to ensure safety.
mulated on the element from falling off. After remov- Abide by road traffic laws, vehicle road acts, vehicle
ing the air cleaner, immediately cover the opening restriction ordinances and other pertinent laws.
(inlet port of air cleaner) with plastic sheet or similar Do not operate engine continuously under
means to prevent dust from entering the engine.
low load
If the engine is equipped with a dust indicator, con-
Load low continuous operation (less than 30%) must
duct maintenance only when the clog warning sign
be limited to one hour or less. Otherwise, incomplete
appears.
combustion may occur due to the carbon buildup
Observe safety rules at work site
inside the cylinder. Also, after low load operation is
Observe the safety rules established at your work-
conducted for approx. 1 hour, conduct load operation
place when operating and maintaining the engine. Do
at 30% or more load for more than 5 minutes.
not operate the engine if you are feeling not well.
Inform your supervisor of your condition. Operation of
Ventilation of engine room
the engine with reduced awareness may cause Always keep the engine room well-ventilated. Insuffi-
improper operation that could result in accidents. cient intake air amount of the engine can cause an
When working in a team of two or more people, use increase in the engine temperature, and could result in
specified hand signals to communicate among work- a decrease in the output power and poor performance.
ers. It is highly recommended to calculate the required

amount of air supply to the engine and install an ade-
Use proper tools for maintenance work
quate ventilation system before installing the engine.
Always keep in mind to select most appropriate tools
for the work to be performed and use them correctly. If
Do not touch high pressure injection fuel
tools are damaged, replace with new tools. If fuel leaks or sprays out from the high pressure injec-
tion pipe, do not touch the fuel. Fuel in the fuel injec-
Avoidance of prolonged time of starter
tion pipes is under high pressure and if the fuel contact
operation
your skin, it goes into deep tissues and may result
Do not use the starter for more than 10 seconds at a
gangrene.
time. If the engine does not start, wait for at least 1
minute before cranking again. Cranking the starter
continuously could lead to a flat battery or starter burn-
ing out.
X
INTRODUCTION
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 missing 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
XI
INTRODUCTION
Tips on disassembling and assem- Tips on assembling

Wash all engine parts, except such parts as oil seals, O-
bling
This service manual specifies the recommended procedures rings and rubber seats, in cleaning oil and dry them with
to be followed when servicing Mitsubishi engines. The compressed air.
Use correct tools and instruments.
manual also specifies the special tools that are required for
Use only high-quality lubricating oils and greases of
the work, and the basic safety precautions to follow when
appropriate types. Be sure to apply oil, grease or adhesive
working. Note that this manual does not exhaustively cover
to designated surfaces.
potential hazards that could occur during maintenance,
Use a torque wrench to tighten parts correctly when their
inspection and service work of engine.
tightening torques are specified. Refer to "Tightening
When working on the engine, follow the relevant instruc-
torque table."
tions given in this manual and also observe the following: Gaskets, packings and O-rings should, as a rule, be
Tips on disassembling replaced with new ones. Also, adhesive should be applied
Use correct tools and instruments. Serious damage to the as required. Use only the proper amount of adhesive.
engine can result from using the wrong tools and instru- Use protective gloves when you touch overheated or
ments. cooled parts. Touching the overheated parts with hands
Do not use jack bolts having sharp edge, as they may cause directly can cause burns.
damage to the surface.
Use an overhaul stand or workbench if necessary, and fol-
low the disassembling procedures described in this man-
ual. Do not place the engine parts on the floor directly.
Place them on the workbench in an orderly manner.
Keep the engine parts in order of removal to prevent losing
them. Arrange parts in order during disassembly.
When reusing the engine parts, unless there are special rea-
sons, install them to the positions where they were.
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.
XII
GENERAL CONTENTS
Chapter 1 GENERAL
1. External view
2. System flow diagrams
3. Engine serial number location
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 mechanism - Disassemble and inspect
3. Front mechanism - Disassemble and inspect
4. Piston, connecting rod, crankshaft and crankcase - Disassemble and inspect
Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

1. Cylinder head and valve mechanism - Inspect and repair
2. Rear mechanism - Inspect and repair
3. Front mechanism - 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. Piston, connecting rod, crankshaft and crankcase - Assemble
2. Front mechanism - Assemble
3. Rear mechanism - Assemble
4. 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. Performance test
Chapter 1 GENERAL
1. External view............................................................................................................ 1-3
1.1 S6S (in-line type fuel injection pump) external view ................................................................. 1-3
1.2 S6S (distributor type fuel injection pump) external view ........................................................... 1-4
1.3 S6S-T (distributor type fuel injection pump) external view........................................................ 1-5
2. System flow diagrams............................................................................................. 1-6
2.1 Outline of fuel system ............................................................................................................... 1-6
2.2 Outline of lubrication system..................................................................................................... 1-7
2.3 Outline of cooling system.......................................................................................................... 1-9
2.4 Outline of inlet and exhaust system........................................................................................ 1-10
3. Engine serial number location ............................................................................. 1-11
4. Main specifications................................................................................................ 1-12
1-1
Chapter 1 GENERAL
Chapter 1 GENERAL
1. External view
1.1 S6S (in-line type fuel injection pump) external view
Fuel filter Oil level gauge

Fan
Coolant drain plug

Water pump
Flywheel
Front Rear
Oil filter
Fuel injection pump
Relief valve
Stop solenoid Engine oil drain plug
Engine left view
Oil filler
Oil filler Hanger
Thermostat case
Alternator
Rear Front
Starter Belt
Damper
Oil pan
Engine right view
1-3
Chapter 1 GENERAL
1.2 S6S (distributor type fuel injection pump) external view
Oil level gauge

Fan
Fuel filter
Water pump Coolant drain plug
Flywheel
Front Rear
Magnet valve Oil filter

(Stop solenoid)
Fuel injection pump
Relief valve
Engine oil drain plug
Engine left view
Oil filler
Oil filler
Hanger
Hanger
Thermostat case
Alternator
Rear Front
Rear plate
Belt
Starter
Damper
Oil pan
Engine right view
1-4
Chapter 1 GENERAL
1.3 S6S-T (distributor type fuel injection pump) external view
Fan
Water pump Coolant drain plug
Flywheel
Front Rear
Magnet valve
(Stop solenoid) Oil filter
Fuel injection pump
Relief valve
Engine oil drain plug
Engine left view
Oil filler Oil filler

Hanger Hanger
Thermostat case
Alternator
Rear Front
Rear plate
Belt
Starter
Damper
Oil pan
Engine right view
1-5
Chapter 1 GENERAL
2. System flow diagrams

2.1 Outline of fuel system
2.1.1 In-line type fuel injection pump
Fuel filter Fuel leak-off pipe
Fuel injection nozzle
Fuel return pipe
Fuel injection pump
Fuel inlet
Outline of fuel system
2.1.2 Distributor type fuel injection pump
Fuel filter
Fuel inlet
Leak-off pipe
Return pipe
Fuel outlet
Fuel injection pump
Outline of fuel system
1-6
Chapter 1 GENERAL
2.2 Outline of lubrication system

2.2.1 In-line type fuel injection pump
Push rod Piston Crankshaft

Valve mechanism
Tappet
Camshaft
Relief valve
Main gallery
Oil filter
Idler gear
Fuel injection pump
(In-line)
Oil pump
Oil strainer Oil pan
Outline of lubrication system
1-7
Chapter 1 GENERAL
2.2.2 Distributor type fuel injection pump
Non-turbocharged engine
Piston
Push rod Crankshaft
Valve mechanism
Tappet
Camshaft
Main gallery
Relief valve
Oil filter
Idler gear
Oil pump
Piston Turbocharger Turbocharged engine

Oil jet
Crankshaft
Push rod
Valve mechanism
Tappet
Camshaft Oil cooler
Main gallery
Relief valve
Oil filter
Idler gear
Oil pump
Safety valve
1-8
Chapter 1 GENERAL
2.3 Outline of cooling system
Coolant outlet
Thermostat
Cylinder head
Bypass hose
Water jacket
Coolant inlet
Water pump
Outline of cooling system
Turbocharged engine
Thermostat Oil cooler
Cooling outlet
Cylinder head
Bypass hose
Water jacket
Cooling inlet
Water pump
Outline of cooling system
1-9
Chapter 1 GENERAL
2.4 Outline of inlet and exhaust system
Breather hose
Exhaust manifold
Inlet manifold
Exhaust Inlet
Outline of inlet and exhaust system
Turbocharged engine
Turbocharger
Inlet
Exhaust
Exhaust Inlet
Blow-by gas
Discharge
Exhaust manifold
Inlet manifold
Outline of inlet and exhaust system
1-10
Chapter 1 GENERAL
3. Engine serial number location

The engine serial number is stamped on the right of the
crankcase. Engine
serial number
Engine serial number location
1-11
Chapter 1 GENERAL
4. Main specifications
Main specifications
S6S S6S S6S-T
Engine model (In-line type fuel (Distributor type fuel (Distributor type fuel
injection pump) injection pump) injection pump)
Type Water cooled, 4 stroke cycle diesel engine
No. of cylinders - arrangement 6 cylinder in-line
Combustion system Swirl chamber
Valve mechanism Overhead
Cylinder bore × stroke 94 x 120 mm [3.70 x 0.472 in.]
Displacement 4.996 L [305 cu. in.]
Compression ratio 22.0 : 1
Main specifications
Fuel Diesel fuel (Equivalent of JIS K2204)
Firing order 1-5-3-6-2-4
Direction of rotation Counterclockwise as viewed from flywheel side
Length 1001 mm [39.41 in.]
Dimensions Width 622 mm [24.49 in.]
Height 805 mm [31.69 in.] 912 mm [35.91 in.]
Dry weight 345 kg [761 lb] 350 kg [772 lb]
Cylinder Type Dry (integral with cylinder block)
Compression ring:2
Piston ring No. of units
Basic engine Oil ring (with expander) :1
Starting system Starter
Starting aid system Glow plug
Type In-line (A type) Distribution (VE type)
Fuel injection Plunger outside diameter ø6.5 mm [0.256 in.] ø 11 mm [0.43 in.]
pump Cam lift 8 mm [0.32 in.] 1.741 mm [0.0685 in.]
Governor type RSV type All speed type
Fuel feed pump Type KS type Vane type
Nozzle type Throttle type
Fuel system
No. of spray holes 1
Spray-hole diameter ø1.0 mm [0.039 in.]
Fuel injection
nozzle Spray angle 15° 0°
14.22 MPa 11.8 MPa
Valve opening pressure {145 kgf/cm²} {120 kgf/cm²}
[2062 psi] [1711 psi]
Fuel filter Type Cartridge type paper element
Lubrication method Forced circulation (pressure feed by oil pump)
Specification Class CF-4 (API service classification)
Engine oil Engine total: 17.5 L [4.62 U.S. gal.],

Capacity Oil pan: 16.5 L [4.36 U.S. gal.] (high level),
oil filter: 1 L [0.26 U.S. gal.]
Type Trochoid
Lubrication system Speed ratio to crankshaft 0.74

Oil pump
38.7 L [10.22 U.S. gal.]/min
Discharge rate
(at pump rotation of 2230 min-1, 0.3 MPa {3 kgf/cm²} [43.5 psi])
Type Piston valve type
Relief valve
Valve opening pressure 0.35 ± 0.05 MPa {3.6 ± 0.5 kgf/cm²} [50.8 ± 7.3 psi]
Oil cooler Type - Plate type
Oil filter Type Cartridge type paper element
1-12
Chapter 1 GENERAL
Main specifications
S6S S6S S6S-T
Engine model (In-line type fuel (Distributor type fuel (Distributor type fuel
injection pump) injection pump) injection pump)
Cooling method Water-cooled, forced circulation
Coolant capacity (engine water jacket) 8 L [2.1 U.S.gal.]
Type Centrifugal
Speed ratio to crankshaft 1.2
Water pump
160 L [42.3 U.S. gal.]/min
Cooling system Discharge rate
(at pump rotation of 3600 min-1, 0.075 MPa {0.75 kgf/cm²} [10.9 psi])
Type Push type (PP fan)
Cooling fan
Outside diameter ø500 mm [19.69 in.]
Type Wax type
Thermostat
Valve opening temperature 76.5 ± 1.5°C [169.7 ± 2.7°F] (90°C [194°F] when fully opened)
Inlet exhaust system Turbocharger - TD06H
Voltage 24 V
Grounding system Negative (-) ground
Model number M008T60373
Pinion meshing type Pinion shift
Starter
Output 24 V, 5.0 kW
No. of pinion tooth/ring gear tooth 10/122
Model number A004TU3586
Type 3-phase alternating current, with rectifier
Output 24 V, 50 A
Alternator Speed in use to 8000 min-1
Rated speed 5000 min-1
Permissible speed 10000 min-1
Speed ratio to crankshaft 1.95
Electrical system Type Sheathed
Glow plug Rated voltage 22 V
Current 4.4 A (When applying rated voltage for 15 sec) x 6
Rated voltage 24 V
Power consumption 14W
ETR type
Starting voltage - 13 V or below
(RUN-ON)
Return voltage 5 V or more
Coil resistance 37 ohm
Magnetic valve
(Stop solenoid) Rated voltage 24 V
Operation voltage 16 to 27 V
ETS type Operation -30 to 90 ºC
-
(RUN-OFF) temperature [-22 to 194 ºF]
Rated time 10 seconds
Rated current 11.7A or below
1-13
1. Maintenance service data ....................................................................................... 2-3
1.1 Engine general ......................................................................................................................... 2-3
1.2 Basic engine ............................................................................................................................. 2-4
1.3 Fuel system .............................................................................................................................. 2-7
1.4 Lubrication system.................................................................................................................... 2-7
1.5 Cooling system ......................................................................................................................... 2-7
1.6 Inlet and exhaust system .......................................................................................................... 2-7
1.7 Electrical system....................................................................................................................... 2-8
2. Tightening torque table........................................................................................... 2-9
2.1 Tightening torque for basic engine ........................................................................................... 2-9
2.2 Tightening torque for fuel system ............................................................................................. 2-9
2.3 Tightening torque for lubrication system................................................................................. 2-10
2.4 Tightening torque for cooling system...................................................................................... 2-10
2.5 Tightening torque for inlet and exhaust system ...................................................................... 2-10
2.6 Tightening torque for electrical system ................................................................................... 2-10
2.7 Tightening torque for standard bolts and nuts ........................................................................ 2-11
2.8 Standard stud tightening torque ............................................................................................. 2-11
2-1
1. Maintenance service data

1.1 Engine general
Unit: mm [in.]
Item Nominal Standard Limit Remarks
0
2650 min-1 2650-50 min-1 S6S in-line type
Maximum rotation speed (no-load) 0

2550 min-1 2550-50 min-1 S6S distributor type
2570 min-1 2570 ± 50 min-1 S6S-T distributor type

+20
680 min-1 680 0 min-1 S6S in-line type
Minimum rotation speed (no-load) 0

820 min-1 820-100 min-1 S6S distributor type
820 min-1 820 ± 25 min-1 S6S-T distributor type

3.2 MPa 2.8 MPa
When oil and water temperatures
Compression pressure (at 300 min-1) {33 kgf/cm2} {29 kgf/cm2}
at 20 to 30°C [68 to 86°F]
[464 psi] or more [406 psi]
Not below than
0.3 to 0.5 MPa
Rated speed 0.15 MPa
{3 to 5 kgf/cm2}
at 1500 min-1 {1.5 kgf/cm2}
[44 to 73 psi] When oil temperatures
Engine oil pressure [22 psi]
at 60 to 70°C [140 to 158°F]
0.10 MPa 0.05 MPa
Idling speed {1.0 kgf/cm }2 {0.5 kgf/cm }2
[14.5 psi] or more [7.3 psi]

Open BTDC 30°
Inlet
Close ABDC 50°
Without turbocharger
Open BBDC 74°
Exhaust
Close ATDC 30° ±2°
Valve timing Valve clearance at 0 [0 in.] mm
Open BTDC 18° (crank angle)
Inlet
Close ABDC 54°
With turbocharger
Open BBDC 66°
Exhaust
Close ATDC 22°
Inlet 0.25 [0.0098]
Valve clearance When cold
Exhaust 0.25 [0.0098]
Fuel injection timing BTDC 5°
2-3
1.2 Basic engine

Unit: mm [in.]
ø19 19.010 to 19.030
Rocker bushing inside diameter
[0.75] [0.7484 to 0.7492]
ø19 18.980 to 19.000
Rockers Rocker shaft outside diameter
[0.75] [0.7472 to 0.7480]
0.010 to 0.050 0.070
Clearance between rocker bushing and shaft
[0.0004 to 0.0020] [0.0028]
ø8 7.940 to 7.955 7.900
Inlet
[0.32] [0.3126 to 0.3132] [0.3110]
Valve stem outside diameter
ø8 7.920 to 7.940 7.850
Exhaust
[0.32] [0.3118 to 0.3126] [0.3091]
Valve and valve 0.065 to 0.095 0.150
Inlet
guide Clearance between valve stem [0.0026 to 0.0037] [0.0059]
and guide 0.080 to 0.115 0.200
Exhaust
[0.0031 to 0.0045] [0.0079]
14 13.9 to 14.1
Valve guide installed length
[0.55] [0.547 to 0.555]
Valve seat angle 30°
0.4 0.3 to 0.5 1.0 Seat width
Inlet
[0.016] [0.012 to 0.020] [0.039]
Valve sinkage
0.5 0.4 to 0.6 1.0
Valve seat and Exhaust
[0.020] [0.016 to 0.024] [0.039]
valve
Valve
1.4 1.26 to 1.54 1.8 seat Valve
Seat width Valve margin
[0.055] [0.0496 to 0.0606] [0.071] angle
sinkage
2.13 1.83
Valve margin
[0.0839] [0.0720]
48.85 47.60
Free length
[1.9232] [1.8740]
A = 1.5º or less A
B=1.3 [0.051] B
Length
Squareness or less
B=1.5 [0.0591] Lf
Valve spring Lf = 48.85
[1.9232]
43 mm [1.69 in.]/
43 mm [1.69 in.]/
176 to 196 N
Installed length/load 147 N {15 kgf}
{18 to 20 kgf}
[33 lbf]
[40 to 44 lbf]
TIR (dial gauge reading) when
push rod is supported along
0.6 center line of spherical surface
Push rod Runout
[0.024] at either end.
(TIR)
(dial gauge reading)
0.05 [0.0020] 0.20
Distortion of bottom surface Reface slightly.
or below [0.0079]
1.2 1.15 to 1.25
Cylinder head Compressed thickness of gasket
[0.0472] [0.0453 to 0.0492]
1.0 to 1.5
Top clearance
[0.039 to 0.059]
Repair limit:
ø94 94.000 to 94.035 94.200 [3.7087]
Inside diameter
[3.70] [3.7008 to 3.7022] Service limit: Refinish cylinder to 0.25
94.700 [3.7283] [0.0098] or 0.50 [0.0197]
Cylinder oversize of nominal valve by
0.01 [0.0004]
Roundness honing.Use oversize piston
or below
and piston ring.
0.015 [0.0006]
Cylindricity
or below
2-4
Unit: mm [in.]
93.955 to 93.985 93.770
Standard
[3.6990 to 3.7002] [3.6917]
+0.25
94.205 to 94.235 94.020
Outside diameter [0.0098] ø 94
[3.7089 to 3.7100] [3.7016]
(at piston skirt) Oversize [3.70]
Piston +0.50
94.455 to 94.485 94.270
[0.0197]
[3.7187 to 3.7199] [3.7114]
Oversize
-0.25 to 0.15
Protrusion from crankcase
[-0.0098 to 0.0059]
Weight difference in one engine ±5 g [0.2 oz.]
No.1 0.30 to 0.50 1.50
compression [0.0118 to 0.0197] [0.0591]
No.2 0.50 to 0.70 1.50
Piston ring End gap
compression [0.0197 to 0.0276] [0.0591]
0.30 to 0.50 1.50
Oil
[0.0118 to 0.0197] [0.0591]
ø30 29.994 to 30.000
Outside diameter
[1.18] [1.1809 to 1.1811]
0.000 to 0.016 0.050
Piston pin Clearance between piston
[0.0000 to 0.0006] [0.0020]
0.020 to 0.091 0.120
Clearance between connecting rod bushing
[0.0008 to 0.0036] [0.0047]
ø30 30.020 to 30.045
Inside diameter of the connecting rod bushing
[1.18] [1.1819 to 1.1829]
0.05/100
0.15/100
Bend and twist [0.0020/3.94]
[0.0059/3.94]
or less
If the specified limit is
exceeded when changing the
Connecting rod Clearance between crankpin and connecting 0.030 to 0.090 0.200
standard size of connecting
rod bearing (oil clearance) [0.0012 to 0.0035] [0.0079]
rod bearing, change it into
undersize bearing.
0.15 to 0.35 0.50
End play Replace connecting rod.
[0.0059 to 0.0138] [0.0197]
10 g [0.35 oz.]
Connecting rod weight rank
or below
0.15 [0.0059] 0.50
Flatness
or below [0.0197]
Flywheel
0.15 [0.0059] 0.50
Runout
or below [0.0197]
0.5 [0.020] 1.5 Replace with new one when
Outer circumference face runout
or less [0.059] engine is operated for 8000
Damper
0.5 [0.020] 1.5 hours
Outer circumference radial runout Replace
or less [0.059]
2-5
Unit: mm [in.]
0.04 [0.0016] 0.10
Runout TIR
or less [0.0039]
6.684 6.384 to 6.784 6.184
Inlet
[0.2631] [0.2513 to 0.2671] [0.2435]
S6S
6.720 6.420 to 6.820 6.220
Cam lift Exhaust
[0.2646] [0.2528 to 0.2685] [0.2449]
(major axis - minor
axis) 6.682 6.382 to 6.782 6.184
Inlet
[0.2631] [0.2513 to 0.2670] [0.2435]
S6S-T
6.722 6.422 to 6.822 6.220
Camshaft Exhaust
[0.2646] [0.2528 to 0.2686] [0.2449]
ø54 53.94 to 53.96 53.90
No.1, 2, 3
[2.13] [2.1236 to 2.1244] [2.1220]
Journal diameter
ø53 52.94 to 52.96 52.90
No.4
[2.09] [2.0842 to 2.0850] [2.0827]
Clearance between camshaft journal 0.040 to 0.090 0.15
and camshaft bushing [0.0016 to 0.0035] [0.0059]
0.10 to 0.25 0.30
Camshaft end play Replace thrust plate.
[0.0039 to 0.0098] [0.0118]
0.009 to 0.050 0.100
Clearance between bushing and shaft
[0.0004 to 0.0020] [0.0039]
0.05 to 0.20 0.35
Idler Idler gear end play Replace thrust plate.
[0.0020 to 0.0079] [0.0138]
0.035 to 0.076
Interference between shaft and crankcase hole
[0.0014 to 0.0030]
0.05 to 0.15 0.25
Timing gear backlash Replace gears
[0.0020 to 0.0059] [0.0098]
Repair limit:
ø78 77.955 to 77.970 77.850 [3.0650]
Crankshaft journal outside diameter
[3.07] [3.0691 to 3.0697] Service limit:
77.100 [3.0354]
ø58 57.955 to 57.970 57.800
Crankpin outside diameter
[2.28] [2.2817 to 2.2823] [2.2756]
Pin maximum
Parallelism defection: 0.01
[0.0004] or less.
0.01 [0.0004] 0.03
Roundness
Pin and journal or less [0.0012]
0.01 [0.0004] 0.03
Cylindricity
or less [0.0012]
Crankshaft
R3 2.8 to 3.2
Fillet radius
[0.12] [0.110 to 0.126]
33 33 to 33.1
Crankpin width
[1.30] [1.30 to 1.303]
31 31 to 31.039
Rearmost crank journal width
[1.22] [1.2205 to 1.2220]
0.04 [0.0016] 0.10
Runout TIR
or less [0.0039]
0.100 to 0.264 0.300
End play standard size of thrust plate,
[0.0039 to 0.0104] [0.0118]
change it into undersize thrust
plate.
0.050 to 0.110 0.200
Main bearing Clearance between crank journal standard size of main bearing,
[0.0020 to 0.0043] [0.0079]
change it into undersize
bearing.
2-6
Unit: mm [in.]
0.05 [0.0020] 0.20
Distortion of top surface Reface slightly.
or below [0.0079]
14.000 to 14.018 14.100
Crankcase Tappet guide hole inside diameter
[0.5512 to 0.5519] [0.5551]
Clearance between tappet and tappet guide 0.016 to 0.052 0.08 Replace a tappet until the
hole [0.0006 to 0.0020] [0.0031] clearance reaches the limit.
1.3 Fuel system

