DIESEL ENGINE FOR MARINE USE | WORKSHOP MANUAL W04D,W04C-T,WO04C-TI Hino Motors,Ltd.FOREWORD procedures on Hino Marine Engine, This workshop manual has boen prepared to provide information covering rep Applicable models: WO4D, WO4C-T, and WOSC-T1 a When marking eny repair of your engine, be careful not to be injured through improper procedures. ‘As for maintenance itams, refer to tho Operation Hand Book. All information and specifications in this manual are bated upon tho latest product information available at the ti of printing. Hino Motors reserves the right to make changes at any time without prior notice. HINO MOTORS, LTD.* INDEX: ENGINE GROUP GENERAL a Ying INTRODUCTION ENGINE Y RKSHOP FOU a TURBOCHARGER a INJECTION PUMP INJECTION PUMP. GOVERNOR GENERATOR | STARTER | INJECTION PUMP CALIBRATION TORS, LTD. [reserved. This manual may not be J or copied in whole or in part, with- {ritten consent of Hino Motors, Ltd.GENERAL INTRODUCTION Gi G1-156E-01 CHAPTER Gi GENERAL INTRODUCTION GENERAL PRECAUTIONS «22.2... eee eeeeee eee GhZ HOW TO USE THIS WORKSHOP MANUAL .............. G13 IDENTIFICATION INFORMATION ...........00.0002006.Gh4 SPECIFICATIONS ..........., TIGHTENING TORQUE OF STANDARD BOLT . RECOMMENDED LUBRICANTS.............00000e00e G16Giz GENERAL INTRODUCTION GENERAL PRECAUTIONS ‘Some recommended and standard maintenance services for your engine are mentioned in this section. |When performing maintenance on your engine be careful not to get injured by improper work, Improper or incomplete work can cause 2 malfunction of the engine which may result in personal injury and/or property amage. WARNING ‘When working on your engine, observe the following general precautions to prevent personal injury and/or property damage in addition to the particular NOTES or WARNINGS. Most threaded fasteners are metric. | Be careful not to mix with threaded fasteners using the inch system. Always wear safety glasses or goggles to protect your eyes. Remove rings, watches, ties, loote hanging jewelry and loose clothing before starting work on the engine, Bind long hair securely behind the head. 0000 ‘To avoid serious burns, keep yourself away from hot metal parts such as the engine, exhaust manifold, radiator, muftler, exhaust pipe and tail Keep yourself, your clothing and your tools away from moving parts such as the cooling fan and V-belts when the engine is running. Always stop the engine by pulling out the engine stop knob. Leave the knob pulled out as long os the engine is stopped. And turn off the starter switch, unless the operation requires the engine running, Removing the key from the switch Is recommended, Run the engine only in a well-ventilated area to avoid inhaling of carbon monoxide. Do not smoke while working on the engine since fuel and gases from the battery are flammable, ‘on the battery. It contains corrosive sulfuric acid. Take utmost care when wor 0000 curtent flows through the battery cable and starter cable, Be careful not to cause a short which Large elect ccan result in personal injury and/or property damage. Be careful not to leave any tool in the engine compartment. The tool may be hit by moving parts and can ‘cause personalDESCRIPTION EXAMPLE: T= 190-260 (14-18) ere Ae 6 S T= 1100-1300 (0-98 Ys. xt) £20 1, Thrust bearing 5. Bushing 2. Camshaft gear 6 3, Oil pump. 1 4, Idler gear T=1,100-1,300 =e a 8 Ieler goar thrust plate Straight pin 8, Idler gear shaft GENERAL INTRODUCTION Gia HOW TO USE THIS WORKSHOP MANUAL. This workshop manual is designed as 2 guide for servicing engine An INDEX is provided on the fiest page of each chapter. ‘TROUBLESHOOTING is dealt with each chapter. When beginning operations, eter to the sections on for guide t0 appropriate diagnoses, SPECIAL TOOLS are dealt with in each chapter When ordering a special tool, make sure that the parts number PART NUMBER. REPAIR PROCEDURES. Repair procedures which are self-explanatory such as simple installation and removal of parts have been omitted. Illustra tions such as the one below have been provided to make such simple procedures clear. Only essential procedures requiring directions have been dealt with explicitly TIMING GEAR AND CAMSHAFT 1 ¢ |. 2 ‘T= Tightening torque kg:cm (lb-ft) 13, Front end plete gatket 14, Front end plate 8, Crankshaft gear 10. Injection pump drive gear 11, Alor goar thrust plats 12, CamshaftG4 GENERAL INTRODUCTION In tome cases, illustrations may be of parte which differ in some nonessential way from the parts found on your par ticular engine, In such cases, however, the principale or procedure being illustrated applies regardless of euch "on: essential differences, IDENTIFICATION INFORMATION ENGINE SERIAL NUMBERS Please quote these numbers when ordering spare parts or reporting technical matter as they will give you prompt service attention The engine serial number it engraved on the engine cylinder blockGENERAL INTRODUCTION Gis SPECIFICATIONS DIESEL ENGINE FOR MARINE USE HINO = WO4D wees: © ENGINE DESCRIPTION 1. Max. output, pleasure craft 82 kW ( 110HP)/3,000 rpm 2, Max, ourput, work boat 69 kW (92 HP)/3,000 rpm (light duty) 3. Type Diesel, 4-cycle, 4-cyl,, in-line, over-head valve, water-cooled 4. Aspiration Natural aspirate 5. Combustion system Direct injection 6. Cylinder Bore x Stroke 104 x 118 mm (4.09 x 4.66 in.) 7. Piston displacement 4,009 liter {244.6 cu.in.) 8. Compression ratio 179 9. Direction of rotation Counter-clockwise viewed from flywheel 10. Dimensions without marine gear (Lx Wx H) Approx, 1,026 x 691 x 780 mm (40.4 x 27.2x 31.1 in.) 11. Dry weight without marine gear Approx. 385 kg (850 Ib) @ FEATURES 1. Cylinder block Mono block cast iron with replaceable dry liner 2. Cylinder head Single piece cast iron 3. Crankshaft Induction hardened die forged special steel with counter weights 4, Piston and rings Heat resistance aluminum alloy Two compression rings, chrome plated One oil ring, chrome plated with coll expander 5. Camshaft Induction hardened carbon stee! 6. Valves Heat resistance steelGis GENERAL INTRODUCTION @ EQUIPMENT + ENGINE 1, Flywheel housing SAE No.3 2, Flywheel SAE 11% 3, Fuel injection pump BOSCH ” A” type with all speed governor 4. Fuel filter Paper element type 5, Water separator Equipped 6. Lube oil pump Full forced pressure feed by gear pump 7. Lube oil filter Paper element type (Full flow) 8. Lube oil cooler Multi plate type, Fresh water cooled 9. Fresh water pump Forced-circulation by volute pump 10, Raw water pump Self priming, Rubber impeller type 11, Intake manifold Inlet position at rear, with air cleaner 12, Exhaust manifold Fresh water-cooled exhaust manifold, integrated heat exchanger with expansion tank 13. Starter 12V, 2.5 KW 14, Alternator 12V, SOA, with built-in voltage regulator 15. Engine stop solenoid Equipped 16. Emergency stop relay Equipped 17, Starter block relay Equipped 18. Glow plug Equipped 19, Rigid mount bracket Equipped 20, Exhaust riser Cooled by raw water ‘* INSTRUMENT PANEL, Px~PNseNa 9. 