Engine 4d94e Be3

4D94E-BE3
00-1
GENERAL
CONTENTS
1. GENERAL............................................................................................................ 1-1
2. TROUBLESHOOTING ......................................................................................... 2-1
3. INSPECTION AND ADJUSTMENT ..................................................................... 3-1
4. ENGINE BODY .................................................................................................... 4-1
5. LUBRICATION SYSTEM ..................................................................................... 5-1
6. COOLING SYSTEM ............................................................................................. 6-1
7. FUEL INJECTION PUMP, GOVERNOR ............................................................. 7-1
8. STARTING MOTOR............................................................................................. 8-1
9. ALTERNATOR..................................................................................................... 9-1
10. SPECIAL SERVICE TOOLS.............................................................................. 10-1
11. SERVICE STANDARDS .................................................................................... 11-1
00-2 4D92E, 4D94LE, 4D98E

1. GENERAL
1. GENERAL
1-1 Specifications......................................................................................................................................... 1- 2
1-2 Fuel oil, lubricating oil and cooling water ............................................................................................... 1- 3
1-3 Engine performance curve..................................................................................................................... 1- 4
1-4 Engine external views ............................................................................................................................ 1- 8
1-5 Structural description ........................................................................................................................... 1- 10
1-6 How to read this manual ...................................................................................................................... 1- 12
1-7 Precautions for service work................................................................................................................ 1- 14
1-8 Tightening torques for standard bolts and nuts ................................................................................... 1- 15
4D92E, 4D94LE, 4D98E 1-1

1. GENERAL
1-1 Specifications
Engine name — 4D92E 4D94LE 4D98E
Engine specification class — For standard forklift truck
Type — Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber — Swirl chamber type
Number of cylinders — 4
Cylinder bore x stroke mm x mm 92 x 100 94 x 110 98 x 110
Displacement l 2.659 3.053 3.318
Revolving speed rpm 2,450 2,450 2,400

Rated output
Output kW {HP} 33.8 {45.3} 44.1 {59.1} 48.9 {65.7}
Fuel injection timing (A.T.D.C.) deg 4 6
MPa 12.3 – 13.3

Fuel injection pressure
{kgf/cm2} {125 – 135}
Ignition order — 1–3–4–2 (No.1 cylinder on flywheel side)
Power take off — Flywheel
Direction of rotation — Counterclockwise (viewed from flywheel)
Cooling system — Radiator
Lubrication system — Forced lubrication with trochoid pump
Starting system — Electric
Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2

Applicable fuel —
(cetane No. 45 min.)
Applicable lubricant — API grade class CC or higher
Battery capacity V-AH 12–64 (5HR) or above
Lubricant capacity Total l 7.5

(oil pan) Effective l 2
Cooling water capacity (engine only) l 4.2
Overall length mm 700 (fan – flywheel)
Engine dimensions Overall width mm 508 (fuel filter – alternator)
Overall height mm 706 (oil pan – rocker cover upper surface)
Dry engine weight kg 225
1-2 4D92E, 4D94LE, 4D98E

1. GENERAL
1-2 Fuel oil, lubricating oil and cooling water

Use proper fuel oil, lubricating oil and cooling water and change them according the Operation and Mainte-
nance Manual.
4D92E, 4D94LE, 4D98E 1-3

1. GENERAL
1-3 Engine performance curve

4D92E [Applicable machine: FD10/15/18-20]
Rated horsepower: 33.8 kW {45.3 HP}/2,450 rpm (Net)
Maximum torque: 147 Nm {15 kgf•m}/1,600 rpm (Net)
1-4 4D92E, 4D94LE, 4D98E

1. GENERAL
4D94LE [Applicable machine: FD20/25/30-16, FD20N/25N/30N-16]

Maximum torque: 178.5 Nm {18.2 kgf•m}/1,500 rpm (Net)
4D92E, 4D94LE, 4D98E 1-5

1. GENERAL
4D98E [Applicable machine: FD20H/25H/30H/35A-16]

Maximum torque: 215.7 Nm {22 kgf•m}/1,700 rpm (Net)
1-6 4D92E, 4D94LE, 4D98E

1. GENERAL
1-4 Engine external views

4D92E/94LE/98E
1) Starting motor 7) Fuel injection pump

2) Exhaust manifold 8) Oil pan
3) Alternator 9) Oil filter
4) Radiator fan 10) Flywheel housing
5) Intake manifold 11) Flywheel
6) Fuel filter
1-8 4D92E, 4D94LE, 4D98E

1. GENERAL
12) Crankshaft pulley
4D92E, 4D94LE, 4D98E 1-9

1. GENERAL
1-5 Structural description

4D92E/94LE/98E
1) Exhaust manifold 9) Tappet

2) Fuel injection nozzle 10) Camshaft
3) Preheater coil 11) Engine oil pan
4) Rocker arm housing 12) Oil strainer
5) Rocker arm 13) Connecting rod cap bolt
6) Intake manifold 14) Engine oil filter (oil cooler: option)
7) Piston 15) Fuel injection pump
8) Cylinder block
1-10 4D92E, 4D94LE, 4D98E

1. GENERAL
16) Water pump 20) Flywheel housing

17) Thermostat 21) Crankshaft
18) Cylinder head gasket 22) Gear case (equipped with oil pump)
19) Cylinder head 23) Gear
4D92E, 4D94LE, 4D98E 1-11

1. GENERAL
1-6 How to read this manual

(1) Range of Operation Explanation
This manual explains the troubleshooting, installation/removal, replacement, disassembly/reassembly,
inspection, adjustment and adjusting operation procedures for the engine.
Refer to the manufacturer’s manual for each of the fuel injection pump, governor, starting motor and alterna-
tor except for their installation.
(2) How to Read the Explanations

(2-1) An exploded view, sectional views, a system diagram, etc. are shown at the beginning of each section
as required for easy understanding of the mounted states of the components.
(2-2) For the removal/installation of each part, the procedure is shown with the procedural step No. in the
illustration.
(2-3) Precautions and key points for disassembly and reassembly of parts are described as Points. In the
explanation for each point, detailed operation method, information, standard and precautions are
described.
Description Example
• Illustration
a The job contents are described in the disassembly procedure for Nos. not shown in the illustration.
• Disassembly procedure • Operation Points

(1) Follow steps (1) to (12) of the cylinder head Disassemble: Service point for removal
disassembly procedure. Reassemble: Service point for installation
(2) Remove the cooling water pump. Disassemble-Reassemble: Service point
(3) Remove the crankshaft pulley. (Point 1) required in both removal and installation.
Operation point to be explained on a later page.
1-12 4D92E, 4D94LE, 4D98E

1. GENERAL
• Contents omitted in this manual

Though the following jobs are omitted in the explanation in this manual, they shold be conducted in
actual work:
(1) Jacking up and lifting
(2) Cleaning and washing of removed parts as required
(3) Visual inspection
(3) Definition of Terms

k Instruction whose negligence is very likely to cause an accident. Always observe it.
Standard: Allowable range for inspection and adjustment.
Limit: The maximum or minimum value that must be satisfied during inspection or adjustment.
(4) Abbreviations
Abbreviation Meaning
Ass’y assembly
Sub-Ass’y sub-assembly
A.T.D.C. after top dead center

B.T.D.C. before top dead center
STD Standard
IN Intake
EX Exhaust
T.D.C top dead center
B.D.C bottom dead center
OS oversize
US undersize
rpm revolutions per minute

HP output (horsepower)
3 Bolt/nut tightening torque
4D92E, 4D94LE, 4D98E 1-13

1. GENERAL
1-7 Precautions for service work

(1) Precautions for Safety
Read the safety precautions given at the beginning of this manual carefully and always mind safety in work.
(2) Preparation for Service Work

Preparation is necessary for accurate, efficient service work. Check the customer ledger file for the history
of the engine.
(2-1) Preceding service date
(2-2) Period/operation hours after preceding service
(2-3) Problems and actions in preceding service
(2-4) Replacement parts expected to be required for service
(2-5) Recording form/check sheet required for service
(3) Preparation before Disassembly

(3-1) Prepare general tools, special service tools, measuring instruments, oil, grease, non-reusable parts,
and parts expected to be required for replacement.
(3-2) When disassembling complicated portions, put matchmarks and other marks at places not adversely
affecting the function for easy reassembly.
(4) Precautions in Disassembly

(4-1) Each time a parts is removed, check the part installed state, deformation, damage, roughening,
surface defect, etc.
(4-2) Arrange the removed parts orderly with clear distinction between those to be replaced and those to be
used again.
(4-3) Parts to be used again shall be washed and cleaned sufficiently.
(4-4) Select especially clean locations and use clean tools for disassembly of hydraulic units such as the
fuel injection pump.
(5) Precautions for Inspection and Measurement

(5-1) Inspect and measure parts to be used again as required to determine whether they are reusable or
not.
(6) Precautions for Reassembly

(6-1) Reassemble correct parts in correct order according to the specified standards (tightening torques,
and adjustment standards). Apply oil to important bolts and nuts before tightening when specified.
(6-2) Always use genuine parts for replacement.
(6-3) Always use new oil seals, O-rings, packings and cotter pins.
(6-4) Apply sealant to packings depending on the place where they are used. Apply oil or grease to sliding
contact portions, and apply grease to oil seal lips.
(7) Precautions for Adjustment and Check

(7-1) Use measuring instruments for adjustment to the specified service standards.
1-14 4D92E, 4D94LE, 4D98E

1. GENERAL
1-8 Tightening torques for standard bolts and nuts

(Lubricating oil not applied)
(Unit: Nm {kgf•m})
Nominal thread
Item Tightening torque Remarks
diameter x pitch
M6 x 1 9.8 – 11.8 {1.0 – 1.2} 1) Use 80% of the value at left when
the tightening side is aluminum.
M8 x 1.25 22.5 – 28.4 {2.3 – 2.9} 2) Use 60% of the value at left for 4T
Hexagon bolt (7T)/nut
M10 x 1.5 44.1 – 53.9 {4.5 – 5.5} bolts and lock nuts.
M12 x 1.75 78.4 – 98 {8.0 – 10}
1/8 9.8 {1.0}

1/4 19.6 {2.0}
PT plug
3/8 29.4 {3.0}
1/2 58.8 {6.0}
M8 12.7 – 16.7 {1.3 – 1.7}
M12 24.5 – 34.3 {2.5 – 3.5}

Pipe joint bolt
M14 39.2 – 49 {4.0 – 5.0}
M16 49 – 58.8 {5.0 – 6.0}
4D92E, 4D94LE, 4D98E 1-15

2. TROUBLESHOOTING
2. TROUBLESHOOTING
2-1 Quick reference table for troubleshooting .............................................................................................. 2- 2

2-2 Troubleshooting by measuring compression pressure .......................................................................... 2- 6
4D92E, 4D94LE, 4D98E 2-1

2. TROUBLESHOOTING
2.1 Quick reference table for troubleshooting

The following table summarizes the general trouble symptoms and their causes. If any trouble symptom occurs,
take corrective action before it developes into a serious problem so as not to shorten the engine service life.
2-2 4D92E, 4D94LE, 4D98E

2. TROUBLESHOOTING
4D92E, 4D94LE, 4D98E 2-3

2. TROUBLESHOOTING
2-4 4D92E, 4D94LE, 4D98E

2. TROUBLESHOOTING
4D92E, 4D94LE, 4D98E 2-5

2. TROUBLESHOOTING
2.2 Troubleshooting by measuring compression pressure

Compression pressure drop is one of major causes of increasing blowby gas (lubricating oil contamination or
increased lubricating oil consumption as a resultant phenomenon) or starting failure. The compression pressure
is affected by the following factors:
1. Degree of clearance between piston and cylinder
2. Degree of clearance at intake/exhaust valve seat
3. Gas leak from nozzle gasket or cylinder head gasket
In other words, the pressure drops due to increased parts wear and reduced durability resulting from long use of
the engine.
A pressure drop may also be caused by scratched cylinder or piston by dust entrance from the dirty air cleaner
element or worn or broken piston ring. Measure the compression pressure to diagnose presence of any abnor-
mality in the engine.
1. Compression pressure measurement method Measuring the compression pressure

(1) After warming up the engine, remove the
fuel injection pump and nozzles from the
cylinder to be measured.
(2) Crank the engine before installing the
compression gauge adapter.
a1 Perform cranking with the regulator han-
dle at the stop position (no injection
state).
a2 See 10.2-18 in Chapter 10 for the com-
pression gauge adapter.
(3) Install the compression gauge and compression
gauge adapter at the cylinder to be measured.
a Never forget to install a gasket at the tip
end of the adapter.
(4) With the engine set to the same state as in
(2) a1, crank the engine by the starter 1) Compression gauge
motor until the compression gauge reading
is stabilized.
2. Standard compression pressure

[Engine compression pressure list (reference value)]
Compression pressure (MPa {kgf/cm2}) at 250 rpm Dispersion among cylinders

Engine model
Standard Limit (MPa {kgf/cm2})
4D92E, 4D94LE, 4D98E 2.84 – 3.04 {29 – 31} 2.35 {24} 0.2 – 0.3 {2 – 3}
2-6 4D92E, 4D94LE, 4D98E

2. TROUBLESHOOTING
3. Engine speed and compression pressure (reference)
4. Measured value and troubleshooting

When the measured compression pressure is below the limit value, inspect each part by referring to the
table below.
No. Item Cause Corrective action
• Clogged element
• Clean the element.
1 • Air cleaner element • Broken element
• Replace the element
• Defect at element seal portion
• Adjust the valve clearance.
2 • Valve clearance • Excessive or no clearance
(See 3.5 in Chapter 3.)
• Adjust the valve clearance.

3 • Valve timing • Incorrect valve clearance
(See 3.5 in Chapter 3.)
• Replace the gasket.

• Retighten the cylinder head
4 • Cylinder head gasket • Gas leak from gasket
bolts to the specified torque.
(See 4.2 (2) B in Chapter 4.)
• Lap the valve seat.
• Gas leak due to worn valve seat
• Intake/exhaust valve (See 4.2 (6) in Chapter 4.)
5 or foreign matter trapping
• Valve seat • Replace the intake/exhaust
• Sticking valve
valve.
• Perform honing and use an

• Piston
• Gas leak due to scratching or oversized part.
6 • Piston ring
wear (See 4.4 (5)-(5-1), (5-4) and (6)
• Cylinder
in Chapter 4.)
4D92E, 4D94LE, 4D98E 2-7

3. INSPECTION AND ADJUSTMENT
3-1 Inspecting water leak from cooling water system and radiator .............................................................. 3- 2
3-2 Fan belt tension inspection and adjustment .......................................................................................... 3- 3
3-3 Adjustment the valve clearance............................................................................................................. 3- 4
3-4 Inspecting the fuel injection nozzle injection pressure and spray pattern .............................................. 3- 5
3-5 Fuel injection timing inspection and adjustment .................................................................................... 3- 9
3-6 Adjusting the no-load maximum (or minimum) revolutions .................................................................. 3- 10
3-7 Sensor inspection ................................................................................................................................ 3- 11
3-8 Battery inspection ................................................................................................................................ 3- 12
3-9 Adjusting operation .............................................................................................................................. 3- 14
3-10 Long storage........................................................................................................................................ 3- 14
3-11 Periodic maintenance schedule........................................................................................................... 3- 15
4D92E, 4D94LE, 4D98E 3-1

3-1 Inspecting water leak from cooling water system and radiator
1. Water leak check in cooling water system Water leak check in cooling water system
(1) Fill cooling water to the normal level in the
radiator, and install the cap tester on the
radiator.
(2) Operate the manual pump to set the
pressure to 90 ± 15 Pa {0.9 ± 0.15 kgf/cm2}.
If the cap tester pressure gauge reading
drops then, water is leaking from the cooling
water system. Check the water leaking point.
1) Cap tester 1
YE0360
2. Radiator cap inspection

Install the radiator cap on the cap tester. Set the Radiator cap inspection
tester pressure to 90 ± 15 Pa {0.9 ± 0.15 kg/cm2}
and see that the cap is opened. If the cap does
not open, replace the cap since it is abnormal.
2) Radiator cap
2
YE0361
3-2 4D92E, 4D94LE, 4D98E

3-2 Fan belt tension inspection and adjustment

V-belt tension
10 – 15 mm/98N {10kgf}
Standard
(7 – 9 mm in initial state) 98N {10kg}
Push the center of the V belt between the alter-