14.22 MPa 14.22 to 15.00 MPa
Double throttle {145 kgf/cm²} {145 to 153 kgf/cm²} Make shim adjustment.
[2062 psi] [2062 to 2176 psi] Pressure varies by 1 MPa
Injection start pressure
11.77 MPa 11.77 to 12.75 MPa {10 kgf/cm²} [144 psi] per
throttle {120 kgf/cm²} {120 to 130 kgf/cm²} 0.1 [0.004] thickness of shim.
[1707 psi] [1707 to 1849 psi]
Check nozzle with a hand
Double throttle 15° tester (at fuel oil temperature
20°C [68°F]). Replace the
Spray angle
nozzle tip if the spray pattern
throttle 0° is still bad after washing in
clean fuel oil.
1.4 Lubrication system

Unit: mm [in.]
0.20 to 0.30 0.50
Clearance between outer rotor and pump case Replace pump assembly.
[0.0079 to 0.0118] [0.0197]
ø16 15.985 to 16.000
Shaft outside diameter (between case)
[0.63] [0.6293 to 0.6299]
Shaft outside diameter ø14 13.957 to 13.975
(between oil pump bushing) [0.55] [0.5495 to 0.5502]
0.032 to 0.074 0.150 Replace pump case or
Oil pump Clearance between shaft and pump case
[0.0013 to 0.0029] [0.0059] pump assembly.
0.025 to 0.111 0.200 Replace pump bushing or
Clearance between shaft and oil pump bushing
[0.0010 to 0.0044] [0.0079] pump assembly.
0.13 to 0.15 0.20 Replace outer rotor and
Clearance between inner rotor and outer rotor
[0.0051 to 0.0059] [0.0079] shaft assembly.
0.04 to 0.09 0.15
End play of rotor and pump case Replace pump assembly.
[0.0016 to 0.0035] [0.0059]
0.35 MPa 0.35 ± 0.05 MPa
Relief valve Valve opening pressure {3.5 kgf/cm²} {3.5 ± 0.5 kgf/cm²}
[50.76 psi] [50.76 ± 7.25 psi]
1.5 Cooling system

Valve opening temperature 76.5 ± 1.5ºC [169.7 ± 2.7ºF]
Thermostat Temperature at which valve lift
90ºC [194ºF]
becomes 9 mm [0.35 in.] or more
1.6 Inlet and exhaust system

Exhaust manifold distortion 0.2 mm [0.008 in.] or less Repair by grinding or replace.
2-7
1.7 Electrical system

Unit: mm [in.]
Outside diameter ø32 [1.26] 31.4 [1.236] Replace
Commutator Runout 0.10 [0.0039] Repair or replace.
Undercut depth 0.5 [0.0197] 0.2 [0.024] Repair
Brush length 18 [0.71] 11 [0.43] Replace
Starter 29.2 to 39.4 N 13.7 N

Pressure of brush springs {3.0 to 4.0 kgf} {1.4 kgf} Replace
[6.56 to 8.86 lbf] [3.08 lbf]
Voltage 23 V -
No-load
Current 85 A or less - Inspection
characteristics
Rotational speed 3300 min-1 or more -
1500 or less 24 A or more
Output current Rotational speed
2500 or less 38 A or more Inspection
(when hot) (min-1)
Alternator 5000 or less 45 A or more
Regulator adjusting voltage 28.5 ± 0.5 V at 20ºC [68ºF]
Resistance value of field coil 6.1 to 7.1 ohm
Rated voltage DC22 V
Glow plug +0.3
Current 4.4 -0.7 A Apply 22 V for 15 seconds
Rated voltage 24 V
Magnetic valve
Resistance 37 ohm
When center of belt pressed at
Belt tension Deflection 12 [0.47]
approx. 98 N {10 kgf} [22 lbf]
2-8
2. Tightening torque table

2.1 Tightening torque for basic engine
Thread size Tightening torque
Description Dia. × Pitch Remarks
(M-thread ) N·m kgf·m lbf·ft
Cylinder head 12 × 1.75 118 ± 5 12 ± 0.5 87 ± 3.6

Cylinder head plug 16 × 1.5 44.1 ± 5 4.5 ± 0.5 33 ± 3.6
Rocker cover 8 × 1.25 11.5 ± 1.5 1.15 ± 0.15 8.5 ± 1.1
Rocker shaft bracket bolt (long) 8 × 1.25 17.2 ± 2.45 1.75 ± 0.25 12.9 ± 1.8
Main bearing cap 14 × 2.0 103 ± 5 10.5 ± 0.5 76 ± 3.6
Connecting rod cap 10 × 1.25 54 ± 5 5.5 ± 0.5 40 ± 3.6
Flywheel 12 × 1.25 83 ± 5 8.5 ± 0.5 61 ± 3.6
Camshaft thrust plate 8 × 1.25 11.5 ± 1.5 1.15 ± 0.15 8.5 ± 1.1
Front plate 8 × 1.25 11.5 ± 1.5 1.15 ± 0.15 8.5 ± 1.1
Timing gear case 8 × 1.25 18.5 ± 1.5 1.9 ± 0.1 13.6 ± 1.1
Crankshaft pulley 30 × 1.5 490 ± 10 50 ± 1 361 ± 7.3
Idler thrust plate 10 × 1.25 34 ± 5 3.5 ± 0.5 25 ± 3.6
Rear plate 10 × 1.25 55.9 ± 5.8 5.7 ± 0.5 41.2 ± 4.2
Rocker adjusting nut 8 × 1.25 20 ± 2 2.0 ± 0.2 15 ± 1.4
2.2 Tightening torque for fuel system

Fuel injection nozzle (engine) 20 × 1.5 58.9 ± 5.8 6 ± 0.5 43 ± 4.3

Fuel injection nozzle retaining nut 16 × 0.75 36.8 ± 2.4 3.8 ± 0.2 27.1 ± 1.8
Fuel injection pump gear 12 × 1.75 63.7 ± 4.9 6.5 ± 0.5 47 ± 3.6
Fuel injection pump overflow valve - 24.5 ± 4.5 2.5 ± 0.46 18 ± 3.3
Fuel injection pipe nut 12 × 1.5 29.5 ± 2.9 3 ± 0.3 21.8 ± 2.1
Fuel return pipe nut 10 × 1.25 19.7 ± 1.9 2 ± 0.1 14.5 ± 1.4
Fuel filter drain plug 14 × 1.0 1.1 ± 0.3 0.1 ± 0.03 0.8 ± 0.22
Fuel filter cartridge 20 × 1.5 13.5 ± 1.5 1.4 ± 0.1 10 ± 1.1
Fuel filter water level sensor assembly 36 × 1.5 13.5 ± 1.5 1.4 ± 0.1 10 ± 1.1
Fuel leak-off pipe mounting nut 12 × 1.5 22.6 ± 1.9 2.3 ± 0.1 16.7 ± 1.4
2-9
2.3 Tightening torque for lubrication system

Oil pan 8 × 1.25 11.5 ± 1.5 1.2 ± 0.1 8.5 ± 1.1

Oil pan drain plug 20 × 1.5 78 ± 5 8 ± 0.5 57 ± 3.6
Oil pump gear 10 × 1.25 33 ± 5 3.4 ± 0.5 24.6 ± 3.6
Relief valve 22 × 1.5 49 ± 4.9 5 ± 0.5 36 ± 3.6
Relief valve plug 18 × 1.5 44 ± 4.9 4.5 ± 0.5 33 ± 3.6
2.4 Tightening torque for cooling system

Thermostat case 8 × 1.25 18.5 ± 1.5 1.9 ± 0.1 13.6 ± 1.1

Water drain plug 1/4-18NPSF 39.2 ± 3.9 4 ± 0.3 28.9 ± 2.8
Water pump - Install
8 × 1.25 9.8 ± 1 1 ± 0.1 7.2 ± 0.7
(Tightening with water pump case cover)
Water pump - Install
8 × 1.25 18.2 ± 3.4 1.9 ± 0.3 13.4 ± 2.5
(Tightening with crankcase.)
Water pump plug R3/8 31.9 ± 2.4 3.3 ± 0.2 23.5 ± 1.8
2.5 Tightening torque for inlet and exhaust system

Description Dia. × Pitch Remark
Exhaust manifold bolt (bolt only) 8 × 1.25 18.5 ± 3.5 1.9 ± 0.3 13.6 ± 2.5
Turbocharger oil supply eyebolt 10 × 1.25 16.2 ± 2.4 1.7 ± 0.2 12.0 ± 1.7
Clamp - 4±1 0.4 ± 0.1 3 ± 0.7
2.6 Tightening torque for electrical system

Description Description Dia. × Pitch Remarks
+2 +0.2 +1.4
B terminal 8 × 1.25 9.8 0 1 0 7 0
Starter
Mounting nut 10 × 1.25 45 ± 15 4.6 ± 1.5 33 ± 11
Alternator pulley 20 × 1.5 147 ± 29 15 ± 2.9 108.4 ± 21.3
Alternator Rectifier assembly - 6.9 ± 1.9 0.7 ± 0.19 5.1 ± 1.4
Regulator assembly - 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.7
Glow plug (main) 10 × 1.25 17.2 ± 2.4 1.75 ± 0.24 12.7 ± 1.7
Glow plug (terminal) 4 × 0.7 1.23 ± 0.24 0.13 ± 0.02 0.96 ± 0.18
2-10
2.7 Tightening torque for standard bolts and nuts

2.7.1 Metric automobile screw thread
Thread size Strength classification
Width across flats
Dia. × Pitch
(mm) [in.] 4T 7T 10.9
(M-thread)
4 7 10
N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
6 × 1.0 10 [0.39] 4 0.4 2.95 9 0.9 6.64 13 1.3 9.59
8 × 1.25 12 [0.47] 12 1.2 8.85 18 1.9 13.28 30 3.1 22.13
10 × 1.25 14 [0.55] 21 2.15 15.49 35 3.6 25.81 60 6.1 44.25
12 × 1.25 17 [0.67] 35 3.6 25.81 64 6.5 47.20 108 11.0 79.66
2.7.2 Metric course screw thread

Thread size Strength classification
Width across flats
Dia. × Pitch
(mm) [in.] 7T 10.9
(M-thread)
N·m kgf·m lbf·ft N·m kgf·m lbf·ft

10 × 1.5 14 [0.55] 32 3.3 23.60 58 5.9 42.78
12 × 1.75 17 [0.67] 57 5.8 42.04 102 10.4 75.23
Note:(a) This table lists the tightening torque for standard bolts and nuts.
(b) The numerical values in the table are the values when spring washers are used.
(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)
2.8 Standard stud tightening torque

Thread size For driving in aluminum materials For driving in ferrous materials
Dia. × Pitch
(M-thread) N·m kgf·m lbf·ft N·m kgf·m lbf·ft
8 × 1.25 5.4 ± 0.5 0.55 ± 0.05 3.98 ± 0.37 12.8 ± 0.9 1.3 ± 0.1 9.44 ± 0.66
10 × 1.25 13.7 ± 1.0 1.4 ± 0.1 10.10 ± 0.74 23.5 ± 1.9 2.4 ± 0.2 17.33 ± 1.40
2-11
1. Special tools............................................................................................................. 3-3
3-1
1. Special tools
Tool name Part No. Illustration Remarks
Engine compression pressure mea-

suring
Compression gauge 35A91-03100
0 to 7 MPa {0 to 71.4 kgf/cm²}
[0 to 1015 psi]
Gauge adapter Engine compression pressure mea-

30691-21100
(swirl chamber) suring
Socket 58309-73100 Turning an engine
Valve spring pusher 30691-04500 Valve spring installation/removal
Valve guide remover 32A91-00300 Valve guide removal
Inlet: 36791-00200
Valve seat insert caulking tool Valve seat installation
Exhaust:34491-03020
Stem seal installer 32A91-10200 Stem seal installation
Rocker bracket installation

Socket 34491-00300 Thrust plate of camshaft installation/
removal
3-3
Valve guide installer 32A91-00100 Valve guide installation
Camshaft bushing installation/

Camshaft bushing installer set 30691-00010
removal
Idler bushing installer 30091-07300 Idler bushing installation/removal
Idler shaft puller MH061077 Idler shaft for pulling out
Piston ring pliers 31391-12900 Piston ring installation/removal
Connecting rod bushing

Connecting rod bushing puller 32A91-00500
for installing and removing
Crankshaft rear side

Oil seal sleeve installer set 30691-13010
for inserting oil seal sleeve
Piston installer 34491-00200 Piston installation
Oil pump bush installer 32A91-00400 Oil pump bushing installation
3-4
Gear puller MH061326 Gear removal
3-5
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 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 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
(a) Be sure to measure the compression pressure

for all the cylinders. It is not a good practice to
Compression gauge
Adapter
measure the compression pressure for only one P/N:30691-21100
P/N:35A91-03100
cylinder, and to assume the compression pres-
sure is the same for all cylinders.
(b) Also be sure to check the engine speed when
measuring the compression pressure, as the
compression pressure varies depending on
engine speed. Compression pressure - Measure
(c) Measuring the compression pressure at regular
intervals is important to obtain correct data.
(d) The compression pressure will be slightly higher
in a new or overhauled engine due to new piston
rings, valve seats, etc. Pressure will drop gradu-
ally by the wear of these parts.
(e) Fuel must never spout.
(1) Remove the glow plug from the cylinder head where
the compression pressure is to be measured.
(2) Attach the compression gauge adapter to the glow plug
mount and connect compression gauge.
(3) Crank the engine with starter. Read the engine speed
and compression pressure while the engine is running at
a stable speed.
Note: Check that the battery is fully charged when cranking
the engine with the starter.
If the battery voltage is decreased, sufficient rotational
speed, which is required for compression pressure test,
cannot be obtained.
(4) If the measured value is lower than the limit, overhaul
the engine.
Basic
Item Standard Limit Rotational
speed
3.2 MPa 2.8 MPa
Compression
{33 kgf/cm2} {29 kgf/cm2} 300min-1
pressure
[464 psi] [406 psi]
Oil and water 20 to 30°C
- -
temperatures [68 to 86°F]
4-4
1. Cylinder heads and valve mechanisms - Disassemble and inspect................... 5-3
1.1 Valve clearance - Inspect ......................................................................................................... 5-4
1.2 Rocker shaft assembly - Remove............................................................................................. 5-4
1.3 Cylinder head bolt - Remove .................................................................................................... 5-4
1.4 Cylinder head assembly - Remove........................................................................................... 5-5
1.5 Valve sinkage - Measure .......................................................................................................... 5-5
1.6 Valve and valve spring - Remove ............................................................................................. 5-5
2. Rear mechanism - Disassemble and inspect........................................................ 5-6
2.1 Flywheel face and radial runouts - Measure............................................................................. 5-7
2.2 Flywheel - Remove ................................................................................................................... 5-7
2.3 Rear plate - Remove................................................................................................................. 5-7
3. Front mechanism - Disassemble and inspect....................................................... 5-8
3.1 Damper face and radial runouts - Measure .............................................................................. 5-9
3.2 Damper and crankshaft pulley - Remove ................................................................................. 5-9
3.3 Timing gear case - Remove...................................................................................................... 5-9
3.4 Timing gear backlash - Measure .............................................................................................. 5-9
3.5 Idler gear and camshaft end play - Measure .......................................................................... 5-10
3.6 Fuel injection pump - Remove ................................................................................................ 5-10
3.7 Oil pan - Remove.................................................................................................................... 5-10
3.8 Oil strainer - Remove.............................................................................................................. 5-10
3.9 Oil pump gear - Remove......................................................................................................... 5-11
3.10 Front plate - Remove .............................................................................................................. 5-11
3.11 Idler gear - Remove ................................................................................................................ 5-11
3.12 Camshaft - Remove................................................................................................................ 5-11
3.13 Camshaft gear - Replace........................................................................................................ 5-12
3.14 Oil pump - Remove................................................................................................................. 5-12
4. Piston, connecting rod, crankshaft and crankcase -
Disassemble and inspect...................................................................................... 5-13
4.1 Piston protrusion - Measure.................................................................................................... 5-14
4.2 Carbon deposits from the upper part of cylinder - Remove .................................................... 5-14
4.3 Connecting rod end play - Measure........................................................................................ 5-14
4.4 Connecting rod cap - Remove ................................................................................................ 5-14
4.5 Piston - Remove ..................................................................................................................... 5-15
4.6 Piston ring - Remove .............................................................................................................. 5-15
4.7 Piston pin and piston - Remove.............................................................................................. 5-15
4.8 Crankshaft end play - Measure............................................................................................... 5-15
4.9 Main bearing cap - Remove.................................................................................................... 5-16
4.10 Crankshaft - Remove.............................................................................................................. 5-16
4.11 Tappet - Remove .................................................................................................................... 5-16
5-1
1. Cylinder heads and valve mechanisms - Disassemble and inspect

Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the
efficient work.
Depending on the maintenance work or purpose, it is desirable to inspect the following before proceeding with any job.
Valve clearance - Inspect
Valve sinkage - Measure
1
Replace
10
9
4 8
3 Wear
Damaged threads, 5
wear on rod contact surface Wear on contact surface with
2 valve cap, clogged oil holes
7
Wear, clogged oil holes 12
6 11 Wear at both ends,

deflection
15
16
Crack, damage, carbon deposits,
Fatigue, damage 17 water scale adhesion
Replace 20
14
Wear 21
Replace
13
Uneven wear
Uneven wear on stems and faces,

damage, fatigue
19
18
Cylinder heads and valve mechanisms - Disassemble and inspect

Disassembling sequence
1 Rocker cover 8 Rocker arm 15 Valve cotter
2 Adjusting screw 9 Rocker shaft spring 16 Valve retainer
3 Rocker bracket bolt (short) 10 Rocker shaft 17 Valve spring
4 Rocker bracket bolt (long) 11 Valve cap 18 Inlet valve
5 Rocker shaft bracket 12 Push rod 19 Exhaust valve
6 Snap ring 13 Cylinder head bolt 20 Valve stem seal
7 Rocker arm 14 Cylinder head 21 Cylinder head gasket
5-3
1.1 Valve clearance - Inspect

Inspect the valve clearance, and know the current condition.
For the inspection procedure, refer to "Valve clearance - 20 ± 2 N·m
Inspect and adjust" of "ASSEMBLY OF BASIC ENGINE. " Adjusting screw {2.0 ± 0.2 kgf·m}
[0.0098 in.]
[15 ± 1.4 lbf·ft]
0.25 mm
Lock nut
Valve clearance - Inspect

1.2 Rocker shaft assembly - Remove
Adjusting screw
Always loosen shorter bolts first. Failing to do so may
Rocker bracket bolt
cause damage to the rocker shaft bracket.
(1) Loosen the adjusting screw of rocker arm.
(2) Remove the rocker bracket bolt (short).
Rocker arm
(3) Remove the rocker bracket bolt (long).
(4) Remove the rocker shaft assembly from the cylinder
head.
Note: Keep the removed rocker shaft assembly and the bolts
as a set. Rocker shaft assembly - Remove
(5) Remove push rods.
(6) Disassemble the rocker shaft assembly.