10. " 12. Battery switch Starter switch with key Instrument panel lamp switch Tachometer (with hourmeter and trip meter} Coolant temperature geuge Oil pressure gauge Fuel gauge Volt meter Pre-heater indicator lamp Coolant temperature warning lamp Charge warning lamp Oil pressure warning lampMemoMemoGENERAL INTRODUCTION Gig SPECIFICATIONS DIESEL ENGINE FOR MARINE USE 3.899 liters, d-cycie, HINO Tice turbocharged © ENGINE DESCRIPTION 1. Max, output, pleasure craft 112 kW (160 HP)/3,000 rpm 2. Max. output, work boat 93 kW (125 HP)/3,000 rpm (light duty) 3. Type Diesel, 4-cycle, 4-cyl,, in-line, over-head valve, water-cooled 4. Aspiration Turbocharged 5, Combustion system Direct injection 6. Cylinder Bore x Stroke 104 x 113 mm (4.09 x 4.45 in.) 7. Piston displacement 3.839 liter (234.2 cu.in.) 8. Compression ratio 179 8. Direction of rotation Counter-clockwise viewed from flywheel 10. Dimensions with marine gear (Lx Wx H) Approx. 1,134 x 661 x 780 mm (44.6 x 26.0 x 31.1 in.) 11. Dry weight with marine gear Approx, 465 kg (1,025 tb) * FEATURES 1. Cylinder block Mono block cast iron with replaceable dry liner 2. Cylinder head Single piece cast iron 3. Crankshaft Induction hardened die forged special steel with counter weights 4, Piston and rings Heat resistance aluminum alloy Two compression rings, chrome plated One oil ring, chrome plated with coil expander Camshaft Induction hardened carbon steel Valves Heat resistance steel 2gia GENERAL INTRODUCTION @ EQUIPMENT ¢ ENGINE 1. Flywheel housing SAE No. 3 2. Flywheel SAE 11% 3, Fuel injection pump BOSCH "A" type with all speed governor 4. Fuel filter Paper element type 5, Water separator Equipped 6. Lube oil pump Full forced pressure feed by gear pump 7. Lube oil filter Paper element type (Full flow) 8. Lube oil cooler Multi plate type, Fresh water cooled 9. Fresh water pump Forced-circulation by volute pump 10, Raw water pump Self priming, Rubber impeller type 11, Intake manifold Inlet position at rear 12. Exhaust manifold Fresh water-cooled exhaust manifold, integrated heat exchanger with expansion tank 13. Turbocharger Cooled by fresh water, with air cleaner 14. Starter 12V, 25 KW 15, Alternator 12V,, BOA, with built-in voltage regulator 16. Engine stop solenoid Equipped 17. Emergency stop relay Equipped 18. Starter. block relay Equipped 19. Grow plug Equipped 20. Rigid mount bracket Equipped 21, Exhaust riser Cooled by raw water 22, Marine gear Equipped * INSTRUMENT PANEL Battery switch Starter switch with key Instrument panel lamp switch Tachometer (with hourmeter and trip meter) Coolant temperature gauge Oil pressure gauge Fuel gauge Volt meter Precheater indicator lamp Coolant temperature warning lamp Charge warning lamp Oil pressure warning lampGENERAL INTRODUCTION Gilt F225 Fear LEFT SIDE VIEW NOTE: These specifications are subject to change without notice. Jéing, HINO MOTORS,LTD. """™MEMOGENERAL INTRODUCTION Gi13 SPECIFICATIONS DIESEL ENGINE FOR MARINE USE 4.839 liters, d-cycle, HINO : soy wou turbocharged and intercooled © ENGINE DESCRIPTION 1. Max. output, pleasure craft 157 kW (210 HP)/3,000 rpm 2. Max, output, work boat 138 KW [185 HP)/3,000 rom (light duty) 3. Type Diesel, 4-cycle, 4-cyl., incline, over-head vatve, water-cooled 4. Aspiration Turbocharged and intercooled 5. Combustion system Direct injection 6. Cylinder Bore x Stroke 104 x 113 mm (4,09 x 4.48 in.) 7. Piston displacement 3.839 liter (224.2 cu.in.) 8. Compression ratio 16.5 9. Direction of rotation Counter-clockwise viewed from flywheel 10. Dimensions with marine gear (L x Wx H) Approx. 1,152 x 694 x 790 mm (45.4 x 27.3 x 31.1 in.) 11. Dry weight with marine gear Approx, 540 kg (1,191 tb) © FEATURES 1. Cylinder block ‘Mono block cast iron with replaceable dry liner . Cylinder head Single piece cast iron 3. Crankshaft Induction hardened die forged special steel with counter, weights 4. Piston and rings Het resistance aluminum alloy ‘Two compression rings, chrome plated ‘One oil ring, chrome plated with coil expander 5. Camshaft Induction hardened carbon steel 6. Valves Heat resistance steelGia GENERAL INTRODUCTION @ EQUIPMENT * ENGINE 1, Flywheel housing SAE No. 3 2. Flywheel SAE 11% 3. Fuel injection pump BOSCH “AD” type with all speed governor 4, Fuel fitter Paper element type 5. Water separator Equipped 6. Lube oil pump Full forced pressure teed by gear pump 7. Lube oil filter Paper element type (Full flow} 8. Lube oil cooler Multi plate type, Fresh water cooled 9. Fresh water pump Forced-circulation by volute pump 10. Raw water pump Self priming, Rubber impeller type 11, Intake manifold Inlet position at rear 12. Exhaust manifold Fresh water-cooled exhaust manifold, integrated heat exchanger with expansion tank 13. Turbocharger Cooled by fresh water, with air cleaner 14, Intercooler Cooled by raw water 15, Starter 12V, 2.5 KW 16. Alternator 12V, 50A, with built-in voltage regulator 17. Engine stop solenoid Equipped 18. Emergency stop relay Equipped 19. Starter block relay Equipped 20. Glow plug Equipped 21, Rigid mount bracket Equipped 22, Exhaust riser Cooled by raw water 23. Marine gear Equipped © INSTRUMENT PANEL, Somnomewne W 12, Battery switch Starter switch with key Instrument panel lamp switch Tachometer (with hourmeter and trip meter) Coolant temperature gauge Oil pressure gouge Fuel gauge Volt meter Pre-heater indicator lamp Coolant temperature warning lamp Charge warning lamp Oil pressure warning lampGENERAL INTRODUCTION G48 F229 LEFT SIDE VIEW NOTE: These specifications are subject to change without notice J#iza HINO MOTORS, LTD. = *°""GENERAL INTRODUCTION G46 ;Payronds you st anbs01 or susuna paydde aq piNou 21GE HAD U Uan6 Soren onbs04 Su, :3L0N ~ init ements} Som oma, corm gee, faeces | ste | sce | gece ate se oe Guruerybis wnuyuinye 40 WOH 35e3 @) - 6 tcap~ ven | tow—seer | isc oer | weer ~earh 1001-900 r-su ee-su eee |" a oveccea| Ge ES | eee, | pte a a a 4 = oy Sas esate | ere | soe | soe | eon Sera see a pea oe aii | aoe | ace | aca | ace | ce “ ee] | \ est eine ere ct 7 v ve ce oz BL OL we eb OL 8 9g v (Fay aed) am L108 GHVGNVIs 40 ANOYOL ONINALHOLLG7 GENERAL INTRODUCTION Kd sassy an OI agvau one wants 1 won ssve0 was ann ing no) ossa rouse xan ve |.58%5) atti | swoutsos sinvomant ANISNA ONIH Tv ¥O4 SLNVOINENT GSGNSWWOo0sye ouMEMOENGINE EN-1 EN-1356-02 CHAPTER EN ENGINE Models WO4D, WO4C-T and W04C-TI DATA AND SPECIFICATIONS... veeteeeees EN-DS7A +1 TROUBLESHOOTING ... EN-TSIC . 1 ENGINE OVERHAUL CRITERIA . : EN-OC3C - 1 ENGINE MOVING PARTS ... . EN-MP7A - 1 CYLINDER HEAD .... cevteeseeess ENMPTA - 5 TIMING GEAR, CAMSHAFT AND OIL PAN... EN.MP7A 16 PISTON, CRANKSHAFT, CYLINDER BLOCK AND FLYWHEEL HOUSING ........ ses. ENMP7A -23 LIQUID GASKET AND APPLICATION PARTS ... EN-MP7A -28 LUBRICATING SYSTEM EN-LS7A . 1 OIL PUMP....... : . EN-LS7A - 3 OIL COOLER AND OIL FILTER. EN-LS7A - 5 FUEL SYSTEM.......... a 7 s+. EN-FS6B - 1 INJECTION NOZZLE sessess EN-FSOB - 2 FUEL FILTER .. . EN-FS6B - 4 COOLING SYSTEM ......... EN-CS7A - 1 COOLANT PUMP be EN-CS7A - 3 HEAT EXCHANGER cess EN-CSTA - 6 THERMOSTAT <1. EN-CS7A - 8 AIR INTAKE AND EXHAUST SYSTEM . ENIEZA - 1 ENGINE COMPONENT PARTS DISMOUNTING AND MOUNTING... acral vevteeeseees EN-CPSB - 1 FUEL INJECTION PUMP ..,.......... EN-CP5B . 