10~15mm
nator and cooling water pump with a finger. The
V-belt tension is normal if the deflection is 10 to
15 mm. If not, adjust the V-belt tension by the
alternator adjuster. 2
1
1) Cooling water pump 3

2) Alternator YE0362
4) Adjuster
Tension adjustment
5) Bar (for adjusting
V-belt tension) 5
6) Alternator
4
6
YE0363
4D92E, 4D94LE, 4D98E 3-3

3-3 Adjusting the valve clearance

Valve clearance adjustment
Standard 0.15 – 0.25 mm
Make adjustment when the engine is cold.
(1) Set the piston in the cylinder to be adjusted

to the compression T.D.C. (Position where
both intake and exhaust valves are closed)
(2) Loosen the lock nut and adjusting screw,
and check the valve cap for any inclination,
entrapped dirt or wear.
(3) Insert a 0.2 mm thickness gauge between
the rocker arm and valve cap, and tighten YE0364
the adjusting screw to adjust the valve
clearance.
(4) Apply oil to the contact between the Valve clearance
adjusting screw and push rod.
2
1
3
YE0365
a If the valve cap head portion is worn,

replace the cap with a new one.
a See that each valve cap is fully covering
the intake/exhaust valve head.
1) Valve clearance
2) Adjusting screw
3) Lock nut
4) Valve cap
3-4 4D92E, 4D94LE, 4D98E

3-4 Testing injection pressure and spraying condition of fuel

injection nozzle
k When performing the injection test of the fuel injection nozzle, put on protective goggles. Do not put your
hand over the nozzle. Since the oil spouting out of the nozzle has very high pressure, it can blind and injure
you.
(1) Disassembly procedure

After performing cylinder head disassembly
steps (7) and (13),
[1] Loosen the nut and remove the nipple (for
overflow).
[2] Grip the body of the nozzle holder in a vice,
loosen the retaining nut, and remove the
nozzle.
1) Body
2) Retaining nut
3) Spacer
4) Push rod
5) Spring
6) Adjustment shim
7) Nozzle
(2) Assembly: Carry out assembly in the reverse
3 Tightening torque:
order to disassembly.
39.2 Nm {4.0 kgf•m}
(3) Point
1) Apply pads to the vice so that the body of
the nozzle holder will not be damaged.
2) Do not grip the retaining nut but grip the
b od y of th e n oz z l e ho l de r t o pr e v en t
deformation.
(4) Testing and measuring parts

i) Remove the nozzle from the engine and
install it to the nozzle tester to check the
injection pressure and spraying condition.
ii) If the nozzle has any fault, disassemble,
clean, and reassemble it, and then install it
to the nozzle tester and adjust it.
4D92E, 4D94LE, 4D98E 3-5

iii) Procedure for testing nozzle tester

1) Install the fuel injection valve to the
tester and operate the lever to test.
2) Read the injection pressure indicated
by the meter just before injection starts.
Operate the lever at a rate of about 1
time/second.
3) Judge the spraying condition visually.
Change the operating rate of the lever
from 1 time/second to 5 – 6 times/
second.
4) Use clean fuel and filter for the test.
1) Fuel injection nozzle

2) Nozzle tester
k Never direct the spray at a human body. The pressure of the fuel injected through the nozzle
is so high that the fuel can break and injure the human skin.
k Do not direct the spray at a fire. The atomized fuel catches fire easily and can cause a fire
and a burn.
iv) Adjusting injection pressure

1) Standard value: 12.3 – 13.3 MPa {125 – 135 kgf/cm2}
2) Adjust the injection pressure with the adjustment shim.
If a shim 0.1 mm thick is added, the injection pressure rises by 1.2 – 2.2 MPa {12 – 22 kgf/cm2}.
3) Shims of the following thickness are prepared. Be sure check the thickness of each shim with a
micrometer before using.
Shim thickness: 0.1, 0.2, 0.3, 0.4, 0.5, 0.52, 0.54, 0.56, 0.58, 0.8 mm
1) Nozzle holder body 4) Acceptable

2) Adjustment shim 5) Rejected
3) Nozzle spring
3-6 4D92E, 4D94LE, 4D98E

v) Criteria for spraying condition

1) Oil-tightness test
Keep the pressure 1.96 MPa {20 kgf/cm2} below the standard value. Under this condition, check
that the fuel does not drip within 10 seconds.
2) Spray test
Change the operating speed of the lever to check the spraying condition. Even if the fuel spouts
out in a line when the lever speed is about 1 time/second, if the fuel is atomized when the lever
speed is 5 – 6 times/second, the nozzle is normal.
Use the following examples to judge the spraying condition of the nozzle
Examples of spraying conditions to judge performance of nozzle and nozzle holder assembly
Since the needle has flat cuts (F cuts), the fuel is sprayed in strings along the flat cuts. This does not indicate a
trouble.
Judgment
A B C D E
Item
Example of
form of spray
Movement of
pressure
gauge pointer
Vibrates continu- Same as A. Stops at about Rises to cracking Does not rise at
ously at about cracking pres- pressure but low- all when tester
cracking pressure and does not ers remarkably. handle is oper-
sure. vibrate. ated.
Fuel is atomized
Spray is but does not indi- Fuel spouts out in
Spray is almost Fuel drips (spouts
Form of spray extremely cate pulsation of line and drips
even. out in line).
uneven. needle (looks like remarkably.
burner).
1) Usually, carbon 1) Much carbon is 1) Seat is dam- 1) Needle is stuck.
is sticking to sticking to noz- aged. 2) Seat is
nozzle tip. zle tip. 2) Fine grain is extremely dam-
2) Needle tip is 2) Foreign matter caught in seat. aged or worn.
Possible damaged or is caught in 3) Seat is 3) Foreign matter
causes of (Normal) broken, injection open- extremely worn. is caught in
trouble although very ing, although seat.
rare. very rare. 4) Internal parts of
nozzle holder
are worn or bro-
ken.
4D92E, 4D94LE, 4D98E 3-7

vi) Cleaning nozzle

1) Clean the periphery of the nozzle body, taking care not to damage the needle.
2) Pull out the needle and clean it, taking care not to damage it. Do not use a hard metallic tool.
3) Check that the needle is free from a bruise, damage, corrosion, wear, etc. In particular, check the
stem and seat of the needle carefully.
4) Clean the needle thoroughly and set it in the nozzle body. Slant the nozzle body to 60° and pull out
the needle about 1/3. At this time, check that the needle slides down by itself. Turn the needle and
check 2 – 3 times.
(Needle with F-cuts)
1) Needle
2) Body
3) Throttle type (F cuts)
3-8 4D92E, 4D94LE, 4D98E

3-5 Testing and adjusting fuel injection timing mark

(1) VE-type pump (Swirl-chamber type engine)
1) Remove the fuel injection pipe and control
wire from the pump and set the piston of the
No. 1 cylinder to the top dead center.
2) Remove the center bolt from the rear end of
the fuel injection pump and set the dial
gauge to measure the lift of the plunger.
3) Check that the match marks A on the fuel
injection pump and gear case are matched
to each other. If they are not matched,
match them.
a Be sure to remove the rear stay.
4) Rotate the crankshaft in reverse about 25° .
Check that the pointer of the dial gauge
does not move any more, and then set it to
0.
5) Rotate the crankshaft forward and set top
mark B of the crank pulley to 4° after the top
dead center (4D92E and 4D94LE) or 6°
after the top dead center (4D98E), and then
measure the lift of the plunger with the dial
gauge.
Standard value 0.97 – 1.03 mm
6) If the lift is out of the standard range, adjust

it by finely shifting the match marks on the
fuel injection pump and gear case.
When the lift of the plunger is
1) insufficient: Move the fuel injection
pump to the left, seeing from the drive
side, to set the lift into the standard
range.
2) excessive: Move the fuel injection pump
to the right, seeing from the drive side,
to set the lift into the standard range.
4D92E, 4D94LE, 4D98E 3-9

3-6 Adjusting no-load engine speed

Warm up the engine before performing the following
test.
1) Maximum no-load engine speed

Loosen maximum engine speed stopper bolt (1)
and adjust the engine speed.
4D92E/94LE/98E
Standard value 2,700 – 2,750 rpm
2) Minimum no-load engine speed

Loosen minimum engine speed stopper bolt (2)
and adjust the engine speed.
Standard value
4D92E 810 ± 25 rpm
4D94LE 845 ± 25 rpm
4D98E 810 ± 25 rpm
3-10 4D92E, 4D94LE, 4D98E

3-7 Sensor inspection

1. Thermostat and Thermal Switch Inspection
(1) Thermostat
Place the thermostat in a container filled 1
with water. Heat it while measuring the
water temperature, and see that the thermo-
stat is actuated at 69.5 – 72.5°C.
2
YE0375
(2) Thermoswitch
Place the thermoswitch in a container filled
with antifreeze or oil. Heat it while measur-
ing the fluid temperature. The switch is nor-
mal if the voltammeter shows continuity
when the fluid temperature is 107 – 113°C.
2. Oil pressure switch

Disconnect the connector from the oil pressure 7
switch. Keep the voltammeter probes in contact
with the switch terminal and cylinder block while
operating the engine. It is abnormal if circuit is
closed.
8
1) Thermometer
2) Thermostat
3) Cover
4) Gasket
5) Thermostat YE0377
6) Housing
Continuity test
7) Thermometer
8) Tester probes
9) Tester probes 9
10) Cylinder block
(flywheel side)
YE0378
4D92E, 4D94LE, 4D98E 3-11

3-8 Battery inspection

1. Battery structure
2 3
1) Battery case 4
2) Terminal
3) Cap
4) Cover 5
5) Cathode plate 6
6) Separator 1 7
7) Glass mat
8) Anode plate
8
YE0379
2. Battery inspection
(1) Electrolyte level
Add distilled water to the upper limit if the
level is low.
9) Upper limit
10) Lower limit 9
10
11) OK
12) Too low
13) Excessive
11 12 13
14) Electrolyte level
15) Battery tester
14
YE0380
Battery charge measurement with battery tester

(2) Battery charge
Use a battery tester or hydrometer and
check the battery condition. If the battery is
discharged, recharge it.
• Measurement with a battery tester
When checking the battery with the bat-
tery tester, connect the red clip of the
tester to the battery positive (+) terminal
and black clip to the battery negative (–)
terminal by pinching them securely, and
judge the battery charge level from the
indicator position.
Green zone: Normal
Yellow zone: Slightly discharged
Red zone: Defective or much
15
discharged
YE0381
3-12 4D92E, 4D94LE, 4D98E

• Measurement with hydrometer Battery charge measurement with a hydrometer

When using a hydrometer, the mea-
sured specific gravity must be corrected
according to the temperature at the time
of measurement. The specific gravity of
battery electrolyte is defined with 20°C
as the standard. Since the specific grav-
ity increases or decreases by 0.0007 1
when the temperature varies by 1°C,
correct the value according to the equa-
tion below.
S20 = St + 0.007 (t – 20)
Electrolyte temperature
at measurement
Specific gravity at measurement

YE0382
Hydrometer structure
Converted specific gravity at 20°C
2
Specific gravity and remaining 3

battery charge
Discharged
Specific Remaining 4
quantity of
gravity charge
electricity
(20°C) (%)
(%)
1.260 0 100 YE0383
1.210 25 75
1.160 50 50
1) Float 3) Glass tube
1.110 75 25 2) Rubber bulb 4) Float
1.060 100 0
How to read hydrometer
(3) Terminals
Clean if corroded or soiled.
(4) Mounting bracket
Repair or replace it if corroded.
Retighten if loosened.
(5) Battery appearance
Replace the battery if cracked or deformed.
Clean with fresh water if contaminated.
YE0384
4D92E, 4D94LE, 4D98E 3-13

3-9 Adjusting operation

Perform adjusting operation as follows after the maintenance job:
(1) Supply the fuel oil, lubricating oil and cooling water.
a Check the levels of the lubricating oil and cooling water again after test running (for about 5 minutes)
and add as required.
(2) Start the engine, and carry out idling at a low revolution (700 to 900 rpm) for a few minutes.
(3) Run in the engine for about five minutes at the rated revolution (no-load). Check any water, fuel or oil leak
and existence of abnormal vibration or noise. Also check the oil pressure, cooling water temperature and
exhaust gas color.
(4) Adjust the no-load minimum and maximum revolutions according to the specifications.
(5) Perform loaded operation as required.
3-10 Long storage

Observe the following instructions when the engine is to be stored for a long period without operation:
1. Always drain cooling water in a cold season or before a long storage. (This is unnecessary when antifreeze
is used.)
k Negligence of water draining will cause the cooling water remaining inside the engine to be frozen and
expanded to damage the engine parts.
Water draining procedure
(1) Remove the radiator cap.
(2) Loosen the water draining valve under the radiator to drain water from the inside.
(3) Loosen the drain valve on the side surface of the cylinder to drain water from the inside.
(4) After draining water, tighten the radiator cap and drain plug and valves.
2. Remove the mud, dust and oil deposit and clean the outside.
3. Perform the nearest periodic inspection before the storage.
4. Drain or fill the fuel oil fully to prevent condensation in the fuel tank.
5. Disconnect the battery cable from the battery negative (–) terminal.
6. Cover the silencer, air cleaner and electric parts with PVC cover to prevent water and dust from depositing
or entrance.
7. Select a well-ventilated location without moisture and dust for storage.
8. Perform recharging once a month during storage to compensate for self-discharge.
3-14 4D92E, 4D94LE, 4D98E

3-11 Periodic maintenance schedule

The engine periodic inspection timing is hard to determine as it varies with the application, load status, qualities
of the fuel and lubricating oils used and handling status. General rules are described here.
Q: User-maintenance w: Parts replacement q: Shop-inspection
Maintenance period
Every Every Every Every
Classification Item Daily Every 250 500 1000 2000
50 hours hours hours hours
hours or 3 or 6 or one or two
months months year years
Fuel tank level check and fuel supply Q
Fuel oil
Fuel tank draining Q
system
Fuel filter element replacement w
Lube oil level check and replenishment Q
Lubricating Lube oil replacement w
oil system w 2nd time
1st time and
Lube oil filter replacement thereafter
Cooling water level check and replenishment Q

Cooling Radiator fin cleaning Q
water
system Cooling water replacement w
Cooling water path flushing and maintenance q
Air intake
Air cleaner cleaning and element replacement Q w
system
Warning lamp & instruments function check Q
Electrical Battery electrolyte level check and battery
Q
system recharging
Alternator V-belt tension check Q
Intake/exhaust valve head clearance adjust-
Cylinder q
ment
head
Intake/exhaust valve seat lapping q
Fuel Fuel injection nozzle pressure inspection q

injection Fuel injection timing adjustment q
pump and Fuel injection pump inspection and adjust-
nozzle q
ment
Item marked "q" should be serviced by an authorized dealer, unless the owner has proficient mechanical ability
and the proper tools.
4D92E, 4D94LE, 4D98E 3-15

4. ENGINE BODY
4. ENGINE BODY
4-1 Introduction ............................................................................................................................................. 4-2

4-2 Cylinder head.......................................................................................................................................... 4-3
4-3 Gear train and camshaft ....................................................................................................................... 4-12
4-4 Cylinder block ....................................................................................................................................... 4-17
4D92E, 4D94LE, 4D98E 4-1

4. ENGINE BODY
4-1 Introduction
Make preparation as follows before starting engine inspection and service:
(1) Fix the engine on a horizontal base.
k Be sure to fix the engine securely to prevent injury or damage to parts due to falling during the work.
(2) Remove the cooling water hose, fuel oil pipe, wire harness, control wires etc. connecting the driven
machine and engine, and drain cooling water, lubricating oil and fuel.
(3) Clean soil, oil, dust, etc. from the engine by washing with solvent, air, steam, etc. Carefully operate so
as not to let any foreign matter enter the engine.
k Always wear glasses or other protectors when using compressed air or steam to prevent any foreign
matter from getting in the eyes.
a Any part which is found defective as a result of inspection or any part whose measured value does not
satisfy the standard or limit shall be replaced.
a Any part predicted to dissatisfy the standard or limit before the next service as estimated from the state
of use should be replaced even when the measured value then satisfies the standard or limit.
4-2 4D92E, 4D94LE, 4D98E

4. ENGINE BODY
4-2 Cylinder head

(1) Components
(2) Disassembly procedure:

