ENGINE BASE SERVICE MANUAL MITSUBISHI S4S, S6S REFERENCE ONLY - EXCAVATOR(16-18TON, -7SERIES) - FORK LIFT(HDF35-70, -7SERIES) HYUMDAIINTRODUCTION This service manual describes the specifications of the Mitsubishi Diesel Engine and the maintenance and adjustment procedures. 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 also to take necessary measures which involves the disassembly, inspection, repair and reassembly of the engine and engine parts. Read this manual carefully and understand the work procedures fully before reassembling, inspecting, repairing or reassembling 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 _IL bJ6 Vebelt . | () Ds D il pan [Right view] Right view of engineGENERAL (©) S4S-DT distributor-type fuel injection pump specification Fan Foelinlet, Fel leak Water pump (coolant inlet), Magnetic valve (top solenoid) Frost Rear Pal ‘ ‘Coolant drain plug Crankshaft pulley i \ Noni Fuel injection pump [Leftview] oj drain plug titer Left view of engine “Turbocharger (exhaust outlet) inlet Oil file. Lad Coolant outlet Hanger | A “Thermostat case Flywheel housing. hj Rear LJ Froat =e] > iterator Ese J U 6 ee (| fl ‘V-belt De Starter Ria view] ‘Oil pan Right view of engineGENERAL (7) 86S distributor-type fuel injection pump specification Fuel filter Fan, ‘ Water pump (Coolant inlet) Front Fuel injection pump’ Oil filler Exhaust outlet Hanger Fuel inlet Flywheel housing, Rear] |= | Starter’ “Magnetic valve Air inlet vise a oe i : oO. | | | a a ‘Oil level gage a — uta ‘Hanger cwimte _ Frm lw, ean U oa ; U = =GENERAL (8) S6S-DT distributortype fuel injection pump specification Fal filter Fuel inet Magnet valve a {top solenoid) \y pape ‘Water pump eo a = = a eee ott ee ‘oil drain plug Left view of engine ‘Turbocharger (exhaust outlet) Aivinlet Hanger Coolant outlet Thermostat case Flywhee! housing, Alternator Rear Front ‘Damper Starter’ ola ‘V-belt [Right view] Right view of engineGENERAL 1.2 Outline of Fuel System (J) S45 in-line fuel injection pump (swirl chamber) specification Fuel filter, Fuel leak-off pipe Fuel injection pump’ Fuel inlet Outline of fuel system @)_S4S-DT in-line fuel injection pump (direct injection) specification Fuel leak-off pipe Fuel injection nozzle Fuel return pipe Fuel injection pump” Fuel Teak "Fuel inlet Outline of fuel system 1-10GENERAL ()_ SAS distributor-type fuel injection pump (swirl chamber) specification ter al Fuel leak-of pi Fuel filter ga pipe te Fuel injestion nozzle Fuel return pipe oct leak Fuel injection pump ‘Outline of fuel system (4) S4S-DT distibutor-type fuel injection pump (direct injection) specification paee. Fuel leakoff pipe Fuel injection nozzle peer Foelretum pipe "Fuel leake Fuel injection pump Outline of fuel systemGENERAL (5) _S6S in-line fuel injection pump (swirl chamber) specification Fuel filter Fuel leak-off pipe Fuel injection nozzle Ory Fuel inlet Outline of fuel system © s6s-DT Fuel filter Fuel leak-off pipe -Fuel injection nozzle Fuel return pipe Fuel injection pump’ "Fuel leak Fuel inlet Cutline of fuel systemGENERAL (1) $68 distibutor-type fue! injection pump (swirl chamber) specification Pal filter Fuel inlet Fuel leake-off pipe Mt Fuel injection nozzle Fuel return pipe ul leak Outline of fuel system (8) $6S-DT distributor-type fuel injection pump (direct injection) specification Foe! filter, uel retum pipe "Fuel leak: Fuel injection pump’ Outline of fuel system 1-13GENERAL 1.3 Outline of Lubrication System (Q)_ S43 in-line fuel injection pump specification Pushrod Piston Valve mechanism (Crankshatt ‘Tappet__| caiman Relief valve Oil main gallery: il filter Teter gear ——t6 Fuel injection pump ill pump’ Ol strainer ‘Oil pan Outline of lubrication system (2) S4S-DT in-line fuel injection pump specification Idler gear Fuel injection pump: ‘Relief valve il pump’ Oil strainer Safery valve are Outline of lubrication system 1-14GENERAL a EEEEEENEEEEma () $48 distributor-type fuel injection pump specification Pison —_Yalve mechanism Pashrod Crankshaft fi Tappet Gusar Relief valve 7 =a Oil main gallery- By Idler gear” >) : Oil pump” ‘Oil filter, Ot ssiner ‘oi pan Outline of lubrication system (4) S4S-DT distributor-type fuel injection pump specification il main gallery. Idler gear: | Retiot valve Crankahat Oil pump’ Pon ater Oi sine’ \afey valve” Oil pan Outline of lubrication systemGENERAL (S) $68 in-line fuel injection pump specification Pushroy “Tappet. Camshaft —} i main gallery —| ‘oil strainer bil pan (Outline of lubrication system (©) S6S-DT in-line fuel injection pump specification Oil strainer ‘Safety valve ‘Oil pan ‘Outline of lubrication system 1-16GENERAL (7) $68 distributor-type fuel injection pump specification Piston Crankshaft Relief valve Oil filter Oil strainer ‘oil pan Outline of lubrication system (8) S6S-DT distributor-type fuel injection pump specification Safety Oil strainer Outline of lubrication system 1-17GENERAL 1.4 Outline of Cooling System a) s4s Coolant outlet, Cylinder head ‘Thermostat Bypass pipe Winer jacket Water pump, Coolant inlet Outline of cooling system @) s4s-vT Coolant outlet, ‘Thermostat Bypass pipe. Water jcc ‘Water pump- Coolant inlet Oil cooler’ Outline of cooling systemGENERAL @) s6s Cylinder head Coolant outlet ‘Thermostat, Bypass pipe. Water jacket Water pump. Coolant infet Outline of cooling system (@) s6s-DT ‘Coolant outlet, (Cylinder head Water jacket Coolant inlet Oil cooler Outline of cooling systemGENERAL 1.5 Outline of inlet and Exhaust Systems (Q)_ Non-turbocharged engine ‘Air breather hose oe mmc P UP lita air Banaust ges PL] « [ = — O Outline of inlet and exhaust systems oo Prt Exhaust gas Sint sir WS Blow-by gas t Air breather hose & (Open {9 atmosphere Exhaust manifold ° inlet manifold Cutline of inlet and exhaust systemsGENERAL —————— 1.6 Engine Serial Number ‘The engine serial number is stamped on the side of the crankcase. Engine serial number HT lol tJ lol A 'S4S engine serial number location te EDs av fl LCL 6 ‘86S engine serial number location 1.7 Engine Model and Application Code ‘Non-turbocharged engine ‘Turbocharged engine {a Swirl chamber Combustion retot { Baas vweweses Direct injection Series code ‘Number of cylinders General Machinery & Special Vehicle Headquarters(Sagamihara)GENERAL 2. Specifications 2.4_S4S indine fuel injection pump specification (may differ in detail) Engine type sS SDT Type Titsubihi diel engine [Cooling method ‘Watercooling No. of strokes -estroke cycle No. of cylinders eylinder arrangement 4 in-line [Combustion method Suir chamber [Dive ingestion Valve mechanism ‘Overhead # [Cylinder bore x stroke ‘aim ia] 3452120 3.701 47H] © [Total displacement 4 {cu in] 3.331 (203) & [Compression ratio Bz 1 7 @ [Fuel ‘Diesel fuel GIS No, D equivalent) & [Firing order 1342 & | Rotational direction “Counterclockwise as viewed from flywheel side f reel aaa 781 (30.7) ‘mm {in] Dimension (Overall width ein oo. $67 22.3} eee 717 (282) 815 (32.11 Dry weight kg fb.) 245 [540] 250 (551) {Cylinder sieeve pe Dry Gatepral with eylinder Block) A ‘Compression ring: 2 § [Piston ring No of ings Oi rig (with expander T = (Open BIDCIO" BIDCIE Blues Inletvalv® [Close ‘ABDC 50° ‘ABDC 54" ane Exhaust — [Open BBDC 74° BBDC 66" 2 vale [Close ‘ATDC30° ‘AIDC 22" 4 | Sartng system lest saver Stating aid Glow plug Type. In-line (Bosch Type A) fen eee Peneetemt 6710.28) 69035] Feed pump ips Piston pump (Boseh) Speed control |Governor stem Contig £ Type. Bosch Type RSV. & [ype Tirole nozzle (Bosch) Hole nozzle (Bosch) i [No. of spray holes. 1 4 aE a ee $1.0 [0.039] 60.28 [0.011] Injection nozle mm fin] Sevan = 155° Valve opening sue 11.77 (120) (1707) 1765 (180) 2561] Pa (kaffem psi] Fue filter Type Paper-clement caridgeGENERAL, Engine pe SS SSDE Tbricating method Forced circulation oil pump pressure feed) (Grade (API service mi ae Seca (Class CF (SAF30 equivalent) gine ol Capacity Entire engine: 10 [2.64], £{US.gal] il pan: Maximum of 9 (2.38, oil filter: 1 [0.26] Tipe ‘Trochoid g Speed ratio to i 2 |oil pump crankshaft a 2 Discharge capacity | 286 7.6] at O3MPa G keen) (43 psi] discharge pressure of & ¢{USgal]/ min ppamp running at 2230min" 3 Type Piston valve 5 | peti Valve opening Bi | Relief valve pressure 0.3820.05 (3.620.5) [5147] ‘MPa (kgficm") [psi] ‘Valve opening Safety valve pressure - 1.10 156} ‘MPa (kgf/cm [psi] [Oil cooler Type = ‘Waier-cooled, multi-plate (Oil filter Type ‘Paper-clement cartridge Cooling method ‘Water-cooled, forced circulation (Coolant capacity (engine water jacket) aa races 55 [145] 1132] Type ‘Ceniifugal volute pamp Speedratio to i Water pump crankshaft 4 Decaecapacly | 160 G3] a 075 Mia C73 eae) [107 pal dicharge 3 £{U.S.gal] / min| ‘pressure of pump running at 3600min"* 2 Type Pusher (PP fan) 5 | cool No. of blades 6 Cooling fan of a & out meer $440 1173) Vibe Type Raw-edge cog V-belt Type B* 1 [ype ‘Wax Thermostat Waive opening 76.5215 [169.722.7] E ‘Approx.90 [194] when fully opened) CLF] i Air cleaner Type Paper element | Turbocharger type - ‘Dom iGENERAL ngine type SS SDT [Voltage ~ polarity TEV =negative ©) ground | 24 V negative C) ground Fiype MBTISITL M2TSSO71 Pinion mesh type Pinion shit Starter [Output V-W. 1222 I 2432 PinionFing gear as 122 Type Sophase alternating: current generator, builtin reciier Output ____V-A BE 24-25 eerie 1000 to 18000 Rated output ahectate generating speed 3000 Maximum permissible speed 22000 min Speed ratio i crankshaft : [Type Sheathed { loons aaa ae a) & s y-a{ _@0-second application) (G0-second application) i Operating 3 voltage 810 14 (for 12.V) 16 t027 (for 24 V) a v ie &]Openting 3 S| temperature 30 t0 90 [-22 to 194] Eater Rated time 10 or less see liana Dar les 17 ores Stop solenoid Rated voltage (option) Vv Ee a Rated 20 [68] ee °C iy Shama i Be absorbing. ss Py A Rated hold current 1 06 AGENERAL 2.2.68 in-ine fuel injection pump specification (may differ in detail) Tngine (ype 3 SDT ie TMiisab ih diesel engine (Cooling method ‘Water coo [No.of strokes “stroke cycle No. of cylinders ~eylinder arrangement in-line [Combustion method Swidchamber——_|___Direet injection Valve mechanism Overhead 4 [Colinder bore x stoke ‘mmfin] 34120 [3.701 AT] [Total displacement ‘fein 4.996 [303] & [Compression ratio. Bl 1 TH ‘G [Fuel Diesel fuel GIS No. 2 equivalent) & [Firing order 15-56-24 & [Rotational direction CountecTockowise as viewed fom Ajwheel side = (Overall engih ae ‘om fin] Dimension Senet] 579 [22.8] ee, 748 [29.4] 839 (33.0) Dryweight ig [ib 335 (7611 335 TH [Cylinder slave riype ‘Diy (integral with cylinder Block) , 5 ‘Compression ring: 2 § [Psonsing Nocorigs ‘Giring (with expander)T £ Tet vane FOREE BIDC0" BIDCIE Bae Ne TClose ‘ABDC 50° “ABDC 54° 2 ing Exhaust [Open BBDC 74° BRDC 66" 2 vatve [Close TATDC 30" ‘ATDC22° © [Saning atom Blecirc sarier Starting aid Glow plug [iipe Treline Bosch Type AD fee eee eet 6710.28) 6910.38) Feed pump Fiype Piston pump (Bosch) Speed contol aan Governor |system al i Type Bosch Type RSV. g [ype “Tiros nozzle (Bosch) Hole nozzle Gosch) q No. of spray holes 1 4 £ Spray hole diameter ; 1.0 [0.039 0.28 0.011 Injection nozzle mm fin) oe Loess) Sprayangle F 15 Valve opening presse 11.77 420) (1707) 17465 (180) (2561) MPa (kgf/cm?) psi} uel Aker Type Paper-lementcarridge 1-25GENERAL Engine pe 36S SET Eubricating method Forced circulation (oil pump pressure feed) Gea GPT seve Class CF (SAESO equivalent Engine oi! Capacity Enlre engine: 12.5 (5.30), £fUS.gal)| __Oil pan: Maximum of 11.5 [3.04], ol filter: 1 [0.26] Tipe Trochoid i ‘Speed ratio to aaa 2 Joi pump crankshaft s Discharge capactiy | 38.7 {10.2} at 03M¢Pa G kaon) [43 pl] discharge pressure of § ¢{US.gal] / min ‘pump running at 2230min 3 ype Piston valve | ketlet vabe Valve opening 3 | Patiet vat pressure 03540.085 (.620.5) [S127] MPa (kgt/em’ [psi Valve opening Safety valve pressure i 1.1 156) MPa (kgflem?) [ps] [Oil cooler Type = ‘Water cooled, muli-plaie [Oil fier Fiype Paper-element cartridge [Cooling method ‘Water-cooled, forced circulation Coolant capacity (engine wate jacket) ahaa opal 8p] ype Centrifugal volute pump ‘Speed ratio to i | Water pump crankshaft a Discharge capacity | 160 [42.3] a 0.75 MPa (7.5 katfem’) (107 psi] discharge B 4£{U.S.gal} / min’ pressure of pump running at 3600min'* # Type Pusher (PP fan) 5 | cool No. oF blades 7 iB eae [Outside diameter $500 [1927 ‘mm fin} Ce VobelE ype ‘Raveedge cog V-belt Type B = 1 [ype Wax Valve opening Thermostat, 76.521.5 (169.722.7] eee (Approx.90 [194] when fully opened) LF Lecce fae Peper nen | Trbocharger Type 7 ‘TEO6H 1-26GENERAL Engine pe 3 SDT [Voltage - polarity ‘12 V- negative (-) ground ‘24 V - negative (-) ground Type ‘3167671. ‘M8T60373 Pinion mesh type Pinion shift Starter | Output | V-KW] 123 L 24-5 Piniowing gear bing ioniz2 [ype 3 phase altemating-curent generator, builtin vecifier Output —__V-A 12:50 l 2425 Working: eee 1000 to 18000. Rated output oe venga 000 Maximam permissible speed 22000 min” Speed ratio a crankshaft = ‘Type Sheathed Eloi sug Rated age 10397 2330 & v-a[ _ G0-second application) (@0-second application) g (Operating i voltage 80 14 (for 2V) 16 t027 (for 24 V) v ig EE] Operating S|temperature 30 to 90 [-22 to 194] & $C PF] {Rated time 0orless see! eeeeena| 22.6 or less 11.7 or less Stop solenoid Rated voltage een a 2 24 Rated 20 [68] sc] BS Rated jobserving Bel 35 29 A Raed hold current 1 06 A 1-27GENERAL 2.3. S4S distributor-type fuel injection pump specification (may differ in detail) i Engine type 3S SEDI ripe ‘iisubihiaisel engine (Cooling method ‘Watercooling [No.of strokes “stroke cycle No. of cylinders~ cylinder arrangement 4 inline (Combustion method ‘Switlchamber | __Direet injection "Valve mechanism Overhead 2 [Cylinder bore x stoke mm fin] 345120 [3.701 x47] [otal displacement “feu in] 3331 [05] & [Compression ratio Dl I 1s = [Ruel Diesel fuel GIS No. 2 equivalent) & [Firing onder 1342 & [Rotational direction ‘Counterclockwise a5 viewed from flywheel side = oreatiagh mai bon Dimension ene 567 [223] Crea [tirana asta Dry weight kg ib] 245 [540] 230/55) [Cylinder sleeve Tipe ‘Dry Gategral with cylinder block) ston ri 5 ‘Compression rng: 2 § [Pstonring No. ofrings ‘ing wth expander 5 Tavane [OPS BIDCI0" BDC BY save an (Close "ABDC 50" ABDC 54 iS eecannee Exhaust [Open ‘BBDC 74" BBDC 66° 2 [valve [close ‘AIDC 30" ‘AIDC22° Staring sytem Blestc ater Starting aid Glow plug Tipe Distributor (Bosch Type VE anaes beeen 101039] 11 [043] Feed pump Type. ‘Vane pump (Bosehy ‘Speed control . [Governor |sysem Centrifugal § ‘Type “All 3 [ype ‘Tiarottle nozzle (Bosch) Hoole nozzle (Bosch) 3 (No. oF spray holes 1 5 a Spray hole diameter 1.0 [0.039] $0.20 [0.008] Injection nozzle 2m fin pray anale © TSO (wares with specification) ‘Valve opening pressure 11.77 (120) (17071 1765 (180) [2561] ‘MPa (kgm! [sil Fuel iter "Type Paper-clementcarridge 1-28GENERAL — Engine ype SS SDT Tabricating method Foreedsirculation oil pump pressure feed) os eee (Class CF (SAE30O equivalent) ae Capacity Entire engine: 10 (264), 2{US.gal) (Oi pan: Maximum of 9 [2.38] ofl filter: 1 [026] Type “roche Speed ratio fo aaa Oil pump crankshaft Discharge capacity | 286 [7.6] at 03MPa G katom') [43 psi] discharge pressure of 2{US.gal] / in ‘pump running at 2230min" Type Piston valve : Valve opening pene pressure 0.35#0.05 (.640.5) [5127] ‘MPa (kgfiem?) [psi] Valve opening Safety valve pressure - 1.1 (11) 156) MPa (ket/em?) [ps (Oil cooler Type = ‘Waier-cooled, multi-plate Oil filter Type Paper-clement cartridge [Cooling method ‘Water-cooled, forced circulation [Coolant capacity (engine water jacket) Cae 55 [143] $1.32] Centrifugal volute Speed ratio to a Water pump crankshaft & [Discharge capacity 160 [42.3] at 0.75 MPa (7.5 kgffem*) [107 psi] discharge 3 ‘{{US.gal] / min ‘ressure of pup running at 3600min 2 —Type Pusher (PP fan) 5 | coslt No, of blades 6 Oana: Outside diameter euntGal ‘mm {in & Webalt Type Raw-edge cog V-belt Type B= 1 ‘Type ‘Wax Thermostat, valve opening 76,521.5 (169.742.7] ‘Approx.90 [194] when fully opened) $c i & | air cleaner Type Paper element i 2 | Rebocharger Type i ‘Too =GENERAL Engine ype MS SDT Voliage~ polarity T2V = negative @) ground | 24 V- negative C) ground [ype MBT7SI71 M2TSSO7L ion mesh type Pinion shift Starter ‘Output VW. 12-22 I 2432 Eee a 1on22 [ype ~3;phae altemating-ourent generator, bul-in rectifier Output VA 1250 1 24-25 eee ier 1000 to 18000 Rated output ase generating speed. 5000 ‘mi Maximum permissible speed 22000 § min 5 Speed ratio to 20 z crankshaft : : Type Sheathed i | Glow plug eee 105-97 23.30 -v-a| _ (0-second application) (G0-second application) eee 2 24 Power consumption 20 “4 al Ww. Start voltage Stop solenoid Fe 7 63 or less 1Borless BQ |Reoovey voltage 2.5 or more 5 ormore v coi resistance 8 37 a)GENERAL —_— 2.4 S85 distributor-type fuel injection pump specification (may differ in detail) Engine ype. So SEDT 7] Tipe ‘Mitsubishi diesel engin [Cooling method. ‘Water cooling No.of strokes a-sroke eycle [No.of cylinders eylinder arangement 6 in-line Combustion method Sor chamber [___ Diet injestion Valve mechanism Overhead Cylinder bore x sake ‘mm fia] 94 120 [3.701 «A724] "Total displacement feu in 4.996 [305] [Compression ratio Tal T cea Fuel ‘Diesel fel GIS No. 7 equivalent) Firing order, 153-624 Rotational recon Countetelociise as viewed fom fijwheel side Overall length 1033 (40.7) mm fin] Overall width Dimension ane 379 (22.8) omnicef aweea Eq Dry weight kg {ib} 345 [761] ‘355 [783] Cylinder sleeve ripe Dy ae wa Best Piston ri No. of in ‘Compress & [Pitonsing es Oisay toma s Tmecvave BIDCIO™ BIDCI Leer [Close ‘ABDCS0> ABDC 54 2 Exhaust [Open BBDC 74° BEDC 66° 3 valve [Close ‘AIDC30® ‘ATC 22° | Starting system Elecite starter Starting ad Glow plug Type Distributor Bosch Type VE) eee erate $10 [039] 11 [0.43] Feed pump os ‘Vane pump (Bosch) Speed control Governor | system Contrifuga! & Type ‘All $ [ype Throne norle Bosch) Hote nozzle ose) 3g No. of spray holes 1 3 g Spray hole diameter 2 ee a 61.0 (0.039) e020 (0.008) pray angle 5 TSOF(waries with specification) ‘Valve opening pressure 11.77 020) (17071 1765 (180) [2561] ‘MPa (ketem?) [oi] Fuel ter Type Paper clement cartridgeGENERAL Engine type 3S S6SDT Lubricating method Forced circulation (oil pump pressure feed) (Grade (APT service a i feoancaia Class CF (SAE30 equivalent) Erect [Capacity Entire engine: 12.5 330), £{US.zal] il pan: Maximum of 11.5 {3.04}, ol filter: 1 (0.26) ype Trochoid g Speed ratio to 3 |oit pump Jrankshaft ae s Discharge capacity | 38.7 [102] at 03MPa ( Kgffem [43 pal] discharge pressure of g #{US gal] min ‘pump running at 2230min" Type Piston valve 3 Valve opening 5 | Relief valve pressure 0.3540.05 (3.60.5) [5147] ‘MPa (kaflem’ [psi] Valve opening Safety valve pressure - 1.111) (156) MPa (kgflem [psi] Oil cooler Type = Water-cooled, multi-plate Oil iter [Type Paper-clement cartridge Cooling method ‘Waier-cooled, forced circulation ‘Coolant capacity (engine water jacket) oA) spa US; Type ‘Centrifugal volute pamp ‘Speed ratio to a ‘Water pump crankshaft g Discharge capacity 160 [42.3] at 0.75 MPa (7.5 kaffem [107 psi] discharge ‘{{USgal]/ min pressure of pump runing a 3600mia" gz Type ‘Pusher (PP fan) 8 | cot No. of blades 7 Cooling fan hes g eee eel $500 [19.71 Webel Type Raw-edge cog V-belt Type BT [Type Wax Valve opening Thermostat T6.521.5 (169.42. Pee (Approx.90 [194] when fully opened) °C [°F] g & | Aircleaner Type Paper element g 2 | Torbocharger Type - ‘TEO6HGENERAL Engine pe 3S sear [Voltage = polarity ‘12 V = negative (-) ground 24 V - negative (-) ground "ype MITSISTL METOS7S Pinion mesh pe Pinion sil Staer Output VW Ba i 25 Pinko ag ar ae ratio ripe pase aliorating-curent generate, buleineciir [ouput WA 12-50 i 24:95 eras 1000 to 18000 Rated opt Fee eeeaine re 5000 Mecimam ; permissible speed 22000 5 ‘nin 3 cnmtshat baud 5 ‘Type Sheathed Bi | Glow plug aed vounee 1059.7 233.0 sent | -Glbsecond application) | G0-econd aplication) a oe 12 4 Power consumption 20 14 a w sop sled E Sfsarvoraee G3 orles pele ‘tion (cption) ES | Recovery © votage 2.5 ormore Sormore vI ‘Coil resistance 8 37 AGENERAL 3. Tips on Disassembly and Reassembly This service manual describes service _provedures, recommended by Mitsubishi Heavy Industries Ltd, and also contains information of special tools and basic safety precautions. It should be noted that the manual cannot cover all potential dangers in maintaining, inspecting and servicing an engine. ‘When working on the engine, follow the directions in this ‘manual and pay close attention to the following cautions. 