1 GENERATOR dant EN-CP5B - 3 STARTER oo. .scceveeeesee es EN-CPSB . 4 ENGINE TUNE.UP : EN-TUSA . 1 PROCEDURE FOR INSTALLING AND GASKETS OF ENGINE PARTS . . EN-PRIB- 1 MARINE TRANSMISSION MOUNTING AND DISMOUNTING .......0.cs0cescee tence J ENMTIA. 1ENGINE EN-DS7A-1 DATA AND SPECIFICATIONS Model woap woact wo4e-TI TYPO eee eee eeee ++ | Diesel, 4-cyele, vertical, 7 « 4 cylinder, inline, overhead valve, water cooled Aspiration Natural aspirate Turbo charged Turbocharged and intercooled Combustion system +++ | Direct injection + < Bore and stroke... + | 104. 118 mm 104 x 113. mm - (4,09 x 4.65 in) (4.09 x 4.48 in} Piston displacement see e+ | 4,099 liters (244,6 cu.in) | 3.839 liters (234.2 cu.in) + Compression ratio... . 17.9 < 165, Firing order... 5.6 1-3-4-2 + - (A number of a cylinder is to be counted in order | from the timing gear side) | Direction of rotation . . . Counter-clockwise viewed 7 + | ‘from flywheel | ‘Maximum revolution (at full lozd) . | 3,000 rpm « « Idling revolution . . . 775-825 rpm - 750-800 rpm Dry weight with marine transmission.| Approx. 430 kg (948 Ib) | Approx. 465 kg (1,025 Ib} | Approx. 520 kg/1,146 1b Valve timing (flywheel travel), Intake opens . - 16° before T.0.C. + + Intake closes ...... 44. .++ | 40° after B.0.C, - - Exhaust opens... 55 before B.D.C. « + Exhaust closed - va [19° after T.0.C. + - Valve clearance (when cold), Intake... 0.30 mm {0.0178 in} « 0,35 mm (0.0738 in) Exhaust .. 0.40 men {0.0157 in} 0.45 mm (0.0177 in} 0.50 mm (0.0197 in} Injection nozzle opening pressure. | 220 kg/em? (3,129 tb/sq.in} - | ‘ Injection timing . . 14° before T.D.C. for No.1 | 17° before T.D.C. for No.1 < ‘eylinder on compression | cylinder on compression stroke strokeEN-DS7A-2 ENGINE a Model Wo4aD PERFORMANCE CURVE PLEASURE CRAFT RATING LIGHT DUTY RATING SAE yo0 8038 SAE saw seaoen Foe eRome 100 (eoHENT 1) po g. aioe 5 3 “te g > i : _ baz z ege fe “eH EA warren wae] is — ei 8 RCO RS 3 ENGINE SPEED vom ean ENGINE SPEED om rae Note: Engine performance at SAE standard 1349 conditions of 90m {300ft) altitude (100 kPa (29.61 inHg] baro- metric pressure), 25°C (77°F) air intake tamperature, and 1 kPa (0.30 in.Hg) water vapor pressure with No.2 diesel fuel wil be within 6% of that shown at the time of engine shipmont. Actual performance may vary with different ambient conditionsENGINE EN-DS7A.3 Model WO4C-T PERFORMANCE CURVE PLEASURE CRAFT RATING LIGHT DUTY RATING £] Sioeeret a PRESae SER rome Ee secrmenia 3" nn 8 LZ. | 7 [fesse : “ Lodesemeromnice | Bf pari" § » Figs mopei.ea oo, a | 8 * AE he |: 3 els 3 aed ENGINE SPEED rem rans ENGINE SPEED tm eae nore: Engine performance at SAE standard J1349 conditions of 90m (300ft) altitude (100 kPa [29,61 in.Hg] baro- ‘metric pressure), 25°C (77°F) air intake temperatura, and 1 kPa (0.30 in.Hg) water vapor pressure with No.2 set fuel wll be within 8% of that shown at the time of engine shipment. Actual performance may vary with differnt ambient conditions. DESCRIPTION bod 2 =A aro 4. (Gye re S Ring 5 I | J onF-206 onF.227EN-DS7A4 Model WO4C-T1 PERFORMANCE CURVE PLEASURE CRAFT RATING SAE soa orate) LIGHT DUTY RATING SAE ir rosa diesel fuel wil be different ambient conditions, DESCRIPTION © EERE omrvaria Eee eee keer sya I l= om : 5 wel Z 5 fie {ot F £fol ve Ev Z el dee rc cs: ls Geant § “|s=5 i | i T 5S z al \S POWER PROPFLLEA Las z oe rn f I we af meme Tote ofa g : fale 3 afte i aise perros ean eeeeanese rare NoTE: Engine performance at SAE standard J1349 conditions of 90m (300ft) altitude (100 kPa [29.61 in.Hg] baro- metric pressure), 25°C (77°F) air intake temperature, and 1 kPa (0.30 in.Hg] water vapor presture with No.2 ithin 5% of that stiown at the time of engine shipment. Actual performance may vary with HF.220‘Symptom ENGINE TROUBLESHOOTING Engine overheating Coolant Insufficient coolant Defective thermostat Overflow of coolant due to leakage of exhaust into cooling system Coolant leakage from cylinder head gasket Defective coolant pump . —— | [Heat Exehanger Clogged with rust and scale Clogged with iron oxide due to. . leakage of exhaust into cooling system Clogged or corroded heat exchanger due to mud or other debris, Defective heat exchanger cap pressure valve ‘Abnormal combustion, Incorsect injection timing . Reduced injection pressure Poor fuel... Poor nozzle spray eee (Other problems Defective or deteriorated angine oll ..... Unsatisfactory operation of oil pump Insufficient oil Broke drag Cooling system Defective sea water pump Loose or slipping V-bett ‘Closed sea water intake valve (Seacack) Clogged sea water strainer Unsatisfactory automatic timer advance angle. EN-TSICA sdy/Prevention Add coolant. Replace the thermostat, Repair « Replace gasket. « Repair or replace, = Clean hest exchanger. Clean coolant passage and correct exhaust leakage, Clean or repiace heat exchanger. Replace heat exchanger cap. «Adjust injection timing, - Adjust injection pressure Use good quality fuel. Adjust or replace nozzle Repair or replace timer, Change engine oil, Replace or repair. «Add oil. Repair or adjust, Repair or replace. Adjust V-belt tension or replace. Open intake valve. Glean strainer.ENTS1C.2 ENGINE Symptom Possible cause Remedy/Pravention Excessive oil consumption Pistons, cylinder liners, and piston rings ‘© Wear of piston ring and eylinder liner... ‘© Worn, sticking or broken piston rings Insufficient tension on piston rings 4 Unsatisfactory break-in of piston rings ‘© Unsuitable ol (vtcosity too low). Incorrectly fitted piston rings , upside down) © Gaps of piston rings in line with each other ‘Valve and valve guides Worn vaive stem Worn valve guide Incorrectly fitted valve stem seal Excess oll feed © Defective oil level gauge © Oil level too high aoe Cooling systern © Overcooled engine .. {low temperature wear) Other problems © Oil leakage from miscellaneous parts Piston seizure Operation ‘Abrupt stoppage of engine after cunning . . . at highspeed Excessive lubricant on rocker arm... ss «Replace piston rings and cylinder liner, «Replace piston rings and cylinder finer, Replace piston rings and cvlinger liner, Replace piston rings and cylinder liner, Change oil as equired and replace piston rings and cylinder liners, Replace piston rings Reassemble piston rings, Replace valve and valve guide. Replace valve guide. Replace the stem seal Check clearance of rocker arm and shaft, = Replace oil level gauge Drain excess cil Warm up engine before moving boat. Check cooling system, Repair, + Operate engine properly.Symptom Piston seizure foi} Lack of power ENGINE Possible cau: # Dintyoil . Ieee # Poor quality oil High oil temperature © Low oil pressure © Defective oil pump Reduced performance due to worn oil pump ‘© Suction strainer sucking air. ‘Abnormal combustion} . Injection pump) Tneake © Clogged air cleaner ‘Overheating Fuel and nozzle # Poor nozzle spray ‘© Clogged nozale with carbon (© Wear