Rocker shaft spring
Note: Do not remove the rocker bushing unless it is defective
or its inside diameter exceeds the limit.
Rocker shaft
Rocker arm
Bracket
Snap ring
Rocker shaft assembly - Disassemble
1.3 Cylinder head bolt - Remove
Loosen cylinder head bolts in the numerical order as shown
in the illustration.
6 14 22 21 13 5
2 10 18 25 17 9 1
Front 4
3 7 11 15 19 23 24 20 16 12 8
Number of bolts: 25
Cylinder head bolt - Remove
5-4
1.4 Cylinder head assembly - Remove
Cylinder head
When removing the cylinder head gasket, be careful
not to damage the cylinder head or crankcase sur-
face with a screwdriver or the like.
(1) Lift up the cylinder head assembly, and remove the cyl-
inder head assembly from the crankcase.
Note: If the cylinder head assembly cannot be removed due
to crimping of the cylinder head gasket, tap the thick
area on the side of the cylinder head using a plastic
hammer to give a shock. Cylinder head assembly - Remove
Do not lift up the crankcase by yourself. Use a crane or
lift it up by two persons.
(2) Remove the cylinder head gasket.
Note: If there is a cylinder head problem, check the bolts for
tightness with a torque wrench before removing the
cylinder head bolts.
1.5 Valve sinkage - Measure

Measure the valve sinkage, and know the current condition.
For the measurement procedure, refer to "Valve sinkage -
Measure" of "ASSEMBLY OF BASIC ENGINE."
1.6 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:30691-04500
Note: If valves are reusable, mark each valve seat and the
mating valve for identifying their original positions.
Do not change the combination of the valve seat and
the valve when reassembling.
Valve and valve spring - Remove
5-5
2. Rear mechanism - Disassemble and inspect

efficient work.
Flywheel face and radial runouts - Measure
Replace
Crack, defect of knock hole
Lip wear, damage, aging
Crack, defect of knock hole, gear damage

Damaged screw
Rear mechanism - Disassemble and inspect

1 Flywheel 2 Rear plate 3 Oil seal 4 Packing
5-6
2.1 Flywheel face and radial runouts - Measure

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

2.2 Flywheel - Remove
(Front) (Rear)
(a) Be careful not to cut your hands with the ring gear
when pulling out the flywheel.
(b) Be careful not to drop or hit the flywheel. Doing so
may not only cause damage to the flywheel but
also lead to personnel injuries.
(c) The personnel who holds the pulley must pay due
Guide bolt
attention to safety. Also, personnel must stay in Prevent the flywheel from
close contact with each other during work. rotating using a wrench.
(1) One personnel must firmly hold the pulley with a Flywheel - Remove
wrench to prevent the flywheel from rotating.
(2) Remove one bolt from the flywheel.
(3) Screw a guide bolt into the threaded hole of the bolt that
has been removed.
(4) Remove remaining bolts from the flywheel.
(5) Hold the flywheel firmly with both hands, and by mov-
ing it back and forth, pull it out straight.
Note: The ring gear is shrink fitted to the flywheel. Do not re-
move the ring gear unless it is defective.
2.3 Rear plate - Remove
Oil seal
Be careful not to damage the oil seal.
(1) Using a guide bolt, remove the rear plate from the
crankcase.
(2) Remove the oil seal from the rear plate.
Rear plate - Remove
5-7
3. Front mechanism - Disassemble and inspect

efficient work.
Damper face and radial runouts - Measure
Timing gear backlash - Measure
Idler gear and camshaft end play - Measure
Wear, damage
Clogged oil hole, 11

Flaking, wear Replace
uneven contact,
damage,
key groove defect,
abnormal wear Wear, damage 5
bushings 13
12
Replace
10 Clogged oil hole,

wear
Replace
Wear 15
7
9 14
Replace
4
6
Flaking, uneven contact, 8
damage,
key groove defect, Replace
abnormal wear bushings
Lip wear, Replace
damage or aging
Worn belt groove
Crack, defect of knock hole

2 Replace
1 Crack, defect of knock hole 3
Front mechanism - Disassemble and inspect

1 Damper 6 Oil pan 11 Camshaft
2 Crankshaft pulley 7 Oil strainer 12 Camshaft gear
3 Cover 8 Oil pump gear 13 Thrust plate
4 Timing gear case 9 Thrust plate 14 Front plate
5 Fuel injection pump 10 Idler gear 15 Oil pump
5-8
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 and crankshaft pulley - Remove
(Front) (Rear)
Prevent crankshaft
The bar that stops the crankshaft from rotating may from rotating
come off. Pay due attention to safety.
(1) Screw two guide bolts into the threaded holes at the rear
end of the crankshaft. Stick a bar across the guide bolts
to prevent the crankshaft from rotating.
(2) Remove the crankshaft pulley and the damper.
Guide bolt
(M12 × 1.25 mm)
Damper and crankshaft pulley - Remove
3.3 Timing gear case - Remove
Cover
The front plate is bolted to the crankcase from inside
the gear case. Do not attempt to remove the front
plate together with the gear case by tapping.
(1) Remove the cover from the timing gear case.
(2) Remove the timing gear case from the front plate.
(3) Remove the front oil seal from the timing gear case.
Note: Bolts have different lengths. Pay attention to the posi- Packing
Timing gear case
tions of bolts to ensure correct assembling.
Timing gear case - Remove
3.4 Timing gear backlash - Measure

Measure the timing gear backlash, and recognize the current
Dial gauge
condition.
For the measurement procedure, refer to "Timing gear back-
lash - Measure" of "ASSEMBLY OF BASIC ENGINE."
5-9
3.5 Idler gear and camshaft end play - Measure

Measure the idler gear and camshaft end play, and recognize
the current condition.
For the inspection procedure, refer to "Idler gear and cam-
shaft end play - Measure" of "ASSEMBLY OF BASIC
ENGINE".
Idler gear and camshaft end play - Measure

3.6 Fuel injection pump - Remove
Remove the fuel injection pump from the front plate.
Fuel Injection pump
O-ring
Fuel injection pump - Remove

3.7 Oil pan - Remove
Oil pan
Do not remove the oil pan inserting a chisel or driver
between oil pan and crankcase. When inserting a
chisel or driver, oil pan flange will deform.
(1) Invert the engine.
(2) To remove oil pan from the crankcase, tap bottom cor-
ners of the oil pan with a plastic hammer.
Bolt
Oil pan - Remove

3.8 Oil strainer - Remove
Remove the oil strainer from the crankcase.
Oil strainer
Oil strainer - Remove
5-10
3.9 Oil pump gear - Remove

Remove the oil pump gear from the oil pump.
Oil pump gear
Oil pump gear - Remove

3.10 Front plate - Remove
Remove the front plate from the crankcase.
Packing
Note: If it is difficult to remove the front plate, lightly tap it
with a plastic hammer.
Front plate
Front plate - Remove

3.11 Idler gear - Remove
Remove the idler gear from crankcase.
Idler gear
Idler gear - Remove

3.12 Camshaft - Remove
Be careful not to damage the cams of camshaft and

the bushings.
(1) Remove the thrust plate bolt. Camshaft gear
(2) Remove the camshaft from the crankcase.
Camshaft - Remove
5-11
3.13 Camshaft gear - Replace

3.13.1 Camshaft gear - Remove
Remove with press
Do not remove the camshaft gear from the camshaft

unless the camshaft gear or the thrust plate is defec- Camshaft gear
tive.
Using a press, remove the camshaft gear and thrust plate

Camshaft Thrust plate
from the camshaft.
Camshaft gear - Remove

3.13.2 Camshaft gear and thrust plate - Install
Press fit with press
(1) Install the woodruff key and the thrust plate on the cam-
shaft.
Note: Be sure to install the thrust plate before installing the
camshaft gear. Camshaft gear
(2) Heat the camshaft gear with a gear heater to a tempera- Thrust plate
ture of about 150°C [302°F].
(3) Press fit the camshaft gear with press. Camshaft
Camshaft gear and thrust plate - Install

3.14 Oil pump - Remove
Remove the oil pump from the crankcase.
Oil pump
O-ring
Oil pump - Remove
5-12
4. Piston, connecting rod, crankshaft and crankcase - Disassemble and inspect

efficient work.
Piston protrusion - Measure
Connecting rod end play - Measure
Crankshaft end play - Measure
Cylinder inside diameter - Measure
Wear, damage
4
5
6 Scratches on outside surface, cracks,
Fatigue damage, wear, carbon deposits
Wear 19
9
7 8
Cracks,
Wear, clogged Wear
clogged oil holes oil holes
10
Damaged threads 14
3
Serration for cracks, wear
Scratches on inside and 2

outside surfaces, adhesion, 18
17
flaking, wear 1
16
Adhesion of water scale, corrosion, flaking
15
Scratches, cracks, dent, 14
clogged oil holes, wear
Flaking, uneven contact
14
12
13
Scratches on inside
Note: When replacing the crankcase, and outside surfaces,
remove the parts installed in adhesion, flaking 11
the crankcase (relief valve,etc.)
carefully for reuse. Cracks Damaged threads
Piston, connecting rod, crankshaft and crankcase - Disassemble and inspect

1 Nut 8 Piston pin 15 Lower main bearing
2 Connecting rod cap 9 Piston 16 Crankshaft
3 Connecting rod bearing 10 Connecting rod 17 Upper main bearing
4 No. 1 compression ring 11 Main bearing cap bolt 18 Tappet
5 No. 2 compression ring 12 Main bearing cap 19 Crankcase
6 Oil ring 13 Side seal
7 Snap ring 14 Thrust plate
5-13
4.1 Piston protrusion - Measure

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

4.2 Carbon deposits from the upper part of cylinder - Remove
Be sure to remove hard carbon deposits from the

upper part of the cylinder before removing the piston.
They could cause damage to the piston and piston
ring.
(1) Lay the engine on its side.
(2) Remove hard carbon deposits from the upper part of
cylinder using a carbon remover.
Hard carbon
Note: Be careful not to damage the inner surface of the cyl-
inder. Carbon deposits from the upper part of cylinder -
Remove
4.3 Connecting rod end play - Measure
Measure the connecting rod end play, and recognize the cur-
rent condition.
For the measurement procedure, refer to "Connecting rod
end play - Measure" of "ASSEMBLY OF BASIC
ENGINE."
Thickness gauge
Connecting rod end play - Measure

4.4 Connecting rod cap - Remove
(1) Mark the cylinder number on the connecting rod and
connecting rod cap so that their combination is not
changed when assembling.
(2) Remove the connecting rod caps.
Note: Mark the cylinder numbers and upper/lower on con-
necting rod bearings to ensure correct assembling.
Connecting rod cap - Remove
5-14
4.5 Piston - Remove

(1) Rotate the crankshaft to bring the piston to top dead
center.
(2) Using a piece of wood such a hammer handle, push the
mating surface of the connecting rod cap, and remove
the piston and connecting rod upward from the cylin-
der.
Piston - Remove
4.6 Piston ring - Remove
Remove the piston rings using piston ring pliers.
Piston ring pliers
P/N:31391-12900
Piston ring - Remove

4.7 Piston pin and piston - Remove
(1) Remove the snap ring with snap ring pliers.
(2) Place a piece of wood against the end face of piston pin
and lightly tap with a hammer to remove the piston pin,
Snap ring pliers
and separate the piston from the connecting rod.
Note:(a) Do not tap the piston pin directly with a hammer.
(b) If the piston is stubborn, heat the piston with a heat-
er or in hot water.
Piston pin and piston - Remove

4.8 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."
5-15
4.9 Main bearing cap - Remove
When removing the main bearing cap from the crank-

case, be careful not to damage the lower main bearing
or the lower thrust plate that are attached to the cap.
Also be careful not to drop those parts from the cap,
which may damage the crankshaft.
(1) Remove the main bearing cap bolt.
(2) Remove the main bearing cap.
(3) Remove the lower thrust plate from the rearmost main
bearing cap. Main bearing cap - Remove
4.10 Crankshaft - Remove
When placing the crankshaft onto a pallet or other

stands, be careful not to damage the crankshaft. Once
placed on a pallet, the crankshaft should be locked in
place to prevent it from rotating.
(1) Suspend the crankshaft in a horizontal position, and
slowly lift the crankshaft upward.
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 Crankshaft - Remove
a chain or other hoists are hooked before raising crank-
shaft.
(2) Remove the upper main bearing from the crankcase,
paying attention to the lug position, and remove the
upper thrust plate on the rear side.
4.11 Tappet - Remove
Remove the tappets using a magnet.
Note: Be sure to arrange the removed tappets for assembling
to the same tappet hole.
5-16
1. Cylinder head and valve mechanism - Inspect and repair................................... 6-3
1.1 Clearance between rocker bushing and rocker shaft - Measure .............................................. 6-3
1.2 Valve stem outside diameter and valve guide inside diameter - Measure................................ 6-3
1.3 Valve guide - Replace............................................................................................................... 6-4
1.4 Valve face - Inspect .................................................................................................................. 6-5
1.5 Valve face - Reface .................................................................................................................. 6-6
1.6 Valve seat - Reface .................................................................................................................. 6-6
1.7 Valve seat - Replace................................................................................................................. 6-7
1.8 Valve and valve seat - Lap ....................................................................................................... 6-8
1.9 Squareness and free length of valve spring - Measure ............................................................ 6-8
1.10 Pushrod runout - Measure ........................................................................................................ 6-8
1.11 Distortion of cylinder head bottom surface - Measure .............................................................. 6-9
1.12 Combustion jet - Replace ......................................................................................................... 6-9
2. Rear mechanism - Inspect and repair.................................................................. 6-10
2.1 Flatness of flywheel - Measure ............................................................................................... 6-10
2.2 Ring gear - Inspect ................................................................................................................. 6-10
2.3 Ring gear - Replace................................................................................................................ 6-10
3. Front mechanism - Inspect and repair................................................................. 6-11
3.1 Damper - Inspect visually ....................................................................................................... 6-11
3.2 Idler bushing inside diameter and idler shaft outside diameter - Measure ............................. 6-11
3.3 Idler shaft - Replace................................................................................................................ 6-11
3.4 Cam lift of camshaft - Measure............................................................................................... 6-12
3.5 Camshaft runout - Measure .................................................................................................... 6-12
3.6 Camshaft journal outside diameter - Measure........................................................................ 6-12
3.7 Camshaft hole (bushing) inside diameter - Measure .............................................................. 6-13
3.8 Camshaft bushing - Replace .................................................................................................. 6-13
3.9 Belt groove wear - Inspect ...................................................................................................... 6-13
4. Piston and connecting rod - Inspect and repair ................................................. 6-14
4.1 Piston - Inspect visually .......................................................................................................... 6-14
4.2 Piston weight .......................................................................................................................... 6-14
4.3 Piston outside diameter - Measure ......................................................................................... 6-14
4.4 Piston ring groove - Inspect .................................................................................................... 6-15
4.5 Piston pin bore diameter and piston pin outside diameter - Measure..................................... 6-15
4.6 Standard for piston ring replacement...................................................................................... 6-15
4.7 Clearance between connecting rod bearing and crankpin - Measure .................................... 6-16
4.8 Clearance between connecting rod bushing and piston pin - Measure .................................. 6-16
4.9 Connecting rod bushing - Replace ......................................................................................... 6-17
4.10 Connecting rod assembly weight rank.................................................................................... 6-17
4.11 Connecting rod bearing - Inspect............................................................................................ 6-17
4.12 Connecting rod bend and twist - Inspect ................................................................................ 6-18
6-1
5. Crankcase and crankshaft - Inspect and repair.................................................. 6-19

5.1 Cylinder inside diameter - Measure ........................................................................................ 6-19
5.2 Crankcase top surface distortion - Measure ........................................................................... 6-20
5.3 Crankshaft crankpin and journal outside diameters - Measure .............................................. 6-20
5.4 Crankpin and rearmost crank main journal width - Measure .................................................. 6-21
5.5 Crankshaft - Grind .................................................................................................................. 6-21
5.6 Crankshaft runout - Measure .................................................................................................. 6-22
5.7 Crankshaft gear - Inspect ....................................................................................................... 6-22
5.8 Crankshaft gear - Replace...................................................................................................... 6-22
5.9 Front oil seal - Replace........................................................................................................... 6-23
5.10 Oil seal contact surface - Inspect............................................................................................ 6-23
5.11 Main bearing - Inspect ............................................................................................................ 6-24
5.12 Clearance between main bearing and crank journal - Measure ............................................. 6-24
5.13 Thrust plate - Inspect .............................................................................................................. 6-24
5.14 Tappet - Inspect...................................................................................................................... 6-25
6-2
1. Cylinder head and valve mechanism - Inspect and repair

1.1 Clearance between rocker bushing and rocker shaft - Measure
Measure the inside diameter of the rocker bushing and the
Measuring
outside diameter of the rocker shaft. If the clearance direction
exceeds the limit, replace either rocker assembly or rocker Measuring
direction
shaft with a new one.
Item Nominal Standard Limit

Rocker bushing ø19 mm 19.010 to 19.030 mm
-
inside diameter [0.75 in.] [0.7484 to 0.7492 in.]
Rocker shaft ø19 mm 18.980 to 19.000 mm
-
outside diameter [0.75 in.] [0.7472 to 0.7480 in.]
Clearance
0.010 to 0.050 mm 0.070 mm
between rocker -
[0.0004 to 0.0020 in.] [0.0028 in.] Clearance between rocker bushing and rocker shaft
bushing and shaft
- Measure
1.2 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 top and bottom
Measuring
ends in orthogonal direction as shown, as the sliding area directions
tends to wear at top and bottom ends. If the outside diameter
is less than the limit, or the clearance exceeds the limit,
replace either the valve or the valve guide with a new one.
Note: Lap the valve and valve seat whenever new valve is in- Measuring
points
stalled.
Valve Inlet
ø8 mm 7.940 to 7.955 mm 7.900 mm Valve stem outside diameter - Measure
stem [0.32 in.] [0.3126 o 0.3132 in.] [0.3110 in.]
outside ø8 mm 7.920 to 7.940 mm 7.850 mm
diameter Exhaust
[0.32 in.] [0.3118 to 0.3126 in.] [0.3091 in.]
Inside Measuring
Clearance 0.065 to 0.095 mm 0.150 mm micrometer directions
Inlet -
between [0.0026 to 0.0037 in.] [0.0059 in.]
valve
stem and 0.080 to 0.115 mm 0.200 mm
valve Exhaust -
[0.0031 to 0.0045 in.] [0.0079 in.]
guide
Valve guide installed 14 mm 13.9 to 14.1 mm
-
length [0.55 in.] [0.547 to 0.555 in.]
Measuring
points
Valve guide inside diameter - Measure
6-3
1.3 Valve guide - Replace
Valve guide remover

P/N:32A91-00300
The valve guide must be inserted to the specified
depth. Be sure to use the valve guide installer when
press-fitting the valve guide.
(1) Remove the valve guide using the valve guide remover.
(2) Use the valve guide installer to press-fit a new valve
guide.
(3) Check contacts between valves and valve seats after
replacing valve guides.
Valve guide - Remove
Press
Valve guide installer
P/N:32A91-00100
13.9 to 14.1 mm
[0.547 to 0.555 in.]
Valve guide - Press fit
6-4
1.4 Valve face - Inspect

Apply a thin lead-free coloring paste on the valve face, and
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 specified limit is
Valve lapper
exceeded, reface or replace the valve.
Note:(a) Inspect the valve face after the valve guide is in-
spected or replaced.
(b) Do not rotate the valve when pressing the valve face
coated with lead-free coloring paste against the Lead-free
coloring paste
valve seat.
Valve face - Inspect
(c) Lap the valve and valve seat whenever the valve is
refaced or replaced.

Valve seat
30° - -
Valve angle
seat 1.4 mm 1.26 to 1.54 mm 1.8 mm
Seat width
[0.055 in.] [0.0496 to 0.0606 in.] [0.071 in.]
2.13 mm 1.83 mm
Valve margin -
[0.0839 in.] [0.0720 in.]
Good Bad
Contact condition between valve seat and valve
Seat width
Valve seat
Valve margin
angle
Valve sinkage
Valve-to-valve seat contact position
6-5
1.5 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 with the valve refacer held at
the specified angle.
(b) The valve margin should not exceed the specified
limit. If the dimensions after refacing does not meet
Grind the valve face
the specified values, replace the valve with a new using the valve refacer
one. at the specified angle.
Valve face - Reface

1.6 Valve seat - Reface
If any damage or inclusions are found, grind the sheet face.
(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. Valve seat cutter
If the seat width exceeds the standard, grind the valve
seat with a valve seat cutter having different angles.
(2) Lap the valve in the valve seat.
Note:(a) Valve seat refacing depth should be kept to mini-
mum.
Valve seat - Reface
(b) If the seat width cannot be repaired to the standard
value, or line contact on valve seat outer periphery
is shown, replace the valve seat with a new one.
(c) If the valve sinkage exceeds the specified limit after
refacing, replace the valve seat with a new one.
6-6
1.7 Valve seat - Replace
Ensure the proper interference. Improper interference Weld

Shaft
could cause the valve seat to fall off or the cylinder
head to crack.
Valve seat
1.7.1 Valve seat - Remove (by welding)
To remove the valve seat, weld a stud to the valve seat as
shown. Then, insert a shaft into the valve guide hole from
the top of the cylinder head, and drive the valve seat out
Stud
with the shaft.
Note: Be careful not to allow spatters to adhere to the ma- Valve seat - Remove
chined surface of the cylinder head during welding.
1.7.2 Valve seat - Install
(1) Before installing the valve seat, measure the inside
diameter of the valve seat fit of cylinder head and the
outside diameter of the valve seat to make sure that the
interference is within the range of standard value. Valve seat cutter
Valve seat fitting bore

(2) Cool the valve seat at least for 4 minutes in liquid nitro-
Valve seat caulking tool
gen before fitting it into the cylinder head cooled to P/N:36791-00200 (Inlet), 34491-03020 (Exhaust)
room temperature.
(3) Install the valve seat into the cylinder head using a
valve seat caulking tool.
Valve seat - Install
6-7
1.8 Valve and valve seat - Lap

Lap the valve against the valve seat whenever the valve seat
is refaced or the valve is replaced.
(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 when it is mixed Compound
with a small amount of engine oil.
(c) Use medium-grain compound (125 to 150 mesh)
for initial lapping, then use fine-grain compound
Compound - Apply
(200 mesh) for finishing.
(2) Use a valve lapper for lapping.
Tap the valve against the valve seat while rotating the
valve little by little. Valve lapper
(3) Wash off the compound using diesel oil.
(4) Apply engine oil to the contact surface of the valve, and
perform a finish lapping.
(5) Apply a thin lead-free coloring paste on the valve seat
face, and tap the valve face against the valve seat using
a valve lapper to check for contact condition.
Valve and valve seat - Lap
1.9 Squareness and free length of valve spring - Measure
Measure the squareness and free length of valve spring. If
the specified limit or standard value is exceeded, replace the Squareness of the spring
valve spring with a new one.
Nominal Standard Limit

Free length 48.85 mm [1.9232 in.] 47.60 mm [1.8740 in.]
A=1.5° or less
A Free length
B B=1.3 mm Length
Squareness [0.051 in.] or less B=1.5 mm
Lf
Lf = 48.85 mm [0.0591 in.]
[1.9232 in.]
Installed 43 mm [1.69 in.]/176 to 196 N 43 mm [1.69 in.]/147 N
length/load {18 to 20 kgf} [40 to 44 lbf] {15 kgf} [33 lbf] Squareness and free length of spring - Measure
1.10 Pushrod runout - Measure

Measure the runout of push rod by TIR. If the run out
exceeds the limit, replace the push rod with a new one.
Item Limit Remarks

Push rod runout 0.6 mm [0.024 in.] TIR V-block
Push rod
1/2 1/2
Surface plate
Push rod runout - Measure
6-8
1.11 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 defective com-
bustion and 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-
ness gauge. If the distortion exceeds the limit, grind the
cylinder head.
Distortion of cylinder head bottom surface - Measure
Item Standard Limit
Distortion of cylinder head 0.05 mm 0.20 mm
bottom surface [0.0020 in.] or less [0.0079 in.]
Note: Do not grind the surfaces more than 0.2 mm [0.0079

in.] in total (cylinder head bottom surface plus crank-
case top surface).
1.12 Combustion jet - Replace
Replace the combustion jet only when it has a defect such as
a crack. Round rod
(1) Insert a round bar (approx. ø6 mm [0.24 in.]) into glow

plug hole, and tap the combustion jet inner face perime-
ter lightly to pull out the combustion jet.
Combustion jet
Combustion jet - Replace