Disassemble in the order of the numbers shown in the illustration.
Remove the alternator assembly. (Point 1)
Remove the fan, pulley and V belt.
Remove the thermostat case. (Point 2)
Remove the fuel filter and fuel oil piping (Point 3)
Remove the oil level gauge assembly.
Remove the oil filter. (Point 4)
Remove the fuel injection pipes. (Point 5)
Remove the intake manifold assembly.
Remove the exhaust manifold assembly.
Remove the bonnet assembly.
Remove the rocker shaft assembly, push rods and valve caps. (Point 6)
Remove the cylinder head assembly and head gasket. (Point 7)
Remove the fuel injection nozzles and fuel return pipe. (Point 8)
Remove the intake/exhaust valves, valve stem seals and valve springs. (Point 9)
Remove the rocker arms from the rocker arm shaft.
4D92E, 4D94LE, 4D98E 4-3

4. ENGINE BODY
(3) Reassembly procedure: V-belt tension

Reverse order of the disassembly procedure.
(4) Servicing points

Point 1
Disassemble:
• Loosen the mounting bolt while supporting
the alternator.
2
k Do not tilt the alternator toward the cylinder 1
block in a haste since it may damage the
alternator or pinch a finger.
3
Reassemble: YE0386
• The belt deflection shall be 10 – 15 mm
(7 – 9 mm for a new belt).
Tension Adjustment
Reassemble:
• Replace the belt with a new one if cracked, 5
worn or damaged.
• Carefully prevent the belt from being 4
smeared with oil or grease.
1) Cooling water pump

2) Alternator
4) Adjuster
5) Bar (for adjusting 6
V-belt tension)
YE0387
6) Alternator
Point 2
Reassemble:
• Check the thermostat function. (See 3-9 in Chapter 3 for the check procedure.)
Point 3
Reassemble:
• Replace the fuel filter element with a new one.
Disassemble:
• Cover the fuel pipe opening with tape to prevent intrusion of foreign matters.
Point 4
Reassemble:
• Replace the oil filter with a new one.
• After fully tightening the filter manually, retighten it with a filter wrench (see 10.1-6 in Chapter 10) by 3/4
turn.
Point 5
Disassemble:
• Cover the fuel injection pipe and pump inlets and outlets with tape or the like to prevent intrusion of
foreign matters.
4-4 4D92E, 4D94LE, 4D98E

4. ENGINE BODY
Point 6
Disassemble:
• Keep the removed push rods by attaching tags showing corresponding cylinder Nos.
Reassemble:
• Always apply oil to the contact portions of the push rods and clearance adjusting screws.
Point 7 Disassembly (Head bolt disassembly order)

Disassemble:
• Loosen the cylinder head bolts in two steps
in the illustrated order.
• Place the cylinder head assembly on a paper
board to prevent the combustion face from
any damage.
Reassemble:
• Remove the head gasket with a new one.
• Uniformly tighten the head bolts manually
Assembly (Head bolt tightening order)
after applying oil on the threaded and seat
portions.
• They shall be tightened in two steps in the
reverse of the order for disassembly.
3
First step: 49 – 58.8 Nm {5 – 6 kgf•m}
Second step: 102.9 – 112.7 Nm {10.5 – 11.5 kgf•m}
Point 8
Disassemble:
• Carefully remove the fuel injection nozzle so as not to leave the tip end protector from being left inside
the cylinder.
Reassemble:
• Replace the fuel injection nozzle protector with a new one.
Point 9
Disassemble:
• When removing each intake/exhaust valve
from the cylinder head, use a valve spring
compressor (1) (see 10-1-4 in Chapter 10)
and compress the valve spring and remove
the valve cotter.
• Keep each removed intake/exhaust valve
after attaching a tag showing the
corresponding cylinder No.
• If cotter burr is seen at the shaft of each intake/exhaust valve stem, remove it with an oilstone and extract
the valve from the cylinder head.
Reassemble:
• Replace the valve stem seal with a new one when an intake/exhaust valve is disassembled.
• Carefully install each valve after oil application so as not to damage the valve stem seal.
• Different valve stem seals are provided for the intake and exhaust valves. Do not confuse them since
those for exhaust valves are marked with yellow paint.
• After assembling the intake/exhaust valve, valve stem seal, valve spring, seat, and cotter, tap the head
of the valve stem lightly for settling.
• Do not forget to install the valve cap.
4D92E, 4D94LE, 4D98E 4-5

4. ENGINE BODY
(5) Parts Inspection and measurement

(5-1) Cylinder head
Clean the cylinder head, mainly the combustion surface, valve seats and intake/exhaust ports, remove
carbon deposit and bonding agent, and check the surface state.
(a) Appearance check

Check mainly discoloration and crack. If Distortion at combustion surface
crack is suspected, perform color check.
(b) Combustion surface distortion

Apply a straight-edge (1) in two diago-
nal directions and on four sides of the
cylinder head, and measure distortion
with a thickness gauge (2).
(Unit: mm)
Standard Limit
Distortion 0.05 or less 0.15

Valve sink
(c) Valve sink

Using depth micrometer (3), measure
with the valve inserted to the cylinder
head.
(Unit: mm)
Standard Limit
0.5 – 0.7 1.0 Valve sink depth

Valve sink Intake
amount a Exhaust
0.6 – 0.8 1.1
(d) Seat width

Using valve caliper (4), measure the
seat width. Valve seat width
(Unit: mm)
Standard Limit
Intake 1.3 2.0

Width
Exhaust 2.2 3.0
4-6 4D92E, 4D94LE, 4D98E

4. ENGINE BODY
(e) Seat contact Valve seat contact

Apply a thin coat of minium on valve
seat (1). Insert the valve in the cylinder
and push it against the seat to check
seat contact.
Continuous contact all

Standard
around
1
YE0395
Valve guide inside diameter
(5-2) Valve guide

Mainly check damage and wear on the 2 2 2
inside wall. Apply supply part code
YM129150-11810 when replacing the part.
(a) Inside diameter
(Unit: mm)
YE0396
Standard Limit
Valve stem
7.965 – 7.980 7.915
O.D.
Intake valve
2) Measuring positions
Valve
8.015 – 8.030 8.100
guide I.D.
Valve stem
0.035 – 0.065 0.185
clearance
Valve stem
7.955 – 7.970 7.905
Exhaust valve
O.D.
Valve
8.015 – 8.030 8.100
guide I.D.
Valve stem
0.045 – 0.075 0.195
clearance
Valve stem outside diameter
(5-3) Intake/exhaust valve

Mainly clean and check damage and wear 3
at the valve stem and seat.
(a) Seat cantact: See 5-1-(e) above.
(b) Stem outside diameter: See 5-2-(a)
above.
YE0397
3) Measuring positions
4D92E, 4D94LE, 4D98E 4-7

4. ENGINE BODY
(c) Valve head thickness Valve head thickness
(Unit: mm)
Standard Limit
Intake 1.71 1.00
Exhaust 1.65 1.00 4
YE0398
(d) Valve stem bend Valve stem bend and length
Limit 0.01 mm 5
(e) Overall length
(Unit: mm)
6
Standard Limit
Intake 115 114.5

Exhaust 115 114.5 YE0399
4) Thickness 6) Stool
5) Length of valve
(5-4) Valve spring Valve spring

Mainly inspect damage and corrosion.
1
(Unit: mm)
Standard Limit
Free length 47.5 —
Inclination — 1.2
YE0400
Valve spring
YE0401
1) Free length of spring 2) Inclination of spring
4-8 4D92E, 4D94LE, 4D98E

4. ENGINE BODY
Rocker arm hole diameter

(5-5) Valve rocker arm
Mainly inspect valve head cap contact sur-
face, inside surface defects and wear.
Slight surface defects shall be corrected
with an oilstone.
(Unit: mm)
Standard Limit
Arm hole diameter 18.50 – 18.52 18.57

YE0402
Shaft O.D. 18.47 – 18.49 18.44
Clearance 0.01 – 0.05 0.13 Rocker arm shaft outside diameter
(5-6) Valve rocker arm shaft

Mainly inspect seizure and wear at the sur-
face in sliding contact with the arm. The
rocker arm shaft diameter shall be as speci-
fied in (5-5) above.
YE0403
Push rod bend

(5-7) Push rod
Mainly inspect the surface in contact with
the tappet and adjusting screw. Slight
defects shall be corrected with an oilstone.
Bend limit 0.03 mm or less

3
(5-8) Valve clearance adjusting screw

YE0404
Mainly inspect the surface in contact with
the push rod.
Slight defects shall be corrected with an oil-
3) Thickness gauge
stone.
(5-9) Rocker arm spring

Mainly inspect surface defects and corro-
sion.
4D92E, 4D94LE, 4D98E 4-9

4. ENGINE BODY
(6) Valve seat correction

k Always check the oil clearance between the valve and valve guide before correcting the valve seat. If it
exceeds the limit, replace the valve or valve guide first to make the clearance satisfy the standard. After
correction, wash the valve and the cylinder head sufficiently with diesel oil to remove all grinding powder
or compound.
Seat cutter
1. If the seat surface is slightly roughened:
perform [A] and [B] below. 1
2. If the seat is heavily roughened but the width
is almost normal, correct with a seat grinder 2
or seat cutter first. Then perform lapping [A]
and [B] below.
Intake Exhaust 3
Seat cutter angle
120° 90°
YE0405
3. If the seat is heavily roughened and the width Seat grinder

is much enlarged, grind the seat inner
surface with a seat grinder whose center 4
angle is 40°, then grind the seat outer
surface with a grinder whose center angle is
150° to make the seat width match the
standard. Then perform seat correction as
described in 2), and then carry out lapping
[A] and [B] below.
Grinding wheel 1 2 5 YE0406

angle
40° 150°
Valve lapping
[A]: Lap the valve and seat with a mixture of
valve compound and engine oil.
[B]: Lap with engine oil only.
YE0407
1) Seat angle
2) Seat width
3) Cylinder head correction angle
4) Grinder
5) Grindstone
4-10 4D92E, 4D94LE, 4D98E

4. ENGINE BODY
(7) Valve guide replacement Valve guide replacement
1. Use a valve guide extraction tool (10.1-1 in 2

Chapter 10) and extract the valve guide from
the cylinder head.
2. Put liquid nitrogen or ether (or alcohol) with 3
dry ice added in a container and put the
valve guide for replacement (code No. 1
YM129150-11810) in it for cooling. Then
insert it in with a valve guide inserting tool
(10.1-2 in Chapter 10).
3. Check the inside diameter and finish to the
4
standard inside diameter as required with a
reamer. YE0408
4. Check the projection from the cylinder head.
Projection 14.7 – 15.0mm

1) Cylinder head
2) Valve guide extracting & inserting tool
3) Projection
4) Valve guide
k Do not touch the cooled valve guide with bare hands to avoid skin damage.
(8) Valve stem seal replacement

Always use a new seal after the intake/exhaust valve is disassembled. Since the one for the exhaust valve
is marked with yellow paint, do not confuse the intake and exhaust valves.
1. Apply engine oil to the lip. Stem seal insertion
2. Push with the inserting tool (10-1-5 in
Chapter 10) for installation.
5) Valve stem seal inserting tool

6) Valve stem seal
7) Valve guide
8) Cylinder head
4D92E, 4D94LE, 4D98E 4-11

4. ENGINE BODY
4-3 Gear train and camshaft

(1) Components
1) Fuel injection pump drive gear 2) Lubricating oil pump

Disassemble in the order of the numbers in the illustration.
Perform steps to of the cylinder head disassembly procedure.
Remove the cooling water pump.
Remove the crankshaft pulley. (Point 1)
Remove the gear case cover. (Point 2)
Remove the fuel injection pump. (Point 3)
Remove the idle gear assembly. (Point 4)
Remove the PTO drive gear. (Point 5)
Remove the PTO lubrication pipe.
Remove the starting motor.
Remove the flywheel. (Point 6)
Remove the camshaft assembly. (Point 7)
Remove the gear case. (Point 8)
Remove the oil seal from the gear case cover. (Point 9)
(3) Reassembly procedure:

Reverse of the disassembly procedure.
4-12 4D92E, 4D94LE, 4D98E

4. ENGINE BODY

Point 1
Disassemble:
• Remove the crankshaft pulley using a gear puller after removing the mounting bolt. When removing the
pulley with the gear puller, use a pad and carefully operate so as not to damage the thread. Set the gear
puller securely to prevent the pulley from being damaged.
Reassemble:
• When installing the crankshaft pulley, apply lube oil to the bolt and carefully assemble so as not to
3 Bolt: 117.6 Nm {12 kgf•m}

damage the oil seal.
Point 2
Reassemble:
• When installing the gear case cover, do not forget to install the two reinforcing bolts at the center.
• Measure the backlash of each gear. Gear train
(Unit: mm)
Standard Limit
Crankshaft gear,
camshaft gear,
Fuel injection 0.08 – 0.14 0.16
pump gear, Idle
gear, PTO gear
Lubricating oil
0.09 – 0.15 0.17
pump gear
• Apply sealant and install the gear case cover

by correctly positioning the two dowel pins.
1) Fuel injection pump drive gear 3) PTO gear 5) Lubricating oil pump gear
2) Camshaft gear 4) Crankshaft gear 6) Idle gear
Point 3
Disassemble:
• Remove the fuel injection pump drive gear mounting nut, remove the gear using the M8 extraction bolt and gear
puller, and remove the fuel injection pump. Do not forget to remove the stay on the rear side. When extracting
the gear using the gear puller, use a pad at the shaft and carefully operate so as not to damage the thread.
Reassemble:
1) Check that the O-ring is fitted and set
the fuel injection pump to match mark a.
2) Set top mark b to 6 degrees after the
top dead center.
3) Check that the lift of the plunger is 1 mm.
4) If the lift is not 1 mm, change the
mounting angle of the pump body.
3 Fuel injection pump drive gear

5) Install the fuel injection pump drive gear.
nut:63.7 Nm {5.6 kgf•m}
Point 4
Reassemble:
• Assemble crankshaft gear A, fuel injection pump drive gear B and camshaft gear C at the same time by aligning
with idle gear A, B and C marks.
• Install the idle gear shaft with the oil hole facing upward.
Point 5
Reassemble:
• Install the PTO gear with its inner spline side facing the flywheel.
4D92E, 4D94LE, 4D98E 4-13

4. ENGINE BODY
Point 6
Disassemble:
• Install a bolt as a handle in the hole at the
end face of the flywheel and remove
carefully so as not to damage the ring gear.
• 3 Flywheel mounting bolt: 186.2 –

Reassemble:
205.8 Nm {19 – 21 kgf•m}, apply lube oil
Point 7 Camshaft end play

Disassemble: 1
• Measure the camshaft end play.
2
(Unit: mm)
Standard Limit
End play 0.05 – 0.20 0.30
• If the measured end play exceeds the limit,

replace the thrust metal.
Disassemble:
• Since the camshaft gear is shrink-fit, heat it 3
to 180 – 200°C for extraction. YE0412
• For camshaft removal, raise the engine with
its mounting flange at the bottom. After
removing the thrust metal mounting bolt from 1) Camshaft gear
the camshaft gear hole, extract the camshaft 2) Thrust metal
carefully so as not to damage the bearing 3) End play
bushing.
• Rotate the camshaft a few turns before
extracting it to prevent the tappet from being
caught by the cam.
• After removing the camshaft, set the engine
horizontal and fix it on the base.
k Unforeseen injury may arise due to falling of slipping when raising the engine vertically or returning it to
the horizontal position. Proceed carefully so as not to lose balance.
Point 8
Reassemble:
• Do not forget to install the oil pan mounting bolts on the bottom side when installing the gear case.
• Apply sealant (code No.YM977770-01212) and install the gear case by matching the two dowel pins.
Point 9
Reassemble:
• Replace the oil seal whenever disassembled.
• Apply lithium grease at the time of assembly.
4-14 4D92E, 4D94LE, 4D98E

4. ENGINE BODY
(5) Parts inspection and measurement

(5-1) Camshaft
Mainly check the contact between the tappet and cam contact surface, bearing seizure and wear, and
gear damage.
Camshaft bend
1. Camshaft bend measurement
Support the camshaft with V blocks. Rotate 1
the camshaft and measure the runout at the
center of the camshaft and at each journal
with a dial gauge. Half of the runout is the
bend.
(Unit: mm)
Standard Limit 2
Bend 0 – 0.02 0.05 YE0413
2. Intake/exhaust cam height measurement Cam height
(Unit: mm)
Standard Limit
3 4
Cam height 42.435 – 42.565 42.185
3. Camshaft outside diameter and bearing hole

diameter measurement
Measure the camshaft outside diameter with YE0414
a micrometer. The oil clearance shall be
calculated by subtracting the measured
camshaft outside diameter from the camshaft
Camshaft outside diameter
bushing inside diameter after insertion to the
cylinder measured with a cylinder gauge.
(Unit: mm)
5
Standard Limit 6
Camshaft O.D. 49.925 – 49.950 49.890

Gear side
Bushing I.D. 49.990 – 50.055 50.130
Oil clearance 0.040 – 0.130 0.240

Intermediate
Camshaft O.D. 49.910 – 49.935 49.875 YE0415

position
Block I.D. 50.000 – 50.025 50.100
Oil clearance 0.065 – 0.115 0.225 1) Dial gauge

2) V-block
Camshaft O.D. 49.925 – 49.950 49.890 3) Cam height
Flywheel
side
Block I.D. 50.000 – 50.025 50.100 4) Micrometer

5) Flywheel side
Oil clearance 0.050 – 0.100 0.210
6) Micrometer
4D92E, 4D94LE, 4D98E 4-15

4. ENGINE BODY
(5-2) Idle gear Idle gear

Mainly check the bushing seizure and wear,
and gear damage.
1. Idle gear shaft outside diameter and bushing 7 10
inside diameter measurement
(Unit: mm) 8 9
Standard Limit
Idle gear shaft outside

45.950 – 49.975 45.900
diameter
YE0416
Bushing inside diameter 46.000 – 46.025 46.075
Clearance 0.025 – 0.075 0.175
7) Idle gear shaft 9) Inside diameter of gear
8) Shaft diameter 10) Idle gear
(5-3) PTO gear

Mainly check sticking of bearings on both
sides, gear damage and looseness, and
gear shaft damage and wear.
(6) Oil seal replacement

1. Replace the oil seal with a new one when the gear case is disassembled. Extract the used oil seal.
2. Insert a new oil seal using the oil seal inserting tool.
3. Apply Lithium grease.
(7) Camshaft bushing replacement

Replace the bushing using the special service tool (see 10-1-7 in Chapter 10).
4-16 4D92E, 4D94LE, 4D98E

4. ENGINE BODY
4-4 Cylinder block

(1) Components
1) Oil filter

Disassemble in the order of the numbers in the illustration.
Perform steps to in the cylinder head disassembly procedure.