or seizure of nozzle © Air in Fuel system © Clogged fuel filter © Use of poor fuel = o (Abnormal combustion Pst eylinder liners, and piston rings Other probiems © Breakage of turbine or blower EN-TSIC-3 «Add oil = Change oil ._ Replace with proper engine oil = Repair Repai = Repair oll pup. Replace oil pump. + Add oil andor cepsir strainer. «See Symptom: “Engine over- heating.” ‘See Symptom: “Engine over- heating.” Refer to CHAPTER IP, FUEL INJECTION PUMP, Clean element or reptace element, ‘See Symptom: “Engine overheating.” «Adjust or replace injection nozzle Clean nozzle Replace nozzle. «Repair and bleed air from fuel syste, Replace element Use good quatity fue. See Symptom Engine overheating.” See Symptom “Engine over heating.” Replace the turbine or blower or turbochargerENTSIC4 ENGINE Symptom Possible cause Remady/Pravention Difficulty starting engine Difficulty starting engine Electrical system © Discharged battery © Detective wiring in starter eirouit © Loose or open-circuit battery cable Breakdown of starter © Break of glow plug or intake air heater (If so equipped) Injection pump, (Air cleaner| © Clogged element 7 Fuel system| © No fuel in tank... © Clogged fue! tine Air sucked into fuel system through fuel line connections © Clogged fuel filter... ‘© Loose connection in high-pressure line © Water in fuel. Nozes| © Seized nozzle © Broken or fatigued nozzle spring (Oiteyseem © Oil viscosity too high [Other problems © Seized piston © Seized bearing . © Reduced compression pressure © Ring gear damaged or worn Improperiy adjusted or broken... accelerator cable Charge battery Repair wiring of starter Tighten battery terminal connec tions or replace battery cable. Replace starter Replace Refer to CHAPTER IP, FUEL INJECTION PUMP, Clean the element or replace the element. ‘Supply fuel and bleed air from fuel system, Clean fuel line, Tighten fue! line connections. Roplece element, Tighten sleeve nut of high pres: sure line, Drain and clean fuel system « Replace nozzle, Replace spring, Use proper viscosity oil, or install an oil immersion heater and warm up oil Replace piston, piston rings, and liner. Replace bearing and/or crankshaft, Overhaul engine, Replace the ring gear andlor starter pinion, Adjust or replace the accelerator cableENGINE ‘Symptom Possible cause Rough idting ——-————f Injection pump Nozeles Uneven injection pressure Poor nozale spray Carbon deposit on nozzle tip Seized needle valve Engine proper| Improper valve clearance Improper contact of valve seat Idling speed too low . . Coolant temperature too tow Compression pressure of cylinders markedly different from one another Leakage of exhaust Gylinder Read gasket Fatigued gasket (aging) Damage Improper installation Cylinder head bolts Loose bolts tightening sequence [Cylinder block Cracking ‘Surface distortion . Fretting of cylinder liner insertion portion {insufficient projection of ‘eylinder liner) Cylinder head Cracking Surtace distortion = Overhaul engine Etongated bolts... wees Improper tightening torque or... EN-TSIC5 Remedy Prevention «Rafer to CHAPTER IP, FUEL INJECTION PUMP. Adjust. «Adjust or replace nozzle, Remove carbon, Replace nozzle, Adjust valve clearance Replace or repair valve and valve seat. Adjust idling speed, Warm up engine. Replace gasket. Replace gasket. Replace gasket. Tighten bolt, Replace bolt, Tighten property. «Replace cylinder block. Repair or replace. Replace cylinder liner or cylinder block. Replace cylinder heat. + Repair or roplace.EN-TS1C-6 ENGINE Symptom Possible cause Remedy/Prevention Leakage of exhaust {Cylinder liners [—[Dther problems © Cracking © Corrosion Insufficient projection of cylinder liner © Incorrect injection timing... 6. eye ev Seawater discharge is not —— sufficient Abnormal noise or vibration Seawater pump] © Sucking air. ¢ Damaged impeller © Clogging of suction pipe and/or seawater strainer —{Seawater pump © Wern bearing '® Foreign material in the pump © Incomplete mounting Bearing wears frequently Seawater pump] © Too tight V-belt tension... eee Damage of impeller ‘Seawater pump] ‘© When it has been operated for a long period... . (© When it has been operated without seawater (© When it has been operated at higher RPM © Too high or low water temperature ‘© Whan it has not baen operated for an extended period © Foreign material in the pump Replace cylinder liner «Replace cylinder liner. = Replace eylinder liner «Adjust injection timing ‘Supply seawater and blaed air from cooling system. Replace impeller. Clean suction pipe and strainer. «Replace bearing, Repair or replace. Mount completely. Adjust V-belt tension, Replace impeller, Replace impeller Replace impeller and operate at normal RPM. = Replace impeller and operate at normal temperature, Replace impeller. Repair or replace,ENGINE EN-0S3C. SPECIAL TOOL ENGINE OVERHAUL CRITERIA Prior to starting an engine overhaul, itis necessary to have these special tools. COMPRESSION GAUGE COMPRESSION GAUGE ADAPTOR (NOZZLE HOLDER) ADAPTOR (GLOW PLUG) ADAPTOR, COMPRESSION GAUGE 09652-1081 (09552.1070 FACTORS WHICH DETERMINE WHEN AN ENGINE OVER. HAUL IS NEEDED. 1. Lowered compression pressure a. Before the measurement a) Correct the vaive clearance. bb} Warm up engine {Bring the coolant temperature to about 80°C (76°F) ©) Charge the battery fully d} Remove the air cleaner, b. Measurement 1) Meature at nozzle holder hole. SAWPLE 3} Remove the nozzle holders. bb) Install the gauge adapter in the nozzle holder hole Special Tool: Compression Gauge Adapter (09408-1041) (09862-1070) 2), Measure at glow plug hole, a] Remove the glow plug. bb) Install the gauge adeptar in the glow plug hote, Special Tool: Compression Gauge Adapter (09552-1061) (09552-1070) Sws.3e8 ‘¢) Connect a compression gauge to the gauge adapter. d) Drive the engine with the starter and read the compression pressure. NOTE: Do not continuously operate the starter for more than 15, seconds at atime ©} Measure the compression pressure for each cylinder. If the compression pressure is low, be sure to repeat the measuring. NOTE: Be sure not to leak through seating face. Unit: kg/em? Ubisa.in) Compression pressure ] Difference between Engine speed Engine model : fa gine sper a Standard Lime each eylinder (cpm) woad) 33-36 (469-5: 5 (38 woac.t Hee ao Less than 3 (43) 350 woacTl 30-33 (427469) 22. (313) ‘WwosD a a [33-36 465-811) 25 (356) a WosD.TI 30-33 (427-468) 22 (513)EN-0830-2 ENGINE SaunE 2. Decreased ol pressur Check the oil pressure warring lamp when the oil and coolant, temperature is hot [about 89°C (176° FI}. 2. If the warning lamp is lighted, check the ol level b. Check oil deterioration {f oil quality is poor, replace with a suitable grade ol © Remove the ol! pressure switch and install the oil pressure gauge. 4. Measure the oil pressure at coolant temperature 80°C (176°F) or more. sws.sée| Standard oil presture: 0.5-5.0 kg/cm? (7.11—71.10 t/q Service limit: Loss than 0.6 kg/em? (7.11 Tb/sqin} ATMOSPHERIC TEMPERATURE sas ~ 3. Other factors Grape | po 5) 70s F & —Theblowby gas increases. “2-180 10 2 S230 [°c b. The engine does not start easily 7 & Engine output decreases. d. Fue! consumption increases. 