(2) When installing the combustion jet, align the position-
ing hole and jet nozzle with the center of the cylinder,
press fit by tapping with a plastic hammer.
Combustion jet
Jet nozzle
Combustion jet - Press-fit
6-9
2. Rear mechanism - Inspect and repair

2.1 Flatness of flywheel - Measure
Place the flywheel on a surface plate and move a dial gauge
onto the friction surface of the flywheel to measure the flat-
ness. Grind the friction surface of the flywheel if the limit is
exceeded.
Item Standard Limit

0.15 mm 0.50 mm
Flatness of flywheel
[0.0059 in.] or less [0.0197 in.]
Flatness of flywheel - Measure

2.2 Ring gear - Inspect
Inspect the ring gear for a missing tooth or wear on teeth,
and if defects are found, replace the ring gear.
2.3 Ring gear - Replace

2.3.1 Ring gear - Remove
(1) Heat the ring gear evenly using an acetylene torch or
Flywheel
other appropriate heat source.
(2) With a rod placed on the periphery of ring gear, tap the
rod with a hammer evenly around the ring gear, and
remove the ring gear.
Ring gear
Ring gear - Remove

2.3.2 Ring gear - Install
(1) Heat the ring gear evenly up to approx. 150°C [302°F]
with an appropriate heater.
(2) Install the ring gear onto the flywheel with the no-gear
chamfering side faced to the flywheel.
Note: Do not heat the ring gear excessively.
6-10
3. Front mechanism - Inspect and repair

3.1 Damper - Inspect visually
Inspect the rubber on the damper. When it has a crack,
replace it with a new one.
Rubber
Damper - Inspect visually

3.2 Idler bushing inside diameter and idler shaft outside diameter - Measure
Measure the idler bushing inside diameter and the idler shaft
outside diameter. If the measurement exceeds the limit, Measuring
replace the idler bushing with a new one. If the outside direction
Measuring
diameter is less than the limit, replace the idler shaft with a points
new one.
Item Standard Limit

Clearance between idler bushing 0.009 to 0.050 mm 0.100 mm
and idler shaft [0.0004 to 0.0020 in.] [0.0039 in.]
Idler bushing inside diameter and Idler shaft outside

diameter - Measure
3.3 Idler shaft - Replace
Remove the idler shaft with the idler shaft puller.
Idler shaft puller
Note: When installing the idler shaft into the crankcase, ori- P/N:MH061077
ent the idler shaft so that its oil hole faces the upper
crankcase.
Item Standard
0.035 to 0.076 mm
Interference between shaft and crankcase hole
[0.0014 to 0.0030 in.]
Idler shaft - Replace
6-11
3.4 Cam lift of camshaft - Measure

Measure the major axis and minor axis of cam to determine
cam lift. If the measured value is less than the limit, replace Measuring
the camshaft with a new one. points

6.384 to
6.684 mm 6.784 mm 6.184 mm Measuring
Inlet directions
[0.2631 in.] [0.2513 to [0.2435 in.]
0.2671 in.]
S6S
6.420 to
6.720 mm 6.820 mm 6.220 mm
Exhaust
Cam lift of [0.2646 in.] [0.2528 to [0.2449 in.]
camshaft 0.2685 in.]
Cam lift of camshaft - Measure
(major axis - 6.382 to
minor axis) 6.682 mm 6.782 mm 6.184 mm
Inlet
[0.2631 in.] [0.2513 to [0.2435 in.]
0.2670 in.]
S6S-T
6.422 to
6.722 mm 6.822 mm 6.220 mm
Exhaust
[0.2646 in.] [0.2528 to [0.2449 in.]
0.2686 in.]
3.5 Camshaft runout - Measure

Measure the camshaft runout. If the specified limit is
exceeded, correct the camshaft using a press, or replace the
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

0.04 mm 0.10 mm
Camshaft runout TIR
[0.0016 in.] or less [0.0039 in.]
Camshaft runout - Measure

3.6 Camshaft journal outside diameter - Measure
Measure the diameter of each camshaft journal in two direc-
tions at right angles to each other. If the specified limit is
Measuring
exceeded, replace the camshaft with a new one.
points

53.94 to
No.1, 2, 3 ø54 mm 53.96 mm 53.90 mm
journal [2.13 in.] [2.1236 to [2.1220 in.] Measuring
Camshaft 2.1244 in.]
journal out- directions
side diameter 52.94 to
No.4 ø53 mm 52.96 mm 52.90 mm
Journal [2.09 in.] [2.0842 to [2.0827 in.]
2.0850 in.]
Camshaft journal outside diameter - Measure
6-12
3.7 Camshaft hole (bushing) inside diameter - Measure

(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.
(2) Measure the camshaft bushing inside diameter with the
bushing installed in the crankcase. Measuring
If the measurement exceeds the limit, replace the bush- directions
ing with a new one.
Note: Be careful not to damage the inner surface of camshaft
bushing when measuring the inside diameter.
Item Standard Limit Camshaft hole (bushing) inside diameter - Measure

Clearance between camshaft 0.040 to 0.090 mm 0.15 mm
journal and camshaft bushing [0.0016 to 0.0035 in.] [0.0059 in.]
3.8 Camshaft bushing - Replace

3.8.1 Camshaft bushing - Remove
(1) Install a camshaft bushing installer set to the camshaft Adapter
Bushing
bushing.
(2) Remove the camshaft bushing by tapping the end of the
rod of camshaft bushing installer set.
Camshaft bushing
installer set Rod
P/N:30691-00010
Camshaft bushing - Remove

3.8.2 Camshaft bushing - Install
Piece Bushing
(1) Install the camshaft bushing to a camshaft bushing
Adapter
installer set.
(2) When driving in a bushing, tap the end of rod of cam-
shaft bushing installer set so that the oil hole in the
bushing aligns with the oil hole to the oil gallery.
Camshaft bushing Rod

installer set Oil hole
P/N:30691-00010
Camshaft bushing - Install

3.9 Belt groove wear - Inspect
Check the belt groove of the pulley for wear. Attach a new
belt around the pulley, apply high tension and measure the
sinkage of belt.
If the wear appears excessive, and the belt top surface sinks
1.6 mm [0.06 in.]
1.6 mm [0.06 in.] or more down from the top edge of
or less
groove, replace the pulley with a new one. If the pulley has
two or more grooves for belt, and the difference of the wear
amount between grooves is significant, replace the pulley
with a new one.
Belt groove wear - Inspect
6-13
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 weight
When replacing pistons, be sure that the weight difference
per engine is within the permissible range.

Weight difference per ±5 g
- -
engine [±0.2 oz.]
4.3 Piston outside diameter - Measure

(1) Measure the piston outside diameter of the piston skirt
Directions at right
at right angles to the piston pin. If the specified limit is angles to piston pin
exceeded, replace the piston with a new one. When
replacing pistons, be sure that the weight difference per Measuring points
engine is within the permissible range.
Piston outside diameter - Measure

(2) The piston weight is stamped on the top of piston head.
Identification Weight stamp
Item Nominal Standard Limit mark
93.955 to
93.985 mm 93.770 mm
Standard
[3.6990 to [3.6917 in.]
3.7002 in.]
94.205 to
Piston +0.25
ø94 mm 94.235 mm 94.020 mm
outside Size [0.0098]
[3.70 in.] [3.7089 to [3.7016 in.]
diameter Over size Number stamp
3.7100 in.]
94.455 to Front mark
+0.50
94.485 mm 94.270 mm
[0.0197]
[3.7187 to [3.7114 in.] Piston weight punch mark location
Over size
3.7199 in.]
6-14
4.4 Piston ring groove - Inspect
Remove carbon deposits from pistons and inspect the

entire circumference of the piston.
(1) Remove all deposits such as carbon from each ring No.1 compression ring
groove
groove.
No.2 compression ring
(2) Check each ring groove for wear or damage. If faulty, groove
replace the piston with a new one. Oil ring groove
Piston ring groove - Inspect

4.5 Piston pin bore diameter and piston pin outside diameter - Measure
Measure the piston pin bore diameter and piston pin outside
diameter. If the limit is exceeded, replace it with a new one.

Piston pin outside ø 30 mm 29.994 to 30.000 mm
-
diameter [1.18 in.] [1.1809 to 1.1811 in.]
Clearance between Measuring points Measuring directions
piston pin bore and 0.000 to 0.016 mm 0.050 mm
-
piston pin outside [0.0000 to 0.0006 in.] [0.0020 in.]
diameter
Piston pin bore diameter and piston pin outside

diameter - Measure
4.6 Standard for piston ring replacement
Replace the piston rings with new ones during period-

ical overhauls. Sustained use of old piston rings can
lead to abnormal engine operation.
If engine disassembly is necessary for some reason before
the next periodical overhaul, piston ring replacement is not
required provided that no abnormalities are found when
making the following inspections.
4.6.1 Piston ring end gap - Measure
Place the piston rings in a gauge or a new cylinder, and mea-
sure the gap of each ring with thickness gauges. If the speci-
fied limit is exceeded, replace piston rings with a new set of Thickness gauge
rings.
Note: Using a piston, push the piston ring squarely into the
gauge or the cylinder.
Item Standard Limit

End gap
No. 1 0.30 to 0.50 mm 1.50 mm
compression ring [0.0118 to 0.0197 in.] [0.0591 in.]
Piston ring end gap - Measure
Piston ring No. 2 0.50 to 0.70 mm 1.50 mm
end gap compression ring [0.0197 to 0.0276 in.] [0.0591 in.]
0.30 to 0.50 mm 1.50 mm
Oil ring
[0.0118 to 0.0197 in.] [0.0591 in.]
6-15
4.7 Clearance between connecting rod bearing and crankpin - Measure
Measuring Measuring 54 ± 5 N·m

directions points {5.5 ± 0.5 kgf·m}
When grinding crankpins, be sure to grind all the pins [40 ± 3.6 lbf·ft]
to the same size.

Finish the fillet radius to the specified dimension.
(1) Assemble the bearing into the big end of the connecting
rod.
(2) Tighten the connecting rod cap to the specified torque.
(3) Measure the inside diameter of the connecting rod bear-
ing.
(4) Measure the crankpin outside diameter. Connecting rod bearing inside diameter - Measure
(5) Calculate the clearance from the difference between the
inside diameter of the connecting rod bearing and out-
side diameter of the crankpin.
(6) If the clearance exceeds the limit, replace the connect-
ing rod bearing with a new one. Measuring Measuring
(7) Measure the clearance between the connecting rod directions points
bearing and the crankpin again. Use the undersize bear-

ing if the limit is exceeded.
(8) If an undersize bearing is used, grind the crankpin to
the specified undersize.
Crankpin outside diameter - Measure
Crankpin outside ø58 mm 57.955 to 57.970 mm 57.800 mm
diameter [2.28 in.] [2.2817 to 2.2823 in.] [2.2756 in.]
Clearance between
crank pin and
0.030 to 0.090 mm 0.200 mm
connecting rod -
[0.0012 to 0.0035in.] [0.0079 in.]
bearing
(oil clearance)
4.8 Clearance between connecting rod bushing and piston pin - Measure
Measure the inside diameter of the connecting rod bushing
and the outside diameter of the piston pin. Replace if the
limit is exceeded.
Measuring
Item Nominal Standard Limit directions
Bushing inside ø30 mm 30.020 to 30.045 mm

-
diameter [1.18 in.] [1.1819 to 1.1829 in.]
Clearance between
connecting rod 0.020 to 0.091 mm 0.120 mm Measuring
-
bushing and [0.0008 to 0.0036 in.] [0.0047 in.] points
piston pin
Connecting rod bushing inside diameter - Measure
6-16
4.9 Connecting rod bushing - Replace

(1) Use the connecting rod bushing puller to replace the
Connecting rod bushing puller
connecting rod bushings.
P/N:32A91-00500
(2) With the bushing joints oriented as shown in the illus- Matching marks side
tration, align the oil hole of bushing with the oil hole of
connecting rod, and press-fit the connecting rod bush-
ing into the connecting rod. Oil hole
(3) After press-fitting, insert the piston pin, and make sure
the smooth movement of the connecting rod and piston
without looseness.
Bushing joint
Connecting rod bushing - Replace
4.10 Connecting rod assembly weight rank
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.
Item Tolerance on weight

Connecting rod weight rank 10g [0.35 oz.] or less
Matching mark
A
for assembly
Weight rank mark
Connecting rod assembly weight rank

4.11 Connecting rod bearing - Inspect
Inspect the sliding surface, back surface and end surface of
connecting rod bearing. If there is any defect such as poor
contact, sliding scratches, corrosion and foreign substance
inclusion, replace the bearing with a new one.
Flaking Scratches
Adhesion
End face
Connecting rod bearing - Inspect
6-17
4.12 Connecting rod bend and twist - Inspect

(1) Measure the dimensions of C and L as shown in the
Connecting rod cap tightening torque
illustration to check the bend and twist of the connect-
54 ± 5 N·m {5.5 ± 0.5 kgf·m} [40 ± 3.6 lbf·ft]
ing rod. Straighten the connecting rod with a press so
C C 0.05 0.0020
[ ]
that the measurement value meets the standard. L 100 3.94
Note: Before checking bend and twist, tighten the connecting L 0.0020
C 0.05 L
Piston pin [ ]
rod cap to the specified torque. L 100 3.94
(2) To inspect the connecting rod with the piston installed, C
turn the piston upside down and place it on a surface

plate. Insert a round bar having the same diameter as Connecting rod bend Connecting rod twist
Unit: mm [in.]
the crankpin into the big-end bore, and measure the
Connecting rod bend and twist - Inspect
height of the bar using a dial gauge.
Unit: mm [in.]
Item Standard Limit
D
Connecting rod 0.05/100 mm 0.15/100 mm C
bend and twist [0.0020/3.94 in.] or less [0.0059/3.94 in.]
C 0.05 0.0020
[ ] A B
D 100 3.94
Measuring with dial gauge
6-18
5. Crankcase and crankshaft - Inspect and repair

5.1 Cylinder inside diameter - Measure
(1) Measure the inside diameter of the cylinder at three lev-
els, i.e., upper (position of No.1 compression ring when Measuring
piston is at top dead center), middle, and lower levels, directions
11 [0.43]
in both directions parallel to and perpendicular to the
150 [5.91]
crankshaft direction.
80 [3.15]
(2) If the measurement is between the repair limit and
replacement limit, re-bore the cylinder to +0.25 mm
[0.0098 in.] or +0.5 mm [0.0197 in.] oversize. Hone the Measuring
points
rebored cylinder to the accuracy of the standard.
Unit: mm [in.]
(3) Use an oversize piston and piston rings to fit the
Cylinder inside diameter - Measure
rebored cylinder.
(4) If the cylinder is worn unevenly, select an oversize that
ensures complete cylindricity when the cylinder is
rebored to the maximum. All cylinders must be rebored
to the same oversize if one cylinder is rebored.
(5) If the cylinder has a slight wear and is reused after
replacing only the piston rings, remove the steps in
worn portion in the upper part of the cylinder using a
ridge reamer. Hone it as necessary.

Repair limit:
Refacing using a ridge reamer
94.200 mm
Cylinder inside ø 94 mm 94.000 to 94.035 mm [3.7087 in.]
diameter [3.70 in.] [3.7008 to 3.7022 in.] Replace limit:
94.700 mm
[3.7283 in.]
0.01 mm [0.0004 in.]
Roundness - -
or less
0.015 mm [0.0006 in.]
Cylindricity - -
or less
6-19
5.2 Crankcase top surface distortion - Measure
Refacing of crankcase should be kept to an absolute

minimum.
Excessive grinding of the crankcase may result in
defects such as defective combustion and stamping
(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 distor-
tion exceeds the limit, grind the cylinder head using a sur-
face grinder. Crankcase top surface distortion - Measure
Note: Do not overgrind the crankcase, as the piston protru-
sion deviates from the standard value.
Item Standard Limit

0.05 mm 0.20 mm
Crankcase top surface distortion
[0.0020 in.] or less [0.0079 in.]
Note: Do not grind the surfaces more than 0.2 mm [0.0079

in.] in total (cylinder head bottom surface plus crank-
case top surface).
5.3 Crankshaft crankpin and journal outside diameters - Measure
(1) Measure the outside diameter of the crankpins and
crank journals. If the limit is exceeded, grind the pin or
journal to fit the diameter of the next undersize bearing.
(2) Determine the out-of-roundness, the out-of-cylindric-
ity (taper) and clearance between bearing based on the
Measuring Measuring
outside diameters that have been measured. directions points
(3) If the measured value is less than the repair limit, grind
it to the specified undersize. If the measured value is
less than the service limit, replace it with a new one.
Item Nominal Standard Limit Crankpin outside diameter - Measure

57.955 to
Service limit:
Crankpin outside ø58 mm 57.970 mm
57.800 mm
diameter [2.28 in.] [2.2817 to
[2.2756 in.]
2.2823 in.]
Repair limit:
77.955 to 77.850 mm
Crank journal ø78 mm 77.970 mm [3.0650 in.] Measuring Measuring
outside diameter [3.07 in.] [3.0691 to Service limit:
directions points
3.0697 in.] 77.100 mm
[3.0354 in.]
0.01 mm 0.03 mm
Roundness -
[0.0004 in.] or less [0.0012 in.]
0.01 mm 0.03 mm
Cylindricity -
[0.0004 in.] or less [0.0012 in.]
Pin and Crank journal outside diameter - Measure
Pin maximum
journal
defection:
0.01 mm
Parallelism - -
[0.0004 in.] or less.
Max. 0.01 mm
[0.0004 in.] or less
6-20
5.4 Crankpin and rearmost crank main journal width - Measure

(1) Inspect the end of crankshaft for harmful scratch and
wear. Rearmost crank
Crankpin width journal width
(2) Measure the crankpin and rearmost crank journal
width.
Item Nominal Standard

33 mm 33 to 33.1 mm
Crankpin width
[1.30 in.] [1.30 to 1.303 in.]
31 mm 31 to 31.039 mm
Rearmost crank journal width
[1.22 in.] [1.2205 to 1.2220 in.]
Note:(a) The purpose of measuring the crankpin and crank

Crankshaft bearing width - Measure
journal width is to make sure the end play of the big
end of the connecting rod and crankshaft are appro-
priate.
(b) The rearmost crank journal width is important to se-
lect the thickness of thrust plate.
(c) Always inspect the width of the crankpin and crank
journal when regrinding the shaft.
5.5 Crankshaft - Grind

The crankshaft should be grinded to the values of grinding
R3 mm
dimension shown as the right table, and assemble it with [0.12 in.] R3 mm
same rank of undersize main bearing, undersize connecting [0.12 in.]
rod bearing or oversize thrust plate.
When grinding, be careful not to change the fillet radius and
width. When grinding the outer surface of shaft, be careful R3 mm
not to change the width. [0.12 in.]
If the hardness is decreased, quench the crankshaft again

and inspect it with magnetic particle method. If the surface
hardness is considered to have been reduced, re-harden the
Crankshaft - Grind
crankshaft and check for flaws by means of magnetic parti-
cle inspection. 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
journal.
Item Undersize Finishing dimension

0.25 mm 77.705 to 77.720 mm
[0.0098 in.] [3.0592 to 3.0598 in.]
0.50 mm 77.455 to 77.470 mm
Crank Journal
[0.0197 in.] [3.0494 to 3.0500 in.]
0.75 mm 77.205 to 77.220 mm
[0.0295 in.] [3.0396 to 3.0402 in.]
0.25 mm 57.705 to 57.720 mm
[0.0098 in.] [2.2718 to 2.2724 in.]
0.50 mm 57.455 to 57.470 mm
Crankpin
[0.0197 in.] [2.2620 to 2.2626 in.]
0.75 mm 57.205 to 57.220 mm
[0.0295 in.] [2.2522 to 2.2528 in.]
6-21
5.6 Crankshaft runout - Measure

Support the crankshaft at the front and rear main journals
with V-blocks, and measure the crankshaft runout at the
center main journal using a dial gauge. If the runout devi-
ates slightly from the standard, correct the crankshaft by
grinding. If the value exceeds the standard considerably,
straighten the crankshaft with a press.
If the value exceeds the limit, replace the crankshaft with a
new one.
If the crankshaft has been repaired by grinding or pressing,
inspect the crankshaft for the crack and other harmful dam-
Crankshaft runout - Measure
age using a magnetic particle inspection.
Item Standard Limit Remarks

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

If there is any defect on the crankshaft gear teeth, such as
flaking, wear, or uneven contact, replace the crankshaft gear
with a new one.
5.8 Crankshaft gear - Replace
Use protective gloves when you touch hot parts. Crankshaft gear
Touching hot parts with bare hands will result in burns.
5.8.1 Crankshaft gear - Remove

Using a gear puller, remove the gear from the crankshaft.
Note: When removing the crankshaft gear by heating, the
Gear puller
heating temperature is 180°C [356°F] or less. P/N:MH061326
Crankshaft gear - Remove

5.8.2 Crankshaft gear - Install
(1) Install the key on the crankshaft.
(2) Press-fit the gear fully in alignment with the key.
Key
Aligning position
Crankshaft gear
Crankshaft gear - Install
6-22
5.9 Front oil seal - Replace

5.9.1 Oil seal sleeve - Remove
When making a cut in the sleeve, be very careful not

to damage the crankshaft with a chisel.
Make a cut at three locations on the periphery of the oil seal

sleeve to reduce its tension. To do so, hold a chisel against
the sleeve periphery in the radial direction and strike it with
a hammer. When the sleeve is loosened, remove the sleeve.
If the sleeve can not be removed by the above procedure,
hold the chisel against the sleeve in the axial direction and Oil seal sleeve - Remove
tap on it lightly to make the sleeve expand. Once the inter-
ference between the crankshaft and sleeve is eliminated, the
sleeve will be removed easily.
5.9.2 Oil seal sleeve - Install

Oil seal sleeve
installer set
Be careful not to hit or damage the outside surface of P/N:30691-13010
sleeve.
Guide
When installing the oil seal sleeve, apply the oil to the P/N:30691-13100
inside of the oil seal sleeve, and drive it into the crankshaft
by using oil seal sleeve installer set.
When the engine is operated again and the oil seal sleeve
Installer
wears, remove the oil seal sleeve by using following method P/N:30691-13200
and replace the oil seal assembly (oil seal and oil seal Oil seal sleeve - Install
sleeve) with the new spare parts.
5.10 Oil seal contact surface - Inspect