Perform steps to in the gear train disassembly procedure.
Remove the oil pan. (Point 1)
Remove the lubricating oil suction pipe.
Remove the piston w/rod. (Point 2)
Remove the flywheel housing. (Point 3)
Remove the bearing metal caps. (Point 4)
Remove the crankshaft. (Point 5)
Remove the tappets.
Remove the piston and piston rings. (Point 6)
Remove the oil seal from the flywheel housing. (Point 7)
4D92E, 4D94LE, 4D98E 4-17

4. ENGINE BODY
(3) Reassembly procedure:

Reverse of the disassembly procedure.
Connecting rod side gap
Point 1
Disassemble:
• Sealant is applied to the oil pan mounting
surface on the cylinder block. Carefully operate
so as not to damage or distort the bonding
surface.
Reassemble:
• Apply sealant (code No.YM977770-01212)
before reassembly.
Point 2 1
Disassemble:
2
• Measure the connectiong rod side gap.
Standard 0.10 – 0.20 mm
YE0418
• Carefully remove the carbon deposit on top
of the cylinder block so as not to damage the
inner side of the cylinder block. 1) Crankshaft
• Set the piston at the B.D.C. position and 2) Thickness gauge
remove the connecting rod cap. Then set the
piston at the T.D.C. position, and push the
connecting rod big end with the wooden shaft
of a hammer. Proceed carefully so as not to
cause the cylinder block catch the rod big
end. Set the connecting rod caps and
crankpin metals in their correct combinations.
Reassemble:
• Apply oil especially carefully to the sliding contact surfaces of the pistons, rods and rings.
• Use the piston insertion tool (See 10-1-9 in Chapter 10) to insert each piston w/rod in the cylinder block
3 Connecting rod metal cap mounting bolt: 53.9 – 58.8 Nm {5.5 – 6 kgf•m}, apply lube oil
and install the bearing metal cap.
Point 3
Disassemble:
Place the engine on a stable base with the cylinder block upper surface facing down, and remove the
flywheel housing carefully so as not to damage the combustion surface.
Reassemble:
Apply sealant (code No.YM977770-01212) and install the flywheel housing by matching the two dowel
pins. After assembly, raise the engine with its mounting flange on the bottom side.
k Unforeseen injury may arise due to falling of slipping when raising or reversing the engine. Carefully
operate so as not to lose balance.
4-18 4D92E, 4D94LE, 4D98E

4. ENGINE BODY
Point 4 Crankshaft end play

Disassemble:
• Before removing the main journal bearing,
measure the crankshaft end play.
(Unit: mm)
Standard Limit
End Play 0.11 – 0.21 —
YE0419
Reassemble:
• If the end play exceeds the standard, replace
the thrust metal with an oversize one.
0.25 mm OS YM129900 – 02370 (Upper)

Code No. YM129900 – 02360 (Lower)
Standard thickness 2.055 – 2.105 mm
Disassemble: Main bearing

• Remove the main metal caps, cap side 2
bearings, and thrust metals. Place each 3
thrust metal with identification of the position 1
and direction. 4
Reassemble:
• Carefully install each thrust metal so that the
grooved one is positioned away from the
cap.
• Do not confuse the upper and lower main 5
bearing metals. The upper main bearing
metal (cylinder block side) has an oil hole,
and the lower one does not. The "wheel and
arrow" marks on the cap shall face the
YE0420
flywheel.
1) Flywheel side 4) Cap side main

2) Thrust metals bearing metals
3) Cylinder block side 5) Timing gear side
main bearing metals
3 Main metal cap mounting bolt: 112.7 Nm {11.5 kgf•m}

apply lubrication oil
Point 5
Disassemble:
• Remove the crankshaft. Remove each main bearing metal upper (cylinder block side) and pair it with the
main metal cap side lower metal.
k Carefully prevent damage to the bearing or finger injury when removing the crankshaft because it is
heavy.
4D92E, 4D94LE, 4D98E 4-19

4. ENGINE BODY
Point 6 Piston ring

Disassemble:
• Use the piston ring replacer (See 10-1-10 in
Chapter 10), remove the piston rings.
• Remove the circlip and remove the piston
pin by pushing it out.
Reassemble:
• Install each piston ring on the piston, with the 1
pu nch ed manu fac ture r’ s ma rk faci ng
upward. YE0421
Reassemble:
• The piston ring joints shall be staggered at Ring joints
by 120° intervals. Do not position the top ring 2
joint vertical to the piston pin. The coil
expander joint shall be opposite to the oil ring
joint.
5
1) Punched manufacturer’s 3
mark (make it face
upward.)
2) Oil ring joint
3) Top ring joint
4) Expander joint 4
5) Second ring joint
YE0422
Reassemble: Assembly direction of connecting rod

• When installing the piston pin to the connect- and piston
ing rod and piston, the punched match mark 7
on the big end of the connecting rod shall be
opposite to the size mark on the piston top.
Reassemble: 6 8
• Install the piston in the cylinder block with the
punched mark on the big end of the connect-
ing rod on the nozzle side. (The embossed
9
mark at the connecting rod I-beam section 10
shall be on the flywheel side.)
11
6) Camshaft side
7) Piston ID mark
8) Fuel injection 12
nozzle side
9) Cylinder block
size mark 13
10) Flywheel side
11) Piston ID mark
12) Embossed mark
(flywheel side)
YE0423
13) Match mark
4-20 4D92E, 4D94LE, 4D98E

4. ENGINE BODY
Point 7
Reassemble:
• Replace the oil seal with a new one whenever disassembled. Apply lithium grease at the time of
assembly.
(5) Parts inspection and measurement

(5-1) Cylinder block
Especially clean head surface, cylinder bores and oil holes, and check after removing any carbon
deposit and bonding agent.
Cylinder bore
1. Appearance inspection
Check if there is any discoloration or crack.
If crack is suspected, perform color check.
Sufficiently clean the oil holes and check
they are not clogged.
2. Cylinder bore and distortion
Measure at 10 mm below the crest of the
liner, at 20 mm from the bottom end and at
the center.
Roundness: Maximum value of the differ-
ence between the measured
values in the same cross sec-
tion.
Cylindricity: Maximum value of the differ- Cylinder bore measurement positions
ence between the measured
values in the same direction. 10mm
(Unit: mm)
Standard Limit
4D92E 92.000 – 92.030 92.130
Bore 4D94LE 94.000 – 94.030 94.130

20mm
4D98E 98.000 – 98.030 98.130
Roundness 0.01 or less 0.03 YE0425
Cylindricity 0.01 or less 0.03

Measure in two directions A and B at points a, b and c.
3. If the limit is exceeded or any surface defect
is found, repair by boring and honing. Use an
oversized piston (and new piston rings) as
required.
Piston assembly code

Standard size of outer Piston ring assembly Boring dimension
0.25 mm OS (incl./Piston ring
diameter (mm) code (mm)
assembly)
4D92E YM129904-22940 92.250 YM129904-22950 92.250 – 92.280
4D94LE YM129931-22900 94.250 YM129901-22950 94.250 – 94.280
4D98E YM129903-22900 98.250 YM129903-22950 98.250 – 98.280
4D92E, 4D94LE, 4D98E 4-21

4. ENGINE BODY
(5-2) Crankshaft Inspection by color check

Mainly check seizure and wear of the crank-
pins and main journals. Since the crankshaft
gear is shrink-fitted, heat to 180 to 200°C
when extraction is necessary.
1. Shaft portion color check
After washing the crankshaft, inspect it by
means of color check or a magnaflux
inspector. Replace it if cracked or heavily
damaged. Slight defects shall be corrected
by grinding.
2. Crankshaft bend
Support the crankshaft journals at both ends
with V-blocks. Use a dial gauge and mea- YE0426
sure the runout at the center journal while
rotating the shaft to inspect the bend.
Crankshaft bend measurement
Limit 0.02 mm or less

1
2
3
4 5
YE0427
1) Bend
2) Deflection
3) Dial gauge
4) V-block
5) V-block
4-22 4D92E, 4D94LE, 4D98E

4. ENGINE BODY
3. Crankpin and main journal measurement Measuring position of the crankpin

Masure the outside diameter, roundness and crank journal
and taper at each crankpin and main jour-
nal.
Correct by grinding if unevenly wear, round-
ness exceeding the limit or insufficient out-
side diameter is found. Replace if the defect
is excessive.
• Crankpin (Unit: mm)
Standard Limit
Crankpin outside
57.952 – 57.962 57.902
diameter
Connecting rod
1.492 – 1.500 —
metal thickness
Connecting rod hole

61.000 – 61.010 0.150
diameter
Oil clearance 0.038 – 0.074 —
If the clearance limit is exceeded, use an

undersized bearing.
6
0.25 mm US bearing 7
YM129900-23350
Part code YE0428

6) Crankshaft journal 7) Crankpin
Crankpin machining
dimension 57.502 – 57.712 mm
• Crank journal (Unit: mm)

If the clearance limit is exceeded, use an
Standard Limit undersized bearing.
Journal O.D. 64.952 – 64.962 64.902

0.25 mm US Crank YM129900-02320 (Upper)
Main metal journal bearing
1.995 – 2.010 — YM129900-02330 (Lower)
thickness Part code
Main metal hole Standard thickness 2.215 – 2.130 mm

69.000 – 69.030 —
diameter
Main journal bearing
64.702 – 64.712 mm
Oil clearance 0.038 – 0.068 0.150 machining dimension
k If the oil clearance is execessive though the thicknesses of the main journal and crankpin metals are
normal or if partial uneven wear is observed, re-grind the crankshaft and use an oversized metals.
k If rust of surface roughening exists on the rear side of the metals, coat it with blue or minimum. Then
assemble the crankpin metal to the connecting rod, and tighten the rod bolt to the specified torque to
check the metal for contact. If the contact surface occupies 75% or more, the metal is normal. If the
contact surface is insufficient, the metal interference is insufficient. Replace the metal with a new one.
4D92E, 4D94LE, 4D98E 4-23

4. ENGINE BODY
(5-3) Thrust metal inspection

Inspect any damage or wear.
1. Thrust metal thickness (Unit: mm)
Standard Limit
Thickness 1.930 – 1.980 1.850
If the side gap is exceeded, use an oversized thrust metal.
0.25 mm OS YM129900-02370 (Upper)

Code No. YM129900-02360 (Lower)
(5-4) Piston Piston outside diameter

Especially clean the combustion surface,
circumference, ring grooves and piston pin
bosses, and check after removing any car-
bon deposit. Any burr at a ring groove or
snap ring groove shall be removed. If crack
is suspected, inspect by color check.
1) Measurement position
1. Piston outside diameter mesurement

1
Measure the long diameter at 22 mm from 22mm
the bottom end of the piston of the oval hole
in the vertical direction to the piston pin hole. YE0429
(Unit: mm)
Piston pin outside diameter
Standard Limit
4D92E 91.950 91.900

Long
4D94LE 93.945 – 93.955 93.900
diameter
4D98E 97.945 – 97.955 97.900
Clearance Min. — 0.050

between piston
and cylinder Max. — 0.080
If the clearance between piston and cylinder

exceeds the limit, use an oversized piston. YE0430
Measure at positions a, b and c in directions A and B.
0.25 mm OS Standard dimension of outer

Boring dimension (mm)
Piston assembly code diameter (mm)
4D92E YM129904-22940 92.200 92.250 – 92.280
4D94LE YM129931-22900 94.250 94.250 – 94.280
4D98E YM129903-22900 98.250 98.250 – 98.280
4-24 4D92E, 4D94LE, 4D98E

4. ENGINE BODY
2. Piston pin hole measurement Piston pin hole
(Unit: mm)
Standard Limit
Piston pin hole

30.000 – 30.009 30.039
diameter
Piston pin outside

29.989 – 30.000 29.959
diameter
Oil clearance 0.000 – 0.020 0.080
YE0431
Measure at positions a and b in directions A and B.

3. Piston ring, ring groove and piston ring end
clearance measurement Piston ring components
• Except for the top ring, to measure the
piston ring groove width, first measure 1
the width of the piston ring. Then insert
the piston ring into the ring. Then insert
the piston ring into the ring groove. Insert 2
a thickness gauge in between the piston
ring and groove to measure the gap
between them. Obtain the ring groove 3
wi dth by ad ding r ing width to the
measured side clearance.
YE0432
1) Top ring
2) Second ring
Measuring side clearance
3) Oil ring
4) Width
5) Thickness
5
YE0433
4D92E, 4D94LE, 4D98E 4-25

4. ENGINE BODY
• To measure the piston ring end clearance, Ring joint end clearance measurement
push the piston ring into the sleeve using
6
the piston head, insert a thickness gauge
in end clearance to measure. The ring
shall be pushed in to approx. 30 mm 7
above the bottom end of the cylinder. For
the top ring, measure only the piston ring
joint end clearance in normal state.
(Unit: mm)
10 8
Standard Limit 9 YE0434
Piston ring groove

2.040 – 2.060 —
width 6) Cylinder block head surface
Piston ring width 1.940 – 1.960 1.920 7) Joint end clearance
Top ring
8) Approx. 30 mm from bottom end of cylinder

Piston side
0.080 – 0.120 — 9) Piston ring
clearance
10) Cylinder block
Piston end
0.250 – 0.450 0.540
clearance
Piston ring groove

2.080 – 2.095 2.195
width
Second ring
Piston ring width 1.970 – 1.990 1.950
Piston side
0.090 – 0.125 0.245
clearance
Piston end
0.450 – 0.650 0.730
clearance
Piston ring groove
3.015 – 3.030 3.130
width
Piston ring width 2.970 – 2.990 2.950

Oil ring
Piston side
0.025 – 0.060 0.180
clearance
Piston end
0.250 – 0.450 0.550
clearance
4-26 4D92E, 4D94LE, 4D98E

4. ENGINE BODY
4. Oversize piston, piston ring and applicable head gasket

1. 4D92E
Item Standard 0.25 OS 0.50 OS 1.00 OS
Piston assembly YM129904-22120 YM129904-22940 YM129904-22960
Piston YM129904-22020 YM129904-22800 YM129904-22810
Ring assembly YM129904-22050 YM129904-22950 YM129904-22970
1st ring YM129904-22100 YM129904-22750 YM129904-22850 None
2nd ring YM129904-22110 YM129904-22760 YM129904-22860
Applicable head
YM129901-01350 YM129901-01350 YM129901-01350
gasket
2. 4D94LE
Piston assembly YM129931-22100 YM129931-22900 YM129931-22920 YM129931-22940
Piston YM129931-22010 YM129931-22700 YM129931-22720 YM129931-22740
Ring assembly YM129901-22050 YM129901-22950 YM129901-22970 YM129901-22990
1st ring YM129901-22100 YM129901-22750 YM129901-22850 YM129901-22650
2nd ring YM129900-22110 YM129900-22760 YM129900-22860 YM129900-22660
Oil ring YM129900-22160 YM129900-22770 YM129900-22870 YM129900-22670
Applicable head
YM129901-01350 YM129901-01350 YM129901-01350 YM129901-01370
gasket
3. 4D98E
Piston assembly YM129903-22080 YM129903-22900

Piston YM129903-22010 YM129903-22700
Ring assembly YM129903-22050 YM129903-22950
1st ring YM129903-22100 YM129903-22750

None None
2nd ring YM129902-22110 YM129902-22760
Oil ring YM129902-22160 YM129902-22770
Applicable head
YM129903-01350 YM129903-01350
gasket
4D92E, 4D94LE, 4D98E 4-27

4. ENGINE BODY
(5-5) Connecting rod Twist and parallelism measurement

1. Appearance inspection
Inspect the portion near the boundary of the
chamfered portion and I-beam section of the
big and small ends of the connecting rod as 1
well as the portion near the oil hole of the
bushing at the small end for cracks, defor-
mation, and discoloration.
2. Twist and parallelism measurement

2
Use a connecting rod aligner and measure 3
the twist and band.
(Unit: mm)
Standard Limit YE0435
dimension dimension
Twist and 0.03 or less Twist measurement using

0.08
parallelism per 100 a connecting rod aligner
3. Connecting rod small end measurement

Measure the piston pin outside diameter
according to (5-4) -1 described above. 4
(Unit: mm)
Standard Limit
Piston pin I.D.