3.1 Disassembly )_ Use correct tools and instruments. (2) Arrange a work bench and boxes for placing removed parts, if necessary, and follow the specified disassembly sequence, (3) Lay down disassembled parts neatly in order to prevent losing them. (4) During disassembly, pay attention to alignment marks to ensure proper reassembly and if necessary, put additional marks on parts to aid reassembly. (S)_ Carefully check each part for abnormalities before disassembly and also during removal and cleaning in order to discover any signs of abnormalities or defects that may not be found after cleaning. (© Exercise utmost caution to ensure safety, particularly for balancing removed parts and transporting heavy parts. (Use jacks and chain blocks when necessary.) 3.2 Reassembly (1) Wash all engine parts, except for oil seals, O-rings, rubber sheets, etc, in cleaning oil and dry them with compressed air. 2). Use correct tools and instruments. G) Use only high-quality lubricating oils and greases. (@) Be sure to apply a coat of oil, grease or sealant to parts as specified. (5) Use a torque wrench to tighten parts to specified tightening torque when tightening torque is indicated. (©) Replace all gaskets, packings and O-rings with new ones unless specified otherwise.MAINTENANCE STANDARDS 1. Maintenance Standards Table-- 1-36 2. Tightening Torque Table 2.1 Important Bolts and Nuts------ 2.2 Standard Bolts and Nuts: 2.3 Standard Eye Bolts - 2.4 Standard Union Nuts. ~ 2.5 Standard Plugs -- - 1-42 1-42 3. Sealants and Lubricants Table---MAINTENANCE STANDARDS 4. Maintenance Standards Table Unit mm fin i Inpetion pois Nominal vai | Standard init | Rema é ‘Maximum speed (no-load) 5 aay jon Adjust governor ‘Minimum speed (no-load) deccemaing 2 eneine Secon setting. 325 MP 2.84 MPa Set cheer sn. 29 hafe0) | ana water ‘Compression (at 300 min") (412 psi] temperature at em Gogten’) ae leery Diet jection @rigtin) [eee (384 psi) (a1 300 in) Taso 049 aaa at 1500 min* (1skatem . . al [Oiltemperure ‘Lubricating, at 70 to 90°C oll preasure, 0.05 MPa_- |[158 to 194°F) Idling (0.5 kgflem’) theater 2p (rare |BTDC 30° [BTDC 18° i niet valve open JABDCSIP Swink |ABDCS4? (Direct Vavetinng tv, sled BDC 14° Gamer) [BDC 60° jection) Exhaust valve sed ee eee |+3° (crank angle) +3° (crank angle) Bob iaeand sive clearance (Col) 025 (0.005 eel ‘The timing for ech mode of gine rks coding is ‘nlecti simnis specification. Ful injeton sar timing peidonion. tc tming by referring to the specifications of cach mode Detection ven ow resed wth beeen [0.39 to 0.47) thumb 98 N (10 my : TOIT THAD g [Reser sing #19 (0.7480) | 16-7484 to 07499] : ; 9800 19.000 | 190-7480) | aSsan2 07 80) 2 | lemance between bakingand @g1O 0050 a shaft [0.0003 to 0.0020) | 0-070 {0.00281 34016 7955 4 ave sem Inlet 681031801 | fo 5126190.3132)| 7900 (03110) | [tim fanaa | esos | 52220079, | 2s 03000 z 0.065 to 0.095 #1 Sls. [om jonas w coosn| 0150100055 ide clerance oad wo. /Exhasut 0.0031 wo 0.0045) °200 10.079] ; ; B90 Tal Heigwiowpotvaveance | 105i [9 d2Ststen 1-36MAINTENANCE STANDARDS Unit: mm fin} 3 Inspection point ‘Nominal value ‘Standard Limit Remark 6 Valve seat angle a [fam | catooisn | PSA Tossa 5 | ave sinkage 04 100.6 (0.0157 wi, z xnaust | asgooion [EEE] 10100304 4 |searwian raroossty [ptzi tsa] tatomin | Ee tete g Reams | gp oe | Valve margin 2.13 [0.0839] | permissible up to 183 (0.0720) ree engi aS LSA 47.60 (1.87) = A=13_ |A=1510.0591) 2 |Perpendicularity a. 10.051] | over entire . , Lf=4885] length 2 i 119) 5 BUTE spar Installation lengttviosd ough ae | 1509 44.1 1b] Bonon aee 0.05 [0.002] or | 9.20 0.0079] | Slightly reface tinder head} stortion Hess Cylinder head Compressed Topo | 1st 135 thickness of gasket _|_ 12104 {0.0453 to 0.0492) Ranout al E pening £ when pushrod is | Push rod Bend 0.3 [0.0118]or less supported along 2 centerline of 7 spherical surface a at either end. Flatness 0-15 10.0059)" | 9.50 (0.1971 Flywheel — TISTLOOT |p 200197 0.050 t0 0.150 y [Psst oad to 0.0039] °25010.096) [Replace sean, 100: Replace trast linwewatom copie) | tO, | onsen [EE E iat 2 canatt gered ey sioar | gotta ea | oxvooonn fS 6.384 106.788 eee linet 6.684 (0.2631) | gosh oo zehny| 6184102895] @,-D) 6.420 to 6.820 Exhaust 6.720 [0.2646] aire sampo2ues| 02 [0.0008] oF Repair or © Rocker cover © Rocker arm ® Valve cotter @ Adjusting screw © Rocker shaft spring ® Valve retainer © Bok (short) @® Rocker shaft @ Valve spring ® Bott (long) @ Valve cap ® Valve (N) © Rocker shaft bracket ® Pushrod ® Valve EX) © Snap ring ® Cylinder head bott @ Valve stem seal © Rocker am ® Cylinder head © Cylinder head gasket (Remove parts ® to @ asa unit)DISASSEMBLY OF MAIN ENGINE PARTS 4.4. Removing Rocker Shaft Assembly (1) Loosen the adjusting screw of the rocker by about one ‘urn, @) Loosen the shorter bolt of the rocker shaft bracket first. Loosen the longer bolt, then. Remove the rocker shaft assembly from the cylinder head. AC ION If these bolts are loosened in reverse order, the rocker shaft bracket may be damaged. 4.2. Disassembling Rocker Shaft Assembly In the course of disassembly, place removed rocker ‘components neatly in the order of disassembly so that they can be reassembled back onto their original locations, Doing so, original clearances between the rocker arms and the rocker shaft are restored upon reassembly. 4.3. Removing Cylinder Head Assembly Remove the cylinder head bolts. Lift the eylinder head and remove it from the crankcase. Note: Be careful not to damage the mount surfaces of the cylinder and crankcase when removing the gasket from the cylinder head, Before removing the cylinder head bolts, check the cylinder head components for any defects or faults. If faulty or defective, check the bolts for tightness ‘with a torque wrench. 1.4 Removing Valves and Valve Springs Push the valve spring evenly using the valve spring pusher (special tool), and remove the valve cotter. ‘Special tool name, Part No. Valve spring pusher 30691-04500 Note: Put match marks for easy identification of the ‘mounting position if the valve may be reused. When reassembling, do not change the combination of the valve seat and valve guide. ‘Removing valve and valve springDISASSEMBLY OF MAIN ENGINE PARTS Disassembly of flywhee! © Flywheel Oil seal @ Flywheel housing @ Gasket (Remove parts @ and @ as a unit) 2-4DISASSEMBLY OF MAIN ENGINE PARTS: 2.1. Removing Flywheel (1). Remove one flywheel mounting bolt. 2). Serew the safety rod (MI2 x 1.25) into the threaded hole, from which the mounting bolt was removed above. Remove the remaining bolts and remove the Tock washers. (3) Hold the flywheel firmly with both hands. Shake it back and forth to pul it out straight. PX Be very careful not fo cut your hand with the ring gear when pulling out the flywheel 2.2 Removing Flywheel Housing Remove the flywheel housing mounting bolts. Remove the flywheel housing, ZX CAUTION Be very careful not to damage the oil seal Removing flywheel housingDISASSEMBLY OF MAIN ENGINE PARTS: 3. Damper, Timing Gears and Camshaft Replace gasket Weuzdamess] 01 . 2 oe s ANC Ley een [Clogeing of ithe, wear] oo Replace O-ring [Wear e x “Wear of lip surface, damage, deterioration og Y ®) ‘Cracks, knock hole defects “Wear of belt groove (Cracks, knock hole defects Firat tamage Disassembly of timing gears © Damper (S68) © Timing gear case @ Camshaft gear @ Crankshaft pulley @® Oil pump gear @® Thnst plate © Cover © Thnust plate Remove parts ® to ® asa unit.) @ Fuel injection pump @ Idler gear ® Front plate © Oil pan ® Camshaft3 32 @ Q Removing Damper (S&S) Remove the mounting bolts, and remove the damper. Removing Crankshaft Pulley ‘Screw two bolts (M12 x 1.25) into the threaded holes at the rear end of the crankshaft. Prevent the crankshaft from rotating using a bar. ‘Remove the nut, and remove the crankshaft pulley. Removing Cover Remove the cover mounting bolts, and remove the Removing Fuel Injection Pump Disconnect the ol pipe. Remove the pump bracket. ction pump mounting bots, and DISASSEMBLY OF MAIN ENGINE PARTS Oil pipe” Pump bracket Removing fuel injection pumpDISASSEMBLY OF MAIN ENGINE PARTS: 3.5 Removing Oil Pan Remove the oil pan mounting bolts, and remove the oil pan, 3.6 Removing Timing Gear Case Remove the timing gear mounting bolts, and remove ‘the timing gears. 3.7 Removing Oil Pump Gear Remove the gear mounting nut, and remove the oil pump gear. 3.8 Removing Idler Gear Remove the thrust plate mounting bolt, and remove ‘the thrust plate and idler gear. ‘Removing idler gearDISASSEMBLY OF MAIN ENGINE PARTS 39 Removing Camshaft (1). Reverse the crankcase. (2). Face the lightening hole in the camshaft gear up and down, Remove the thrust plate tightening bolts, and remove the camshaft from the erankease. PAOLO) NI ‘Be careful not to damage the cam of the camshaft and ‘the camshaft bearing of the crankcase. 3.10 Separating Camshaft Gear Punch out the camshaft gear from the camshaft using a hydraulic press. Note: The camshaft gear and thrust plate will not separate unless they are defective. 3.11 Removing Front Plate ‘Remove the front plate mounting bolts, and remove the front plate from the crankcase. Removing eamshaft Punch out with press ‘Removing front plateDISASSEMBLY OF MAIN ENGINE PARTS. 4. Pistons, Connecting Rods, Crankshaft and Crankcase ‘Wear, damage Fatigue] Vv. @ Cracks, clogging ofoil hole ‘Wear, clogging of ol hole Oo Thread damage || ~ Cracks, wear of seration Flaws of inner and outer peripheries, ‘fusing, separation, wear Clogging of oil hole Scale adhesion, corrosion, sganiin | of oil hole, wear Flaws, cracks, denis, clogging Separation, uneven contact Note: [fnew crankcase isto be installed, carefully remove relief valve and other parts from old crankease and reuse them. racks ‘Thread damage Disassembly of pistons, connecting rods, crankshaft and crankcase < Nat @ Piston pin ® Tost plate ® Connecting rod cap © Piston © Lower main bearing © Connecting od bearing @ Connecting rod © Crankshaft @ No. ring ‘Remove parts ® to @ asavnit) (® Upper main bearing © No. 2ring ® Bearing cap bolt ® Tapper © Oilsing ® Main bearing cap © Crankcase © Snap ring ® Side sealDISASSEMBLY OF MAIN ENGINE PARTS 4.1, Removing Connecting Rod Caps (1) Remove each connecting rod cap tightening nut, hit the tip of the tightening bolt evenly almost squarely with an iron hammer, and remove the cap when the cap-side reamer comes off @) Clazfy the cylinder number and the upper and lower parts of the removed connecting rod bearings. 