Inspect the oil seal contact surface located on the crankshaft
rear part. If the crankshaft wears due to the oil seal, replace
the oil seal and the oil seal sleeve with new spare parts.
Oil seal
Oil seal
Oil seal sleeve contact surface
Oil seal contact surface - Inspect
6-23
5.11 Main bearing - Inspect

main bearing. If any defect such as poor contact, sliding
scratches, corrosion and foreign substance inclusion is Damage, corrosion,
flaking
found, replace the main bearing with a new one.
End face
Main bearing - Inspect

5.12 Clearance between main bearing and crank journal - Measure
(1) Install the main bearings.
(2) Secure the main bearing cap to the specified torque.
Measuring
(3) Measure the inside diameter of the main bearings. directions
(4) Measure the outside diameter of the crank journal.
(5) Calculate the clearance between the inside diameter of
the main bearing and outside diameter of the crank
journal. Measuring
points
(6) If the clearance exceeds the limit, replace the main
bearing. 103 ± 5 N·m {10.5 ± 0.5 kgf·m}
[76 ± 3.6 lbf·ft]
(7) Measure the clearance between the main bearing cap
Main bearing inside diameter - Measure
and the crank journal again. Use the undersize bearing
if the limit is exceeded.
(8) If an undersize bearing is used, grind the crank journal
to the undersized specification.
Item Standard Limit Measuring Measuring

Clearance between main 0.050 to 0.110 mm 0.200 mm directions points
bearing and crank journal [0.0020 to 0.0043 in.] [0.0079 in.]
Crank journal outside diameter - Measure

5.13 Thrust plate - Inspect
thrust plate. If any defect such as poor contact, sliding
scratches, corrosion and foreign substance inclusion is
found, replace the thrust plate with a new one.
Scratch, corrosion
flaking
Thrust plate - Inspect
6-24
5.14 Tappet - Inspect

5.14.1 Contact surface of tappet and camshaft
Inspect the cam contact surface of the tappet. If the tappet is
Flaw, local wear Flaw, local wear
worn unevenly, replace it with a new one.
Good Bad Bad
Contact surface of tappet and camshaft

5.14.2 Contact surface of tappet and push rod
(1) Apply lead-free coloring paste on the push rod, and
Good Bad
check the contacts.
(2) Check that the push rod contacts the tappet concentri- Section A - A
cally. If it does, replace the tappet and push rod with a

new one. A A
It should be round.
Dent should not be
Push rod should exist.
not contact tappet
concentrically.
Contact surface of tappet and push rod
5.14.3 Clearance between tappet and tappet guide
Measuring Measuring
hole - Measure points directions
Measure clearance between the tappet and tappet hole. If the
limit is exceeded, replace the tappet with a new one.
Item Standard Limit

Tappet guide hole inside 14.000 to 14.018 mm 14.100 mm
diameter [0.5512 to 0.5519 in.] [0.5551 in.]
Clearance between tappet and 0.016 to 0.052 mm 0.08 mm
tappet guide hole [0.0006 to 0.0020 in.] [0.0031 in.]
Clearance between tappet and tappet guide hole -

Measure
6-25
1. Piston, connecting rod, crankshaft and crankcase - Assemble ......................... 7-3
1.1 Crankcase - Invert .................................................................................................................... 7-3
1.2 Tappet - Install .......................................................................................................................... 7-3
1.3 Upper main bearing - Install...................................................................................................... 7-3
1.4 Rear upper thrust plate - Install ................................................................................................ 7-4
1.5 Crankshaft - Install.................................................................................................................... 7-4
1.6 Lower main bearing shell and lower thrust plate - Install.......................................................... 7-4
1.7 Main bearing cap - Install.......................................................................................................... 7-5
1.8 Crankshaft end play - Measure................................................................................................. 7-5
1.9 Side seal - Insert....................................................................................................................... 7-6
1.10 Piston and connecting rod - Assemble ..................................................................................... 7-6
1.11 Piston ring - Install .................................................................................................................... 7-7
1.12 Piston installation - Prepare...................................................................................................... 7-7
1.13 Connecting rod bolt and upper connecting rod bearing - Install ............................................... 7-7
1.14 Piston - Install ........................................................................................................................... 7-8
1.15 Connecting rod cap - Install ...................................................................................................... 7-8
1.16 Connecting rod end play - Measure.......................................................................................... 7-9
1.17 Piston protrusion - Measure...................................................................................................... 7-9
2. Front mechanism - Assemble............................................................................... 7-10
2.1 Oil pump - Install..................................................................................................................... 7-10
2.2 Front plate - Install .................................................................................................................. 7-10
2.3 Camshaft - Install.................................................................................................................... 7-10
2.4 Idler gear - Install .................................................................................................................... 7-11
2.5 Oil pump gear - Install............................................................................................................. 7-11
2.6 Fuel injection pump - Install .................................................................................................... 7-11
2.7 Timing gear backlash - Measure ............................................................................................ 7-12
2.8 Idler gear end play - Measure................................................................................................. 7-12
2.9 Camshaft end play - Measure................................................................................................. 7-12
2.10 Front oil seal - Install............................................................................................................... 7-12
2.11 Timing gear case - Install........................................................................................................ 7-13
2.12 Oil strainer - Install.................................................................................................................. 7-13
2.13 Oil pan - Install........................................................................................................................ 7-14
2.14 Crankcase - Invert .................................................................................................................. 7-14
2.15 Cover - Install.......................................................................................................................... 7-15
2.16 Damper and crankshaft pulley - Install ................................................................................... 7-15
2.17 Damper face and radial runouts - Measure ............................................................................ 7-15
3. Rear mechanism - Assemble................................................................................ 7-16
3.1 Rear oil seal - Install ............................................................................................................... 7-16
3.2 Rear plate - Install................................................................................................................... 7-16
3.3 Flywheel - Install ..................................................................................................................... 7-16
3.4 Flywheel face and radial runouts - Measure........................................................................... 7-17
7-1
4. Cylinder head and valve mechanism - Assemble............................................... 7-18

4.1 Cylinder head - Assemble....................................................................................................... 7-18
4.2 Valve sinkage - Measure ........................................................................................................ 7-18
4.3 Cylinder head gasket - Install ................................................................................................. 7-19
4.4 Cylinder head assembly - Install............................................................................................. 7-19
4.5 Cylinder head bolt - Tighten.................................................................................................... 7-19
4.6 Push rod - Insert ..................................................................................................................... 7-19
4.7 Rocker shaft assembly - Install............................................................................................... 7-20
4.8 Valve clearance - Check and adjust ....................................................................................... 7-21
4.9 Rocker cover - Install .............................................................................................................. 7-22
7-2
1. Piston, connecting rod, crankshaft and crankcase - Assemble

1.1 Crankcase - Invert
Using a rotating table, invert the crankcase. When the rotat-
ing table is not available, tie wire ropes to the crankcase
using batten and cloth pads, and raise the crankcase using a
hoist and crane and lay it on the wooden block with its side
facing downwards. Then, change the positions of the wire
ropes, and turn over to invert the crankcase.
Crankcase - Invert
1.2 Tappet - Install
Apply engine oil onto the periphery of tappets, insert them
into the tappet holes.
1.3 Upper main bearing - Install
(a) Do not apply engine oil to the back faces of the main bearing shells and main bearing fitting bores in the crank-
case when installing the main bearings. Install the main bearings only after cleaning off foreign matters, oil and
grease from these surfaces using cleaning solvent.
(b) When installing main bearings, be careful not to confuse upper shells with lower shells.
The upper main bearing shells are identified by machined oil holes. The lower main bearing shells have no oil
holes or grooves. Be careful not to install the main bearing upside down.
(c) Be careful not to damage the bearings when installing.
(1) Clean the main bearing fitting bores and main bearing
Upper main bearing
cap mating surfaces using cleaning solvent, and make
sure that these surfaces are free from any foreign sub-
stances.
(2) Make sure that the main bearings are neither damaged
nor contaminated.
(3) Fit the upper main bearing shell in the crankcase bore
while aligning the notch on the shell with the lug of the
Align with lug groove.
crankcase.
Note:(a) Make the main bearing end protrusion from the
Upper main bearing - Install
crankcase bore even at both ends.
(b) The oil hole in the upper main bearing shell will be
aligned with the oil hole in the crankcase by align-
ing the notch of upper shells with the lug of the
crankcase.
(4) Apply an even coat of clean engine oil to the sliding
surface of upper main bearing shells.
7-3
1.4 Rear upper thrust plate - Install
Be careful not to damage the thrust plate when

installing.
(1) With the oil grooves facing the engine rear side, install
the rear upper thrust plate to the dowel pins on the Oil groove
crankcase rearmost.
(2) Apply engine oil evenly to the sliding surface.
Align with lug groove.
Rear upper thrust plate - Install

1.5 Crankshaft - Install
(1) Make sure that the upper main bearing shells that are
installed in the crankcase bores have their inner periph-
ery (the surface comes into contact with the journal)
lubricated with an even coat of fresh engine oil.
(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 crankshaft
journals.
Note: When washing crankshaft, be sure to thoroughly wash
oil holes so that they are free from foreign substances,
Crankshaft - Install
dust and dirt. Make sure that oil holes are free from any
burrs.
(3) Lift the crankshaft horizontally and slowly install it to
the crankcase.
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.
1.6 Lower main bearing shell and lower thrust plate - Install
(1) Install the lower main bearing shell, aligning with the
Lower main
lug of the main bearing cap. bearing
Note: Make a protrusion amount of bearings even.
(2) Apply an even coat of clean engine oil to the sliding
surface of lower main bearing shells.
(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 Main bearing cap
outer side of its cap.
Lower thrust plate
Lower main bearing shell and lower thrust plate -
Install
7-4
1.7 Main bearing cap - Install
Apply ThreeBond 1212

Be sure to observe the specified tightening sequence to corner of cap
when installing the main bearing cap bolts.
(1) Make sure that the main bearings and thrust plates,
which have been installed to main bearing caps, are
evenly coated with clean engine oil.
(2) Install the main bearing cap from the front side to the
rear side of the engine with the arrow on the bottom of
the main bearing cap facing the front side of the engine.
All of the lug grooves on the main bearing cap should Main bearing cap - Install
be in the same position.

(3) Coat the main bearing cap bolt and washer with engine
oil, and install the bolts and washer temporarily.
(4) Tap the main bearing caps with a soft-head hammer
evenly to install them in position.
103 ± 5 N·m
Note: The foremost and rearmost main bearing caps should
{10.5 ± 0.5 kgf·m}
be flat with the end face of the crankcase. [76 ± 3.6 lbf·ft]
(5) Apply engine oil to the threads and bolt seat surface. [Wet]
(6) Tighten the main bearing cap bolts alternately and pro-
gressively to the specified torque.
Main bearing cap bolt - Install
(7) Tighten the rearmost main bearing cap bolt until its seat
surface contacts lightly with the main bearing cap.
Measure the crankshaft end play in this condition.
1.8 Crankshaft end play - Measure

(1) Measure the crankshaft end play (clearance between the
crank arm at the thrust force receiving journal and the
bearing cap with thrust plate attached). If the limit is
exceeded, replace the thrust plate with a new one.
(2) If the limit is still exceeded after a new thrust plate has
been installed, use an oversize thrust plate.
Note: In general, the rear thrust plate wears faster than the
front thrust plate. Therefore, in most cases, the correc-
tion is achieved by replacing the rear thrust plate with
a next oversize one.
Item Standard Limit
0.100 to 0.264 mm 0.30 mm
Crankshaft end play
[0.0039 to 0.0104 in.] [0.0118 in.]
Crankshaft thrust size after grinding

One side Both sides
Item Tolerance
oversize oversize
+0.15 mm [0.0059 in.] 31.15 mm 31.30 mm
+0.039
Oversize [1.2264 in.] [1.2323 in.] 0 mm
+0.0015
+0.30 mm [0.0118 in.] 31.30 mm 31.45 mm [ 0 in.]
Oversize [1.2323 in.] [1.2382 in.]
7-5
1.9 Side seal - Insert

(1) Apply a sealant (ThreeBond 1212) to the outer periph-
ery of new side seals. Side
Crankcase
seal
(2) With the round section of the side seals facing outward, Bearing
press them partway into the front and rear caps using cap
hands.
(3) When the side seals are installed partway into caps, use
a tool with flat surface such as flat-head screwdriver to
install completely, taking care not to bend them.
R section
Apply Threebond 1212 to side seal.

Side seal - Insert
1.10 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.
Note: The piston and piston pin are assembled with each oth- Front mark
er by a clearance fit. However, the piston pin is more
easily inserted into the piston if the piston is warmed Matching
up with a heater or with hot water. mark with
Weight stamp connecting
(2) Install the snap ring with ring pliers. Make sure the rod cap
snap ring is fully inserted into the ring groove.
Piston and connecting rod - Assembling orientation
Snap ring pliers
Piston and connecting rod - Assemble
7-6
1.11 Piston ring - Install
Piston ring plier

No.1 Top mark
Every piston ring has a top mark near the end gap. P/N:31391-12900
compression
Install piston rings with this mark facing upward. ring
If the rings are installed upside down, it could cause No.2
malfunctions such as excessive oil consumption or compression
ring
engine seizing.
(1) Install the piston rings to the piston with a ring Oil ring
expander.
(2) Install the oil ring with its end gap 180° away from the
joint of the coil spring, as shown in the illustration. Combination of piston and piston ring
Coil spring joint
180°
Oil ring ends
Oil ring end gap and coil spring joint - Orientation

1.12 Piston installation - Prepare
(1) Lay the engine along its side.
(2) Clean the cylinder inner surface and the crankpin, and
apply engine oil to the cylinder.
Cleaning cylinder inner surface and applying engine oil

1.13 Connecting rod bolt and upper connecting rod bearing - Install
Lug groove
Do not apply engine oil to the back face of the bear-
ings.
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. Apply engine oil.
Note: When press fitting the bolt, make sure that the bolt ful-
ly contacts its seating position without any interference
with the shoulder of mounting surface.
Connecting rod bolt
upper connecting rod bearing - Install
7-7
1.14 Piston - Install
Camshaft side
No.1
Do not forcefully insert the piston, as it may cause Thrust direction compression
damage to the piston rings and crankpin. 180° ring ends
(1) Apply engine oil to the circumference of the piston and

piston rings.
(2) Place the piston ring end gaps equally spaced each No.2
compression Oil ring ends
other, avoiding thrust and anti-thrust direction, and pin ring ends
60° 60°
direction. Anti-thrust
(3) Rotate the crankshaft to bring the crankpin of the cylin- direction Combustion chamber side
der to bottom dead center. Orientation of piston ring end gaps

(4) Orientate the front mark on the top of piston toward
Piston installer
engine front. P/N:34491-00200
(5) Insert the piston from the top face of crankcase using a
piston installer.
Front mark
Piston - Install
1.15 Connecting rod cap - Install
(a) Check that the matching mark of connecting rod is

on the same side as cap's.
(b) When fitting the connecting rod caps, make sure
that dust, metal particles, etc. are not caught
between bolt seating surfaces and in the bolt
threads. 54 ± 5 N·m
{5.5 ± 0.5 kgf·m}
(1) Install the lower connecting rod bearing, aligning its [40 ± 3.6 lbf·ft]
lug with the lug groove of the connecting rod bearing
cap. Connecting rod cap - Install
(2) Apply engine oil to the connecting rod bolt threads and
seating surface, and the sliding surface of the connect-
ing rod bearing shell.
(3) Install the connecting rod cap with its matching mark
facing on the same side as the matching mark on the
connecting rod.
(4) Tighten the connecting rod cap nuts evenly and alter-
nately to the specified torque.
(5) Inspect end play of the connecting rod. If end play is
small, loosen and retighten the cap nuts.
7-8
1.16 Connecting rod end play - Measure

(1) Install the connecting rods onto the respective crank-
pins and tighten the connecting rod cap bolts to the
specified torque.
(2) Measure the clearance to the crank arm (end play) at
two positions (above and below the crankpin) with a
thickness gauge.
(3) If the limit is exceeded, replace the connecting rod with Thickness gauge
a new one.
Item Standard Limit
Connecting rod end play

0.15 to 0.35 mm 0.50 mm Connecting rod end play - Measure
[0.0059 to 0.0138 in.] [0.0197 in.]
1.17 Piston protrusion - Measure
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
instructions below. If the measured value does not meet the
standard, 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 Piston protrusion - Measure
crankcase, and zero the dial gauge.
(3) Measure the protrusion at four points on the piston
head, and calculate the mean value.
Note: The top clearance (clearance between the piston top
surface and the cylinder head bottom surface) can be
determined by the measured piston protrusion and
thickness of the cylinder head gasket.
Top clearance = Thickness of cylinder head gasket -
Piston protrusion

-0.25 to 0.15 mm
Piston protrusion
[-0.0098 to 0.0059 in.]
Thickness of 1.2 mm 1.15 to 1.25 mm
cylinder head gasket [0.0472 in.] [0.0453 to 0.0492 in.]
1.0 to 1.5 mm
Top clearance
[0.039 to 0.059 in.]
7-9
2. Front mechanism - Assemble

2.1 Oil pump - Install
Install the new O-ring to the oil pump case, then, install the
oil pump to the crankcase.
Oil pump
O-ring
Oil pump - Install

2.2 Front plate - Install
(1) Apply sealant (ThreeBond 1211) to the front plate
Packing
packing mounting surface of the crankcase, and install
the packing.
Front plate
(2) Apply the same sealant (ThreeBond 1211) to the pack-
ing, and then install the front plate.
(3) Tighten the bolt with the specified torque.
(4) Make sure that the lower end of the front plate is flush
with the bottom surface of the crankcase. Cut off any 11.5 ± 1.5 N·m
excess packing neatly. {1.15 ± 0.15 kgf·m}
[8.5 ± 1.1 lbf·ft]
Front plate - Install
2.3 Camshaft - Install
Be careful not to damage camshaft journals, cams and

camshaft holes during insertion. 11.5 ± 1.5 N·m
{1.15 ± 0.15 kgf·m}
(1) Apply engine oil to the camshaft journals and cams. [8.5 ± 1.1 lbf·ft]
(2) Slowly insert the camshaft assembly.
(3) Tighten the thrust plate bolts to the specified torque.
(4) Make sure that the camshaft rotates lightly. Move the
camshaft gear back and forth, and check the end play.
Camshaft - Install
7-10
2.4 Idler gear - Install

(1) Apply engine oil to the idler shaft.
(2) Install the idler gear onto the shaft fitting the matching
mark. Idler gear
(3) Tighten the thrust plate bolts to the specified torque.

(4) Move the idler gear back and forth, and check the end
play.
34 ± 5 N·m
{3.5 ± 0.5 kgf·m}
[25 ± 3.6 lbf·ft]
Idler gear - Install
Oil pump gear Crankshaft gear
Fuel injection
pump gear 1
11
22
3
33
2
Idler gear Camshaft gear
Timing gear train

2.5 Oil pump gear - Install
(1) Install the oil pump gear to the oil pump shaft.
(2) Tighten the jam nut to the specified torque.
Oil pump gear
33 ± 5 N·m
{3.4 ± 0.5 kgf·m}
[24.6 ± 3.6 lbf·ft]
Oil pump gear - Install
2.6 Fuel injection pump - Install
Install the fuel injection pump gear with its matching marks
aligned with the marks on the idler gear, then, tighten the Fuel injection
bolt. pump gear
Fuel injection pump - Install
7-11
2.7 Timing gear backlash - Measure

Measure the backlash of the timing gears using either
method: measure the gear play with the dial gauge plunger
applied to a tooth flank on the pitch circle at a right angle to
Dial gauge
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 specified limit is exceeded,
replace the gears with new ones.
Item Standard Limit

0.05 to 0.15 mm 0.25 mm
Timing gear backlash
[0.0020 to 0.0059 in.] [0.0098 in.]
2.8 Idler gear end play - Measure
Measure the end play of the idler gear. If the specified limit
is exceeded, replace the thrust plate with a new one.
Item Standard Limit

0.05 to 0.20mm 0.35 mm Dial gauge
Idler gear end play
[0.0020 to 0.0079 in.] [0.0138 in.]
Idler gear end play - Measure

2.9 Camshaft end play - Measure
Measure the camshaft end play. If the specified limit is
exceeded, replace the thrust plate with a new one.
Item Standard Limit

Dial gauge
0.10 to 0.25mm 0.30 mm
Camshaft end play
[0.0039 to 0.0098 in.] [0.0118 in.]
Camshaft end play - Measure

2.10 Front oil seal - Install
Using an installer, install new oil seal to the timing gear
case. Make sure the oil seal is flush with the gear case.
Installer
Front oil seal - Install
7-12
2.11 Timing gear case - Install

(1) Apply sealant to the packing to prevent it from displac-
Packing
ing and install the packing on the front plate.
(2) Apply engine oil to the oil seal lip. Timing gear case
(3) Install the timing gear case and tighten the bolts to the
specified torque.
18.5 ± 1.5 N·m

{1.9 ± 0.1 kgf·m}
[13.6 ± 1.1 lbf·ft]
Timing gear case - Install

2.12 Oil strainer - Install
Set a new O-ring to the oil strainer, and install the oil
strainer to the crankcase. Oil strainer
Oil strainer - Install
7-13
2.13 Oil pan - Install

(1) Clean the mount surfaces of the crankcase, timing gear
case, and oil pan.
(2) Squeeze ThreeBond 1207C (32A91-05100: liquid gas-
ket) in a 4 mm [0.16 in.] diameter bead all around the
oil pan flange periphery, and spread it evenly.
(3) Install the oil pan to the crankcase within five minutes
of applying the liquid gasket.
Note: Cutting the top of the sealant tube at the point shown
Apply ThreeBond 1207C all around the oil pan flange.
in the illustration will provide a 4 mm [0.16 in.] bead.
Liquid gasket application position
Oil pan
11.5 ± 1.5 N·m

{1.2 ± 0.1 kgf·m} Bolt
[8.5 ± 1.1 lbf·ft]
Oil pan - Install
Cut here
Cutting point of the liquid gasket tube nozzle

2.14 Crankcase - Invert
Using a rotating table, invert the crankcase. When the rotat-
ing table is not available, tie wire ropes to the crankcase
using batten and cloth pads, and raise the crankcase using a
hoist and crane and lay it on the wooden block with its side
facing downwards. Then, rehang the wire ropes. Invert the
crankcase on the wooden blocks and turn it to the normal
position.
Crankcase - Invert
7-14
2.15 Cover - Install