30 e. Engine makes greater noise 2owi20 {Excessive ol consumption. 150/40ENGINE EN-MP7A-1 ENGINE MOVING PARTS DESCRIPTION Representative engine model WO4C-TI 1 ). Heat exchanger cap Heat exchanger Generator Engine coolant pump Crankshaft pulley ‘Seawater pipe ”. Seawater pump Oil pan . Water separator ). Fual filter i 11. Engine stop solenoid iS 7 12, Oil level gauge et 13. Intercooler & de Ae 14, Fual feed pump i 15, Fuel injection pump 16. Starter 2 an i x cc au]ENMP7A2 SPECIAL TOOL ENGINE Prior to starting an engine overhaul, itis necessary to have the following. SLIDING HAMMER ADAPTOR (USED WITH 09420-1442) ADAPTOR (USED WITH 09420-1442), D x ig GE 09420-1442 CYLINDER HEAD BOLT WRENCH 09462-1370 for model Wo4D EYE BOLT (USED WITH 09470-1022) (09462-1120 for models WO4C-T ‘and WO4G-TI wire ee 09411-1260 VALVE SPRING PRESS 09433:1070 VALVE LAPPING TOOL 09491-1010, VALVE STEM SEAL PRESS a 09470-1022 CRANKSHAFT PULLEY PULLER, 09431-1010 TIMER SETTING TOOL 09472-1660 IDLER GEAR SHAFT PULLER 8 V) 09420-1500 09512-2090 for model WO4D (09512-2100 for models WO4C-T ‘and WO4C-TI 09420-1100TIMING GEAR COVER OIL ENGINE EN-MP7A-3 SEAL PRESS PISTON RING EXPANDER CYLINDER LINER PULLER 09482-1530 09442-1180 (09420-1460 CYLINDER LINER GUIDE GUIDE PRESS SUB ASSEMBLY 09480-1120 09481-1130 (09402-1460 WING NUT ‘SPINDLE SPINDLE i sj 9233-10360, 09402-1470 tor models WO4C-T (08402-1460 for model WO4D and WO4C-T! GUIDE GUIDE BOLT (09481-1120 for model WO4D. 9191-06252 (09481-1140 for models WO4C-T and WOAC-TIEN-MPTA4 FLY WHEEL HOUSING OIL SEAL ey a oeENGINE EN-MP7A-5 CYLINDER HEAD OVERHAUL ME 11~040.-0002 (1310) T= 190-260 (14-18) 190-260 (14-18) 2 [ | 7 7 8. 16 T= Tightening torque kg.cm (Ib.ft) 1. Cylinder head 7. Push rod 13, Vaive stem oil seal 2. Rocker arm shaft 8. Tappot 14. Vaive spring lower seat 3. Bushing 9. Cotter key 15, Exhaust valve 4, Rocker arm 10. Valve spring upper seat 16. Intake valve 5. Rocker arm support 11. Inner valve spring (For WO4D) 6. Valve clearance adjusting screw 12. Outer valve springENMPTA-6 ENGINE OVERHAUL ‘T= 450~500 (33-36) 130-190 (10-13) T= 1,300—1,400 (94-101) T= 130-190 (10-13) T+ Tightening torque: kg-om (tb.ft) Cylinder head Oil filer cap Cylinder head cover |. Cylindar head cover gasket Cylinder head gasket . Valve guide - Valve seat . Expansion plug 1. Nozzle holder gaskat 10, Packing ring 11. Shim 12. Nozzle holder 13. Nozzle 14, Nozzle holder adapterINTAKE S108 sm3.201| ENGINE ENMP7A7 IMPORTANT POINTS — DISASSEMBLY CLEAN OFF SURROUNDING AREA OF THE NOZZLES AND ‘THE FUEL LINE CONNECTORS. NOTE: If foregin matter is allowed to enter the combustion chamber, engine trouble may result. REMOVE THE INJECTION PIPES, NOTE: Cover open ends of the pipes to prevent entry of dirt. REMOVE THE NOZZLE ASSEMBLY. Using 2 special tool, if the nozzle is difficult to remove by hand. Spocial Tool: Sliding Hammer (09420-1442) Adapter (09462-1370) for WO4D (09462-1130) for Wo4C-T, Wo4c-TI NOTE: © After removal of the nozzle holder, cover the nozzle holder with cloth. Also cover the cylinder head with » ‘cloth to prevent dust trom gatting in, REMOVE THE CYLINDER HEAD ADDITIONAL BOLTS AND ROCKER ARM SUPPORT BOLTS. Loosen the cylinder head additional bolts and rocker arm support bolts in the numerical order as shown. LOOSEN THE CYLINDER HEAD BOLTS AND REMOVE THEM. Loosen the cylinder head bolts little by little in three stages and in the numerical order as shown, ‘Special Tool: Wrench (09411-1260) * Mark position (Cylinder head additional bolts)EN-MP7A8 ofA, PLACE CHISEL [AT THIS JCORNER ONLY PLY UP AND DOWN Poo ren 6.0 0 fit CYLINDER BLOCK smase a lands “\polealestan 1 2 8M3-893, svoa2s ENGINE LIFT THE CYLINDER HEAD FROM THE DOWELS ON THE CYLINDER BLOCK AND PLACE IT ON WOODEN BLOCKS 1. If the cylinder head is difficult to lift off, pry with @ chisel between the cylinder head and block. NOTE: Do not damage the machined surtece of the head or block when removing the eylinder heed, Special Tool: Eye Bott (08433-1070) Wire (09491-1010) REMOVE THE VALVE SPRINGS, 1. Remove the valve stom cotters, upper valve seats, and inner {for WO4D) and outer vaive springs from cylinder head. Special Tool: Valve Spring Press (09470-1022) 2. Remove the intake and exhaust valves 3. Tag valves to identify their eylinder numbers and to eliminate valve lapping. IMPORTANT POINTS — ASSEMBLY CLEAN THE CYLINDER HEAD THOROUGHLY WITH A SUIT- ABLE SOLVENT, NOTE: Be careful not to damage the cylinder head surface, IF NECESSARY, HAND-LAP THE VALVE AND VALVE SEAT. Lightly apply lapping compound to the valve face. Install the valve with a special tool, tap and rotete the valve against the seat, Special Tool: Valve Lapping Too! (09431-1010)ENGINE EN-MPTA-9 _NALVE SEAT. } ane weLoinc POSITIONS $3.96 / ExHausT, ‘53.386 su 524 IF NECESSARY, GRIND THE VALVES AND VALVE SEATS, NOTE: © Grinding of valves and valve seats should only be per- formed when hand-lapping does not result in proper seating. (© After grinding, always recheck the valve sink. Standard: Valve Seat (Intake) : 30° — 30°30" Valve Face (Intake) : 29°46’ — 30°15" Valve Seat (Exhaust): 45° — 45°30" Valve Face (Exhaust): 44°45" ~ 45°15" IF NECESSARY, REPLACE THE VALVE SEAT. 1, Gut the circumference of a valve head at three places with ‘a grinder and install it into the seat as shown and weld the valve to the seat, Then drive the valve and the seat out with ‘a hammer and a brass block 2. Valve seat section machining specifications. Unit: wm tn) lotake | _—~Exhaust Fe], | 46500-48516 | 41,000-41.016 i ? (1.8308-1.8313)_|_(1,6142-1.6148) a8]. 88-90 72-74 & (0.3465-0.3643) | (0.2835.0.2913) ee | c¢. | s585-48.600 | 41,130-41.145 ag (1.8341~-1.8346) | (1,6193-1,6198) ira 75-77 60-62 ee (0.2953-0.3031) | (0.2363-0.2440) 3, Valve seat installation Heat the cylinder heed to 80°~100°C (176~212°F) with hot water, On the other hand, cool the valve seat with dry ice oF liquid freon for approx. 