42. Preparation for Pulling Out Pistons (1) Tumthe crankease on its side. @)_Ifcarbon adheres to the upper part of the cylinder, the piston may be difficult to draw up. Remove carbon ‘with waste cloth or oil paper. 43. Pulling Out Pistons Move the connecting rod to the top, apply the hammer grip to the larger end of the connecting rod, and pall out the piston to above the crankcase. 4.4, Removing Piston Rings Remove the piston ring with the piston ring pliers (special tool). ‘Special tool name PartNo. Piston ring pliers 31391-12900 Preparation for pulling out pistons Pulling out piston 2-11DISASSEMBLY OF MAIN ENGINE PARTS 45 QM @ @ Removing Piston Pins ‘Remove the snap ring using the snap ring pliers. ‘Draw out the piston pin. Separate the piston from the ‘connecting rod. ‘Heat the piston with a piston heater or hot water if the piston pin is hard to draw out. 4.6 Removing Main Bearing Caps Remove the main bearing cap tightening bolts, and remove-the main bearing cap with the lower main bearing attached. Remove the rearmost main bearing cap using the drawing puller. Note: Be careful not to damage each lower main bearing. Put the removed main bearings inorder so as to re- assemble them inthe same positions. 4.7 Removing Crankshaft Attach a hoist to the crankshaft, host it horizontally, and remove the crankshaft upward slowly. Note: Be careful not to damage each upper main bearing. ut the removed main bearings in order so as to re- assemble them in the same positions. 4.8 Removing Tappets ‘Remove the tappet. Note: Put the removed tappets in order so as to reassemble them in the same positions. Removing crankshaftINSPECTION AND REPAIR OF MAIN ENGINE PARTS 1. Cylinder Head and Valve Mechanisms -- 4.1 Measuring Rocker Bushing Inside. Diameter and Rocker Shaft Outside Diameter 4.2. Measuring Valve Stem Outside Diameter =~ 4.3. Meesuring Glearance between Valve Stems and Valve Guides «++-++++++ 2-14 + 2-14 14 Replacing Valve Guides 245 4.5 Checking Valve Faces - 2-46 116 Repairing Valve Faces 2-16 4.7. Repairing Valve Seats sees 2-7 1.8 Replacing Valve Seats -+--~ + 247 1.9 Facing Up Valves and Valve Seats + 2-48 4.10 Measuring Tilt and Free Length of Valve Springs «++ ses 218 4.11, Measuring Distortion of Cylinder Head Bottom Surface - + 249 4.12 Measuring Bend of Pushrods «++-- 2-19 4.13 Replacing Combustion Jets - . Flywheel, Camshaft and Timing Gears * 2.1 Measuring Flatness of Flywheel ---- 2-20 2.2. Checking Flywheel for Deflection «-- 2-20 2-20 2 2.3. Checking Ring Gear 2.4 Replacing Ring Gear - 2.6 Measuring Backlash and End Play «== cana 224 2.6 Measuring Cam Height: --~ 2-24 2.7. Measuring Bend of Camshaft 2-22 2.8 Measuring Camshaft Joumal Outside Diameter and Camshaft Bore Diameter ===> 2.9 Driving Camshaft Bushi 2.40 Measuring Idler Bushing Inside Diameter and Shaft Outside | Diameter = 2.11 Replacing Idler Shaft -++++ 2.42 Checking V-Belt Groove of Crankshaft Pulley for Wear =~ 2.43 Checking Damper (S6S) ---- tos 8 3. Crankcase, Pistons, Connecting Rods, Crankshaft and Tappets: - - 2-25 3.1. Measuring Distortion of Crankcase Top + 2-25 ‘Surface «++ 32. Measuring Cylinder Inside Diameter 3.3 Measuring Piston Outside Diameter -- 34 Measuring Clearance of Piston Ring Abutments *+ 3.5 Measuring Piston Ring Grooves ---- 3.6 Measuring Piston Pin Bore Diameter ‘and Piston Pin Outside Diameter --- 2-27 3.7. Measuring Piston Projection «------ 2-27 3.8 Measuring Clearance between Connecting Rod Bearings and Crank Pins -- vs 2-28 3.9 Measuring Clearance between Connecting Rod Bushings and Piston Pins 2-28 3.10 Replacing Connecting Rod Bushings-~ + 2-29 3.11 Checking Bend and Twist of Connecting Rods «-+ 2-29 3.12 Checking Connecting Rod Bearings +++" 3.13 Measuring End Pl Rods «-* 3.14 Replacing Connecting Rods 3.45. Measuring Crank Journal Outside Diameter -- 3.46 Measuring Crank Pin Outside + 2-30 2-30 2-30 + 2-30 ++ 2-31 2-31 3.17 Grinding Crankshaft -~ 3.18 Measuring End Play of ‘Crankshaft ++++-+ 2-32 3.19 Measuring Bend of Crankshaft 2-32 3.20 Replacing Crankshaft Gear ++ 2-33 3.21 Checking Oil Seal Contact ‘Surface feneniee 2-33 3.22 Checking Main Bearing Surfaces -+» 2-34 3.23 Measuring Clearance of Main Bearing ~~ s+ 2-35 3.24 Checking Contact Surfaces of Tappet Cams: sete sees 2-35, 3.25 Measuring Clearance between Tappets and Tappet Guide Holes -- + 2-35INSPECTION AND REPAIR OF MAIN ENGINE PARTS. 1. Cylinder Head and Valve Mechanisms 1.1. Measuring Rocker Bushing Inside Diameter and Measuring Rocker Shaft Outside Diameter esasance Measure the inside diameter of the rocker bushing and the outside diameter of the rocker shaft, and calculate the clearance between them. Replace the rocker arm until the clearance reaches the limit. Also replace the rocker shaft if the clearance exceeds the limit, Unit: mm [in,] Nominal | Standard [Limit eanoe “Measuring rocker bushing inside diameter and rocker Rocker bushing | O19 | “to s4si3t0 shaft outside diameter fnsidediameter_ | [60.75] | Qrappi], Rocker shaft o0 |S. outside diameter | (0.75) | “O7agos} Carano TH10%0050 | 5 o7p oetweenrocker | - tncons9%6 | io oa76y bushing and shaft ooois7) _| 1 1.2 Measuring Valve Stem Outside Diameter Measure the outside diameters of the valve stems, Replace the valve stems if the limit is exceeded. Also replace the valve stems with remarkable uneven wear. ‘Unit: mm fin Nominal [ Sendard [Limit 734010 mer |_.28 | 7955 | 7.900 Valve [60.31] | (031260 | [0.31102] stem 031319) outside os | ame diameter 7940 | 7.850 Exhaust | 49:31) | 03118110] [0.30906] 031260] 1.3. Measuring Clearance between Valve Stems and Valve Guides ‘Measure the inside diameters ofthe valve guides. It is necessary o measure the inside diameters at the top @ and bottom ends at right angles with the inner surface, since the valve guides are subject to wear at both ends. Replace the valve guides when wear exceeds the limit. Unit: mm fin Measuring ‘Nominal | Standard | Limit position 0.0650 “Measuring valve guide inside diameter 0095 | 0.150 Ghaance | Inlet | =} .0025640| (0.00591) are 0.00374) valve stem 0.080% hardened : ais | 0200 ride | Bahaust |= | .0315 | (0.00787) 0.00453] Valve guide mounting] 14 [OIE length toss) | ssa 2-14INSPECTION AND REPAIR OF MAIN ENGINE PARTS 1.4 Replacing Valve Guides (1). Use the valve guide remover (special to! to draw out Vat guide J the valve guide. rover Special wool name PartNo. Valve guide remover 32491-00300 (2) Use the valve guide installer (special tool) to press-fit, the valve guide. E Special tool name PartNo. Valve guide installer 32491-00100 LAS N ‘The amount of press-ftting the valve Thus, be sure to use the valve guide installer. is specified, IS ‘Drawing out valve guide Unit: mm fin.] Valve guide Dez Press-fitting valve guideINSPECTION AND REPAIR OF MAIN ENGINE PARTS. 1.5. Checking Valve Faces Apply a shinmeitan thinly on the valve faces, and check contact with the valve seats using the valve lapper. Repair or replace the valves and valve seats ‘whose contact is not uniform all over the surface and some abnormality is detected or the limit is exceeded. Note: (a) Check the valve faces after checking or replacing the valve guides. (b) Do not rotate the valves with a shinmeitan applied when pressing them against the valve seats (©) Be sure to face up the valves and valve seats after repairing or replacing the valves or valve seats. Contact of valves with valve seals Unit: mm fin Nominal | Sundari [Limit Valveseatangio | 30° o4 | 03005 anit | ighf6) | (012% give ox) | 10 3 inkaye gs) b4008] (0.039) & xa] (oh3p) | (0I6t0 s 0.025) Ta |i26w 134 etree ar raosoy | Pacer | cou] Weis 23 (0.0720) eee (0.0839) when refaced 1.6. Repairing Valve Faces Repair remarkably worn valve faces with the valve re-fcer. Note: (@) Grind the valve face with the re-facer at an angle of 30 degrees. (©) Keep the valve margin exceeding the limit, Replace valves with new ones if their dimensi not meet the standard. 1s do ‘Valve lapper: Lae e_om ‘Checking valve face Good NG ‘Contact of valve with valve seat (1) angle Valve seat Valve Valve margin sinkage ‘Contact of valve with valve seat (2) Correcting valve faceINSPECTION AND REPAIR OF MAIN ENGINE PARTS 1.7 Repairing Valve Seats Grind the valve seats with a valve seat cutter or valve seat grinder. After grinding, polish them with #400 or ‘equivalent sandpaper placed between the cutter and valve seat. Note: (a) Keep the degree of repair of the valve seats to um. (B) Replace the valve seats whose widths exceed the limit due to wear or repair. 1.8. Replacing Valve Seats (1). Punching valve seats ‘Weld a stud or rod to valve seat, insert the shaft into the valve guide hole from the top of the eylinder head, ‘and press the tip against the welded stud to punch the valve seat. Note: Be careful not to allow spatters to adhere tothe machined surface ofthe cylinder head during welding. Q) Inserting valve seats Measure the inside diameter of the valve seat engagement ofthe cylinder head to make sure that it {is upto standard before inserting the valve seat. @) Insert the valve seat into the cylinder head by cooling it with either of the methods shown below. Cool the valve seat for four minutes or more in liquid nitrogen (at approximately -170°C [-274°F}) and then insert it, while keeping the cylinder head at room temperature. Heat the cylinder head at 80 to 100°C [176 to 212°F]. Cool the valve seat sufficiently in ether or alcohol ‘with dry ice, and then insert it. Insert the valve seat cooled with an insert caulking tool into the cylinder head. ‘Special tool name PartNo. ; Tnlet 36791-00200 Valve insert caulking 1901 Fsnqust 34491-03020 ‘Repairing valve seat veld Shaft, Valve seat Stud, ete ‘Punching valve seat Unit: mm fin] xy ery 45" | petartomn | [teas pom] 450 Inlet Exhaust Valve seat engagement g erting valve seatINSPECTION AND REPAIR OF MAIN ENGINE PARTS. 