Install the cover to the timing gear case.
Cover
Cover - Install
2.16 Damper and crankshaft pulley - Install
(Front) (Rear)
Prevent crankshaft
The bar could come off. Be very careful. from rotating
(1) Screw two guide bolts into the threaded holes at the rear
end of the crankshaft. Place a bar across the two guide
bolts so that the crankshaft does not rotate.
(2) Install the woodruff key on the crankshaft.
(3) Install the damper to the crankshaft pulley. Crankshaft pulley
490 ± 10 N·m Guide bolt
(4) Tighten the nut to the specified torque. {50 ± 1 kgf·m}
[361 ± 7.3 lbf·ft] (M12 × 1.25 mm)
Damper and crankshaft pulley - Install
2.17 Damper face and radial runouts - Measure

Measure the face and radial runouts of the damper. Attach
the dial gauge plunger on the outer circumference of the
damper to measure the radial runout, or on the end face near
the perimeter to measure the face runout, and slowly turn
the crankshaft. If the limit is exceeded, replace the damper
with a new one. Face
runout
Item Standard Limit
Face runout 0.5 mm [0.020 in.] or less 1.5 mm [0.059 in.] Radial
runout
Radial runout 0.5 mm [0.020 in.] or less 1.5 mm [0.059 in.]
7-15
3. Rear mechanism - Assemble

3.1 Rear oil seal - Install
Apply a small quantity of grease to the new oil seal, and
install the oil seal to the rear plate.
Apply grease Rear plate
Be careful of the oil seal installation direction.
Note: Use an oil seal with a sleeve if the oil seal contacting
surface of the crankshaft is worn.
Engine side Flywheel side
Oil seal
Rear oil seal - Install

3.2 Rear plate - Install
(1) Clean the mounting surface of the packing.
Apply engine oil
(2) Apply sealant to the packing to prevent it from falling.
(3) Install the packing.
(4) Install the rear plate aligning with the dowel pin by
using the guide bolt, and tighten the bolts to the speci-
fied torque.
Note: When the dowel pins are worn or when the rear plate
is replaced, replace the dowel pins with new ones. 55.9 ± 5.8 N·m
{5.7 ± 0.5 kgf·m}
[41.2 ± 4.2 lbf·ft]
Rear plate - Install

3.3 Flywheel - Install
(Front) (Rear)
The person holding the pulley must be very careful to Guide bolt
assure safety by communicating with the person who
is installing the flywheel.
(1) One person must firmly hold the pulley with a wrench
to prevent the crankshaft from rotating.
(2) Screw the guide bolt into the rear end of the crankshaft.
83 ± 5 N·m
(3) Align the bolt hole of flywheel with the guide bolt and Prevent the flywheel from {8.5 ± 0.5 kgf·m}
rotating using a wrench. [61 ± 3.6 lbf·ft]
install the flywheel to the crankshaft.
(4) Temporarily tighten the bolts. Flywheel - Install
(5) Remove the guide bolt and temporarily tighten the last
bolt.
7-16
3.4 Flywheel face and radial runouts - Measure

Measure the runouts of the flywheel in the installed condi-
tion. If the measured value exceeds the standard, check the
bolt for looseness as well as the accumulation of foreign
matter on the mounting face. Face runout
measuring point
Item Standard Limit
0.15 mm 0.50 mm
Face and radial runouts
[0.0059 in.] or less [0.0197 in.]
Radial runout
measuring point
7-17
4. Cylinder head and valve mechanism - Assemble

4.1 Cylinder head - Assemble
Stem seal
installer
(a) Be careful when inserting the stem seal through P/N:32A91-10200
Valve
the valve, as the edge of the valve can cause
damage to the lip of stem seal.
Stem seal
(b) Do not apply oil or liquid sealant to the fitting por-
tion between the stem seal and the valve guide. 15.2 ± 0.1 mm
Valve guide [0.598 ± 0.03 in.]
(c) Always replace the stem seal with a new one once
it has been removed.
(1) Apply engine oil to the valve stem, and insert the valve
onto the valve guide. Valve stem seal - Install
(2) Insert the stem seal through the valve guide using a
Valve spring pusher
stem seal installer. P/N:30691-04500
Note: Before the installation of stem seal, the valve should be
installed so that valve stem seal is centered on the
valve stem upon installation.
(3) Apply engine oil to the lip of stem seal.
(4) Install the valve spring and retainer to the valve guide,
and then install the valve cotter with a valve spring
pusher.
Valve and valve spring - Install

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

4.2 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. Lap the valve and valve seat
whenever the valve or valve seat has been refaced or
replaced.

Valve seat
0.4 mm 0.3 to 0.5 mm 1.0 mm Valve margin
Inlet angle
[0.016 in.] [0.012 to 0.020 in.] [0.039 in.] Valve sinkage
0.5 mm 0.4 to 0.6 mm 1.0 mm
Exhaust
[0.020 in.] [0.016 to 0.024 in.] [0.039 in.]
Valve sinkage - Measure
7-18
4.3 Cylinder head gasket - Install
Do not use the liquid gasket to the cylinder head.

(1) Wipe off oil, grease and other contamination from the
cylinder head bottom surface and the crankcase top sur-
face.
(2) Place new gasket on the crankcase by aligning it with
dowel pins on the crankcase.
4.4 Cylinder head assembly - Install
Install the cylinder head to fit the dowel pins on the crank-
case top surface with guide. Cylinder head
Note:(a) Install the cylinder head gasket with paying atten-
tion not to displace the cylinder head gasket.
(b) Do not lift up the crankcase by yourself. Use a crane
or lift it up by two persons.
Cylinder head assembly - Install

4.5 Cylinder head bolt - Tighten
Progressively tighten the cylinder head bolts in the numeri-
cal order and to the specified torque as shown in the illustra-
tion. 118 ± 5 N·m {12 ± 0.5 kgf·m} [87 ± 3.6 lbf·ft]
20 12 4 5 13 21
24 16 8 1 9 17 25
Front 22
23 19 15 11 7 3 2 6 10 14 18
Number of bolt (25)
Tightening sequence of cylinder head bolts

4.6 Push rod - Insert
(1) Insert each push rod into its hole in the cylinder head.
(2) Make sure that the ball end of each push rod is placed
correctly on the tappet cup. Push rod
Tappet
Push rod - Insert
7-19
4.7 Rocker shaft assembly - Install
17.2 ± 2.45 N·m Bolt

{1.75 ± 0.25 kgf·m} (short)
Always tighten the long bolt first. Failing to do so may
[12.9 ± 1.8 lbf·ft]
cause damage to the rocker shaft bracket.
(1) Apply engine oil to the rocker shaft.
(2) Assemble the rocker shaft assembly. Bolt
(3) After assembling, make sure the rocker arm move (long)
freely.
(4) Install the valve caps to the valve heads.
(5) Install the rocker shaft assembly.
(6) Tighten the rocker bracket bolt (long) to the specified Rocker shaft assembly - Install
torque.
(7) Tighten the rocker bracket bolt (short).
7-20
4.8 Valve clearance - Check and adjust

The valve clearance should be inspected and adjusted when
the engine is cold.
Item Standard
Inlet
Valve clearance (when cold) 0.25 mm [0.0098 in.]
Exhaust
(1) Inspect the valve clearance for all cylinders in the firing
order by turning the crankshaft to the specified degrees
Injection timing
in the normal direction (clockwise when viewed from 1-5-3-6-2-4
engine front side) to bring each piston to compression Turning angle:
120°
top dead center.
Note: To rotate the crankshaft, fit a socket and ratchet handle

on the crankshaft pulley nut.

(2) When the No. 1 piston is at compression top dead cen-
ter, the scribed line on the periphery of the damper is Socket for turning
P/N:58309-73100
aligned with the "0" graduation mark on the pointer.
Crankshaft - Rotate
Neither 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
valve cap to inspect the clearance.
No. 1 cylinder compression top dead center - Check

(4) Insert the thickness gauge of the specified thickness
between the rocker arm and valve cap, then adjust the 20 ± 2 N·m
clearance by turning the screw in either direction so that Adjusting screw {2.0 ± 0.2 kgf·m}
[0.0098 in.]
[15 ± 1.4 lbf·ft]

0.25 mm
Lock nut
the gauge is gripped softly between the rocker arm and
bridge cap.
(5) After adjustment, tighten the lock nut firmly. Then,
check the clearance again.
Valve clearance - Adjust
7-21
4.9 Rocker cover - Install

(1) Make sure that the gasket is firmly installed into the
rocker cover.
11.5 ± 1.5 N·m
(2) Tighten the bolt with the specified torque. {1.15 ± 0.15 kgf·m}
[8.5 ± 1.1 lbf·ft]
Rocker cover - Install
7-22
1. Fuel system - Remove and inspect........................................................................ 8-3
2. Fuel system - Disassemble and inspect................................................................ 8-5
2.1 Fuel filter - Disassemble, inspect and assemble (paper element) ............................................ 8-5
2.2 Fuel injection nozzle - Disassemble and inspect ...................................................................... 8-8
2.3 Fuel injection nozzle - Inspect and adjust................................................................................. 8-9
2.4 Fuel injection nozzle - Assemble ............................................................................................ 8-11
2.5 Gauze filter of distribute type fuel injection pump - Inspect and clean.................................... 8-12
3. Fuel system - Install .............................................................................................. 8-13
3.1 Fuel injection timing (in-line type fuel injection pump) - Inspect ............................................. 8-15
3.2 Fuel injection timing (distributor type fuel injection pump) - Inspect ....................................... 8-16
8-1
1. Fuel system - Remove and inspect

In-line-type fuel injection pump
6
Replace
1
9
Replace
Fuel system (in-line type injection pump) - Remove and inspect

Removing sequence
1 Fuel hose 4 Fuel return pipe 7 Fuel injection nozzle
2 Fuel filter 5 No. 1 to No. 6 8 Bracket
3 Fuel filter bracket Fuel injection pipe 9 Fuel injection pump
6 Fuel leak-off pipe
Cover the openings on the fuel injection pipe, nozzle and fuel injection pipe to prevent dust from entering the fuel
system.
8-3
Distributor-type fuel injection pump
Replace
2
6
5
3
7
4
Replace
Fuel system (distributor type injection pump) - Remove and inspect

Removing sequence
1 Fuel hose 4 Fuel return pipe 7 Fuel injection nozzle
2 Fuel filter 5 No. 1 to No. 6 8 Bracket
3 Fuel filter bracket Fuel injection pipe 9 Fuel injection pump
6 Fuel leak-off pipe
Cover the openings on the fuel injection pipe, nozzle and fuel injection pipe to prevent dust from entering the fuel
system.
8-4
2. Fuel system - Disassemble and inspect

2.1 Fuel filter - Disassemble, inspect and assemble (paper element)
In-line type fuel injection pump
Crack, damaged threads
Clogged, cracks.
Replace: Every 500 hrs.
Fuel filter - Disassemble and inspect

1 Filter element 2 Filter bracket
8-5
Distributor type injection pump
Crack, damaged threads
Replace
2
Clogged, cracks.
Replace
Fuel filter - Disassemble and inspect

1 Level sensor 2 Filter element 3 Body
8-6
2.1.1 Fuel filter - Assemble
(a) Make sure that there is no flame around the area before handling fuel.
(b) Wipe off any spilled fuel. Spilled fuel can cause fires.
(1) Clear the fuel filter and its surroundings. 5 ± 1 N·m
(2) Disconnect the fuel filter level sensor from its connec- {0.51 ± 0.10 kgf·m}
[3.69 ± 0.74 lbf·ft]
tor.
(3) Prepare the fuel plate and place it under the fuel filter.
(4) Loosen the drain plug and drain fuel from the fuel filter.
(5) Remove the level sensor from the fuel filter.
(6) Remove the fuel filter element.
(7) Wipe off any fuel on the fuel filter element mounting 1.1 ± 0.3 N·m
13.5 ± 1.5 N·m
surface of fuel filter body with a waste cloth. {1.4 ± 0.1 kgf·m} {0.1 ± 0.03 kgf·m}
(8) Prepare the new fuel filter element and make sure that [10 ± 1.1 lbf·ft] [0.8 ± 0.22 lbf·ft]
Fuel filter - Assemble
the gasket is properly seated on the groove.
Do not use the filter that has damaged case. If the

case is dented, it can cause damage to the filter, lead-
ing to fuel leaks during operation, and result in a fire.
(9) Install the fuel filter element to the filter body.
Be careful not to dent or scratch the surface of the fuel

filter.
(10)Install the level sensor to the fuel filter element through

new O-ring.
(11)After completion of the fuel filter change, bleed the fuel
system.
(12)Start the engine and idle for a few minutes.
(13)Check the fuel filter element mounting surface for fuel
leakages. If leakages are found, loosen the fuel filter
and check the gasket for seating or damage. Then
retighten the fuel filter.
8-7
2.2 Fuel injection nozzle - Disassemble and inspect

efficient work.
Fuel injection start pressure - Inspect
Fuel injection nozzle spray - Inspect
Replace
Wear 7
Fatigue, breakage
6
4
Wear, damage
3
Carbon deposit,
nozzle hole clogging 1
Fuel injection nozzle - Disassemble and inspect

1 Nozzle retaining nut 4 Pressure pin 7 Nozzle holder
2 Nozzle tip assembly 5 Pressure spring 8 Gasket
3 Distance piece 6 Shim
8-8
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 nozzle

injection test.
(1) Mount the nozzle on 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 retain- Fuel injection nozzle with nozzle tester - Inspect
ing nut, and change the shim. Changing the shim with a
thicker one increases the pressure, and changing the
shim with a thinner one decreases the pressure.
(4) After adjustment, tighten the retaining nut with the
specified torque.
(5) After tightening the retaining nut, check if the injection
start pressure is within the standard again.

14.22 MPa 14.22 to 15.00 MPa
Double
{145 kgf/cm2} {145 to 153 kgf/cm2}
throttle
Injection start [2062 psi] [2062 to 2176 psi]
pressure 11.77 MPa 11.77 to 12.75 MPa
throttle {120 kgf/cm2} {120 to 130 kgf/cm2}
[1707 psi] [1707 to 1849 psi]
Note:(a) Standard value shows a value when it is new.

(b) A change in thickness of the shim by 0.1 mm [0.004
in] results in a change in the fuel injection pressure
by 1.0 MPa {10 kgf/cm2} [142 psi]. Shims are
available in 10 thicknesses from 1.25 to 1.70 mm
[0.0492 to 0.0669 in].
2.3.2 Fuel injection nozzle spray - Inspect
When adjusting for nozzle opening pressure using the noz- Defective spray pattern
zle tester, inspect for nozzle hole condition and fuel spray
pattern. If spray condition is faulty, clean or replace the noz-
zle tip.
Checking points of fuel spray are as follows:
Fuel is injected from all spray holes simultaneously. Good Large After Deflected Branched
spray dribble spray spray
Fuel is injected conically at the specified spray angle. angle
Fuel is injected in a spray of fine droplets.
Fuel is injected without after-dribbling.
Fuel injection nozzle spray - Inspect
8-9
2.3.3 Nozzle tip - Clean and replace
(a) Be careful not to hit the nozzle tip.

(b) The needle valve and body are precision finished Nozzle tip end
components. Handle them carefully, and never
change the combination of the valve and body.
(1) Remove the retaining nut.

(2) Remove the nozzle tip.
Fuel injection nozzle tip - Remove

(3) 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.
(4) Tighten the nozzle tip tightening retainer nut to the
specified torque.
(5) If the spray pattern is still faulty after cleaning and
adjusting, change the nozzle tip with a new one. Needle
New nozzle tips are coated with anti-corrosive agent, valve Body
therefore, it is necessary to wash the nozzle tips before
use. First wash it in wash oil, and wash it again with Nozzle tip - Clean
clean diesel fuel before installation.
2.3.4 Pressure pin - Inspect

Inspect the pressure pin visually. If its spring seat wears
Spring seating
unevenly, or its needle valve contact surface wears remark- surface wear
ably, or the cavitation occurs on its tapper part, replace the (Uneven wear)
pressure pin with new one.
Cavitation
Needle valve
contact surface wear
Pressure pin - Inspect

2.3.5 Distance piece - Inspect
Inspect the distance piece visually. If its needle valve con- High-pressure
tact surface and high pressure seal surface wear remarkably, seal face
replace the distance piece with a new one.
High-pressure
seal face
Needle valve width
ø4 mm [0.16 in.]
Distance piece - Inspect
8-10
2.4 Fuel injection nozzle - Assemble
36.8 ± 2.4 N·m

{3.8 ± 0.2 kgf·m}
[27.1 ± 1.8 lbf·m]
58.9 ± 5.8 N·m

{6 ± 0.5 kgf·m}
[43 ± 4.3 lbf·m]
Fuel injection nozzle - Assemble
8-11
2.5 Gauze filter of distribute type fuel injection pump - Inspect and clean
Keep away from flame when handling diesel oil. Wipe off any spilled fuel. Spilled fuel can cause fires.
Cover the injection pump openings to prevent the injection pump from contamination of dust, water and etc. If for-
eign material, water and etc. enter the inside of injection pump, faulty sliding, seizure and rusting of inner parts
could occur.
When output shortage and/or hunting of the engine
occurred, the gauze filter may be dirty. Clean the gauze fil- Fuel hose
ter accordingly.
(1) Clean around the injection pump. Fuel pipe
(2) Drain the fuel in the injection pump, and remove the
Gasket
fuel hose and fuel pipe.
(3) Remove the spring with a tweezer.
(4) Remove the gauze filter with a tweezer.
Note: Do not damage the metal mesh when removing the
gauze filter.
Fuel hose and fuel pipe - Remove
(5) Remove the dirt and dust from the gauze filter cleaning
with compressed air or diesel fuel. When damage is
Spring
found, or when the gauze filter is still dirty after clean-
ing, replace the gauze filter with a new one.
(6) Install the cleaned gauze filter and new gasket, and in
reverse order of disassembly, install the fuel pipe and
fuel hose.
Spring - Remove
Gauze filter
Gauze filter - Remove
8-12
3. Fuel system - Install
29.5 ± 2.9 N·m 19.7 ± 1.9 N·m

{2 ± 0.1 kgf·m} In-line-type fuel injection pump
{3 ± 0.3 kgf·m}
[21.8 ± 2.1 lbf·ft] 22.6 ± 1.9 N·m [14.5 ± 1.4 lbf·ft]
58.9 ± 5.8 N·m {2.3 ± 0.1 kgf·m}
{6 ± 0.5 kgf·m} [16.7 ± 1.4 lbf·ft]
[43.4 ± 4.3 lbf·ft]
Replace
Replace
Fuel system - Install
8-13
29.5 ± 2.9 N·m

{3 ± 0.3 kgf·m} Distributor-type fuel injection pump
[21.8 ± 2.1 lbf·ft]
Replace
22.6 ± 1.9 N·m
{2.3 ± 0.1 kgf·m}
[16.7 ± 1.4 lbf·ft]
58.9 ± 5.8 N·m
{6 ± 0.5 kgf·m}
[43.4 ± 4.3 lbf·ft]
19.7 ± 1.9 N·m

{2 ± 0.1 kgf·m}
[14.5 ± 1.4 lbf·ft]
Replace
Fuel system - Install
8-14
3.1 Fuel injection timing (in-line type fuel injection pump) - Inspect
The fuel injection timing varies with the output, speed and
other engine specifications. Be sure to check the engine's
specification sheet.
3.1.1 No. 1 cylinder compression top dead center -
Check
(1) Attach a socket and ratchet handle to the nut of crank-
shaft pulley, and rotate the crankshaft in the normal
direction (clockwise when viewed from the front of the
engine).
(2) Stop rotating the crankshaft when "0" notch mark

stamped on crankshaft pulley is aligned with the timing
gear pointer. Turning socket
P/N:58309-73100
(3) Move No.1 cylinder inlet and exhaust valve rocker arm
No. 1 cylinder compression top dead center - Check
up and down. Make sure that the push rods are not
pushing the inlet and exhaust valves off their seats
(Both inlet and exhaust valves have valve clearance.).
3.1.2 Fuel injection timing - Check

(1) Bring the piston to the top, and check top dead center.
Remove the delivery valve holder, delivery valve, Delivery valve
holder
spring and stopper from the No. 1 cylinder of the fuel
Spring
injection pump, and reinstall the delivery valve holder
only.
Delivery valve
(2) Install a spare injection pipe to the No. 1 plunger of the
fuel injection pump. Face the other end of the injection
pipe to downward so that the fuel flow-out condition
can be seen clearly.
Fuel injection timing - Check (1)
(3) Rotate the crankshaft to 60 degree compression top
dead center of No. 1 cylinder.
(4) Feed the injection pump using the priming pump. With
flowing the fuel out from the injection pipe, rotate the
crankshaft gradually in the normal direction.
(5) When the fuel flow is getting fewer, rotate the crank-
shaft more slowly. When the fuel flow stop completely,
stop rotating the crankshaft.
(6) Make sure the pointer indicates the fuel injection timing
of the graduation mark on the crankshaft pulley.
Fuel injection timing - Check (2)
8-15
3.2 Fuel injection timing (distributor type fuel injection pump) - Inspect
When the fuel injection pump is replaced, confirm the fuel
injection timing after the replacement. To confirm it, bring
No. 1 cylinder piston to compression top dead center. Make
sure that the marks on the flange plate and the fuel injection
pump body are aligned.
(1) Remove the gear case cover.
Gear case cover
Gear case cover - Remove

(2) Attach the turning socket to the pulley nut and rotate
the crankshaft in the normal direction (clockwise as
Injection timing
viewed from the front end). 1-5-3-6-2-4
Turning angle:
120°

Socket for turning

P/N:58309-73100
Crankshaft - Rotate
(3) Stop rotating the crankshaft when the marks of the fuel
Camshaft gear Idler gear
injection pump gear and idler gear are aligned.

Fuel Injection
pump gear
Crankshaft gear Oil pump gear

Matching mark of gears
8-16
(4) Put the mark B on the flange plate where aligned with
the mark A of the fuel injection pump. B A
Matching mark of fuel injection pump
Flange plate Fuel injection

When removing the flange plate from the fuel injection pump
Front Plate
pump assembly, be sure to put a mark on the flange
plate before removal to ensure proper assembly. Bracket
(5) Unscrew the pump bracket retaining bolt and remove

the fuel injection pump from the front plate.
(6) Unscrew the mounting bolts of fuel injection pump, and
Bracket
remove the flange plate.
Fuel injection pump - Remove
(a) When changing parts, be sure to use our desig-

nated parts. Unless our designated parts are
used, the exhaust emission regulations cannot be
met.
(b) Take care that the parts may be partly modified
due to improvement, for example.
(c) Work related to the exhaust emission regulations
can be conducted only at our designated service
factories. However, do not change the adjustment
by cutting and removing the tamper-proofs on the
fuel injection pump assembly.
(d) Replace the fuel injection pump as assembly.
(7) Replace the fuel injection pump with a new one.
8-17
(8) Install the flange plate and the fuel injection pump gear
to the fuel injection pump. B A
(9) Align the mark A of the fuel injection pump with the
mark B which was marked above procedure (4) and
tighten the nut. Then install the retaining bolt to the nut.
Matching mark of fuel injection pump

(10)Install the fuel injection pump to the rear plate. Match
Camshaft gear Idler gear
the matching mark of fuel injection pump gear to the
idler gear matching mark.