30.025 – 30.038 30.068
bushing
Piston pin O.D. 29.987 – 30.000 29.959 YE0436
Oil clearance 0.025 – 0.051 0.109

Connecting rod small end
If the bushing is to be replaced because the
oil clearance exceeds the limit, use spare
part code No. YM129900-23910.
4. Connecting rod big end measurement

Measure the crankpin and metal according
to (5-2) -3 described above.
YE0437
1) Parallelism 4) Connecting rod aligner

2) Twist 5) Cylinder gauge
3) Mandrel
4-28 4D92E, 4D94LE, 4D98E

4. ENGINE BODY
(5-6) Tappet Tappet

Mainly check the tappet contact surface with
the cam and push rod. Slight surface
defects shall be corrected with an oilstone.
1. Tappet stem outside diameter measurement
(Unit: mm)
Standard Limit
Tappet stem
11.975 – 11.990 11.955
O.D.
1 2 YE0438
Tappet hole I.D. 12.000 – 12.018 12.038
Oil clearance 0.010 – 0.043 0.083
1) Abnormal contact surface
2) Normal contact surface
Tappet stem outside diameter measurement
YE0439
Items to be prepared for honing

(6) Cylinder bore correction
1. Slight uneven worn, flawed, etc. shall be
corrected by honing only. If the cylinder is
unevenly worn partially, flawed or otherwise
damaged and cannot be repaired simply by
honing, rebore the cylinder first and then
h o n e . S e e ( 5) ( 5- 1) - 3 f o r th e bo r i ng 4
dimension.
2. Items to be prepared for honing 6 7
• Flex-Hone (see 10-1-8 in Chapter 10) 50% 50%
• Electric drill
• Honing fluid (50:50 mixture of lube oil
and diesel oil) 3
5 YE0440
3) Flex-hone
4) Electric drill
5) Honing fluid
6) Lube oil
7) Diesel oil
4D92E, 4D94LE, 4D98E 4-29

4. ENGINE BODY
3. Apply the honing fluid to the Flex-Hone and Honing cross hatch
turn the electric drill at 300 to 1,200 rpm.
Then insert the Flex-Hone into the cylinder
bore while turning it, and move it up and
down for about 30 sec. to obtain a honing
mark with a cross hatch angle of 30 to 40°.
YE0441
k Avoid faster revolution than 1,200 rpm since it may cause breakdown.
k Do not insert or extract the Flex-Hone in stopped state because the cylinder will be damaged.
k Limit the honing depth to 1/1,000 mm each time.
• Cylinder overhaul (reference)
Service life of cylinder block (H3)

(H3 = 3H1)
Boring and honing interval (H2)

(H2 = 1.5H1)
Time for honing (H1)
Increase in
Increase in lubricating Increase in lubricating Increase in lubricating lubricating
oil consumption oil consumption oil consumption oil consumption
or blow-by or blow-by or blow-by or blow-by
Honing Boring Honing
(Study if an oversized piston or piston ring is usable.)

YE0568
(7) Piston pin bushing replacement

Replace bushing by using the special service tool (see 10-1-3 in Chapter 10).
(8) Oil seal replacement

1. Replace oil seal, when flywheel housing is removed. Extract the used oil seal.
2. Insert a new oil seal with the oil seal insertion tool.
3. Apply lithium grease.
4-30 4D92E, 4D94LE, 4D98E

5. LUBRICATION SYSTEM
5-1 Lubrication system diagram ................................................................................................................... 5- 2

5-2 Trochoid pump components .................................................................................................................. 5- 2
5-3 Disassembly (reverse the procedure below for assembly) .................................................................... 5- 3
5-4 Servicing points ..................................................................................................................................... 5- 3
5-5 Parts inspection and measurement ....................................................................................................... 5- 4
4D92E, 4D94LE, 4D98E 5-1

5-1 Lubrication system diagram
1) Crankshaft bearing 5) Oil pan

2) Camshaft bearing 6) Lube oil pump
3) To cylinder head (with built-in pressure regulator valve)
(valve rocker arm lubrication) 7) Fuel injection pump
4) To gear case 8) Lube oil filter
(oil pump gear lubrication)
5-2 Trochoid pump components
1) Outer rotor 2
2) Gear case
3) Crankshaft
4) Punch mark 1
4
3
YE0444
5-2 4D92E, 4D94LE, 4D98E

5-3 Disassembly (reverse the procedure below for assembly)

1. Loosen the belt, and remove the radiator pulley, fan and V-belt. See 4-2 (2) 2 in Chapter 4.
2. Remove the crankshaft pulley. See 4-3 (2) in Chapter 4.
3. Remove the gear case cover. See 4-3 (2) in Chapter 4.
4. Remove the lubricating oil pump ass’y from the gear case. (Point 1)
5. Remove the pressure regulator valve from the lubricating oil pump body. (Point 2)
5-4 Servicing points

Point 1
Disassemble:
• Check if the oil pump rotates smoothly and see that there is no play between the shaft and gear, and
inner rotor.
Reassemble:
• Install the outer rotor in the gear case so that the punch mark on the end face is seen.
• When replacing the lubricating oil pump, replace the whole ass’y.
Point 2
Disassemble-Reassemble:
• Only wash the pressure regulator valve. Disassembly is unnecessary unless any abnormality in
operation is detected.
4D92E, 4D94LE, 4D98E 5-3

5-5 Parts inspection and measurement

(1) Outer rotor Oil clearance
• Oil clearance between the outer rotor and
inside diameter of the gear case hole.
2
• Side clearance between outer rotor and gear
case hole. 1
(Unit: mm)
Standard Limit
Oil clearance 0.100 – 0.155 0.25

Side clearance 0. 05 – 0.10 0.15
YE0445
(2) Rotor shaft

Side clearance
(Unit: mm)
Standard Limit
Shaft O.D. 12.955 – 12.970 12.945

Bearing I.D. 12.980 – 13.020 13.050
Clearance 0.010 – 0.065 0.105
YE0446
Lube oil pump bearing
4 5
6
YE0447
1) Gear case
2) Outer rotor
3) Rotor shaft
4) Shaft O.D.
5) Bearing I.D.
6) Gear case
5-4 4D92E, 4D94LE, 4D98E

6. COOLING SYSTEM
6. COOLING SYSTEM
6-1 Cooling water system ............................................................................................................................ 6- 2

6-2 Cooling water pump components .......................................................................................................... 6- 3
6-3 Disassembly (reverse the procedure below for assembly) .................................................................... 6- 3
6-4 Servicing points ..................................................................................................................................... 6- 3
4D92E, 4D94LE, 4D98E 6-1

6. COOLING SYSTEM
6-1 Cooling water system
1) From cylinder head

2) Cooling water pump
3) Radiator
4) Bypass
6-2 4D92E, 4D94LE, 4D98E

6. COOLING SYSTEM
6-2 Cooling water pump components
6-3 Disassembly (reverse the procedure below for assembly)

Remove the alternator. See 4-2 (2) - in Chapter 4.
Remove the fan, fan V-belt and fan pulley. See 4-2 (2) - in Chapter 4.
Remove the thermostat cover. See 4-2 (2) - in Chapter 4.
Remove the cooling water pump. (Point 1)
Remove the thermostat. (Point 2)
6-4 Servicing points

Point 1
Disassemble-Reassemble:
• Check to see that the cooling water pump bearing is free from abnormal noise, sticking or play and water
leakage from the bearing. If replacement is necessary, replace the whole cooling water pump ass’y.
Point 2
Disassemble:
• Check the thermostat function. See 3-9-1 (1) in Chapter 3 for the inspection method.
4D92E, 4D94LE, 4D98E 6-3

7. FUEL INJECTION PUMP, GOVERNOR
7-1 Specifications......................................................................................................................................... 7- 2
7-2 Component parts ................................................................................................................................... 7- 3
7-3 Fuel injection pump system diagram ..................................................................................................... 7- 4
7-4 Removal and installation of fuel injection pump..................................................................................... 7- 5
7-5 Fuel system ........................................................................................................................................... 7- 6
7-6 Structure and operation of pump ........................................................................................................... 7- 8
7-7 Operation of plunger ............................................................................................................................ 7- 12
7-8 All speed governor ............................................................................................................................... 7- 18
7-9 Structure and operation of timer .......................................................................................................... 7- 26
7-10 Magnet valve ....................................................................................................................................... 7- 28
7-11 Improvement of startability at very low temperature ............................................................................ 7- 29
4D92E, 4D94LE, 4D98E 7-1

7-1 Specifications
Type — VE
Number of injection cylinders — 4
Turning direction
— Right
(Seen from gear side)
Max. revolving speed (Pump) rpm 2,490
Plunger diameter mm 12
4D92E deg./rpm 5 / 800 – 1,500

Advance angle of
4D94LE deg./rpm 3.5 / 800 – 1,350
speed timer
4D98E deg./rpm 5 / 500 – 1,350
Revolving speed control — All-speed governor
Fluctuation (750 rpm) % 4
Weight kg Approx. 5.5
Lubrication method — Lubrication with fuel oil
Max. pressure in pipe MPa {kgf/cm2} Approx. 53.9 {550}
Safety device against reverse revolution — Installed
7-2 4D92E, 4D94LE, 4D98E

7-2 Component parts
1) Drive shaft 8) Plunger

2) Control lever 9) Delivery valve
3) Flyweight 10) Plunger spring
4) Governor lever 11) Timer
5) Full-load adjustment screw 12) Cam disc
6) Magnet valve 13) Roller holder
7) Distributor head 14) Feed pump
4D92E, 4D94LE, 4D98E 7-3

7-3 Fuel injection pump system diagram
1) Fuel injection valve

2) Fuel tank
3) Fuel injection pump
4) Fuel filter and water separator with priming pump
7-4 4D92E, 4D94LE, 4D98E

7-4 Removal and installation of fuel injection pump

(1) Disassembly procedure: Perform the steps according to the indicated numbers.
1) Perform steps and of the disassembly procedure for the cylinder head.
2) Perform steps and of the disassembly procedure for the gear train and camshaft. (Point 1)
(2) Assembly procedure: Carry out assembly in

the reverse order to disassembly.
(3) Point of work

Point 1: Fuel injection pump drive gear
Removal • Make engagement marks B
on the fuel injection pump
drive gear and the idle gear
with a marker, and then re-
mov e the fuel injection
pump drive gear.
Installation • When assembling, match
marks B of the gears.
3 Gear mounting bolt:
63.7 Nm {6.5 kgf•m}
(4) Testing and measuring parts

Ask the service network of the pump manufacturer to test and measure the parts and adjust the setting of
them.
4D92E, 4D94LE, 4D98E 7-5

7-5 Fuel system
1) Fuel tank 6) Regulating valve 11) Overflow valve

2) Sedimenter 7) Feed pump 12) Overflow pipe
3) Priming pump 8) Plunger 13) Nozzle
4) Fuel filter 9) Plunger barrel
5) Drive shaft 10) Magnet valve
7-6 4D92E, 4D94LE, 4D98E

7-6 Structure and operation of pump
1) Drive shaft 11) Magnet valve

2) Regulating valve 12) Plunger
3) Control lever shaft 13) Outlet port
4) Control lever 14) Delivery valve
5) Flyweight 15) Control sleeve
6) Governor spring 16) Plunger spring
7) Idle spring 17) Cam disc
8) Full-load adjustment screw 18) Cross coupling
9) Tension lever 19) Drive gear
10) Governor lever assembly 20) Feed pump
7-8 4D92E, 4D94LE, 4D98E

(1) Outline
1) Pump
• Drive shaft (1) receives the engine
power directly through the timing belt (or
gear) and transmits it to cam disc (3)
through cross coupling (2).
• Since the positioning pin fitted to cam
disc (3) is fitted to the groove of the
plunger flange, plunger (4) revolves
similarly to cam disc (3).
• Cam disc (3) has a face cam and
reciprocates by the specified cam lift on
roller (5) of the roller holder assembly.
• There are 2 plunger springs having set
forces on the outside of plunger (4),
which return down the plunger pushed
up by cam disc (3).
• In this way, the plunger is rotated by
drive shaft (1) and reciprocated by cam
disc (3).
• When the fuel oil pressurized high by the
plunger flows into outlet port (6), delivery
valve (7) opens and the fuel oil is
injected through the nozzle and nozzle
holder into the combustion chamber of
the engine.
4D92E, 4D94LE, 4D98E 7-9

2) Governor
• The governor is installed above the
pump chamber and consists of flyweight
holder (1), governor lever assembly (2),
etc.
• Flyweight holder (1) holds 4 flyweights
(3) and governor sleeve (4) and is
supported by the governor shaft. Drive
gear (5) is engaged with flyweight holder
gear (6) to increase the speed of drive
shaft (7) and rotate flyweight holder
assembly (1).
• Governor lever assembly (2) is
supported by the pivot bolt of the pump
housing. Ball pin (8) at the lower part of
the governor lever assembly is inserted
in control sleeve (9) which rocks the
outside of plunger (15).
• Governor spring (10) at the upper part is
connected to tension lever (12) by
retaining pin (11) and its end is
connected to control lever (14) through
control lever shaft (13).
• Control lever (14) is connected to the
accelerator pedal through the link. It
changes the set force of governor spring
(10) according to the leaning angle.
• The difference between the set force of
governor spring (10) and the centrifugal
force of flyweight (3) corresponds to the
moving distance of control sleeve (9), or
the injection rate.
3) Timer
• The timer is installed in the bottom of the
injection pump. Timer spring (2) having
a set force is installed to low-pressure
side A of timer piston (1).
• On the opposite side (high-pressure side
B), the fuel oil pressure in the pump
chamber is applied directly. Timer
piston (1) moves to rotate roller holder
(4) through roller holder pin (3),
according to the balance between the
fuel oil pressure and timer spring (2).
• When the piston moves to compress
timer spring (2), the injection timing is
advanced (roller holder (4) moves in the
reverse direction).
• In this way, the timer controls the
injection timing according to the fuel oil
pressure in the pump chamber.
7-10 4D92E, 4D94LE, 4D98E

(2) Feed pump (Vane type)