1.9 Facing Up Valves and Valve Seats (1) Be sure to face up the valves and valve seats after repairing or replacing the valves or valve seats. @ Apply compound uniformly and thinly to the valve surface to be faced up. Note: (a) Do not apply compound to the valve stem. (©) Use medium-grain compound (120- to 150- mesh) first. Then, use fine-grain compound (200-mesh or finer) then. (© Compound spreads more evenly if it is mixed with a small amount of engine oi. ) Faco up the valves and valve seats with the valve Japper. Hit the valve lapper against the valve seat while rotating the valve litle by little, (4) Remove compound with cleaning oil, ete. (5) Apply engine oil to the contact surface and face it up with oil (©) Check the contact of the valve faces. 1.10 Measuring Tit and Free Length of Valve Springs ‘Check the tlt and reduction of the free length of the valve springs. Replace the valve springs if the limits are exceeded. Unit: mm fin} Sandard iit 48.85 47.60 Free length [1.9232] [1.8740] @ =1.5° or less| A (ap)=13 |, @ 1.5 0.059] ‘Squareness [0.051] or less at Ylfeagas | Mloverleneth (1.9232) Mounting Tengtt/load, | 43/176 to 196 43/147 mmN| (43/180 20) (43/13) (mm/kgf) | [1.69/40 to 44] [1.69/33] fin /ib4] 2-18 ‘Compound ‘Applying compound acing up valve and valve seat Spring squareness (Gap) Free ‘Measuring tilt and free length of valve springINSPECTION AND REPAIR OF MAIN ENGINE PARTS 4.11 Measuring Distortion of Cylinder Head Bottom Surface ‘Apply the straight edge against the bottom of the cylinder head, and measure the distortion with the thickness gage. Grind the cylinder head with distortion exceeding the limit by a small quantity with the surface grinder. Unit: mm fin, Standard Limit Distortion of eylinder 0.20 hed bottom serfuce, | 00510-0020] orless | 19979) | 4.12 Measuring Bend of Pushrods Measure the bend of the pushrods. Replace the pushrods with the bend exceeding the limit with new part. Unit: mm [in] [Standard (Limit Bend of pushrod oar 1.13 Replacing Combustion Jets Replace the combustion jet only when it has cracks or other defects. (1) To draw out the combustion jet, insert a round rod of approximately 6 mm [0.24 in] in diameter through the glow plug mounting hole and hit the periphery of the inner surface ofthe jet lightly. @) Place the combustion rod with the jet hole horizontally and hit it with a plastic hammer, etc. ‘Measuring distortion of eylinder head bottom surface “Measuring bend of pushrod ‘Drawing out combustion jet ress-fiting combustion jet, 2-19INSPECTION AND REPAIR OF MAIN ENGINE PARTS 2. Flywheel, Camshaft and Timing Gears 2.1. Measuring Flatness of Flywheel Place the flywheel on the level block. Move a dial gage on the fiction surface of the flywheel to measure the flatness. Grind the friction surface ofthe flywheel if the limit isexceeded, Unit: mm [in ‘Standard Limit, Os [0.0059] 0.50 Flywheel flatness erica oo197 ‘Measuring flatness of flywheel 2.2 Checking Flywheel for Deflection Check deflection of the flywheel to see if it meets the standard Retighten the bolt ifthe deflection exceeds the limit. Unit: mm fin} ‘Standard Limit O.15 [0.0055] 0.50 Flywheel deflection Ain [00197 Chet ‘flywheel for deflection 2.3 Checking Ring Gear ‘Check the ring gear. Replace the ring gear if the teeth are cracked or abnormally worn. a yw 24 Replacing Ring Gear (Q)__ Removing ring gear Heat the ring gear evenly with an acetylene torch, etc. any Hit the ring gear evenly around the periphery with a hammer and a rod. Ring far @) Installing ring gear Heat the ring gear with a heater, etc. up to — approximately 100°C [212°F], and install it onto the ‘Removing ring gear {flywheel from the side of the non-beveled gear teeth. Note: Do not heat the ring gear excessively. 2-20INSPECTION AND REPAIR OF MAIN ENGINE PARTS: 2.8 Measuring Backlash and End Play ‘Measure the backlash and end play of each gear. Replace all gears with new parts, in principle, if the measured backlash exceeds the limit. Replace the thrust plates with new parts if the ‘measured end play exceeds the limit. Unit: mm fin] Standard Limit 0.050 0 0.150 0.250 Inter-gear backlash [0.00197 to o.oosery _{f9-00984] 0.050%00.200 | 9 350 End play of idler gear {0.00197 t0 Coo (0.01378) 0.100 to 0.250 0.300 End play of camshaft {0.00394 to o.oose4) [0.01181] 2.6 Measuring Cam Height ‘Measure the longer and shorter diameters of each cam with a micrometer. Replace the cams if the limit is exceeded. it: mm fin, Nominal] Stand — | Limit S384 106.784 6.84 6.184 cm [stm] Sin) Haste | Sta Profile 20 to 6.820 ©1-Da)| Bxtaust| 6.720 | S70 EEO | 6.200 cam foasisn) 0252764 lo.2ss]INSPECTION AND REPAIR OF MAIN ENGINE PARTS. 2.7 Measuring Bend of Camshaft Measure the bend of the camshaft. Repair camshaft with bend exceeding the limit with a press or replace them, Note: Apply a dial gage to the camshaft, rotate the ‘camshaft by one turn and read shaking of the pointer. Half of the reading is bend. Unit: mm Standard Limit. 0.02 [0.0008] | 0.05 eae cece: or less (0.0020) ‘Measuring bend of camshaft 2.8 Measuring Camshaft Journal Outside Diameter and Camshaft Bore Diameter ‘Measure the outside diameter ofthe camshaft journal. Replace the camshaft journal ifthe limit is exceeded. Unit: mm fin.) ‘Nominal | Standard | Limit No. 1,2 33.94 10 (S4S)_| 454 | 53.96 | 33.90 Camshatt No. 1,2,3] [62.13] | (2:1236t0 | (2.1220) journal | _(Sés) 2.1244) outside [No.3 32.94 10 diameter |_(S43)_| $53 | 5296 | 52.90 ‘No.4 | [62.09] | (2.0843 to | [2.0827] 8) 2.83] es sa fearon | aa esmatsotcamnatire | 028% | os ‘Measuring camshaft bore diameterINSPECTION AND REPAIR OF MAIN ENGINE PARTS. 2.9 Driving Camshaft Bushing (1). Bore the camshaft bore to the dimensions of 37mm diameter, H6 “°° 23 and drive bushing into it, if the clearance between the camshaft journal and camshaft bore exceeds the limit. @) Drive the camshaft bushing using the camshaft bushing installer et pecialto). ‘Special tool name Part No. ‘Camshaft bushing installer set_| 30691-00010 @) Adjust the oil hole from the oil gallery to the oil hole of the bushing when driving the bushing. 2.10 Measuring Idler Bushing Inside Diameter and ‘Shaft Outside Diameter Measure the inside diameter of the idler bushing and outside diameter of the idler shaft. Replace the idler ‘gear of idler shat if the clearance exceeds the limit. Unit: mm fin.) Saad Lin erase bervecn ier | B92 050 919 bashing and sa n0onssio | saab 2.14 Replacing Idler Shaft Pull out the idler shaft using the idler shaft puller. ‘Special tool name Part No. Idler shaft puller ‘MHO61077 Bushing APT piace Bushing Wa Adept =! A = F | 1 ad t Rod Rod Punching out Driving ‘Oilhole Driving camshaft bushing “Measuring inside diameter of idler bushing and outside diameter of idler shaft Ilr shaft ae paler Pulling out idler shaftINSPECTION AND REPAIR OF MAIN ENGINE PARTS, 2.12 Checking V-Belt Groove of Crankshaft Pulley for Wear Check the pulley V-belt groove for wear. Attach a new V-belt around a wom pulley, apply higher tension to the belt, and check that the top surface of | the belt is out of the pulley groove or inside it 10 ccheck the degree of wear. ‘When the top of the V-belt is out of the pulley groove, itis normally considered that the pulley has sufficiently long service life. Ifthe belt top is 1.6 mm [0.063 in.] or more below the groove edge on the contrary, the pulley is not usable. Replace the pulley. 2.13 Checking Damper (S6S) Check the damper for apparent cracks, swelling, cracks in the mirror plate, paint discoloration, Separation due to overheating, tc. Replace the damper with a new part when it has been used for £000 hours or more, even if it is free from defects. “Measure the deflection and tlt ofthe oxter periphery with the dial gage. Replace the damper if the limit is exceeded av EE rebar lle Checking wear of Vis ove (Outer periphery tlt ‘Outer periphery deflection Unit: mm fin.) Sina Linit_[ Remark Outer : os (ooo | 15 i periphery | ““orless | [0.059] | Pace wie jection pars ater using Outer for 8000 hours or * 0.5 [0.020] 1s periphery | “oriess | poss | TO ‘Checking deflection and tilt of damper outer peripheryINSPECTION AND REPAIR OF MAIN ENGINE PARTS. 3. Crankcase, Pistons, Connecting Rods, Crankshaft and Tappets 3.1. Measuring Distortion of Crankcase Top Surface Apply a straight edge to the top surface of the crankcase and measure the distortion with a thickness ‘gage. If the distortion exceeds the limit, grind the crankcase with a surface grinder. Be careful not to ‘grind it excessively. Unit: mm fin] Standard Limit Distortion of 0.05 [0.0020] 020 crankcase top surface | ot less {0.00791 _| ‘Measuring distortion of crankcase top surface 3.2. Measuring Cylinder Inside Diameter (1) Measure the inside diameter of the cylinder at three points each, ie., upper point (with much staggered ‘wear), middle point, and lower point, inthe direction ‘of the crankshaft and the perpendicular direction. Unit: mm fin.] Timi Repair_| Replace Standard 94.000 10 Cylinder inside | 94.035 | 94.200 | 94.700 diameter [3.70079 to } [3.70866] | [3.72835] 3.70217) ‘0.01 Roundness | [0.00039] or less 001s (Cylindricity | [0.00059] cor less @ Bore the cylinder to +0.25 mm [0.0098 in] or +0.5 ‘mm [40.0197 in.] oversize, if the measured value is between the repair limit and replacement limit. Hone- finish the bored cylinder to an accuracy of 0 to 0.035 “Measuring eylinder inside diameter ‘mm [0.00138 in. @)_ Use an oversized piston and piston rings to fit the oversized cylinder. (4) Ifthe eylinder is wom unevenly, take maximum wear {nto consideration and select an oversize that allows complete eylindricty. All cylinders must have the same oversize, if one cylinder is oversized. (6) If the cylinder has a slight amount of wear and is reused after replacing the piston rings only, scrape the staggered wear portion in the upper part of the cylinder with a ridge reamer, etc. Hone-finish it as necessity requires.INSPECTION AND REPAIR OF MAIN ENGINE PARTS. 