30 minutes. Hold the seat with pincers and place it into the heated cylinder head.EN-MP7A-10 ENGINE wale IF NECESSARY, REPLACE THE VALVE GUIDE, GUIDE | pYUNDER HEAD 1. Remove the valve stem seal eee 2. Using a brass rod and hammer, drive out the valve guide. B53 3, Install the valve quide as shown. see NOTE: Apply engine ail lightly to the valve guide outer circum- EEE EEE ference before installing. ‘5M3-389 IF NECESSARY, REPLACE THE VALVE STEM SEAL, 1. Remove the valve stem seal 2. Install the vaive stem seal, First, Install the lower spring seat (for stopper of spécial tool) and valve. Then apply engine oil to the lip of the stem seal and drive the special too! until it hits the lower spring seat. Spocial Tool: Valve Stem Seal Press (09472-1650) 39.827 NOTE: © After installing stom soal, make sure that check the RUBBER GOAT OWL. rubber position for cracks or any other damage, Ft © Do not use the special too! if its tip (surface contacting f ower spring seat) is worn of deformed. M3708 ASSEMBLE THE CYLINDER HEAD. NOTE: © Apply engine oil to contact surfaces of all parts © Make sure that the valves are installed in the correct, cylinders. (© Install the valve springs with their painted side down, since they have variable pitches, PAINTED SIDE sias-907 Press upper spring seats and install the valve stem keys securely. in the upper spring seats Special Took Valve Spring Press (09470-1022) NOTE: © When pressing with the valve spring press, be careful not to damage the stem seale by contacting the upper seats, © Drive the valve stem lightly with 2 hammer to assure proper fit the valve stem key.No, 5. SUPPORT ARROW MARK TIMING GEAR SIDE Intake exhaust OILHOLE ROCKER AAM SHAFT fi No. 5 SUPPORT 9M3.204 53.28 5M32014\ ENGINE EN-MP7A-11 ASSEMBLE THE ROCKER ARM, Lubricate the rocker arm shaft and bushing, NOTE: Confirm that oil hole of rocker atm assembly No. 5 support aligns with shaft oil hole. Improper installation will result in burning of the entire vaive assembly. INSTALL THE TAPPETS IN THE CYLINDER BLOCK IN COR- RECT ORDER. NOTE: Apply engine oil to the tappet faces and tappet guide when ij them in the cylinder block, INSTALL THE CYLINDER HEAD AND ROCKER ARM ASSEM- BLY. 1. Install the eylinder head gasket. NOTE: Always use new cylinder hes surfaces of the cylinder hed, cyl gasket free of all ditt, water and grease. gasket after cleaning the block and head Install the cylinder head over the dowels on the cylinder block. 3. Insert the push rods in correct order, after applying engine oil ‘to both ends. 4, Mount the rocker arm assembly on the cylinder head, make sure that the push rods interlock with the adjusting serews. NOTE: Always loosen the lock nut and raise the adjusting screws fully to the top. 5, Tighten the cylinder head bolts litte by little in three stages and in the numerical order as shown, NOTE: Apply engine oil to the bolt threads and under the bolt head. + Mark bolts (cylindar head additional bolt): $10 mm (0.39 in} No. 1 — No. 18 Bolts (Cylinder head bolt): ¢ 12 mm (0.47 in} Special Tool: Wrench (09411-1260)EN-MP7A-12 ENGINE 6 Tighten the cylinder head additional bolts and rocker arm support bolts little by litle in three stages and in the nu= merical order as shown, Tighten the bolts to the specified torque, 7. Retighten the oylinder head bolts NOTE: Refer to SECTION ENGINE TUNE-UP.ENGINE INSPECTION AND REPAIR EN-MP7A-13 Unit: men fal Inspection Item Standard Limit Remedy Inspection Procedure Cylinder Head Flatness Less than 0.05, 0.1 | Regrind or (0.0019) (0.0039) | replace Cylinder Head Height 37.0 86.8 | Replace (3.425) (3.417 Cylinder Head Cracks and Replace, i Damage recesary * Using a Dye Penetrant 4 SM3832 Valve Seating Condition | There shauld be good | Hana-top with —~ * Using Red Lead Marking | contact around entire tapping com: : Compound sireumtrence of valve pound head. : aa 2 Oe 7 Oo Pee A swoe0 Valve Seat Angle | Intake 20-3030 Resring or replace valve ' ! exhaust | 45°—49°30 andor valve N\A ~ | sex VI Valve Ange Inake | 29°46'—30°15" PS Exhaust | 44° €5'—45"95" Nozzle Protrution from 2.75-3.25, Replace nozzle Cylinder Head Surface (0,1083-0,1279) gasket (eae He = ant 3-301 Intake Valve Sink Replace valve 7 -o- is CYLINDER, and/or MEADSURFACE valve seat Wose-TI | _(0,0019-0.0737) | (-0.0079) Exhaust Valve Sink 0.47 ~ -0.77 -087 (-0.0185 ~ ~0.0303) | (-0.0342) sm2-209|EN-MPTAA4 ENGINE Unit: mom fn) Inspection Item Limit Remedy Inspection Procedure Intake Valve Stem Diameter § 8.90 | Replace valve (0.3524-0.3531) | (0.3903) | guide and/or Exhaust Velve Stem Diameter 8.93-8.95 ao | ave (03516-03524) | (0.3484) Intake and ExhaustValve Guide | 9.000-0.015 AaB Diametor (0.3544-0,3549) 9.05 (0.3562) ce 810.197) gus.gga 9.10 25 (0.984) _ (0.3882) 45(1.771) ‘Clearance between Valve Stern 0035-0068 | A&B: ‘and Valve Guide (Intake) (0.0004-0.0026) | 9-10 (0.0040) 0.18 (0.0071) ‘Clearance betwean Valve Stem 0.050-0.083 ‘a and Valve Guide (Exhaust) (0.0020-0.0032) | 912 : (0.0047) ¢: 02 (0.0078) ‘Rocker Arm Shaft Diameter 18,97-18.98 18.95 | Replace rocker (0.7489-0.7472) | (0.7461) | arm bushing and/or shaft Clearance between Rocker Arm 0.036-0.079 01 Shaft and Rocker Arm Bushing | (0.0016-0.0031) | (0.0039) Inner Valve Spring Setting Load | 8.8kg (19.416) at | 80g | Replace (For WO4D only} 43.0 mm (1.69 in) | (17.6 1b) Outer Valve Spring Setting Lood | 27.4 kg (54.5 Ib) at | 25.5 kg 485mm /(1.79in) | (56.2 1b) ‘Valve Spring Straightness 2 Replace (oner and Outer! (0.0787) Valve Spring Seat for Weer A: 25 Repalee (0.0984) 8: 5.0 (0.1969) = c: 10 (0.0384) $M3.908ENGINE EN-MP7A-15 Unit: om tin Inspection Item ‘Standard Limit Remedy Inspection Procedure \Vaive Stem Tip Surtaca for Rewurface or ‘Visual Check Wear replace of Racker Arm for Push Rod Bend 0.3 | Replace (0.0118) 26.95--26.97 Replace tappet {1,06 11~1,0618) ‘Tappet Guide Inside Diameter 27.00-27.02 (1,0630-1.0637) Clearance between Tappet and 0.025-0,071 ot Tappet Gi (0.0010-0.0029) | (0.0039) M3420 sM9-293, ‘Tappet for Wear Should not be worn Replace, if unevenly. necessary - Visual CheckEN-MP7A-16 ENGINE TIMING GEAR, CAMSHAFT AND OIL PAN OVERHAUL Poin T= 190-260 (14-18) T= 190-260 (14-18) 800-5,700 (348-412) T= Tightening torque: kgicm (lb-ft 1. Cylinder block 9. Ball bearing 17. Oi drain plug 2. Gasket 10. Bearing holder case 18. Oil drain hose 3. Timing gear plate |. Oil seal 19. Connector bolt 4. Connector Crankshaft pulley 20. Soft washer 5. Expansion plug 13. Plain washer 21. Oil level gauge 6 Timing gear cover 14, Oil pan 22. Oil level gauge guide 7. Ovring 15. Tachometer drive assembly 8. Retainer ring 16. ConnectorENGINE EN-MP7A.7 OVERHAUL T= 1,100-1,300 (80-94) T= 190-260 (14-18) T= 190-260 (14~18) 8 & T= 1,100~1,300 (80-94) ‘T= 300-350 (22-25) T= Tightening torque: kg-em (lb-ft) 1. Camshaft 7. Idler gear theust plate 13. Injection pump drive gear 2. Key 8. Straight pin 14, Coupling flange 3. Thrust bearing 9. Adler gear shatt 16. O-ring 4. Camshaft gear 10. Be 16. Timer cover 5. Thrust wash 11, Idler ge 17. Soft washer 6. Oil pump drive gear 12, Crankshaft goar 18, PlugENMP7A18 M3838 Times cov ENGINE IMPORTANT POINTS — DISASSEMBLY REMOVE THE CRANKSHAFT PULLY. 1. Remove the nut and spacer. 2. Using a special tool, remove the pulley. Special Tool: Crankshaft pulley Puller (09420-1500) DISMOUNT THE FUEL INJECTION PUMP, 1, Remove the plug from the part on the timer cover. 2. Turn the crankshaft counterclockwise viewed from flywheel side to align the injection timing mark. 3. Lock the coupling flange with a special tool Special Tool: Timer Setting Toot (09512-2090) for WO4D (09512-2100) for WO4C-T, WO4C-TI NOTE: Do not loosen the injection pump dri 4, Loosen the timer cover fittting bolts and then remove the injec: tion pump with timer cover. NOTE: Do nat loosen the injection pump body fitting nuts. REMOVE THE CAMSHAFT WITH GEAR. NOTE: Pull out the camshaft, slowly turning it so as not damage the bearings. REMOVE THE IDLER GEAR SHAFT. Using 2 special tool, remove the idler gear shaft. ‘Special Tool: Sliding Hammer (08420-1100)sMa.g41 ENGINE EN-MP7AA9 If NECESSARY, REMOVE THE CAMSHAFT GEAR, 1. Hold the camshaft with a vice through wooden piates. 