• The feed pump sucks up fuel oil A from
the tank and sends it into the pump
chamber.
• The feed pump consists of rotor (1),
blades (2) (vanes), and liner (3). Rotor
(1) is driven with drive shaft (4). Liner (3)
is eccentric to rotor (1), and there are 4
blades (2) (vanes) between the rotor and
liner.
• If rotor (1) starts revolution, blades (2)
are pressed against the inside wall of
liner (3) by the centrifugal force. As rotor
revolves, the volume of each chamber
changes.
• When the volume of each chamber is
increased, fuel oil A is sucked up from
the fuel tank. When the volume of each
chamber is decreased, the fuel oil is
pressurized and sent to pump chamber
B.
(3) Regulating valve

• Regulating valve (5) adjusts the feed
pump pressure so that the fuel oil pres-
sure in the pump chamber will be kept in
a specified range.
• If the injection pump speed rises, the
feed pump pressure rises, too. Then,
the fuel oil compresses regulating valve
spring (6) and pushes up piston (7). As
a result, the fuel oil is returned to suction
side C of the feed pump as indicated by
the arrows in the figure.
• Accordingly, the pump chamber pres-
sure can be adjusted by changing the
set force of regulative valve spring (6).
• The figure shows an example of the re-
lationship between the pump speed and
the pump chamber pressure. The hy-
draulic timer utilizes the pump chamber
pressure directly to control the injection
timing.
4D92E, 4D94LE, 4D98E 7-11

7-7 Operation of plunger
1) Drive shaft 7) Inlet slit 13) Outlet port

2) Drive gear 8) Plunger barrel 14) Plunger spring
3) Face cam 9) Plunger 15) Cut-off port
4) Control sleeve 10) Delivery valve spring 16) Cam disc
5) Magnet valve 11) Outlet slit 17) Roller
6) Inlet port 12) Delivery valve 18) Feed pump
(1) Operation
• Drive shaft (1) drives feed pump (18), cam disc (16), and plunger (9) simultaneously. Plunger spring (14)
presses plunger (9) and cam disc (16) against roller (17).
• If drive shaft (1) rotates cam disc (16), face cam (3) moves on roller (17) to reciprocate plunger (9). When
inlet port (6) of plunger barrel (8) fitted to the distributor head comes to inlet slit (7) of the plunger (9),
plunger (9) sucks and pressurizes the fuel oil.
• When outlet port (13) of plunger barrel (8) is connected to outlet slit (11) of the plunger, the high-pressure
fuel oil opens delivery valve (12) and is injected into the combustion chamber of the engine through the
nozzle.
• When cut-off port (15) of the plunger moves out of control sleeve (4), feeding of the fuel oil from plunger
(9) finishes.
7-12 4D92E, 4D94LE, 4D98E

1. Suction stroke
• When inlet port (6) of the plunger barrel
comes to inlet slit (7) of plunger (9) in the
lowering stroke of plunger (9), the fuel oil
in the pump chamber is sucked in the
plunger.
A. Pressurizing chamber
2. Injection stroke
• If the cam disc starts rising, plunger (9) starts
turning. When plunger (9) blocks inlet port
(6) of the plunger barrel, feeding of the fuel
oil starts.
• When outlet slit (11) of plunger (9) comes to
outlet port (13) of the plunger barrel, the
high-pressure fuel oil pushes up delivery
valve (12). Then, the fuel oil is injected into
the combustion chamber of the engine
through the nozzle and nozzle holder.
4D92E, 4D94LE, 4D98E 7-13

3. End of injection
• When the cam disc raises plunger (9) further
and cut-off port (15) of plunger (9) moves out
of control sleeve (4), the high-pressure fuel
oil returns to the pump chamber through cut-
off port (15).
• As a result, the pressure of the fuel oil in the
plunger lowers below the set force of
delivery spring (10). Accordingly, delivery
valve (12) closes and feeding of the fuel oil
finishes.
4. Pressure equalizing stroke

• After injection finishes, when plunger (9)
turns 180° more, outlet slit (11) of the
plunger comes to outlet port (13) of the
plunger barrel. As a result, the pump
chamber is connected to outlet port (13) and
the fuel oil pressures in them become equal
to each other.
• By this pressure equalizing stroke, the
pressure in outlet port (13) is equalized and
the spraying condition is stabilized.
• Strokes 1 – 4 described above are carried
out every turn of the crankshaft in the order
of the cylinders.
7-14 4D92E, 4D94LE, 4D98E

(2) Reverse revolution prevention mechanism

• While plunger (9) is revolving in the normal
direction, inlet port (6) of plunger barrel (8)
opens and fuel oil is sucked in plunger (9)
sufficiently in the plunger lowering stroke. In
the plunger rising stroke, inlet port (6) closes
and the fuel oil is injected.
• On the other hand, if the engine revolves in
reverse, inlet port (6) of plunger barrel (8)
does not close in the rising stroke of plunger
(9). Accordingly, the fuel oil is neither
pressurized nor injected.
(3) Fuel injection rate control mechanism

• The fuel injection rate is changed by moving
control sleeve (4) to change the effective
stroke.
• The effective stroke means the stroke of the
plunger after inlet port (6) and inlet slit (7) are
closed until cut-off port (15) moves out of
control sleeve (4), which is in proportion to
the fuel injection rate.
• That is, if control sleeve (4) moves in leftward
direction B as shown in the figure, effective
stroke (S2) is reduced. If the former moves
in rightward direction C, effective stroke (S1)
i s in c r e as e d , o r t he i n j ec t i on r a te i s
increased.
B. Fuel injection rate is decreased
• The position of the control sleeve (4) is
decided by controlling the governor. C. Fuel injection rate is increased
D. Effective stroke
4D92E, 4D94LE, 4D98E 7-15

(4) Delivery valve assembly

• The delivery valve assembly consists of
delivery valve (12) and valve seat (19).
• If the pressure of the fuel oil sent from the
plunger becomes higher than the spring
force of delivery valve spring (10), delivery
valve (12) opens and the fuel oil is sent to the
nozzle and nozzle holder through the
injection pipe.
• After injection is finished, some pressure is
left in the injection pipe for the next injection.
Delivery valve (12) prevents the fuel oil in the
injection pipe from flowing back to the
plunger.
• If the residual pressure is too high, the fuel oil
may not stop sharply after injection is
finished.
• The delivery valve sucks back the fuel oil in
the injection pipe by back suction stroke b of
piston a so that fuel oil stops sharply after
injection is finished.
A. Pressurizing stroke
B. Start of back suction (End of feeding of oil)
C. End of back suction
7-16 4D92E, 4D94LE, 4D98E

(5) Delivery valve holder with damping valve

• Delivery valve holder with damping valve (1)
prevents cavitation-erosion in the pipe in
high-speed operation, uneven injection, and
secondary injection.
• If high-pressure fuel oil is sent from the
plunger, delivery valve (5) and damping
valve open, and then the fuel oil is sent to the
nozzle mainly along the periphery of
damping valve (3). After injection is finished,
damping vale (3) closes earlier than delivery
valve (5). Accordingly, the fuel oil flows
through only small orifice (6) of damping
valve (3).
• As a result, the seating speed of delivery
valve (5) is lowered to prevent sharp drop of
the pressure in the pipe and suppress
transmission of the reflected waves in the
pipe, thus injection is stabilized.
a What is cavitation-erosion
• A phenomenon that oil pressure in a
pipe drops and bubbles are produced
locally is called cavitation.
• And a phenomenon that the pipe is
eroded by cavitation is called cavitation-
erosion.
1) Delivery valve holder

2) Damping valve spring
3) Damping valve
4) Delivery valve spring
5) Delivery valve
6) Orifice
A. While fuel oil is sent

B. While fuel oil is not sent
4D92E, 4D94LE, 4D98E 7-17

7-8 All speed governor
1) Drive shaft 12) Full load adjustment screw

2) Feed pump 13) Start spring
3) Governor shaft 14) Start lever
4) Flyweight holder gear 15) Governor lever assembly
5) Flyweight 16) Plunger
6) Flyweight holder 17) Spring
7) Control lever 18) Control sleeve
8) Governor spring 19) Governor sleeve
9) Idle spring 20) Cam disc
10) Collector lever 21) Drive gear
11) Tension lever
7-18 4D92E, 4D94LE, 4D98E

(1) Operation
• The structure of the all speed governor is shown in the figure at left. Revolution of drive shaft (1) is
transmitted to the speed increasing gear of flyweight holder (6) through drive gear (21), and then used
to rotate flyweight holder (6).
• Flyweight holder (6) is supported on governor shaft (3) and has 4 flyweights (5) in it, which are opened
outward by the centrifugal force.
• Flyweights (5) push governor sleeve (19) to push governor lever assembly (15) to the right. Governor
lever assembly (15) consists of collector lever (10), tension lever (11) and start lever (14).
• Fulcrum M1 of collector lever (10) is fixed with the pivot bolt of the pump housing. Since collector lever
(10) is pressed by lower spring (17) and upper full load adjustment screw (12), it does not move.
• Tension lever (11) and start lever (14) move around shaft M2 fixed onto collector lever (10).
• When the engine is started, start spring (13)
presses start lever (14) against governor
sleeve (19). Then, start lever (14) is turned
to the left around fulcrum M2 to move control
sleeve (18) to the start increasing position.
While the engine is running, start lever (14)
and tension lever (11) keep in contact with
each other and move as one unit.
• Governor spring (8) is installed above
tension lever (11) and connected to control
lever (7) through control lever shaft (22).
The set force of governor spring (8) can be
changed by adjusting the movement of
control lever (7). Idle spring (9) is installed
upper back side of tension lever (11).
• Accordingly, the governor is controlled in the
all revolution speed range by start spring
(13), governor spring (8), and idle spring (9).
• An example of the injection rate control
characteristics of the all speed governor is
shown in the figure.
4D92E, 4D94LE, 4D98E 7-19

(2) When engine is started
1) Idling stopper bolt 8) Tension lever M1 Fixed

2) Maximum speed stopper bolt 9) Start spring M2 Fulcrum
3) Control lever 10) Collector lever M3 Press fitted pin
4) Governor spring 11) Control sleeve
5) Governor sleeve 12) Plunger
6) Idle spring 13) Start lever
7) Full load adjustment screw 14) Flyweight
• When the engine is started, the fuel injection rate must be increased so that the engine starts easily.
While the engine is stopped, if the accelerator pedal is pressed, tension lever (8) is pulled to the left by
governor spring (4) until it reaches press fitted pin M3.
• At the same time, start lever (13) is separated from tension lever (8) by start spring (9) and pushes
governor sleeve (5) to the left. At this time, flyweight (14) is fully closed and start lever (13) turns around
M2 to move control sleeve (11) to start increasing position A (to the right).
• As a result, the engine can be started easily by pressing the accelerator pedal lightly.
7-20 4D92E, 4D94LE, 4D98E

(3) While engine is idling
• If the accelerator pedal is released after the engine is started, control lever (3) returns to the idling
position and the tension of the governor spring (4) is reduced to 0. Accordingly, flyweights (14) open
outward and push governor sleeve (5) to the right even if the engine is running at low speed.
• This movement turns start lever (13) to the right around M2 and moves control sleeve (11) in the fuel
reducing direction. When the centrifugal force of flyweight (14) is balanced with idle spring (6), idling
speed is stabilized.
4D92E, 4D94LE, 4D98E 7-21

(4) When full-load max. speed control is applied
• When the accelerator pedal is fully pressed and control lever (3) reaches maximum speed stopper bolt
(2), the tension of governor spring (4) becomes maximum and tension lever (8) is fixed to pin M3 press
fitted to the pump housing.
• At this time, idle spring (6) is fully compressed and start lever (13) and tension lever (8) become one at
point A and keep control sleeve (11) to the full load position.
• At this time, flyweight (14) is pressed and fully closed by governor sleeve (5).
7-22 4D92E, 4D94LE, 4D98E

(5) When no-load max. speed control is applied
• If the engine speed is increased and the centrifugal force of flyweights (14) exceeds the set force of
governor spring (4), governor sleeve (5) moves to the right and turns the governor lever assembly to the
right around M2.
• As a result, control sleeve (11) moves in the non-injection direction B (to the left) so that the engine speed
will not exceed the full-load maximum speed.
• If the accelerator pedal is not fully pressed, the set force of governor spring (4) changes freely. When
the engine is partially loaded, governor is controlled according to the set force of governor spring (4).
4D92E, 4D94LE, 4D98E 7-23

(6) Full load position adjustment mechanism

• The full load position is decided by the
tightening distance of full load adjustment
screw (7). If screw (7) is tightened, collector
lever (10) turns to the left (counterclockwise)
around fulcrum M1 of collector lever (10) to
m o v e c o nt r o l s l e ev e ( 11 ) in th e fu e l
increasing direction A.
• If screw (7) is loosened, control sleeve (11)
moves in the fuel decreasing direction B.
7-24 4D92E, 4D94LE, 4D98E

(1) Outline
• The fuel oil in the fuel tank (1) is sucked by
the feed pump (7) in the injection pump
through the sedimenter (2) and fuel filter (4)
to the fuel inlet of the injection pump.
• The fuel filter (4) filtrates the fuel oil. It may
have a sedimenter (2) to separate water in its
bottom.
• The fuel oil sucked to the fuel inlet is
pressurized by the feed pump (7) and
supplied into the pump changer.
• The pressure of the fuel oil in the pump
chamber is in proportion to the pump speed.
If it exceeds a certain level, however, the
excessive oil is returned to the suction side
by the regulating valve (6).
• The fuel oil in the pump chamber is sent
through the fuel oil passage in the distributor
head to the plunger (8). Then, the fuel oil is
pressurized high by the plunger (8) and sent
through the injection pipe to the nozzle (13)
and nozzle holder.
• The overflow valve (11) on the injection
pump keeps the oil temperature in the pump
chamber constant and returns excessive fuel
oil to the fuel tank (1).
4D92E, 4D94LE, 4D98E 7-7

7-9 Structure and operation of timer

(1) Structure
• The time lag in ignition in a diesel engine is increased as the engine speed is increased.
• To advance the injection timing of the injection pump and correct the time lag in ignition, a timer is
installed to the bottom of the injection pump.
FIG. 1. While timer is not operating FIG. 2. While timer is operating
1) Drive shaft A. Low pressure side Revolving direction of drive shaft

2) Roller holder assembly B. High pressure side Revolving direction of roller holder
3) Timer piston C. High pressure chamber
4) Pin
5) Timer spring
6) Roller
7-26 4D92E, 4D94LE, 4D98E

(2) Operation (Standard automatic timer)

• As shown in the figure, the inside of the timer housing is divided by timer piston (3) into low pressure side
A and high pressure side B which receives the pump chamber pressure directly.
• Timer spring (5) having a set force is installed to low pressure side A. Timer piston (3) slides inside the
housing according to the change of the force of timer spring (5) and pressure in the pump chamber to
turn roller holder assembly (2) through pin (4).
• If the pump speed is increased and the pressure in the pump chamber exceeds the set force of timer
spring (5), timer piston (3) moves to compress the spring. (FIG. 2)
• The above movement turns roller holder assembly (2) in the opposite direction to the pump through pin
(4). As a result, the top of the cam disc approaches roller (6) of the roller holder quickly and the injecting
timing is advanced consequently.
• On the other hand, when the pump speed lowers and the force of timer spring (5) exceeds the pressure
in the pump chamber, timer piston (3) moves in the lagging direction.
4D92E, 4D94LE, 4D98E 7-27

7-10 Magnet valve
When magnet valve is ON When magnet valve is OFF
1) Magnet valve A. Fuel oil passage

2) Spring B. Inlet port
3) Armature
(1) Operation
• Magnet valve (1) is turned ON and OFF to open and close fuel oil passage A connected to inlet port B
of the plunger barrel, according to the operation of the ignition switch.
• If the ignition switch is turned ON, magnet valve (1) is turned ON and armature (3) is pulled up to open
fuel oil passage A.
• On the other hand, if the ignition switch is turned OFF, armature (3) is pushed down by spring (2) in it to
close fuel oil passage A.
• As a result, the fuel oil is not sent to the plunger and the engine is stopped immediately.
7-28 4D92E, 4D94LE, 4D98E