3.3. Measuring Piston Outside Diameter Measure the piston skirt at aright angle to the piston pin with the micrometer. Replace the piston with a new part if the limit is ‘exceeded. (©) es © = Unit: mm [in. Saad] Baas OT sep | “pes | (2377, Soma _| 6 pwmtie | 925 | “isrotscio | (240%, — diameter 3.71004] ‘Measuring outside diameter of piston cae | BASSES year os | B78 | Bria E 3.71988) = 3.4 Measuring Clearance of Piston Ring Abutments Insert the piston ring into the gage or new crankcase, horizontally using a piston and measure the abutment. Replace the piston ring set ifthe limit is exceeded. Gage inside diameter: 694 +0.035/0 mm Thickness © {$3.70 0.001380 in.] sage Unit: mm fin. Standard [Limit No. ring | 030000500 (Clearance ‘oie, | (0.01181 10 ofpiston | 40M | “oo1969) | 1.500 Abctmant clearance ring 01500 t0 0.700} {0.05906} : sont fabutment | No.2ring | (0.01969 t0 ‘Measuring clearance of piston ring abutment 0.02756] 3.5 Measuring Piston Ring Grooves Insert a piston ring with known thickness into the ring ‘groove, apply the straight edge to it, and insert the thickness gage further to measure the ring groove of the piston. Replace the piston if the limit is exceeded. ‘Unit: mm fin cq —— Sided [Limit O.70%0 ing|_ 0110 | 0200 ei [0.00276 to | [0.00787] 000433] 0.04510 = Clearance between | ring | 0085 | 0.150 “Measuring ring groove of piston ee ‘0-2 TINE | (0.00177 to | [0.00591] ee 0.00335) 0.02010 ‘tring |, 0.080 | 0.150 Oltring [0.00079 to | [0.00591] 0.00236]INSPECTION AND REPAIR OF MAIN ENGINE PARTS 3.6 Measuring Piston Pin Bore Diameter and Piston Pin Outside Diameter Measure the diameter of the piston pin bore and the ‘outside diameter of the piston pin. Replace the piston pin if the limit is exceeded. Unit: mm fin] Nomina] Standard Limit 29,994 t0 Piston pin outside | 630 | 30.000 ‘diameter [61.18]} [1.18087 to 1.18119) Serene beeen 0.000 100.016) 9.959 ‘Measuring clearance between piston pin bore piston pin bore and) —- | 0.000001 | ry oo197) and piston pin piston pin 0.00063) _ |! 3.7 Measuring Piston Projection Measure the degree of projection of the piston as shown below. Check the clearance of each part if the measured value is below standard. (Q)_ Find the top dead center of the piston with the dial gage. (2) Apply the dial gage to the top surface of the crankcase, and adjust the zero point. Measure projections at three points on the top of the piston, and find the mean value, Subtract the projection from the gasket thickness in the condition where the eylinder head is tightened. The clearance between the piston top and cylinder head is known. Unit um fin] ‘Standard 0.05 10 0.45 Projection of piston from erankease | 19 0099 0 0.0177] 1.20.05 "Thickness with gasket installed ‘The projection of the piston has great influence upon ‘engine performance. It must be as specified in order to prevent valve interference, too. _{0.04720.0020]_| ce ‘Measuring piston projectionINSPECTION AND REPAIR OF MAIN ENGINE PARTS 3.8 Measuring Clearance between Connecting Rod Bearings and Crank Pins ‘Measure the outside diameter of the crank pin and the inside diameter of the connecting rod bearing. Replace the bearing ifthe clearance exceeds the limit, If the crank pin has excessive wear or uneven wear, grind the crank pin and use an undersized bearing. ‘The connecting rod bearings are available in three undersizes: -0.25, -0.50 and -0.75 mm [-0.0098, 0.0197 and -0.0295 in. Note: When measuring the inside diameter of the bearing, be careful not to mistake the upper and lower sides of the bearing, install the bearing in the connecting rod, tighten the cap to the specified ‘torque, and measure. Unit: mm fin, Nominal] Standard [Limit 37.955 to [Crank pin outside | $58 | 57970 | 57.800 diameter [62.28] | [2.281690 | [2.27559] 228228) Clearance between crank 0.030 to 0.090 pin and - [0.00118 to jooren connecting rod 0.00354) | © {bearing 3.9 Measuring Clearance between Connecting Rod Bushings and Piston Pins Measure the inside diameter of the connecting rod bushing and the outside diameter of the piston pin, Replace if te limit is exceeded. Mena (S505 kgf) 9.83.6 bff) ‘Measuring inside diameter of connecting rod bearing sit um Nominal] Standard | Limit 30.020 to Rod bushing 630 30.045 inside diameter |{$1.18}| [1.18189 t0 - “2 [Clearance ‘Measuring inside diameter of connecting rod bushin; femeneed |_| S220 051 | aag0 7 ee eshing and 1000790 | gots ponin iINSPECTION AND REPAIR OF MAIN ENGINE PARTS 3.10 Replacing Connecting Rod Bushings March mak side (1) Replace the connecting rod bushing using the connecting rod bushing puller (special tol). eee Special tool name Part No- =a ‘Connecting rod bushing paller_| 32491-00500, oihore —fy- ® Aajust the oil hole of the bushing to that of the ' connecting rd. Locate the seam of the bushing inthe L$ position shown on the right. ——————— (@) After pres fing, insert the piston pin and make sure that it slides smoothly, free from rattling. ‘seam of bushing Replacing connecting rod 3.11 Checking Bend and Twist of Connecting Rods Unit: mm (1) Measure the values "C" and "é" shown on the right. ee Repair connecting rods below the standard using & cc <_00s peat a <0 Unit: mm ,, 1 Standard Limit k Sg 005 1a a ‘ston $< Too" C Bend an sy | osnig0 | 015/100 pin connecting rod (C/4) ‘Twist of connecting rod ‘Bend of connecting rod @)_ Use the connecting rod aligner, in general, to check the bend and twist ofthe connecting rod. Note: ‘Tighten the connecting rod cap to the specified Tightening torque 36.2 19 43.4] (@) When measuring the bend and twist with the piston installed, place the piston upside down on the level block, insert a round rod equivalent to the crank pin diameter, and measure the height of the round rod surface with the dial gage. ‘Checking bend and twist of connecting rod ‘Measurement with connecting rod aligner “Measuring bend with dial gageINSPECTION AND REPAIR OF MAIN ENGINE PARTS 3.12 Checking Connecting Rod Bearings Check the inner surfaces of the connecting rod bearings. Replace the connecting rod bearings with hit flaws, damage due to foreign matter, ete., on the surface with new parts. 3.1 Measuring End Play of Connecting Rods Install the connecting rod on the corresponding crank pin, tighten it to the specified torque, and measure the clearance between it andthe crank arm (Le, end play) ‘with the thickness gages. Replace the connecting rod with a new part ifthe clearance exceeds the limit. Unit: mm fin Siandard Limit 0.150 t0 0.350 0500 End play {0.00591 to 0.01378) _| (0.01969 | 3.14 Replacing Connecting Rods ‘When replacing a connecting rod, use a rod having the same weight mark (stamped rank). 3.15 Measuring Crank Journal Outside Diameter, ‘Measure the outside diameter of the crank journal with the micrometer in the vertical and horizontal directions, and check the roundness, cylindrcity, and clearance from the bearing. Grind the crank journal to an undersize if the repair limit is exceeded. Replace ‘the crank journal if the replacement limit is exceeded. aim in} ‘Nominal | Standard Limit Repair 7798510 | 7850 Outside O78 77.970 | [3.06496] diameter | [63.07] | [3.06909 to | Replace: 3.06968) | "77100 crank (3.03843) journal 3010 Rowdies 0.0035) | 28%, orless |! C010 _ 0030 Gfindkcty {0.00039} ‘or less _| [0.00118] ‘Measuring end play of connecting rod ‘Match marks ‘when setting ‘Weight rank mark LE ‘Weight rank stamp postion on connecting rod ‘Measuring outside diameter of crank journalINSPECTION AND REPAIR OF MAIN ENGINE PARTS. 3.16 Measuring Crank Pin Outside Diameter ‘Measure the outside diameter of the crank pin in the vertical and horizontal directions, and check the roundness, cylindricity, and clearance from the Deering. Grind the crank pin to an undersize or replace it with a new part if the limit is exceeded. Measuring Measuring direction position Unit: mm fin} Nominal [Standard [Limit 57.955 to Outside | 658 | 57970 | 57.800 diameter | [62.28] | [22816910 | [2.27559] 2.28228} (Crank 0.010 - 0.030 pin | Rous 0.00039) ‘orless_|{0-00118] ‘0.010 oki i 0.030 indict (0.00039) “orless _{{0.00118] 3.17 Grinding Crankshaft Grind the crankshaft to an undersize of the main ‘bearing and connecting rod bearing. In grinding, be careful not to change the fillet R and width, If the surface hardness of the crankshaft has reduced remarkably, re-quench and check it by means of magnetic-field inspection. The normal hardness is, ‘Measuring outside diameter of erank pin ALTE {aan (0x2 ing oo Vickers 620 or more. Undersize grinding dimensions of crankshaft Unit: mm fin] Undersizing | Finished dimension 025 7.705 to 77.720 0.0098} __| {3.05925 t0 3.05984] \Crank 0.50 T1A55 10 T7470 journal 0.0197] _| {3.04941 to 3.05000] 075 "772085 0 77.220 0.0295) __| [3.03957 +0 3.04016) 025 57.105 to 57.720 fo.o0vs) _| 2.27185 02.2724 | : 050 37.455 0 57.470 (Crank pin 0.0197 26201 to 2.26260] 075 7205 to 37.220 fo.0295)__| 225217 102.5276) ‘When grinding the journal or pin of the crankshaft, be sure to grind all journals or pins. Finish the fillet R to R3 mm [0.12 in. Finished dimension of fillet RINSPECTION AND REPAIR OF MAIN ENGINE PARTS 3.18 Measuring End Play of Crankshaft (1) Replace the thrust plate with a new par ifthe end play of the crankshaft exceeds the limit. Note: ‘The end play of the crankshaft means the difference between the width of the thrust receiver of the crankshaft and the width of the thrust plate installed inthe bearing cap. 2). Use oversized thrust plates when the limit is exceeded even if new thrust plates are inserted. Thrust plates are available in two oversizes: +0.15 and +0.30 mm [+0.0059 and +0.0118 in. Jn general, the purpose may be fulfilled in many cases iflonly the rear thrust plate is oversized. Unit: mm fin) ‘Standard Limit napeyot | AM 00257 | 0 crankshaft 0.01039] 0.01181] ‘nie mm fin] Sige OS] BohO. 5] Toleranee 31.15 3130 HO.150S. | i264) | 112323) 3130 3143] +0039 #03008. | 1.2323) | (1.2382) _| (¥0.001540] 31.60, fs a 1.2441] 0757 Oversized 3.19 Measuring Bend of Crankshaft Support the front and rear journals of the crankshaft with V-blocks, and measure deflection (both-side deflection) of the center journal with the dial gage. Grind the crankshaft with light deflection in accordance with the standard. Repair the crankshaft with large deflection using a press, ete. Replace the crankshaft with remarkable deflection with a new part, Unit: mm [in] ‘Standard Limit Bend of 0.020 [0.00079] 0.050. crankshaft cor less [0.00197] 31-90% Units mm fing h x2 tmsy ‘Width of thrust receiver of crankshaft ‘Measuring end play of crankshaft “Measuring bend of crankshaftINSPECTION AND REPAIR OF MAIN ENGINE PARTS. 