Fuel Injection
pump gear
Crankshaft gear Oil pump gear

Matching mark of gears
(11)Install the gear case cover.
Gear case cover
Gear case cover - Install
8-18
1. Lubrication system - Remove and inspect............................................................ 9-3
2. Lubrication system - Disassemble, inspect and assemble ................................. 9-4
2.1 Oil pump - Disassemble and inspect ........................................................................................ 9-4
2.2 Oil pump - Inspect..................................................................................................................... 9-5
2.3 Oil pump - Assemble ................................................................................................................ 9-7
2.4 Oil cooler - Disassemble and inspect ....................................................................................... 9-8
2.5 Oil filter - Inspect....................................................................................................................... 9-9
2.6 Relief valve - Inspect .............................................................................................................. 9-10
3. Lubrication system - Install .................................................................................. 9-11
9-1
1. Lubrication system - Remove and inspect
With turbocharger
Replace
Replace Replace
3 2
When removing oil strainer,

refer to “DISASSEMBLY
OF BASIC ENGINE”.
When removing oil pump,

refer to “DISASSEMBLY 5
OF BASIC ENGINE”.
6
When removing oil pan,

refer to “DISASSEMBLY 4
OF BASIC ENGINE”.
Lubrication system - Remove and inspect

Removing sequence
1 Oil filter 4 Oil pan 7 Oil cooler
2 Relief valve 5 Oil strainer
3 Oil pump 6 Oil level gauge
9-3
2. Lubrication system - Disassemble, inspect and assemble

2.1 Oil pump - Disassemble and inspect
1 Replace
Oil pump - Disassemble and inspect

1 O-ring 2 Shaft assembly 3 Outer rotor 4 Pump case
9-4
2.2 Oil pump - Inspect

2.2.1 Clearance between inner rotor and outer rotor -
Measure
Measure the clearance between the inner rotor and outer
rotor. If the measured value exceeds the limit, replace the oil
pump with a new one. Thickness gauge
Item Standard Limit

Clearance between inner rotor 0.13 to 0.15 mm 0.20 mm
and outer rotor [0.0051 to 0.0059 in.] [0.0079 in.]
Clearance between outer rotor and inner rotor -

Measure
2.2.2 End play of rotor and pump case - Measure
Measure the end play of the rotor and the pump case. If Straight edge
measured value exceeds the limit, replace the oil pump with
a new one.
Item Standard Limit

End play of rotor and pump 0.04 to 0.09 mm 0.15 mm
case [0.0016 to 0.0035 in.] [0.0059 in.]
Thickness gauge
End play of rotor and pump case - Measure

2.2.3 Clearance between outer rotor and pump case -
Measure
Measure the clearance between the outer rotor and the pump
case. If measured value exceeds the limit, replace the oil
pump with a new one.
Thickness gauge
Item Standard Limit

Clearance between outer rotor 0.20 to 0.30 mm 0.50 mm
and pump case [0.0079 to 0.0118 in.] [0.0197 in.]
Clearance between outer rotor and pump case -

Measure
2.2.4 Clearance between shaft and pump case -
Measure Measuring
Measuring
Measure the diameter of the shaft and the inside diameter of directions directions
the bore in the pump case for the shaft to find the clearance
between the two. If the clearance exceeds the limit, replace Measuring
points Measuring
the oil pump assembly with a new one. points

Shaft outside ø16 mm 15.985 to 16.000 mm
-
diameter (Case side) [0.63 in.] [0.6293 to 0.6299 in.]
Clearance between 0.032 to 0.074 mm 0.150 mm
shaft and pump case [0.0013 to 0.0029 in.] [0.0059 in.] Clearance between shaft and pump case - Measure
9-5
2.2.5 Clearance between shaft and bushing

- Measure
Measuring Measuring
Measure the diameter of the shaft and the inside diameter of directions directions
the oil pump bushing in the crankcase. If the clearance
exceeds the limit, replace the bushing or the oil pump Measuring
assembly with a new one. points

Shaft outside
diameter ø14 mm 13.957 to 13.975 mm
Measuring
- points
(oil pump bushing [0.55 in.] [0.5495 to 0.5502 in.]
side) Clearance between shaft and bushing - Measure
Clearance between
0.025 to 0.111 mm 0.200 mm
shaft and oil pump
[0.0010 to 0.0044 in.] [0.0079 in.]
bushing
2.2.6 Oil pump bushing - Install

Crankcase
Oil pump bushing Flush
Install the oil pump bushing in the crankcase so that it
is even with the front face of the crankcase.
Install the oil pump bushing by using the oil pump bushing
installer.
Oil pump bushing installer Flush

P/N:32A91-00400
Oil pump bushing - Install
9-6
2.3 Oil pump - Assemble
Flush
Flush
Oil pump - Assemble
9-7
2.4 Oil cooler - Disassemble and inspect
Replace
Clogging, crack
Crack, deformation
1
2
Replace
Oil cooler - Disassemble and inspect

1 Oil cooler case 2 Oil cooler element
9-8
2.5 Oil filter - Inspect
When attaching, apply

engine oil to the gasket.
Clogged, cracks.
Oil filter - Inspect
9-9
2.6 Relief valve - Inspect

(1) Check the relief valve and valve seat for contact. Check
the spring for settling and damage. If any defects are
found, replace the relief valve with a new one.
(2) Measure the relief valve opening pressure. If the mea-
sured value does not meet the standard, replace the
relief valve with a new one.

44.1 ± 5 N·m 49 ± 4.9 N·m
0.35 MPa 0.35 ± 0.05 MPa
{4.5 ± 0.5 kgf·m} {5 ± 0.5 kgf·m}
Valve opening pressure {3.5 kgf/cm2} {3.5 ± 0.5 kgf/cm2}
[50.76 psi] [50.76 ± 7.25 psi] [33 ± 3.6 lbf·ft] [36 ± 3.6 lbf·ft]
Relief valve - Inspect
9-10
3. Lubrication system - Install
With turbocharger
Replace
Replace 49 ± 4.9 N·m

{5 ± 0.5 kgf·m} Replace
[36 ± 3.6 lbf·ft]
When installing oil strainer,
refer to “ASSEMBLY OF BASIC ENGINE”.
When installing oil pump,

refer to “ASSEMBLY
OF BASIC ENGINE”.
11.5 ± 1.5 N·m

{1.2 ± 0.1 kgf·m}
[8.5 ± 1.1 lbf·ft]
When installing oil pan,
78 ± 5 N·m
refer to “ASSEMBLY
{8 ± 0.5 kgf·m}
OF BASIC ENGINE”.
[57 ± 3.6 lbf·ft]
Lubrication system - Install
9-11
1. Cooling system - Remove and inspect................................................................ 10-3
2. Cooling system - Disassemble, inspect and assemble ..................................... 10-4
2.1 Thermostat - Disassemble and inspect .................................................................................. 10-4
2.2 Thermostat - Inspect............................................................................................................... 10-5
2.3 Water pump - Disassemble and inspect ................................................................................. 10-6
3. Cooling system - Install ........................................................................................ 10-7
10-1
1. Cooling system - Remove and inspect
10 11
Replace
Crack, deformation,
damage
Crack, deterioration, damage 9
7
Crack, water leakage,

damage
8
5
Replace
2 4
Crack, extension, wear,
3 damage
6
Cooling system - Remove and inspect

Removing sequence
1 Plate 5 Belt 9 Hose
2 Fan 6 Water pump pulley 10 Thermostat assembly
3 Spacer 7 Water pump assembly 11 Packing
4 Spacer 8 Packing
10-3
2. Cooling system - Disassemble, inspect and assemble

2.1 Thermostat - Disassemble and inspect
Replace
4
Replace
Thermostat - Disassemble and inspect

1 Cover assembly 2 Gasket 3 Thermostat 4 Thermostat case
10-4
2.2 Thermostat - Inspect
Valve lift (mm [in.])

Be very careful of hot water and flames.
9
Otherwise, you may get burned or cause a fire. [0.35]
(1) Immerse the thermostat in a container filled with water. 0 76.5 90

(2) Heat the water while measuring the water temperature. [170] [194]
Temperature (°C [°F])
Record the temperature at which the valve start to open,
and at which valve lift becomes the standard value.
Replace the thermostat if a deviation from standard
temperature is significant.
Note:(a) Stir the hot water to maintain even temperatures Thermostat - Inspect
during the test.
(b) At assembly, confirm the valve opening tempera-
ture stamped on its mounting flange.
Item Standard
Valve opening temperature 76.5 ± 1.5°C [169.7 ± 2.7°F]
Temperature at which valve lift
90°C [194°F]
becomes 9 mm [0.35 in.] or more
10-5
2.3 Water pump - Disassemble and inspect

deformation
Replace
Crack, water leakage, damage,

impeller and shaft rotation
3
Water pump - Disassemble and Inspect

1 Water pump cover 2 Packing 3 Water pump
10-6
3. Cooling system - Install

18.5 ± 1.5 N·m
{1.9 ± 0.1 kgf·m}
[13.6 ± 3.7 lbf·ft]
Crack, deformation,
damage Replace
Mounting bolt for

water pump and
cover (×3)
9.8 ± 1 N·m
{1 ± 0.1 kgf·m} Crack, deterioration, damage
[7.2 ± 0.7 lbf·ft]

damage
Replace
31.9 ± 2.4 N·m

{3.3 ± 0.2 kgf·m}
[23.5 ± 1.8 lbf·ft] Crack, extension, wear,
Mounting bolt for
damage
water pump
and crankcase (×5)
18.2 ± 3.4 N·m
{1.9 ± 0.3 kgf·m}
[13.4 ± 2.5 lbf·ft]
Cooling system - Install
10-7
1. Inlet and exhaust systems - Remove and inspect.............................................. 11-3
2. Inlet and exhaust systems - Disassemble, inspect and assemble ................... 11-5
2.1 Exhaust manifold distortion - Measure ................................................................................... 11-5
3. Inlet and exhaust systems - Install ...................................................................... 11-6
11-1
1. Inlet and exhaust systems - Remove and inspect
Without turbochager
4
Replace
Replace
Replace
Inlet and exhaust systems - Remove and inspect

Removing sequence
1 Breather hose 2 Air inlet elbow 3 Inlet manifold 4 Exhaust manifold
11-3
With turbochager
Replace Replace
4
A
5
1 8
Replace Replace
Replace
7
Replace 6
Inlet and exhaust systems - Remove and Inspect

Removing sequence
1 Oil return pipe 4 Turbocharger cover 7 Inlet manifold
2 Oil pipe 5 Turbocharger 8 Exhaust manifold
3 Air hose 6 Inlet elbow
11-4
2. Inlet and exhaust systems - Disassemble, inspect and assemble

2.1 Exhaust manifold distortion - Measure
(1) Check the flange for crack.
(2) Check the flange surface for distortion. If the distortion Straight edge
exceeds the standard, reface the surface or replace it
with a new one.
Item Standard
Exhaust manifold distortion 0.2 mm [0.008 in.] or less
Thickness gauge
Exhaust manifold distortion - Measure
11-5
3. Inlet and exhaust systems - Install
Without turbochager
Replace
18.5 ± 3.5 N·m
{1.9 ± 0.3 kgf·m}
[13.6 ± 2.5 lbf·ft]
Replace
Replace
Inlet and exhaust systems - Install
11-6
16.2 ± 2.4 N·m With turbochager

{1.6 ± 0.2 kgf·m}
Replace [12.0 ± 1.7 lbf·ft]
A
Replace
4 ± 1 N·m
{0.4 ± 0.1 kgf·m}
[3.0 ± 0.7 lbf·ft]
Replace Replace
18.5 ± 3.5 N·m

{1.9 ± 0.3 kgf·m}
[13.6 ± 2.5 lbf·ft]
Replace
Replace
Inlet and exhaust systems - Install
11-7
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
1.4 Magnetic valve (stop solenoid) - Remove and inspect ........................................................... 12-4
1.5 Glow plug - Remove and inspect............................................................................................ 12-4
2. Electrical system - Disassemble, inspect and assemble................................... 12-5
2.1 Inspection before disassembling starter ................................................................................. 12-5
2.2 Starter - Disassemble and inspect.......................................................................................... 12-7
2.3 Starter - Inspect and repair ................................................................................................... 12-10
2.4 Starter - Assemble ................................................................................................................ 12-14
2.5 Alternator - Disassemble and inspect ................................................................................... 12-17
2.6 Alternator - Inspect and repair .............................................................................................. 12-20
2.7 Alternator - Assemble ........................................................................................................... 12-22
2.8 Glow plug - Inspect and repair.............................................................................................. 12-24
2.9 Magnetic valve (stop solenoid) - Inspect and repair ............................................................. 12-24
3. Electrical system - Install.................................................................................... 12-25
3.1 Glow plug - Install ................................................................................................................. 12-25
3.2 Magnetic valve (stop solenoid) - Install................................................................................. 12-25
3.3 Stop solenoid - Install (in-line type fuel injection pump, RUN-OFF type).............................. 12-25
3.4 Alternator - Install.................................................................................................................. 12-25
3.5 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
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

Pay full attention when handling, as improper handling
could result in damage or failure.
(1) Never connect the battery terminal reverse. The B ter-
minal 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.
(6) When using a steam cleaner, be careful not to allow the
steam to come into contact with the alternator.
12-3
1.3 Alternator - Remove and inspect

(1) Remove the alternator.
(2) Remove the adjusting plate. Adjusting plate
Alternator
Alternator
bracket
Alternator - Remove and inspect
1.4 Magnetic valve (stop solenoid) - Remove and inspect
(1) Remove the wire assembly.
(2) Remove the magnetic valve. Wire assembly
Fuel Injection pump
Magnetic valve
assembly
Magnetic valve (stop solenoid) - Remove and inspect

1.5 Glow plug - Remove and inspect
(1) Loosen the fixing nut and remove the connection plate.
Connection plate
(2) Remove the glow plug.
Nut
Glow plug
Glow plug - Remove and inspect
12-4
2. Electrical system - Disassemble, inspect and assemble

2.1 Inspection before disassembling starter
2.1.1 Magnetic switch - Inspect
Inspect the magnetic switch as described below. If faulty,
replace the magnetic switch with a new one. Switch
Do not apply current continuously for longer than 10

seconds.
Battery
Pull-in test 12V
(1) Disconnect the connector of M terminal.

Remove the connector Starter
(2) Connect the starter to the circuit as shown in the illus-
tration. Pull-in test
(3) The magnetic switch is normal if the pinion pops out
when the switch is turned ON.
Holding test
(2) Connect the starter to the circuit as shown in the illus- Switch
tration.
(3) Turn ON the switch and pull out the pinion fully by
hand.
Battery
The magnetic switch is normal if the pinion does not
12V
return when it is released.
Starter
Holding test
Return test
(2) Connect the starter to the circuit as shown in the illus- Switch
tration.
(3) Turn OFF the switch and pull out the pinion fully by
hand. The magnetic switch is normal if the pinion
Battery
returns immediately when it is released. 12V
Starter
Return test
12-5
2.1.2 Test at no-load

Switch
(a) Use a thick wire and firmly tighten each terminal.

A Ammeter
(b) Be careful that the pinion pops out during opera-
tion when measuring the rotation speed at the tip
of the pinion. Battery V
24V Voltmeter
(1) Connect the starter to the circuit as shown in the illus-
tration.
(2) In normal condition, the pinion pops out when the
switch is turned ON, and the starter rotates at more than Test at no-load
the specified rotation speed. If the terminal voltage,
current or rotation speed does not meet the standard,
disassemble, inspect and repair the starter.
Item Standard
Starter model number M008T60373
Nominal output 24 V, 5.0 kW
Terminal voltage 23 V
No-load
Current 85 A or less
characteristics
Rotational speed 3300 min-1 or more
12-6
2.2 Starter - Disassemble and inspect
Open circuit, short circuit

of magnetic switch
18
16 Contamination,
17 Open circuit, seizing, wear
1
short circuit,
ground Replace
6
Wear, damage
Replace 14
Replace 8
7
12
13
Wear, damage Wear of
bearing hole
11 12
9 3
10
Replace
Function of 15 4 Brush dust deposit,
overrunning clutch uneven wear,
Replace brush movement inside
the holder, rust,
Open circuit, deterioration,
Replace short circuit of yoke insulated condition of
5 holder
Starter - Disassemble and inspect

1 Auxiliary switch 7 Ball bearing 13 Lever assembly
2 Magnetic switch assembly 8 Packing set 14 Pinion set
3 Rear bracket 9 Washer set 15 Overrunning clutch
4 Brush holder 10 Internal gear 16 Ball bearing
5 Yoke assembly 11 Gear shaft 17 Oil seal
6 Armature 12 Gear 18 Front bracket
12-7
2.2.1 Pinion set - Remove
SW1 B
The starter will generate heat if the current is being S
applied. Remove the pinion within 10 seconds. M
(1) Connect the starter to the circuit as shown in the illus- Battery SW2
tration. 24V
(2) Turn the switches SW1 and SW2 ON to move the pin- Disconnect lead wire with
terminal, which connected
ion out, and turn the SW2 OFF to stop the rotation of to M terminal.
the armature and the pinion.
(3) Place an appropriate tube on the pinion stopper. Tap the Connection to move the pinion forward
tube with a hammer to drop the pinion stopper to the
clutch side. This will expose the stopper ring.
(4) Remove the stopper ring with pliers and remove the
pinion. Overrunning
Note: Do not reuse the stopper ring and pinion stopper when clutch shaft
assembling.
Pinion stopper
Stopper ring
Pinion spring
Pinion
Pinion - Remove
2.2.2 Magnetic switch - Remove
(1) Remove the safety switch and the lead wire. Magnetic switch
(2) Remove the magnetic switch.
Magnetic switch - Remove

2.2.3 Rear bracket - Remove
(1) Remove the through bolts and brush holder screws.
Rear Bracket
(2) Remove the rear bracket.
Rear bracket - Remove
12-8
2.2.4 Brush holder and brush assembly - Remove

(1) Apply a socket (of the same diameter as the commuta- Brush holder
tor) to the commutator of the armature.
(2) Remove the brush holder and brush assembly by sliding
on the socket.
Brush holder and brush assembly - Remove

2.2.5 Armature and yoke assembly - Remove
(1) Remove the armature and yoke assembly. Yoke assembly
Lever
(2) Remove the packing from the internal gear.
(3) Remove the packing and plate on the lever support.
(4) Remove the ball from the internal gear.
(5) Remove the planetary gears. Planetary gear
Armature
Packing set
Ball
Armature and yoke assembly - Remove
2.2.6 Overrunning clutch - Remove
(1) Remove the E-ring.
Gear shaft
Note: Remove the gear shaft from the overrunning clutch as
following procedure because the spline part of gear
shaft is hooking into overrunning clutch.
(2) Shift the spline of gear shaft by a tooth with pressing
the gear shaft to the overrunning clutch.
(3) Remove the gear shaft from the overrunning clutch.
E-ring
Overrunning clutch
Overrunning clutch - Remove
Overrunning clutch
Gear shaft
Spline part
Spline of gear shaft
12-9
2.3 Starter - Inspect and repair

2.3.1 Magnetic switch coil - Inspect
B terminal
(1) Check for continuity between M terminal and the case. S terminal
If there is no continuity, replace the magnetic switch
with a new one.
(2) Make sure there is no continuity between the M termi-
nal and the B terminal. If there is continuity, replace the
magnetic switch with a new one.
M terminal
Magnetic switch coil - Inspect
2.3.2 Brush - Inspect for wear
Measure the length of the brushes.
If it is less than the limit, replace the brush holder assembly
and brush assembly with new ones. Measure the
height, and
replace parts
Item Standard Limit
if it is less than
Brush length 18 mm [0.71 in.] 11mm [0.43 in.] the limit.
Brush - Inspect for wear

2.3.3 Brush spring load - Inspect
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

29.2 to 39.4 N {3.0 to 4.0 kgf} 13.7 N {1.4 kgf}
Brush spring load
[6.56 to 8.86 lbf] [3.08 lbf]
Brush spring load - Inspect

2.3.4 Brush holder for insulation - Inspect
Check the isolation between the brush holder and the brush Insulated brush holder
holder base. If there is continuity, replace the brush holder
assembly with a new one.
Check the brush holders for looseness.
Brush holder base
Brush holder for insulation - Inspect
12-10
2.3.5 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
ø 32.0 mm [1.26 in.] 31.4 mm [1.236 in.]
diameter
Commutator outside diameter - Measure

2.3.6 Commutator runout - Measure
(1) Inspect the commutator surface. If the surface is rough,
polish it using a 400 to 600 grit sandpaper.
(2) Measure the commutator runout with a dial gauge.
If the measured value exceeds the limit, replace the
armature with a new one.
Item Limit
Commutator runout 0.10 mm [0.0039 in.] Commutator
Commutator surface - Polish

2.3.7 Undercut depth - Measure
Measure the depth of undercutting between the commutator
segments. If the measured value is less than the limit, repair Undercut
or replace the commutator. Segment

Mica
Item Standard Limit
Undercut depth 0.5 mm [0.0197 in.] 0.2 mm [1.236 in.]
Undercut depth - Measure

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

(1) Inspect the armature coil using a growler tester.
Iron plate
Place the armature on a growler tester, and attach a thin
sheet of iron (e.g. teeth of a saw) to the core of arma-
ture.While holding the iron sheet, rotate armature
slowly one revolution by hand. If the coil is shorted, the Growler tester
iron plate is sucked on that position.
If the coil is shorted, replace the armature with a new
one.
Armature coil - Check for short circuit

(2) Check that the commutator and the shaft (core) are iso-
lated. If there is continuity, replace the armature with a
new one.
Commutator and shaft (core) isolation - Inspect

(3) Check that there is continuity between each segment. If
there is no continuity, replace the armature with a new
one.
Continuity between segments - Inspect

2.3.10 Rear bracket - Inspect
If the rear bearing box becomes worn, replace a rear bracket
with a new one.
2.3.11 Overrunning clutch operation - Inspect
The overrunning clutch is coated with grease, thus, do

not wash it in wash oil.
Make sure that, when attempting to turn the overrunning

clutch, it locks in one direction and rotates smoothly in the
opposite direction.
Overrunning clutch operation - Inspect
12-12
2.3.12 Starter gear - Inspect

Inspect each starter gear. If it is worn or damaged, replace
the gear with a new one.
12-13
2.4 Starter - Assemble
9.8 +20 N·m

{1 +0.2
0 kgf·m} Apply Multemp #6129
[7 +1.4
0 lbf·ft]
Apply Multemp OA-171
Apply Molykote AG650 Apply Multemp #6129
Starter - Assemble
Note: Be sure to use proper harness.