2, Remove the bolt and plain washer, then using a gear puller, remove the gear. IMPORTANT POINTS — ASSEMBLY IF NECESSARY, REPLACE THE TIMING GEAR CASE COVER OIL SEAL, 1. Using a screwdriver, ramave the ol sel. 2. Using s special tool, install the new oil seal. Special Tool: Press (08482-1830) ASSEMBLE THE CAMSHAFT GEAR AND SHAFT, Install the camshaft gear with thrust bearing NOTE: When installing the gear to the camshaft: © Heat the gear in hot water (Approx, 100°C (212°F)], ‘them install tha goa to the camshaft by using» press, © When tightening the bott, apply engine oll to the threads and plate surface of the bolt. INSTALL THE CAMSHAFT. Lubricate all journals of the camshaft and insert the camshaft assembly into the cylinder block. NOTE: © Insert the camshatt, slowly turning while inserting so that the bearing will not be damaged. © When installing the camshaft, be sure that the match marks of the oil pump drive gear and camshaft gear aro aligned correctly.EN-MP7A-20 ENGINE INSTALL THE IDLER GEAR SHAFT. Install the idler gear shaft with thrust plate using @ plastic hammer, NOTE: Be suro thet the oll hole is downward, if installed the wrong way, damage to the idler gear shaft end bearing ‘can rosult INSTALL THE IDLER GEAR. NOTE: When installing the idler goar, be sure that the matching marks of the crankshaft gear, oil pump drive gear and idler ‘gear are aligned correctly. INSTALL THE INJECTION PUMP TEMPORARILY. NOTE: When installing the injoction pump, be sure that the match marks of the idler gear and injection pump drive gear are aligned correctly. MEASURE THE GEAR BACKLASH. Meacure the backlash of each gear using @ dial indicator. Replace the goar if necossary. Rotor to INSPECTION AND REPAIR, INSTALL THE TIMING GEAR CASE, 1. Clean the faces 2. Apply the liquid gasket as shown and install the timing gear cover within 20 minutes. NOTE: If leaving it more than 20 minutes, clean the liquid gasket completely and reapply the liquid gasket. Coating Width (AJ: 1.5 — 2.5 mm (0.06 ~ 0,10 in)TIMING GEAR PLATE CYLINDER. SLock sm3.268 ENGINE EN-MP7A-21 INSTALL THE OIL STRAINER. Rofer to “OIL PUMP AND OIL STRAINER” in SECTION LUBRICATING SYSTEM. INSTALL THE OIL PAN. 1, Cut the protrusion of the timing gear plate gasket from the oil ‘pan mounting surface. 2. Clean the faces, 3. Apply the liquid gasket as shown and install the oil pan within 20 minutes. NOTE: If leaving it more than 20 minutes, clean the liquid gasket completely and reapply the liquid gasket. Coating Width (A); 3 ~ 4mm (0.12 ~ 0.15 in) INSTALL THE CRANKSHAFT PULLEY. 3.2168) NOTE: Apply engine oil to the nut threads. INSPECTION AND REPAIR elastaatte Inspection Item Standard Limit Remedy Inspection Procedure Replace, if Visual check necessary am a Er —————s~ su 845| Idler Gear Shaft Diameter 49,95-49,97 49.94 | Replace bushing (0.9311-1.9318) (1.9307) | and/or shaft 50.00-50.03, ‘\ (1,9685~1.9696) | (1.9705) ete ! NS Glearance between Idler Gear 0.03-0.08 on BY Shaft and Bushing (0.0012~0.0031) _| (0.0039) 33.847] Idler Gear End Play 040.10 | 0.15 | Replace thrust (0.0016~0.0039) (0.0059) | plate sw3.a71EN-MP7A-22 ENGINE Unit: mm {in} Inspection ttem ‘Standard Limi Remedy Inspection Procedure Camshaft Bend 0.05 | Replace (0.0020) | ‘Camshaft Com Height 49.44 48.44 | Replace {Untake) (1.9865) (1.9071) Camshaft Cam Height 49.50 48.50 (exhaust) (19488) (1.9095) sa. Sa Camshaft end Play 0.10-0.18 03 | Replace thrust (0.0040-0.0070) | (0.0118) | plete Camshaft Journal Diameter | No.1: 67.0 $6.85 | Replace shaft Journal No, (2.2481) (2.2382) | and/or bearing Woz 868 36.55 (2.2362) (2.2303) Nad 568 35.45 (2.2283) (2.2224) Camshaft Journat Beating Not: 87.0 87.18 sunose Inside Diameter (2.2441) (2.2500) Journal No,: [Wo ® 86. 56.35 (2.2362) (2.2421) No.3 568 36.78 (2.2283) (2.2342) Clearnace between Camshatt 0.03-0.12 0.15 Journal and Bearing (0.0012~0,0047) | (0.0059) Crankshaft Gear ~ Idler Gear | 0.088-0.194 03 | Replace geer, (0.0027-0.0076) | (0.0118) | it necessary § | Idior Gear — O11 Pump Gear 3 0.085-0.182 a (0.0026-0.0071) % | Oil Pump Gear — Camshaft & | Gear EI dlr Geur~tnjecton Pump | 0.005-0232 E | Gear (0.0026-0.0091) sw3.344ENGINE EN-MPTA.23 PISTON, CRANKSHAFT, CYLINDER BLOCK AND FLYWHEEL HOUSING OVERHAUL T= Tightening torque kg-em (tb-ft) M3264 1, Piston ring 7. Crankshaft gear 13, Crankshaft bearing 2. Piston & Key 4 3. Piston pin 9. Crankshaft 18. 4. Retainer ring 10. Connecting rod cap 16 0 5. Connecting rod 11, Collar 12, Cylinder block 8. Connecting rod bearing 12, Crankshaft thrust washer 18, Bearing capEN-MP7A-24 ENGINE OVERHAUL T= 450-500 (33-36) a ” 2) T= 1,800-2,000 (131-144) @ Ke : 2).ENGINE ENMPTA-25 ll IMPORTANT POINTS — DISASSEMBLY = oC 9, 2 0 REMOVE THE PISTONS WITH CONNECTING RODS. ° 1. Remove te chon fo he vp a he pr er ~ mi super ov owery paper fecsrmande N15 3 ) ° ¢ a See ——— Bi 290 Extract the piston and connecting rod assembly out through the top of the cylinder. NOTE: © Arrange the piston and connecting rod caps in order. GMARE 2 MATCH MARK 3 REMOVE THE CRANKSHAFT, ; 3 ae Ar ll Ll bead oo eer ire : DoCRELS | t 2 39.052 REMOVE THE CONNECTING AOD. 1. Remove the retainer ring installed on both ends of the piston ‘pin, by means of retainer ring pliers. 2. Apply # metal pad to the pin and strike out the pin with a hammer. NOTE: Warm up the piston first in hot water 80-90°C (176— 194°F) for approx. 5 minutes before removing the pin. 33.204 REMOVE THE PISTON RINGS Special Tool: Piston Ring Expander (09442-1180) NOTE: © Handle the piston rings carefully because they are made of a special casting which is easily broken, © Keep the rings for each cylinder separate.EN-MP7A-26 sMa.a51 WX, ANOZ MARK 3-387 Dy) SMa.) ENGINE REMOVE THE CYLINDER LINER. 1. Place the metch marks with a pen on the cylinder block and liner flange, before removing the cylinder fir NOTE: Do not put the match marks with a punch. 2. Using a special tool, remove the cylinder liners, Special Tool: Cylinder Liner Puller (09420-1460) NOTE: After removing the cylinder liners, put numbers on their periphery or arrange them in sequence, IMPORTANT POINTS — ASSEMBLY INSERT THE CYLINDER LINER INTO THE CYLINDER BLOCK. 1. When @ new cylinder liner is used, make sure thet the liner has the same mark as the mark on the cylinder block. NOTE: © There are 4 different liner and eylinder block matches. The flange section of each liner has a marking any, W, X, Y, Z, or indicating the size of the outer diameter of the finer on which it Is stamped. The markings W, X, ¥ and 2, indicating the inner diameter of the cylinder bore supporting the liner on the sides and top of the oylinder block (the boss section for attaching the cool- ant gallery cover), are inscribed on each cylinder. 