8.20 Replacing Crankshaft Gear (1) Pull out the gear from the crankshaft using the gear puller. Note: Do not hit the gear to pull it out. (2) Warm the gear up to approximately 100°C [212°F] with a gear heater, etc, ‘Adjust the position so that the key om the crankshaft is inserted into the notch of the gear, and hit the end face of the gear lightly with a copper hammer to ‘engage the gear. Tnstalling crankshaft gear 8.21 Checking Oil Seal Contact Surface ‘Check the oil seal contact surface at the rear end of Ln the crankshaft. Use spare oil seal and an cil seal sleeve if the crankshaft is worn by the oil seal. Oil seal il seal contact surface ‘Checking oil seal contact surface (1) Installing sleeve ‘Sleeve ‘Apply ol to the inner surface of the sleeve and drive Soe in the sleeve using the oil seal sleeve installer set (Gpecial to). ‘Special tool name_ Part No. Guide ‘il seal sleeve installer set 30691-13010 (60691-13100) ‘Be very careful not to make dents or flaws on the outer ae Besiphery of the sleeve (0691-13200) Installing sleeveINSPECTION AND REPAIR OF MAIN ENGINE PARTS If the oil seal sleeve gets worn when running the ‘engine again, remove the sleeve in the procedures shown below and replace the oil seal and oil seal sleeve with new spare parts again. (2) Removing sleeve ‘Apply @ graver to the end face of the sleeve at the right angle of three positions, hit it with a hammer, and remove the sleeve when the tension is reduced. If the sleeve cannot be removed, apply the graver in the axial direction, hit it lightly to elongate the sleeve, and remove it when the tightening margin is reduced. BX Be very careful not to damage the crankshaft with the agzaver when spliting the sleeve. 3.22 Checking Main Bearing Surfaces (Check the main bearings for contact on the crankshaft contact surface, scratches, and corrosion due to foreign matter, separation, etc. Also check the back bearing contact surfaces of the crankcase, main bearing caps, and bearings. oe ‘Oil seat sleeve ‘Checking oil seal contact surface ‘Removing sleeve Flaws, scratches and corrosion ‘on inner and outer surfaces ‘Checking main bearing surfacesINSPECTION AND REPAIR OF MAIN ENGINE PARTS 3.23 Measuring Clearance of Main Bearing (Q) To measure the clearance of the main bearing, assemble the main bearing with the crankease and ‘main bearing cap and tighten the main bearing cap to ‘the specified torque. Measure the inside diameter of ‘the bearing at two front and rear positions in the longitudinal direction of the crankshaf, find the mean value, and find the difference between the crankshaft joumal and ouside diameter Uni: mm in ‘Standard Limit Ceeranee beeen T Gosom.10 | 0200 je io a4 [0.00197 to 0.00433] | [0.00787] @) Replace the main bearing with @ new part if the clearance between the main bearing and crank journal is below the limit. Re-grind the crankshaft and use an undersized bearing (-0.25, -0.50 or -0.75 mm [-0.0098, 0.0197 or -0.0295 in.}) if the clearance exceeds the limit, If grinding is done to the specified dimension based ‘on the main bearing hole, no facing up is needed after installation, @) 8.24 Checking Contact Surfaces of Tappet Cams. Check the uneven wear of the tappet surfaces in contact with the camshaft. Replace defective tappets. 3.25 Measuring Clearance between Tappets and Tappet Guide Holes Replace the tappet with a new part if the clearance between the tappet and tappet guide hole exceeds the limit, position (10.00 11.0 kgfm) [723 t0 79.6 1bF-A} “Measuring inside diameter of main bearing @09 Contact surface of tappet with camshaft Measuring ‘Measuring position direction “oe Unie um fi Tonka [Sani tim 000 |Tappet hole 14 14.018 14.100 diameter [60.55] | [0.55118t0 | [0.55512] 0.55189] Gerace Tots ouasT Teasing SOD bameT appa Sewecvtrpc | - | (000030 | O88, eee sadtapattor | ‘uoonosy | IINSPECTION AND REPAIR OF MAIN ENGINE PARTS:REASSEMBLY OF MAIN ENGINE PARTS 1. Crankcase, Tappets, Crankshaft, Pistons and Connecting Rods-: 1.1 Installing Main Bearings, Thrust Plates and Tappets ~ 1.2. Installing Crankshaft 1.3. Installing Main Bearing Caps- 1.4 Installing Main Bearing Cap Bolts 1.5 Measuring Crankshaft End Play. - 2-38 2-38 2-38 2-38 716 Reassembling Pistons and Connecting Rods: 2-39 1.7 Installing Piston Rings. 2-40 1.8 Preparation for Installing Pistons: 2-40 1.9 Installing Connecting Rod Tightening Bolts and Bangs 2-4 1.10 Orienting Piston Ring Abutments - 2-41 1.11 Installing Pistons-- 1.12 Installing Connecting Rod Caps: y Timing Gears «++ 2.1 _Instaling Front Plate- 2.2. Installing Camshaft Gear and Thrust Plates ~ 2.3 Installing Camshaft 2.4 Installing Idler Gear 2.5. Installing Oil Pump Gear. 26 Check and Adjustment afer instaling Timing Gears 2-44 2.7 Checking Valve Timin 2-45 2.8 Installing Oil Seat . 2-46 2.9 Installing Timing Gear Case ~ 2-46 2.10 Installing Oil Pan-- . 2-48 2.11 Installing Fuel Injection Pump -~ 2-47 2.12 Installing Cover: 2-47 2.1 Installing Crankshaft Pull 2.14 Installing Damper (S6S) 3. Flywheel-.-- 3.1 Installing Oil Seals. 3.2 Installing Fiywheel Housing 3.3 Installing Fiywheel - Cylinder Head and Valve Mechanisms: 4.4 Installing Stem Seals - 4.2. Installing Valves and Valve Springs: 433 Installing Cylinder Head -~ 44 Reassembling Rocker Arms and Rocker Shaft Assembly 4.5 Inserting Pushrods- 4.6 Installing Rocker Shaft Assembly 47. Gheoking Top Dead Center of NO. 1 Piston on Compression Stoke 4.8 Adjusting Valve Clearance >REASSEMBLY OF MAIN ENGINE PARTS. 1. Crankcase, Tappets, Crankshaft, Pistons and Connecting Rods Reassemble these parts in the reverse order of the disassembly procedures. 4.1 Installing Main Bearings, Thrust Plates and Tappets ‘Adjust the upper main bearing to the lug groove on ‘the erankease and push it The oil hole ofthe main bearing is aligned with the oil hole ofthe erankease now. Apply a small quantity of engine oil to the inner surface ofthe main bearing. Install the thrust plate with the oil grooves facing outside to the back of the crankcase. Apply engine oil to the tappet and insert it into the crankease. @ @ @ o 12 @ @ @ Installing Crankshaft Clean the crankshaft sufficiently with cleaning oil and. blow compressed air onto it to clean. Hold the crankshaft horizontally and insert into the crankcase slowly. Apply a small quantity of engine oil to the crankshaft joumal. 13 ay Installing Main Bearing Caps Apply engine oil to each bearing and instal the cap. before installing the main bearing cap. @ cap. Apply Three Bond 1212 to the edges of the rear cap Install the main bearing cap so thatthe back of the crankcase is flush with the back of the main bearing Installing main bearing capREASSEMBLY OF MAIN ENGINE PARTS @)_ Apply Three Bond 1211 to the side seal and insert it {nto the main bearing cap groove. . Insert the side seal with the R portion outside. Press it Bearing by hand to some extent, and then press it completely using flat jig taking care not to bend it. (S) Apply Three Bond 1211 to the periphery of the side seal. Note: Install the main bearing caps from the front side in the order of the numbers marked on them. Side . 7 R portion Inserting side seal 4.4 Installing Main Bearing Cap Bolts (1) Tighten the main bearing cap bolts with engine oil and apply the specified torque. (2) Make sure that the crankshaft rotates smoothly. (10.0 11.0 kgf-m) 1723 1079.6 Ff} 4.8. Measuring Crankshaft End Play ‘After installing the main bearing caps, measure the fend play of the crankshaft and make sure that its value is within the standard, Unit: mm fin] ‘Standard Limit 0.100 100.264 | 9.399 Crankshaft end play | [0.00398t0 | ggiigiy 0.01039] : 1.6 Reassembiing Pistons and Connecting Rods (2). Reessemble the piston and connecting rod so that the ‘weight mark on the piston and the match mark on the connecting rod face the same side. 2) Apply engine oll to the piston pin and insert the piston pin to join the piston with the connecting rod. ‘Reassembling piston and connecting rod 2-39REASSEMBLY OF MAIN ENGINE PARTS: (@)_Install the snap ring into the ring groove of the piston using the ring pliers. Check the tension of the snap ring and the insertion condition in the groove. Note: Adjust the splits of the snap ring toward the bottom of the piston. 1.7. Installing Piston Rings (Install the compression rings and oil ring to the piston _using the piston ring pliers (special tool). ‘Special tool name. PartNo. Piston ring pliers 31391-12900 Note: Install the compression rings with the °T* mark on the top ring and the "2T" mark on the second ring oon the upper side of the piston, ‘The oil ring may be installed in any direction. (2) Install the oil ring so that the abutment is located at the 180° position to the both-end butting position of the coil spring. 18 a @) Preparation for Installing Pistons ‘Tum the crankcase on its side. Clean the cylinder inner surface with a waste cloth, and apply engine oil to it. ‘Combination of piston and piston ring Both end butting position of coil spring ‘Oi ing abutment Abutment position on oil ring Preparation for installing pistons4.9 Installing Connecting Rod Tightening Bolts and Bearings (1) Insert the notch surface on the head of the connecting rod cap tightening bolt firmly before instaling the bearing. (2) Insert the rod bearing (upper) to the larger end of the connecting rod to fit into the lug groove, and apply engine oil to the inner surface. 1.10 Orienting Piston Ring Abutments Apply engine oil to the piston rings, and orient the ‘abutments of the piston rings to the proper positions by avoiding the pin position, thrust position, and the pposition opposite to the thrust. 4.11 Installing Pistons (1). Move the erank pin for installing the piston to the top position, turn the front mark (O) on the piston to the front of the engine, and insert the piston into the cylinder using the piston installer (special tool). ‘Special tool name Part No. Piston installer 34491-00200 @ When the larger end of the connecting rod is brought {nto close contact with the crank pin, tum the crankshaft 180° while pressing the piston head to the ‘position where the cap may be installed easily. REASSEMBLY OF MAIN ENGINE PARTS Lug. groove, i Installing connecting rod tightening bolts and bearing ‘Abutment of No. 1 ing ft Time postion mig side 180% Arvutment of oiling Abutment of No.2 ri ¥Opposite-to-thrust position rienting piston ring abutments, op Installing pistonREASSEMBLY OF MAIN ENGINE PARTS 1.12 Installing Connecting Rod Caps (1) Fit the connecting rod bearing (lower) to the lug ‘groove of the connecting rod cap, and apply engine oil to the inner surface. Q) Tighten the cap mounting nuts to the specified torque. EXOTIC ‘Make sure thatthe match mark on the cap ison the same i asthe match mark on the connecting rod Lug groove Installing connecting rod cap (1) (00 6.0 kgf-m) [362 to 43.4 Ibf-A] Installing connecting rod cap (2)2. Timing Gears Reassemble the timing gears in the reverse order of the disassembly procedures. 