If the harness is modified, the starter will not function properly.
12-14
2.4.1 Gear shaft - Install

Gear shaft
(1) Put the washer, internal gear and overrunning clutch
through the gear shaft. Washer
(2) Shift the spline of gear shaft by a tooth. Internal gear
(3) Pull the overrunning clutch.
(4) Make sure the overrunning clutch does not come off
from the gear shaft.
(5) Install the E-ring. E-ring
Overrunning clutch
Gear shaft - Install
Overrunning clutch
Gear shaft
Spline part
Spline of gear shaft

2.4.2 Pinion - Install
(a) Before assembling, apply grease to the inner race

groove of the front bracket bearing. Overrunning
(b) Be sure to use a new stopper ring and pinion stop- clutch shaft
per. Do not reuse the stopper ring and pinion stop-
per that has been removed. Pinion stopper
Stopper ring
(1) Put the overrunning clutch through the front bracket. Pinion spring
(2) Install the pinion spring, pinion and pinion stopper in Pinion
this order onto the shaft of the overrunning clutch. Pinion - Install
(3) Install the stopper ring firmly to the shaft groove of
overrunning clutch.
(4) Using a gear puller, firmly pull the pinion stopper
closer to the stopper ring to fix.
2.4.3 Yoke and armature - Install

(1) Install the planetary gears on the gear shaft. Yoke assembly
Lever
(2) Install the plate and packing.
(3) Install the yoke on the front bracket.
(4) Apply grease to the armature shaft end and install a ball
on it. Planetary gear
(5) Install the armature.
Armature
Packing set
Ball
Yoke and armature - Install
12-15
2.4.4 Brush holder and brush assembly - Install

(1) Attach the socket to the commutator of the armature. Brush holder
(2) While sliding the brushes on the socket, install the
brush holder and brush assembly on the armature.
Brush holder and brush assembly - Install
12-16
2.5 Alternator - Disassemble and inspect
seizure
5
Rotation condition
10
3 12
Rotation condition
Crack, damage 11
2
Crack, damage
7
Deformation,
damage
Short circuit,
6
open circuit
8
Broken wire and ground of coil
coil resistance
Alternator - Disassemble and inspect

1 Nut 5 Rotor assembly 9 Regulator assembly
2 Pulley 6 coil 10 Rectifier assembly
3 Through bolt 7 Stator 11 Nut set and bolt
4 Front bracket assembly 8 Rear bracket
12-17
2.5.1 Stator and Front bracket - Separate

Rear bracket
(a) Disassembly of alternator should be conducted

only when repair is necessary.
(b) Use care not to insert the screwdriver deeply. Oth-
erwise its tip may damage the stator.
(1) Remove the through bolts.

(2) Insert the tip of a flat-blade screwdriver between the
stator and front bracket, and separate them each other. Stator core Front bracket
Stator and Front bracket - Separate

2.5.2 Field coil - Remove
(a) When removing the field coil, be sure to observe

the removal order of screws. If removed in wrong Screw B
order, the outgoing line of the field coil will be
damaged.
(b) If all the screws are removed, the coil will drop by
its own weight. Be careful not to let the coil drop.
(c) When removing the field coil, the exit of the coil
Screw A
may be caught with the stator. Do not pull the coil
Field coil - Remove
forcibly.
(1) Remove screw A.

(2) Remove screw B.
(3) Remove the field coil.
2.5.3 Pulley - Remove
Pulley assembly
When holding a rotor with a vise, be sure to hold at the

base of claw with a vise. Holding the tip of claw can Front bracket
cause damage.
(1) Wrap the rotor in cloth and clamp it in the vise.

(2) Remove the pulley nut, and then pull out the pulley
assembly.
(3) Remove the rotor from the front bracket. Rotor
Pulley - Remove
2.5.4 Rear bearing - Remove
Using the bearing puller, remove the rear bearing from the Rotor
Rear bearing
rotor.
Rear bearing - Remove
12-18
2.5.5 Front bearing - Remove

Remove the screw, and remove the bearing retainer and the Front bearing Front
front bearing from the front bracket. Screw bracket
Bearing retainer
Front bearing - Remove

2.5.6 Stator - Remove
The solder must be removed in a short time. If the

heat is applied for a long time, the diode will be dam-
aged.
Melt the solder of stator and rectifier, and remove the stator
from the rectifier. Stator core
Rectifier
Soldering
Stator - Remove
2.5.7 Regulator assembly - Remove
Screws
(1) Remove the screws from the regulator assembly.
(2) Remove the regulator assembly. Regulator
assembly
Rectifier
assembly
Soldering
Regulator assembly - Remove
2.5.8 Rectifier assembly - Remove
(1) Remove the screws and nuts from the rectifier. Rear bracket
(2) Remove the rectifier assembly.
Rectifier
Mould
Nut
Regulator assembly
Rectifier assembly - Remove
12-19
2.6 Alternator - Inspect and repair

2.6.1 Stator - Inspect
(1) Conduction of stator terminals - Inspect Terminal 2
Terminal 3
Make sure the terminals shown in the illutration are
conducted.If there is no continuity, replace the stator Terminal 1
with a new one.
Inspection items
Terminal 1 and Termimal 2
Terminal 2 and Terminal 3
Terminal 2 and Terminal 4
Conduction of stator terminals - Inspect

(2) Insulation between terminal of stator coil and core -
Terminal 2
Inspect Terminal 3
Make sure the terminal 2 of stator coil and the stator
core are isolated. If there is continuity, replace the stator Terminal 1
with a new one.
Insulation between terminal of stator coil and core -

Inspect
2.6.2 Rectifier - Inspect
Check continuity or isolation between diodes using an ana-
log tester.
If inspected result does not match the table below, replace D F
the rectifier with a new one.
Polarity of tester
Condition
Negative (-) Positive (+)
A C
G Conducted B E
A,B,C,D
E Isolated
G Isolated
A,B,C,D Rectifier - Inspect
E Conducted
F A,C,D Isolated
A,C,D F Conducted
Note: A,B,C,D: Stator coil lead wire connection portion

E,G: Heatsink portion
F: Regulator connection portion
12-20
2.6.3 Rotor - Inspect

(1) Check for conduction between slip rings. If isolated,
replace the rotor with a new one.
Conduction between slip rings (rotor coil) - Inspect

(2) Check that the slip ring and the shaft (or core) are iso-
lated. If there is continuity, replace the rotor with a new
one.
Isolation between slip rings and shaft - Inspect

2.6.4 Field coil - Measure
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]) 6.1 to 7.1 ohm
Field coil - Measure
12-21
2.7 Alternator - Assemble
147 ± 15 N·m
{15 ± 1.5 kgf·m}
[108.4 ± 11.0 lbf·ft]
Alternator - Assemble
Note: Be sure to use proper harness.

If the harness is modified, the alternator will not function properly.
12-22
2.7.1 Rectifier assembly and

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

Regulator assembly - Install
2.7.2 Stator - Install
Solder must be applied in a short period of time. If the

heat is applied for a long time, the diode will be dam-
aged.
(1) Install the stator.

(2) Solder the lead wire of stator to the rectifier. Stator core
Rectifier
Soldering
Stator - Install
2.7.3 Front bearing - Install
(1) Install the front bearing to the front bracket. Front bearing Front
(2) Secure the bearing retainer with the screw. Screw bracket
Bearing retainer
Front bearing - Install

2.7.4 Rear bearing - Install
Install the rear bearing to the rotor. Rotor
Rear bearing
Rear bearing - Install
12-23
2.7.5 Pulley - Install

Pulley assembly
(1) Insert the rotor to the front bracket.
(2) Wrap the rotor in cloth and clamp it in a vise.
(3) Install the pulley assembly and secure it with the nut. Front bracket
Rotor
Pulley - Install
2.8 Glow plug - Inspect and repair
2.8.1 Heating test of glow plug
Connect the wiring to the terminal and ground the body as
shown in the illustration. If the glow plug heats red, it is nor-
mal.
Item Standard Remarks

Rated voltage - +0.3
44 -0.7 A Apply DC22 V for 15 seconds.
armature current
Heating test of glow plug

2.9 Magnetic valve (stop solenoid) - Inspect and repair
2.9.1 Conduction test of magnetic valve
(stop solenoid) - Inspect
Test the resistance between the terminal and body as shown
in the illustration. If isolated or if the resistance is lower
than the standard value, replace the magnetic valve assem-
bly with a new one.
Item Standard
Resistance 37 ohm
Conduction test of magnetic valve

2.9.2 Magnetic valve (stop solenoid) operation
- Inspect
Check visually for rubber strips of the tip of the armature
and damages. Also, check the armature moves smoothly by
rotating with a hand.
Armature
Magnetic valve operation - Inspect
12-24
3. Electrical system - Install

3.1 Glow plug - Install
(1) Install the glow plug, and tighten it to the specified
torque. Connection plate
(2) Install the connection plate and tighten the fixing nuts Nut
to the specified torque. 1.23 ± 0.24 N·m
{0.13 ± 0.02 kgf·m}
[0.96 ± 0.18 lbf·ft]
17.2 ± 2.4 N·m

{1.75 ± 0.24 kgf·m}
[12.7 ± 0.17 lbf·ft]
Glow plug
Glow plug - Install

3.2 Magnetic valve (stop solenoid) - Install
Install the magnetic valve assembly to the injection pump
distributor head with the specified torque. Magnetic valve
assembly
20 ± 5 N·m
{2 ± 0.5 kgf·m}
[15 ± 3.6 lbf·ft]
Injection pump
distributor head
Magnetic valve (stop solenoid) - Install

3.3 Stop solenoid - Install (in-line type fuel injection pump, RUN-OFF type)
(1) Install the stop solenoid to the solenoid bracket.
RUN 44.8 mm [1.764 in.]
(2) After installing the stop solenoid, energize the stop STOP 34.8 ± 0.4 mm
solenoid again to check that the stop solenoid operates [1.374 ± 0.016 in.]
normally.
Stop lever
Stop solenoid
35°
STOP 50° RUN
Stop solenoid - Install
3.4 Alternator - Install
(1) Install the adjusting plate.
(2) Install the alternator. Adjusting plate
Alternator
Alternator
bracket
Alternator - Install
12-25
3.5 Starter - Install

(1) Install the starter.
Starter terminal B
(2) Connect the harness, and tighten the fixing nut to the 9.8+20 N·m
specified torque. {1+0.2
0 kgf·m}
[7.2+1.4
0 lbf·ft]
Starter
45 ± 15 N·m
{4.6 ± 1.5 kgf·m}
[33 ± 11 lbf·ft]
Starter - Install
12-26
1. Engine - Adjust ...................................................................................................... 13-3
1.1 Valve clearance - Check......................................................................................................... 13-3
1.2 Fuel system - Drain................................................................................................................. 13-3
1.3 Fuel system - Bleed air ........................................................................................................... 13-4
1.4 Belt and belt tension - Inspect and adjust............................................................................... 13-5
2. Break-in operation ................................................................................................. 13-6
2.1 Engine start-up ....................................................................................................................... 13-6
2.2 Break-in operation .................................................................................................................. 13-6
3. Performance test ................................................................................................... 13-7
3.1 Engine equipment condition ................................................................................................... 13-7
3.2 Test items and purposes ........................................................................................................ 13-7
3.3 Other inspections.................................................................................................................... 13-7
3.4 Engine output adjustment ....................................................................................................... 13-7
13-1
1. Engine - Adjust
1.1 Valve clearance - Check
Check the valve clearance.
If it is unadjusted, adjust it to the standard value.
For the adjusting procedures, refer to "Valve clearance -
Inspect and Adjust" of "ASSEMBLY OF BASIC ENGINE.
"
1.2 Fuel system - Drain
(a) When draining the fuel filter, fuel flows out

together with the water. Wipe off any spilled fuel.
Spilled fuel can cause fires.
(b) Tighten the drain plug securely after draining the
water. Failure to do so could cause a fire.
If water trapped in the bottom of the fuel filter exceeds the
specified level, the water may enter into the fuel system.
1.2.1 Fuel filter - Drain
(1) Loosen the drain plug on the bottom of the fuel filter.
(2) Water is easily drained by pressing the priming pump
repeatedly (approx. 7 times) to feed the fuel.
(3) Tighten the drain plug securely after draining the water.
(4) Always bleed the air in the fuel system after draining
the water.
Drain plug
Fuel filter - Drain (1)
Priming pump
Fuel filter - Drain (2)
13-3
1.3 Fuel system - Bleed air
Wipe off fuel spilled from the air vent plug thoroughly
with a cloth. Be sure to tighten the air vent plug after
air bleeding. Failure to do so could cause a fire.
1.3.1 Fuel filter - Bleed air
(in-line type fuel injection pump) Filter for in-line type
air vent plug Priming button
(1) Loosen the air vent plugs of the fuel filter by approx.
1.5 turns.
(2) Unlock the priming pump cap by turning it counter-
clockwise, then move the cap up and down repeatedly.
(3) When fuel flowing from the vent holes no longer con-
tains air bubbles, loosen the air vent plugs.
Fuel feed pump
Fuel filter - Bleed (in-line type fuel injection pump)

1.3.2 Fuel injection pump - Bleed (in-line type fuel
Air vent plug
injection pump)
(1) Loosen the air vent plugs of the fuel injection pump by
approx. 1.5 turns.
(2) Move the cap up and down repeatedly.
(3) When fuel flowing from the vent holes no longer con-
tains air bubbles, the air vent plugs should be tightened.
However, before tightening the last air vent plug, lock
the priming pump by turning the cap clockwise while
pushing it down. Priming pump
Fuel injection pump - Bleed air
(4) Follow the same procedure for the fuel injection pumps
(in-line type fuel injection pump)
on both right and left sides.
Note:(a) If all the vent plugs are tightened before the priming
pump cap is locked, fuel pressure acts on the feed
pump, making it impossible to return the cap to the
original position.
(b) Wipe off fuel spilled from the air vent plug thor-
oughly.
13-4
1.3.3 Fuel filter - Bleed air

(distributor type fuel injection pump)
(1) Loosen the air vent plug of the fuel filter with a wrench.
(2) Repeatedly press the priming pump with the cloth
applied to the air vent plug. When fuel with air bubbles
no longer comes out, tighten the air vent plug securely.
(3) Be sure to tighten the air vent plug after air bleeding.
Air vent plug
Fuel filter - Bleed (1)
Priming pump
Air vent plug
Fuel filter - Bleed (2)

1.4 Belt and belt tension - Inspect and adjust
If any defects such as cuts or surface separations are found during inspection, replace the belt with a new one.
Keep oil and grease off the belt. Oil or grease on the belt causes 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 below:
1.4.1 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 belt.
Inspect the belt deflection by pressing it with approx. 98 N {10 kgf} [22 lbf] force at the center of its span. The belt deflec-
tion should be 12 mm [0.47 in.].
If the deflection is out of standard, adjust the belt tension.
1.4.2 Belt tension - Adjust
98 N
(1) Loosen all retaining bolts of the alternator and adjusting rox.
App 0 kgf} Water pump
Adjusting bolt {1 lbf]
plate. [22 pulley
(2) Adjust belt tension properly.
(3) Tighten all retaining bolts of the alternator and adjust- mm
Adjusting 12 in.]
ing plate. . 4 7
plate [0
Alternator Crankshaft
pulley pulley
Fixing bolt
Belt tension - Adjust
13-5
2. Break-in operation
2.1 Engine start-up
(1) Before starting the engine, check the levels of fuel, engine oil and coolant, and then bleed the fuel system and cooling sys-
tem.
(2) Stop the fuel supply, and crank the engine with the starter for 10 seconds to lubricate the engine.
(3) Move the control lever slightly in the fuel increase direction (but not to the "full injection" position), and then turn the
starter switch key to the [START] position to start the engine.
(4) After the engine has started, adjust the control lever to let the engine operate at a minimum no-load speed (low idle speed).
(5) Turn the starter switch key to the [OFF] position and make sure that the engine is stopped.
2.2 Break-in operation
To prepare for unforeseeable circumstances during engine operation, make sure that an emergency stop is avail-
able.
2.2.1 Break-in operation load and operation time

The load during break-in operation should be increased progressively as shown in the table.
Note that the time shown in the table is the minimum time required to check the engine in a stable condition.
Break-in operation
Time
Rotation speed (min-1) Load (PS)
(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
4 25 % 20
5 50 % 20
Rated speed
6 75 % 30
7 100 % 20
2.2.2 Inspection while the engine is running

During the break-in operation, pay attention to the following and make sure there are no abnormalities.
Oil pressure and oil temperature Exhaust temperature
Coolant level and water level Blow-by gas (amount and color)
Any leakage of oil, water, fuel, and gas (air) Rotational fluctuation
Noise and vibration Face and radial runouts of rotating parts
Intake air pressure and intake air temperature Indication and operation of meter and alarm
Exhaust color and odor
2.2.3 Inspection and adjustment after break-in opera-
tion
Valve clearance Belt tension
Fuel injection timing Inspection of defects such as oil leakage, and repair
Bolts and nuts around the engine - Retighten
13-6
3. Performance test
The following describes the procedures specified in "Earth
moving machinery - Engines - Part 1: Test code of net
power (JIS D0006-1)" and "Earth moving machinery -
Engines - Part 2: Standard format of specifications and test-
ing methods of diesel engines (JIS D0006-2)." Other test
items may be required in some applications. All test results
should be evaluated comprehensively in order to determine
the engine performance.
3.1 Engine equipment condition
The engine must be equipped with standard auxiliary
devices such as cooling fan, air cleaner and alternator.
3.2 Test items and purposes

3.2.1 Operation load test
Conduct this test to evaluate the engine output, torque, fuel
consumption rate and governor performance under various
load conditions.
3.2.2 Continuous load test
Operate the engine continuously for 10 hours at 90% load
(continuous load application) of nominal net brake power
while the engine speed is maintained at revolutions corre-
sponding to the nominal brake power. In this test, evaluate
the fuel consumption rate and operating condition, and con-
firm that the engine is capable of continuous operation.
3.2.3 No-load minimum engine speed test
Conduct this test to confirm that the engine can operate sta-
bly at the specified no-load minimum engine speed.
3.3 Other inspections

Check for gas, coolant and oil leaks; abnormal odors; and
hunting. Make adjustments as needed.
3.4 Engine output adjustment

Diesel engine output is affected by atmospheric pressure,
temperature and humidity. Therefore, correction calcula-
tions must be performed to obtain the value of engine output
under the standard atmospheric conditions.
3.4.1 Standard atmospheric conditions
Base temperature: 298 K (25°C) [77°F]
Total pressure: 100 kPa (750 mmHg)
Dry pressure: 99 kPa (743 mmHg)
13-7
3.4.2 Calculation of corrected power

Multiply the measured brake power or torque by the calcu-
lated diesel engine correction factor to obtain a corrected
value. If the applicable range of the correction formula is
exceeded, indicate the corrected values and record the test
conditions on the test record.
Calculation output = Correction factor ( ) × Measured brake power

Atmospheric conditions during test
Temperature( ):283 K(10°C)[50°F] T 313 K(40°C )[104°F]
Dry atmospheric pressure( ):80 kPa(600 mmHg) 110 kPa(825 mmHg)
=( ) :Atmospheric factor :Engine factor
Range of correction equation use

The range of correction factor ( ) is as follows:
0.9 1.1.
Calculation of engine factor ( )
Calculation of correction factor ( ) =0.036 -1.14
Natural aspiration engine and engine with :Corrected fuel supply volume
mechanically driven air charger =
99 0.7
=( )·( ) ( ) × (Fuel flow rate g/s)
298 =
(Stroke volume ) × (Engine speed min-1)
Turbocharged engine without air cooler = 120000 (4-cycle engine)
or with air-to-air cooler :Ratio between pressure at turbocharger or
99 0.7 1.2 air cooler outlet and atmospheric pressure
=( ) ·( )
298 ( =1 for natural aspiration engine)
Turbocharged engine with air-to-liquid · Applicable range of engine factor ( )
cooler 37.2 65mg/( -cycle)
99 0.7 0.7 · 37.2mg/(l -cycle): =0.2 (constant)
=( ) ·( )
298 · 65mg/( -cycle) : =1.2 (constant)
13-8
February 2010 SERVICE MANUAL for CHINA FOLKLIFT TRUCK STD. Pub. No. 99619-33100
Printed in Japan Pub. No. 99619-33100

Manuel Reparation Moteur

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SERVICE MANUAL

for CHINA FORKLIFT TRUCK STD.

How to use this manual

Terms used in this manual

Keep fire extinguishers and first-aid kit

Stay away from 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

Service battery When abnormality occurs

Never modify engine Warm-up the engine before use

occur. but also excessive carbon deposits inside the engine.

ers. It is highly recommended to calculate the required

Maintenance of warning labels

Tips on disassembling and assem- Tips on 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 8 FUEL SYSTEM

Chapter 10 COOLING SYSTEM

Chapter 11 INLET AND EXHAUST SYSTEMS

Chapter 12 ELECTRICAL SYSTEM

Chapter 13 ADJUSTMENT AND OPERATION

Fuel filter Oil level gauge

Coolant drain plug

Fuel injection pump

Engine left view

Engine right view

1.2 S6S (distributor type fuel injection pump) external view

Oil level gauge

Water pump Coolant drain plug

Magnet valve Oil filter

Fuel injection pump

Engine oil drain plug

Engine left view

Engine right view

1.3 S6S-T (distributor type fuel injection pump) external view

Water pump Coolant drain plug

Fuel injection pump

Engine left view

Oil filler Oil filler

Engine right view

2. System flow diagrams

Fuel filter Fuel leak-off pipe

Fuel injection nozzle

Fuel return pipe

Fuel injection pump

Outline of fuel system

2.1.2 Distributor type fuel injection pump

Fuel injection nozzle

Fuel injection pump

Outline of fuel system

2.2 Outline of lubrication system

Push rod Piston Crankshaft

Oil strainer Oil pan

Outline of lubrication system

2.2.2 Distributor type fuel injection pump