7-11 Improvement of startability at very low temperature

The startability of 4D92E and 4D94LE engines at
very low temperature can be improved by removing
shim (1) at starting fuel increase adjustment part A.
Shim (1): YM129930-61990
a After the above adjustment, the exhaust gas col-

or at start becomes bad a little.
4D92E, 4D94LE, 4D98E 7-29

8. STARTING MOTOR
8. STARTING MOTOR
8-1 Specifications......................................................................................................................................... 8- 2
8-2 Components .......................................................................................................................................... 8- 3
8-3 Troubleshooting ..................................................................................................................................... 8- 4
8-4 Names of parts and disassembly procedure ......................................................................................... 8- 5
8-5 Inspection and maintenance .................................................................................................................. 8- 9
8-6 Service standards ................................................................................................................................ 8- 15
8-7 Assembly ............................................................................................................................................. 8- 16
8-8 Characteristic test ................................................................................................................................ 8- 18
4D92E, 4D94LE, 4D98E 8-1

8. STARTING MOTOR
8-1 Specifications
Manufacturer’s model (Hitachi) — S13-204 S13-205
Code — YM129900-77010 YM129900-77020

Nominal output kW {HP} 2.3 {3.1}
Weight kg 5.5
Revolution direction (as viewed from pinion) — Clockwise
Engagement system — Magnetic shift
Terminal voltage/current V/A 11/140 or less

No-load
Revolution rpm 4,100 or above
Terminal voltage/current V/A 2.5/1,050 or less
Loaded
Torque Nm {kgf•m} 24.5 {2.5} or above
Clutch system — Overrunning
Pinion projection voltage (at 100°C) V 8.6 or less
Pinion DP or module/number of teeth — M3/9
Difference (O-ring, oil seal) — Dry type (none) Wet type (equipped)
Application — Standard If equipped
8-2 4D92E, 4D94LE, 4D98E

8. STARTING MOTOR
8-2 Components
1) Magnetic switch
2) Shift lever
3) Gear case
4) Oil seal
5) Pinion shaft
6) Bearing retainer
7) O-ring
8) Clutch assembly
9) Armature
10) Rear cover
11) Through bolt
12) Brush
13) Field coil
4D92E, 4D94LE, 4D98E 8-3

8. STARTING MOTOR
8-3 Troubleshooting
8-4 4D92E, 4D94LE, 4D98E

8. STARTING MOTOR
8-4 Names of parts and disassembly procedure

Disassembling order
(1) Nut M8 (10) Dust cover
(Disconnect the connecting wire.) (11) Shift lever
a See the disassembly drawing. (12) Screw M4 (3)
(2) Screw M4 (2) (13) Bearing retainer
(3) Through bolt M5 (2) (14) Gear case
(4) Rear cover (15) Pinion stopper clip
(5) Brush holder (16) Pinion stopper
(6) Yoke assembly (17) Return spring
(7) Armature (18) Pinion shaft
(8) Bolt M6 (2) (19) Clutch assembly
(9) Magnetic switch
Disassembly drawing
4D92E, 4D94LE, 4D98E 8-5

8. STARTING MOTOR
Disassembly procedure
1) Nut M8 Fig. 1
Remove the magnetic switch nut M8 (12 mm),
and disconnect the connecting wire.
YE0478
a) Connecting wire
Fig. 2
2) Screw M4 (2)
3) Through bolt M5 (2)
4) Rear cover
Remove the M4 screw fastening the brush
holder and remove through bolt M5 for rear
cover removal.
YE0479
Fig. 3
5) Brush holder
Pull the brush spring up with the brush spring
puller. On the negative (–) side, bring the brush
spring into contact with the side of the brush for
lifting from the commutator surface. On the posi-
tive (+) side, extract the brush from the brush
holder.
YE0480
8-6 4D92E, 4D94LE, 4D98E

8. STARTING MOTOR
6) Yoke assembly Fig. 4

7) Armature
Remove the brush holder. The armature and
yoke assembly can now be removed.
YE0481
8) Bolt M6 (2) Fig. 5

9) Magnetic switch
Remove bolt M6 (10 mm), and the magnetic
switch can be removed.
YE0482
10) Dust cover Fig. 6

11) Shift lever
Take the dust cover out from the gear case. The
shift lever can be removed.
YE0483
4D92E, 4D94LE, 4D98E 8-7

8. STARTING MOTOR
12) Screw M4 (3) Fig. 7

13) Bearing retainer
14) Gear case
Remove Screw M4, and the bearing retainer and
clutch assembly can be removed.
YE0484
15) Pinion stopper clip Fig. 8

Remove the bearing retainer at the edge and
the bearing, and shift the pinion stopper toward a
the pinion. Use a plain (–) screwdriver and pry to
remove the pinion stopper clip.
b
YE0485
a) Pinion stopper clip

b) Plain (–) screwdriver
Fig. 9
16) Pinion stopper
17) Return spring
18) Pinion shaft
19) Clutch assembly
Remove the pinion stopper clip. The pinion
stopper, return spring, pinion shaft and bearing
retainer can be removed.
Disassembly is completed now.
YE0486
8-8 4D92E, 4D94LE, 4D98E

8. STARTING MOTOR
8-5 Inspection and maintenance

(1) Armature Fig. 10
(a) Commutator outside diameter
Measure the commutator outside diameter
and replace the commutator if the measured
value is less than the limit.
(Unit: mm)
Standard Limit
36.5 35.5
YE0487
(b) Armature coil continuity test Fig. 11

Check continuity between commutator seg-
ments with a multimeter. Good if continuity
exists. 1
(Coil disconnection)
No continuity
Replace the armature.
YE0488
1) Multimeter
(c) Armature coil insulation test Fig. 12

Inspect the continuity between a commuta-
tor segment and the shaft or core with a 1
multimeter. Good if no continuity exists.
(Coil short circuit)

Continuity exists
YE0489
1) Multimeter
4D92E, 4D94LE, 4D98E 8-9

8. STARTING MOTOR
(d) Armature and commutator runout Fig. 13

Use a dial gauge and measure the armature
core runout and commutator runout. Correct 2
or replace if the limit is exceeded.
1
(Unit: mm)
Standard Limit
Armature 0.03 0.2
Commutator 0.03 0.2
YE0490
1) Commutator 2) Armature
Fig. 14
(e) Commutator surface inspection
If the commutator surface is roughened,
grind with #500 to #600 emery cloth.
YE0491
Fig. 15
(f) Commutator insulation depth
Measure the depth of the insulating material
between commutator segments, and correct
it if it is less than the limit. 3
(Unit: mm) 4
Standard Limit 5 8
6
0.5 – 0.8 0.2
7 9
YE0492
3) Hack-saw 7) Abnormal
4) Commutator 8) Chamfering
5) Commutator segment 9) Normal
6) Insulating material
8-10 4D92E, 4D94LE, 4D98E

8. STARTING MOTOR
(2) Field coil Fig. 16

(a) Field coil continuity test
Check continuity between field coil termi- 1
nals. Good if continuity exists.
(Coil disconnection)
No continuity
Replace the field coil.
YE0493
1) Multimeter
Fig. 17
(b) Field coil insulation test 1
Check continuity between field coil terminal
and yoke. Good if no continuity exists.
(Coil short circuit)

Continuity exists
YE0494
1) Multimeter
Fig. 18
(3) Brush
Measure the length of the brush. Replace with a
good one if the length is less than the limit.
(Unit: mm)
Standard Limit
15 9
YE0495
2) Brush
4D92E, 4D94LE, 4D98E 8-11

8. STARTING MOTOR
(4) Brush holder Fig. 19

(a) Brush holder insulation test
Check the continuity between the brush
holder (+ side) and base (– side) with a mul-
timeter. Good if no continuity exists.
Insulation defect
Continuity exists
Replace the brush holder.
YE0496
1) Multimeter
Fig. 20
(b) Brush spring inspection
Inspect the brush spring pressure.
Standard spring pressure
31 – 39 N {3.1 – 3.9 kgf}
YE0497
(5) Magnetic switch Fig. 21

k When the starting motor is wetted with
water, always replace the magnetic switch
with a new even if the function is normal.
(a) Shunt coil continuity test

Check the continuity between the S terminal 1
and the switch body. Good if continuity
exists.
Coil disconnection
No continuity
Replace the magnetic switch.
YE0498
1) Multimeter
8-12 4D92E, 4D94LE, 4D98E

8. STARTING MOTOR
(b) Series coil continuity test Fig. 22

Check continuity between the S and M ter-
minals. Good if continuity exists.
Coil disconnection
No continuity Replace the magnetic
switch. 1
YE0499
1) Multimeter
Fig. 23
(c) Contact continuity test
Depress the magnetic switch with the 1
plunger at the bottom. Check continuity
between the B and M terminals with a multi-
meter. Good if continuity exists.
Contact continuity defect

No continuity Replace the magnetic
switch.
YE0500
1) Multimeter
Fig. 24
(6) Pinion clutch
(a) Pinion inspection
Manually rotate the pinion. Inspect if it is
rotated smoothly in the driving direction, and
is locked in the opposite direction. Replace
the pinion clutch if abnormal.
YE0501
4D92E, 4D94LE, 4D98E 8-13

8. STARTING MOTOR
(b) Pinion sliding inspection Fig. 25

Check if the pinion slide smoothly in the
axial direction.
If damaged, rusted or heavy in sliding,
repair it.
If grease is applied too much on the pinion
shaft, sliding becomes heavy.
YE0502
(c) Ball bearing inspection Fig. 26

Rotate the ball bearing while holding the
outer race with fingertips. Inspect if it is
sticking or if there is play.
YE0503
8-14 4D92E, 4D94LE, 4D98E

8. STARTING MOTOR
8-6 Service standards
Spring force N {kgf} 35 {3.6}

Bush
Standard height/wear limit mm 15/9
Magnetic switch resistance, series coil/shunt coil (at 20°C) z 0.27/0.60
Standard diameter/limit diameter mm 36.5/35.5
Difference between maximum

Commutator Repair limit/repair accuracy mm 0.2/0.03
and minimum diameter
Mica undercut depth chips Repair limit/repair accuracy mm 0.2/0.5 – 0.8
Armature front — 6903DDU
Armature rear — 608DDU

Bearing type Nominal number
Pinion front — 6004DDU
Pinion rear — 6904DDU
l dimension (pinion projection length) mm 0.3 – 1.5
4D92E, 4D94LE, 4D98E 8-15

8. STARTING MOTOR
8-7 Assembly
The assembly procedure is the reverse of the disassembly procedure, but pay attention to the following
points:
(1) Grease application points

• Gears in the gear case
• Shift lever operating portion
• Pinion sliding portion
• Magnetic switch plunger sliding portion
a Use the grease as C of HITACHI electrical equipment or equivalent for all the parts.
(2) Magnetic switch assembly Fig. 27

(a) Install the shift lever on the magnetic switch
with the torsion spring in-between.
YE0504
(b) For installation on the gear case, install the Fig. 28

magnetic switch with the shift lever on the
gear case after pulling the pinion out. Fix the
magnetic switch by tightening a built-in bolt
M6. Do not forget to install the dust cover
(adjusting shim).
YE0505
8-16 4D92E, 4D94LE, 4D98E

8. STARTING MOTOR
(3) Pinion projection length Fig. 29

Connect the positive (+) lead from the battery to
terminal S and negative (–) lead to terminal M.
Turn the switch ON and measure the pinion
moving distance l in the thrust direction.
Perform this test within 10 seconds.
Standard
l 0.3 – 1.5 mm
a Before measuring the dimension, pull the

pinion out lightly in the direction of the arrow.
YE0506
If the measured l dimension is outside the stan- Fig. 30

dard range, either insert or remove the dust
cover (adjusting shim 0.5 mm, 0.8 mm) for 1
adjustment.
YE0507
1) Dust cover (adjusting shim: 0.5 mm, 0.8 mm)
4D92E, 4D94LE, 4D98E 8-17

8. STARTING MOTOR
8-8 Characteristic test

Since the characteristics can be checked roughly by means of a simple no-load test as explained below.
a Complete the test quickly since the rating of the starting motor is 30 seconds.
1. No-load test
Fix the starting motor on a test bench and connect wiring as shown in Fig.31. When the switch is closed, a
current flows in the starting motor, which is rotated at no-load. Measure the current, voltage and number of
revolutions then and check if they satisfy the specified characteristics.
Fig. 31
1) Ammeter
2) Voltmeter
3) Battery
8-18 4D92E, 4D94LE, 4D98E

9. ALTERNATOR
9. ALTERNATOR
9-1 Specifications......................................................................................................................................... 9- 2
9-2 Sectional view........................................................................................................................................ 9- 3
9-3 Troubleshooting ..................................................................................................................................... 9- 4
9-4 Parts names and disassembly procedure.............................................................................................. 9- 5
9-5 Inspection and overhaul......................................................................................................................... 9- 8
9-6 Assembly ............................................................................................................................................. 9- 12
9-7 Service standards ................................................................................................................................ 9- 13
9-8 Performance test ................................................................................................................................. 9- 14
4D92E, 4D94LE, 4D98E 9-1

9. ALTERNATOR
9-1 Specifications
Manufacturer’s model (Hitachi) — LR140-714
Code — YM119836-77200
Rating — Continuous
Battery voltage V 12
Nominal output VxA 12 x 40
Rated revolution rpm 5,000
Operating revolution rpm 1,050 – 12,400
Grounding characteristics — —
Direction of revolution (viewed from pulley) — Clockwise
Weight kg 3.5
Pulley (outside diameter) mm 70

V-belt shape — Type A
9-2 4D92E, 4D94LE, 4D98E

9. ALTERNATOR
9-2 Sectional view
1) Front cover
2) Stator
3) Rotor
4) IC regulator
5) Brush
6) Slip ring
7) Ball bearing
8) Diode
9) Rear cover
10) Through-bolt
11) Ball bearing
12) V-pulley
4D92E, 4D94LE, 4D98E 9-3

9. ALTERNATOR
9-3 Troubleshooting
9-4 4D92E, 4D94LE, 4D98E

9. ALTERNATOR
9-4 Parts names and disassembly procedure

Disassembly Procedure e: Refer to the disassembly drawing.
e (1) Through bolt M5 (10) Rear cover
(2) Pulley nut M15 e (11) Lead wire assembly
(3) Pulley assembly e (12) Stator
e (4) Rotor (13) Nut M4
(5) Screw M5 e (14) Fan guide (Disassembly hereafter is
(6) Bearing retainer unnecessary if the diode is faulty.)
(7) Ball bearing e (15) Battery terminal, bolt M5
e (8) Front cover (16) Diode
(9) Nuts M5 and M6 (17) Capacitor (Capacity: 0.25 µF)
e (18) Brush regulator assembly
Brush length: 18/6 mm
Brush spring preload:
2.5 – 3.4 N {0.26 – 0.35 kgf}
Disassembly Drawing
4D92E, 4D94LE, 4D98E 9-5

9. ALTERNATOR
Disassembly Procedures Fig. 1

1) Through bolt M5
Remove the M5 through bolt. Increase the tem-
perature at the center of the rear cover by about
20°C using a soldering iron, insert two flat (–)
screwdrivers between the front cover and the
stator core and separate the assembly into the
front side (front cover and rotor) and the rear
side (rear cover and stator).
YE0512
2) Pulley nut M15
3) Pulley assembly
4) Rotor
Fix the rotor in a vice and remove the M15 (22 Fig. 2
mm) pulley nut to separate the pulley, front
cover and rotor.
5) Screw M4
6) Bearing retainer YE0513
7) Ball bearing
8) Front cover
Remove the M5 screw securing the bearing Fig. 3
retainer to separate the bearing retainer, ball
bearing and front cover.
9) Nuts M5 and M6
10) Rear cover
11) Lead wire assembly YE0514
Remove the M5 and M6 nuts securing the diode

and IC regulator. Press in the grommet and Fig. 4
lead wire of the lead wire assembly into the hole
in the rear cover to separate the stay and rear
cover.
YE0515
9-6 4D92E, 4D94LE, 4D98E

9. ALTERNATOR
12) stator Fig. 5

Disconnect soldering of the diode to remove the
stator.
YE0516
13) Nut M4
14) Fan guide Fig. 6
Remove the M4 nut securing the fan guide to
separate the fan guide.
YE0517
15) Battery terminal, M5 bolt

16) Diode
17) Capacitor Fig. 7
18) Brush regulator assembly
Remove the M5 bolt and battery terminal. Dis-
connect the diode L-terminal and soldering of
the brush regulator to remove the brush regula-
tor assembly, capacitor and diode.
YE0518
4D92E, 4D94LE, 4D98E 9-7