2. When reusing a liner, insert the liner its original position aligning the marking marked before disassembly.ers 33.953 Unit: mm fn ‘Guteie diameter Ganka oumel o2s | 8189-6171 7269-7271 (247e—2.425) | (2.8619~2.86251 oso |, 81.44-61.46 7246-72-46 i (zatea—2.4196) | (29620-28527) 1.19-61.21 078 | i2a001-2.4008) 0.94-60,96 300 | (23992"2.4000) conneer L_—__— wrona——] sMa-sat ENGINE EN-MP7A.27 Apply a small amount of fresh engine oil on the outer periphery of the liner, and apply pressure on the entire flange section of the liner. If insertion by hand is difficult, use a ceylinder guide, and the cylinder liner will easily be pushed in, Special Tool: Cylinder Liner Guide (09480-1120) NOTE: © Do notuse a liner that has been dropped. (© Take extra care when handling the liner sinco the liner is easily deformed. MEASURE THE PROJECTION OF THE CYLINDER LINER. Tighten 2 special tool with a tightening torque of 100 kg:cm (7.23 lb-ft} and measure the amount of projection of the top tend of the finer from the cylinder block with a dial gauge or straight edge and a thickness gauge. Special Tool: Cylinder Liner Puller (09420-1460) Tightening Torque: 100 kg-cm (7.23 Ib.ft) Assembly Standard: 0,010.08 mm (0.0004—0.0031 in) IF NECESSARY, GRIND THE CRANKSHAFT AND USE UNDER SIZE BEARINGS, Dimension of Fillet R: Crank pin: 3.60 ~ 4.00 mm (0.1378 ~ 0.1574 in) Journal: 3.05 ~ 3.50 mm (0.1201 ~ 0.1377 in}EN-MP7A-28 sma-78| TIMING GEAR ARROW SIDE No. 1.2.3, 52.855 ENGINE INSTALL THE CRANKSHAFT, 1. Install the crankshaft bearings on the cylinder block and bearing cap. NOTE: Apply fresh engine oit to each bearing surface, 2, Install the crankshaft on the cylinder block 3. Insert the crankshaft thrust bearings along the groove of the cylinder block. 4. Install the thrust bearings on the No, 4 bearing cap sides. NOTE: Apply fresh engine oil to each thrust bearing surface, 5. Install the crankshaft bearing caps. Install the bearing caps in numbered order from timing gear side with the arrow point toward the timing gear side, 6. Tighten the cap bolts in three stages following the tightening order. NOTE: Apply engine oil to the bolt threads and under the bolt head. Tightening order: 3—2-4—1-5 NOTE: © Make sure that the erankshstt rotates smoothly. © Inspect the crankshaft end play.- @ Tae PRESS SUB ASSEMBLY 3.-1565| GONNECTING ROD Ris =e PRESS SUB ASSEMBLY swo-1869 ‘Model woaD Groove. “ASSEMBLY sw3-15678| ‘Models Woac-T and wOaG-TT ‘genous Gnooven ay BUSHING /CONNECTING Roo Ol HoLEs-7 PRESS sua ‘ASSEMBLY sma.15678| ENGINE ENMP7A-29 IF NECESSARY, REPLACE THE PISTON PIN BUSHING, 1. Prepre the special tools. ‘Assemble the guide and press sub assembly inserting its pin into the guide, then secure ther with the wing aut. Special tools: Guide (09481-1130) Press sub assembly (09402-1450) Wing nut (9233-10360) NOTE: © Bring leter “W" punched on the guide above the pin, © Make sure to align both supporting surface of the guide and press sub assembly flush on a flat plane, 2. Using a special tool, remove the piston pin bushing. a. Set the connecting rod assembled without crank pin bore bearing on the guide and press sub assembly. b. Set the spindle on the bushing Special Tool: Spindle (09402-1460) for WOAD (09402-1470) for WO4C-T and Wo4C-TI Nov! Align the grooving of the spindle with the oil hole of the bushing,EN-MP7A:30, CONNECTING ROD, 10. 05-6.1.0 mm CONNECTING Roo sm3-1569] ‘Model WORD | _-sroove Oil Howe: ay ‘OIL HOLE Guide 7 CeUsHING a 3013-16708 ‘Models W04G-T and WO4CTT = SPINDLE GROOVE it HOLE: a sue a, ou, HOLE BUSHING sour swa.is70| J press OIL HOLE tans | O1L PATH: Sw3.1871C] ENGINE ©. Using a hydraulic press, remove the bushing. NOTE: Always operate the press slowly and smoothly, ‘Assemble the piston pin bushing, Chamfer one edge of the bushing hole at the small end of the connecting rod uniformly by C 0.51.0 mm (0.0196~0.0393, in), NOTE: © Irregular chamfaring can cause out-of-roundness of the pressed bushing, which may result in jamming during insertion. (© Remove dust from the inner surface of the small-end hole, 4. Mount the bushing on the spindle. a. Set the bushing and guide on the spindle aligning oil hole (AP in the bushing the grooves on the both the spindle and guide, b. Secure the bushing and guide with the bolt Special Tool: Spindle {09402-1460} for WOAD (09402-1470) for WOAC-T and WO4C-T1 Guide (09481-1120) for Wo4D (09481-1140) for WOSC-T and WO4C-T1 Bolt (9191.08252) NOTE: © Be sure to stip the bu: proper direction so that ail hole (A) wil with the oil path in the connecting rod, (© Apply fresh engine oil to the bushing and guide, over the spindle in the later align 5. Install the bushing in the connecting rad, Position the bushing-special tool assembly 0 that oil hole (A) align with the oil path through the connecting rod, NOTE: © Fully coat the bore in the connecting rod with fresh engine oil. (© Always operate the press slowly and smoothly.BUSHING f CONNECTING ROD 113-1872] sus.azal OMARK MATCH MARKS ‘sm3.407) ENGINE ENMP7A-31 6, Inspect the bushing position after installation, NOTE: © Make sure that tho oil holes of the bushing and connect: ing rod are aligned. © Insert a pin of 3 mm (0.1781 in) dia. into an hole at the end of the connecting rod, and make sure that the pin fully penetrates. If there is any deviation in the alignment of the oil holes correct it with a drill of 3 mm (0.1181 in) © Misalignment of the oil holes can lead to insufficient lubrication, which may resutt in seizure. © Insert a new piston pin and rotate it slowly to make sure that there is no rattling, ASSEMBLE THE PISTON AND CONNECTING ROD. Make sure that the O-mark at the top of the piston and the connecting rod match marks in opposite directions. NOTE: © Use the new retainer rings. (© Heat the piston to 80-90°C (176--194°F} in hot wat approx. 5 minutes.EN-MP7A-32 SISCRIMINATION MARK ga Ot TOP RING (woeop JOINT SECOND RING OIL AING 33.295 S¥3.s08 sM-4a3 OIL RING, SECOND RING OMARIC TOP RING sMa.270| GH TAPPET CHAMBER, 53.387 Massa MARK MATCH MARKS 8M3.407 ENGINE INSTALL THE PISTON RING. 1. Install the piston rings in the sequence oil rng, second ring and top ring with the identification mark at the top of the ring facing up. NOTE: © Identification mark of second ring and oil ring is applied! with gold paint. (© Apply oil to the piston rings. Special Tool: Piston Ring Expander (09442-1180) 2. Connect the ends of the coil expander and then fit the coit inside the piston ring after encuring that the gap of the piston, 1g is 180° away from the joint of the coil 3. Arrange the piston rings so that their gaps are equally spaced INSTALL THE PISTON IN THE CYLINDER LINER, 1. Apply engine oil to the piston, eylinder liner and connecting rod bearing surface, 2. Using a special tool, hold the piston rings and push the piston with connecting rod assembly with a wooden rod. Nor! Check the piston that the O:mark on the top ie on the tappet chamber side, Special Tool: Piston Ring Holder (09441-1260) INSTALL THE CONNECTING ROD CAP. 1. Apply engine oil to the eap bearing surface 2. Align the match marks on the connecting cod and cap, 3. Apply engine oil to the bolt thraads end under the bolt hesd. 4, Tighten the cap bolt in three stages.