24 Q @ @ Installing Front plate Install the gasket to fit the dowel pin ofthe crankcase. ‘Tighten the front plate to the crankcase to the specified torque. Cut the excess portion of the gasket below the crankcase bottom entirely with a cutter. 2.2 Installing Camshaft Gear and Thrust Plates Warm the camshaft gear and insert the thrust plate ‘without fail when installing the gear. ‘Be careful not to damage the cam of the camshaft and the bushing. 2.3. Installing Camshaft (Q)_ Apply engine oil to the camshaft journal and cam. (2) Insert the camshaft slowly into the crankcase. G) Tighten the thrust plate mounting bolts to the specified torque. REASSEMBLY OF MAIN ENGINE PARTS ‘Tightening torque: 10.0 t0 13.0N-m (1.010 13 kgm) [7209.4 1bt-A) Installing front plate (1) Installing front plate (2) S CHU ie ‘Thrust plate Camshaft gear Installing camshaft gear and thrust plate Tightening torque: 10.00 13.0N-m (1.0 0 1.3 kgf-m) [72 109.4 bf]REASSEMBLY OF MAIN ENGINE PARTS 24 @ 2 @ 25 @ @ 26 Instaling Idler Gear Fit the match mark of each gear, and install the idler eat. Install the thrust plate, and tighten the bolt to the specified torque. ‘The match mark positions of the gears fit each other as shown right atthe top dead center of the No. 1 Piston on the compression stroke, Installing Oil Pump Gear Install the oil pump gear to the oil pump shaft. Tighten the jam nut to the specified torque. ‘Check and Adjustment after Instaling Timing Gears Be sure to check and adjust the backlash and end play of each timing gear when the gear is disassembled and reassembled. Unit: mm [in.] ‘Standard Limit TOOT imergertectin | Toootsrie | 225% cosy | 5030100300] — asap Idler gear end play [0.00197 to 0.00787} (001878) 310010025] — op ‘Camshaft end play [0.00394 to 0.00984) (0.01181) 2-44 Fuel injection ‘Pump gear il pump gear ‘Match marks of timing gears 2.9 03.9 kgf-m) [21.0 t0 282 WE ) © Checking timing gears for backlashREASSEMBLY OF MAIN ENGINE PARTS 27 ao @ @ Checking Valve Timing It is unnecessary to check the valve timing, in the gears are reassembled withthe match jgned to each other. However, check the valve timing to make sure. “Make the valve clearance between the inlet valve and exhaust valve of cylinder No. 1 using a flat 3-mm {0.118+in] thick plate Insert the thinnest thickness gage (0.05 mm [0.002 in.) between the top face of the valve cap and rocker, ‘and turn the crankshaft slowly. Find the position where the thickness gage is caught tight (ie, the valve begins to open) and the position where the thickness gage begins to move (ie, the valve is closed). Check that these positions coincide with the angle shown in the valve timing chart in the condition where there is a 3-mm [0.118-in] clearance onthe valve sie, Bottom dead center ‘Valve timing chart (Swirl chamber) Bottom dead center ‘Valve timing chart (Swirl chamber) (with 3-mm [0.118-in] clearance on valve side) "Top dead center ‘Bottom dead center Valve timing chart (Direct injection) (with 3-mm [0.118-in] clearance on valve side) 2-45REASSEMBLY OF MAIN ENGINE PARTS 2.8 Installing Oil Seals Apply a small quantity of oil to the oil seal. Drive it into the crank gear case using the installer. 2.9 Installing Timing Gear Case (1) _ Install the gasket to fit the crankcase dowel pin. @) Apply engine oil tothe oil seal lip. G) Install the timing gear case and tighten the bolts to the specified torque. 2.40 Installing Oil Pan (1). Clean the mount surfaces of the crankcase, timing ‘gear case, and oil pan. (2) Squeeze ‘Three Bond 1207C (32A91-05100: liquid gasket) in a 4-mm [0.16-in] diameter bead all around the oil pan flange periphery, and spread it. Install the oil panto the crankcase within five mimutes of applying the liquid gasket. ‘Tighten the mounting bolts to the specified torque. @ @ Note: (@) Cut the nozzle tip ofthe liquid gasket tube at ‘the position shown on the right when squeezing the liquid gasket in a 4-mm [0.16- in] diameter bead. Using the common gasket (32A 13-03200) is also allowed ifit is difficult to use liquid gasket. o ‘Tightening tora 17.010 20.0N-m (0.7 t 2.0 kgf-m) [12.3 145 TFA Installing timing gear case Installing oil panREASSEMBLY OF MAIN ENGINE PARTS 2.14 Installing Fuel Injection Pump (1) Insta the fuel injection pump, and tighten the bolts. @)_ Install the pump bracket. G)_ Install the oil pipe. 2.42 Installing Cover Install the cover, and tighten the bolts. 2.48 Instaling Crankshaft Pulley ‘Screw two safety rods (MI2 x 1.25) into the threaded and prevent the holes at the rear end of the crankshaft from rotating with a bar. “Tighten the erankshaft pulley to the specified torque. PAXTON ‘The bar may come off. Be very careful. 2.14 Installing Damper (S6S) Install the damper, and tighten the bolts. Installing cover ‘Tightening torque: 480 to 500N-m (49 to 51 kgf-m) [354 to 369 tbe Installing damper 2-47REASSEMBLY OF MAIN ENGINE PARTS 3. Flywheel Reassemble the flywheel in the reverse order of the disassembly procedures. 3.1. Installing Oil Seals Apply a small quantity of grease to the new oil seal, and install the oil seal to the flywheel housing, Be careful of the ol seal installation direction. Note: Use an oil seal with a sleeve if the oil seal- contacting surface of the crankshaft is wor. 3.2 Installing Flywheel Housing (Q) Install a new rear gasket. (@) Fitthe flywheel housing to the crankcase dowel pin, and tighten the bolts. Note: Ifthe starter is installed on the housing in advance, the post-work may be done easly. 3.3. Installing Flywheel (1). Screw the safety rod (M12 x 1.25) into the rear end of the crankshaft. (2) Install the flywhee! to the crankshaft while fiting it to the safety rod. G) Tighten the bolts (five) temporarily. (@)_ Unscrew the safety rod, and tighten the last bolt (one) ‘temporarily. () Prevent the crankshaft pulley nut from rotating with a torque wrench, ete. (©) Tighten the flywheel! mounting bolts to the specified torque. PNT ‘The person who holds the pulley shouldbe very careful Both persons should make signs mutually to proceed with the work. Flywheel housing Apply grease, Engine side Flywheel side }}—Oil seal Installing oil seat ‘Apply engine oil 785 to 8.3 N-m (8.0 09.0 kgf-m) [57.9 to 65.1 bff) Installing flywheel (2)4, Cylinder Head and Valve Mechanisms Reassemble these parts in the reverse order of the disassembly procedures. 4.1 Installing Stem Seals Install the stem seal to the valve guide using the stem seal installer (special tool) after installing the valve. ‘Special tool name, Part No. ‘Stem seal installer ‘S2A91-10200 ZX CAUTION ‘Do not apply liquid seal to the stem seal's engagement ‘with the valve guide. Apply engine oil to the valve stem and install the stem seal in order to ensure the initial lubrication of the stem seal lip. Do not draw out the valve after installing the stem seal in order not to damage the lip. 4.2. Installing Valves and Valve Springs (Q)_ Install the valve spring and retainer into the valve guide. Install the valve cotter using the valve spring pusher (special tool). ‘Special tool name Part No. Valve spring pusher 30691-04500 2) Hit the valve stem top lightly several times with a soft hammer to make sure that the valve spring and valve cotter are installed and seated firmly. REASSEMBLY OF MAIN ENGINE PARTS ‘Stem seal installer y—awe | ‘Stem seal hem Installing stem seal ‘Checking valve cotter for installationREASSEMBLY OF MAIN ENGINE PARTS. 4.3. Installing Cylinder Head (1) Fit the cylinder head gasket to two dowel pins on the top of the erankease to prevent it from shifting. (2) Install the cylinder head to fit the dowel pins, and tighten the cylinder head bolts. Do not use liquid packing. Make sure that there are no dents on the top surface of the crankcase, (3). Tighten the cylinder head bolts evenly to the specified ‘torque in the order shown on the right. 113 to 123 Nem (LS to 12.5 kef-m) [83.2 to 90.4 IbF-A] ‘Namber ofbolts: 17 Order of tightening cylinder head bolts 44 Reassembling Rocker Arms and Rocker Shaft ‘Assembly Face the reassembly marks on the shaft toward the front of the engine when reassembling the rocker arm. Afier reassembly, make sure that the rocker arm moves lightly Reassembling rocker shaft assembly 48. Inserting Pushrods Insert the pushrod into the pushrod hole of the cylinder head. ‘Make sure that the ball end of the pushrod is placed securely on the R portion of the tappet.REASSEMBLY OF MAIN ENGINE PARTS 48 oO 2 Installing Rocker Shaft Assembly Install the valve cap. Install the rocker shaft assembly to the cylinder head. Tighten the longer bolt to the specified torque. Note: In reverse order of disassembly, tighten the longer Ar a of the rocker shaft bracket tightening bolts first, and then tighten the shorter bolt. Checking Top Dead Center of No. 1 Piston on ‘Compression Stroke Engage the turning socket (special tool) with the nut of the crankshaft pulley and tum it in the forward direction of the engine (clockwise when viewed from ‘the front of the engine). Special tool name PartNo. ‘Turning socket 38309-73100 @ @) ‘Stop tuming the socket at the position where the "0" ‘mark on the outer periphery of the crankshaft pulley is aligned with the pointer on the timing gear case. ‘Move the rocker arms of the inlet and exhaust valves of the No. 1 cylinder up and down to check that the pushrods do not push up the rocker ans. The position where the pushrods do not push up the rocker arms of the inlet and exhaust valves (i.e. there is a clearance) isthe top dead center of the No. 1 piston on ‘the compression stroke. If the pushrods push up the rocker arms, rotate the crankshaft by another tum. ‘Tightening torque: Shorter 10.010 20.0N-m go (1.0 to 20 kgf-m) [7.2t0 14.5 be) ‘Checking top dead center on compression stroke (2)