9. ALTERNATOR
9-5 Inspection and overhaul

(1) Diode Fig. 8
The diode makes the current flow only in the
direction shown in Fig. 8. Check electrical conti- 2
nuity between two terminals (for example, termi-
nals BAT and U) using a tester as shown in Fig.
9 and, if they are continuity, the diode is accept-
able. if not, the diode is damaged. The diode is
acceptable if two terminals are not continuity
when the tester is connected in the reverse 1 3
manner. The diode is damaged if they are conti-
nuity.
YE0519
If even a single diode is faulty as a result of the
above measurements, replace the entire diode
assembly.
1) Current flow direction 3) (–) diode
2) (+) diode
Tester leads (Checking (+) diode) Tester leads (Checking (–) diode)
E terminal E terminal
(+) (–) (+) (–)
U, V and U, V and
W terminals W terminals
(+) — Not continuity (+) — Continuity
(–) Continuity — (–) Not continuity —
k Never use a high-voltage insulation ohmmeter Fig. 9

such as a megger for testing. Otherwise, the di-
4
ode may be damaged.
(2) Rotor
(a) Wear limit for slip spring
Measure the outside diameter of the slip
spring. If wear exceeding 1 mm from the
standard size is measured, replace the rotor
assembly.
Standard: 27 mm, Wear limit: 26 mm
(b) Check of slip ring surface
Check that the slip ring surface is smooth YE0520
and free from contamination by oil, etc. If
the surface is rough, polish using #500 to
#600 emery cloth. If it is dirty, clean using Fig. 10
alcohol.
5
4) Tester
5) Slip ring O.D.
YE0521
9-8 4D92E, 4D94LE, 4D98E

9. ALTERNATOR
(c) Rotor coil continuity test Fig. 11

Check electrical continuity between slip 1
rings using a tester.
Open circuit of rotor coil

No continuity
Replace the rotor.
Rotor coil resistance at 20°C: 3.45 z
1) Tester
2) Slip ring
2
YE0522
(d) Rotor coil insulation test

Check electrical continuity between the slip
Fig. 12
ring and the rotor core or shaft using a
1
tester.
Short-circuiting of rotor coil

Continuity exists
Replace the rotor.
1) Tester
2) Slip ring
2
YE0523
(e) Checking ball bearing

Check the rear ball bearing. If rotation is Fig. 13
unsmooth or abnormal noise is generated,
replace the ball bearing.
YE0524
(3) Stator
(a) Stator coil continuity test
Check electrical continuity between two Fig. 14
respective terminals using a tester.
3
Open circuit of stator coil 4
No continuity
Replace the stator.
Stator coil resistance at 20°C:

0.108 z/phase
Resistance between terminals U and V:
0.216 z
3) Tester
4) Stator
YE0525
4D92E, 4D94LE, 4D98E 9-9

9. ALTERNATOR
(b) Stator coil insulation test Fig. 15

Check electrical continuity between one of
the stator coil terminals and the stator core 1
using a tester.
Short-circuiting of rotor coil

Continuity exists 2
Replace the stator.
YE0526
1) Tester
2) Terminal
3) Stator core
(4) Brush
Measure the brush length. If wear exceeds the Fig. 16
limit (6 mm), replace with a new brush holder
assembly. The wear limit line is indicated on the
brush.
Standard: 18 mm, Wear limit: 6 mm
Caution on Brush Lead:

(a) Temperature of soldering iron: 4
300 – 350°C
Always use the non-acidic paste.
YE0527
4) Wear limit line
9-10 4D92E, 4D94LE, 4D98E

9. ALTERNATOR
(5) Check of IC regulator

Prepare the connection for test setup as shown Fig. 17 Test circuit for IC regulator alone
in Fig. 17, using a variable resistor, two 12V bat-
teries, an ohmmeter and a voltmeter.
(a) Jigs required
1. Variable resistor (Rv): 0 – 300 z, 12W (1)
2. Resistor (R1): 10 z, 3W (1)
3. Battery (BAT1, BAT2): 12V (2)
4. DC voltmeter (4 measurement points):
0 – 50V, Class 0.5 (1set)
(b) Measurement procedure

(Refer to Fig. 17.)
1. Measure voltage at V1 (BAT1). If the
measured value is between 10 – 13V,
the battery is acceptable.
2. Measure voltage at V3 (voltages of
BAT1 + BAT2). If the measured value is
between 20 – 26V, both batteries 1 and
2 are acceptable.
3. Measure voltage at V2 (voltage across
terminals F and E) while gradually
increasing the resistance of the variable
resistor starting from 0V. Check that
there is a point where the V2 voltage
reaches 2.0V or less of the V1 value of
BAT1 measured in 1. above. If no
change occurs, the regulator is faulty.
So, replace it with a new one.
4. Measure voltage at V4 (Voltage across
YE0528
the intermediate tap of the variable
resistor and E-terminal), with variable
resistor Rv being fixed. If the measured
value is within the specified range, the
regulator is acceptable. If not, the
regulator is faulty. So, replace it with a
new one.
4D92E, 4D94LE, 4D98E 9-11

9. ALTERNATOR
9-6 Assembly
While the reassembly procedures are the reverse of the respective disassembly procedures, pay attention to
the following precautions.
(1) For the tightening torque of each screw, see page 9-5, Disassembly drawing.
(2) High-temperature soldering is used for connection between the diode and the stator coil lead, and the diode
and the brush holder.
Work condition: Soldering iron temperature: 300 to 380°C
Connection time: Must be complete within 5 seconds.
Solder used: 1:5 solder (JIS H16A)
(3) Reassembly of the front and rear 1

(a) Since the rear ball bearing is fixed by the
dead stopping method, increase the
temperature at the center of the rear cover
by about 20°C using a soldering iron before
beginning reassembly.
YE0529
1) Pin
(b) Insert the pin from the outside of the rear

cover and press the brush into the brush
holder before reassembling.
(c) After reassembly is complete, remove the

pin by pulling it out. 1
YE0530
1) Pin
9-12 4D92E, 4D94LE, 4D98E

9. ALTERNATOR
9-7 Service standards
Characteristic Unit Standard

Revolution at 13.5 V (cold at 20°C) rpm 1,050 or less
Adjustment voltage V 14.2 – 14.8
Standard temperature slope V /°C –0.01

13.5 V constant output current (hot at 20°C) A / rpm 40 / 5,000 or above
Stator 0.108 (phase)

Coil resistance (at 20°C) z
Rotor 3.45
4D92E, 4D94LE, 4D98E 9-13

9. ALTERNATOR
9-8 Performance test

Fig. 20 Test Circuits
1) Ammeter 3) Battery 5) Minimum position

2) Variable resistor 4) Voltmeter 6) Lamp
1. The 0.25 z resistor is connected when the battery is discharging.
Measurement Jigs required:

1. Voltmeter : DC voltmeter 0 to 30V, Class 0.5 (1 set)
2. Ammeter : DC ammeter 0 to 100A, Class 1 (1 set)
3. Variable resistor : 0 to 0.25 z, 1kW (1)
4. Resistor : 0.25 z, 25W (1)
(1) Voltage measurement for adjustment

With the test circuits shown in Fig. 20, open SW1 and close SW2, increase the alternator revolution to the
rated speed of 5,000 rpm and measure the voltage.
Adjustment voltage: Acceptable if the measured value is between 14.2 – 14.8V.
(2) Revolution at 13.5V

With the test circuits shown in Fig. 20, open SW1 and close SW2, gradually increase the alternator revolu-
tion until the voltmeter reads 13.5V and measure the revolution. The measured value is the operating
speed at 13.5V.
Operating speed: Acceptable if the measured value is 1,050 rpm or less.
(3) Output current measurement

With the test circuits shown in Fig. 20, set the variable resistor to the min. position, close SW1 and SW2,
and increase each output of the alternator. Adjust the variable resistor so the the voltmeter reads 13.5V
and measure the current. The measured value is at each output current.
(4) Cautions on performance test

(a) Use thick wires having a min. Cross section of 8 mm2 and max. length of 2.5 m long connecting the
alternator B and battery (+) terminals, and the E and battery (–) terminals.
(b) Use switches having small contact resistances.
9-14 4D92E, 4D94LE, 4D98E

10. SPECIAL SERVICE TOOLS
10-1 Special tools ........................................................................................................................................ 10- 2

10-2 Measuring instruments ........................................................................................................................ 10- 4
4D92E, 4D94LE, 4D98E 10-1

10.1 Special tools
No. Tool name Applicable model and tool size Illustration
(Unit: mm)
Valve guide tool l1 l2 d1 d2
1
(for extracting valve guide)
20 75 7.5 11
a Locally manufactured
YE0532
(Unit: mm)
Valve guide tool l1 l2 d1 d2

2
(for inserting valve guide) 15 65 14 20
YE0533
(Unit: mm)
Connecting rod bushing
replacer l1 l2 d1 d2
3
(for removal/installation of
connecting rod bushing) 10 100 30 –0.3
–0.6 33 –0.3
–0.6
a Locally manufactured YE0534
Valve spring compressor Code No.

4 (for removal/installation of
valve spring) YM129100-92630
YE0535
(Unit: mm)
Valve stem seal inserter
l1 l2 d1 d2
5 (for inserting valve stem
seal) 19 65 16.5 23
YE0536
10-2 4D92E, 4D94LE, 4D98E

No. Tool name Applicable model and tool size Illustration
Filter wrench
6 (for removal/installation of Available on the market
filter)
YE0537
(Unit: mm)
Camshaft bushing tool l1 l2 d1 d2
7 (for extracting camshaft
bushing) 18 70 50 –0.3
–0.6 53 –0.3
–0.6
a Locally manufactured YE0538
Flex-Hone
8 (For re-honing of Code No.
cylinder liner) YM129400-92430
YE0539
Code No.
YM95550-002476
Piston insertion tool
9
(for inserting piston)
a The above piston insertion tool is
applicable to 60 – 125 mm diameter
pistons. YE0540
Piston ring replacer

10 (for removal/installation of Available on the market
piston ring)
YE0541
4D92E, 4D94LE, 4D98E 10-3

10.2 Measuring instruments
No. Instrument name Application Illustration
Measurements of shaft bending, and strain

1 Dial gauge
and gap of surfaces
YE0542
Measurements of narrow or deep portions

2 Test indicator
that cannot be measured by dial gauge
YE0543
For holding the dial gauge when measur-

3 Magnetic stand ing using a dial gauge, standing angles
adjustable
YE0544
For measuring the outside diameters of

4 Micrometer
crankshaft, pistons, piston pins, etc.
YE0545
For measuring the inside diameters of cyl-

5 Cylinder gauge
inder liners, connecting rod metal, etc
YE0546
For measuring outside diameters, depth,

6 Calipers
thickness and width
YE0547
7 Depth micrometer For measuring of valve sink
YE0548
For measuring valve spring inclination and

8 Square
straightness of parts
YE0549
10-4 4D92E, 4D94LE, 4D98E

9 V-block For measuring shaft bend
YE0550
YE0551
For tightening nuts and bolts to the speci-
10 Torque wrench
fied torque
YE0552
For measuring gaps between piston ring

11 Thickness gauge and ring groove, and shaft joints during
assembly
YE0553
12 Cap tester For checking cooling water leakage
YE0554
For checking concentration of antifreeze

13 Battery coolant tester
and the battery electrolyte charge status
YE0555
For measuring injection spray pattern of

14 Nozzle tester
fuel injection nozzle and injection pressure
YE0556
15 Digital thermometer For measuring temperatures

1
1) Probe
YE0557
4D92E, 4D94LE, 4D98E 10-5

For measuring revolution by contacting

Contact type
the mortise in the revolving shaft
YE0558
2
For measuring revolution by sensing the
reflecting mark on the outer periphery of
Photoelectric type the revolving shaft
Speedometer
2) Revolving shaft
3) Reflection mark
16 3 YE0559
Measures the revolution regardless of the 4

center or periphery of the revolving object.
Fuel high-pressure
pipe clamp type
4) High-pressure pipe
YE0560
For measuring resistance, voltage and

17 Circuit tester
continuity of electrical circuits
YE0561
For measuring compression pressure
18 Compression gauge kit Code No.
YMTOL-97190080
YE0562
10-6 4D92E, 4D94LE, 4D98E

11. SERVICE STANDARDS
11-1 Engine tuning....................................................................................................................................... 11- 2

11-2 Engine body ......................................................................................................................................... 11- 3
11-3 Lubricating oil system (trochoid pump) ................................................................................................ 11- 7
11-4 Tightening torques for main parts ........................................................................................................ 11- 8
4D92E, 4D94LE, 4D98E 11-1

11-1 Engine tuning
Reference
No. Inspection item Unit Standard Limit
page
1 Gap at intake/exhaust valve heads mm 0.15 – 0.25 — 3-4
V-belt tension Used part mm 10 – 15 — 3-3

2 Finger pressure:
98N {10kg} New part mm 7–9 — 3-3
MPa
3 Fuel injection pressure 12.3 – 13.3 {125 – 135} — 3-6
{kg/cm2}
4D92E degrees 4 — 3-9
Fuel injection timing 4D94LE (A.T.D.C)
4
(When plunger 1 mm lifted) degrees
4D98E 6 — 3-9
(A.T.D.C)
4D92E
Specification/Model — 4D94LE — —
4D98E
5 No-load revolution —
Max. rpm 2,700 – 2,750 3-10
Min. rpm 845 ± 25 810 ± 25 — 3-10
MPa 2.35
6 Compression (at 250 rpm) 2.84 – 3.04 {29 – 31} 2-6
{kgf/cm2} {24}
7 Top clearance mm 0.812 – 0.944 — —
8 Cooling water capacity l 4.2 (engine only) — —
Lubricating oil capacity Total l 7.5 — —

9
(oil pan) Effective l 2.0 — —
MPa
Max. (in cold state) 0.59 {6.0} or less — —
{kgf/cm2}
Lubricating oil MPa

10 At rated output 0.29 – 0.39 {3.0 – 4.0} — —
pressure {kgf/cm2}
MPa
At idling 0.06 {0.6} or above — —
{kgf/cm2}
MPa
11 Oil pressure switch operating pressure 0.05 ± 0.01 {0.5 ± 0.1} — —
{kgf/cm2}
12 Thermostat valve opening temperature °C 69.5 – 72.5 — 3-11

13 Themoswitch actuating temperatue °C 107 – 113 — 3-11
11-2 4D92E, 4D94LE, 4D98E

11-2 Engine body

(1) Cylinder head
(1-1) Cylinder head
Reference
Inspection item Unit Standard Limit
page
Combustion surface distortion mm Max. 0.05 0.10 4-6
Intake mm 0.5 – 0.7 0.79 4-6
Valve sink
Exhaust mm 0.6 – 0.8 0.89 4-6
Intake mm 1.3 2.0 4-6
Seat width
Valve seat Exhaust mm 2.2 3.0 4-6
Intake Deg. 120 — 4-10
Seat angle
Exhaust Deg. 90 — 4-10
Seat correction angle Deg. 40,
1 2 150 — 4-10
(1-2) Intake/exhaust valve and guide
Reference
page
Valve stem outside diameter mm 7.965 – 7.980 7.915 4-7
Intake Valve guide inside diameter mm 8.015 – 8.030 8.100 4-7
Valve clearance mm 0.035 – 0.065 0.185 4-7
Valve stem outside diameter mm 7.955 – 7.970 7.905 4-7
Exhaust Valve guide inside diameter mm 8.015 – 8.030 8.100 4-7
Valve clearance mm 0.045 – 0.075 0.195 4-7
Valve guide driving-in method — Cold-fitted — 4-11
Valve guide projection from cylinder head mm 14.7 – 15.0 — 4-11
Replacement valve guide inside diameter after insert mm 8.015 – 8.030 — 4-9, 11
(1-3) Valve spring
Reference
Page
Free length mm 47.5 — 4-8
Inclination mm — 1.2 4-8
Load for compressing uneven pitch portion by 1 mm N {fkg} 22.1 {2.257} — —
(1-4) Rocker arm and shaft
Reference
page
Rocker arm shaft hole diameter mm 18.50 – 18.52 18.57 4-9
Rocker arm shaft outside diameter mm 18.47 – 18.49 18.44 4-9
Clearance mm 0.01 – 0.05 0.13 4-9
4D92E, 4D94LE, 4D98E 11-3

(1-5) Push rod
Reference
page
Bend mm — 0.03 4-9
(2) Gear Train and Camshaft

(2-1) Camshaft
Reference
page
End play mm 0.05 – 0.20 0.30 4-14
Bending (1/2 the dial gauge reading) mm 0 – 0.02 0.05 4-15
Cam height mm 42.435 – 42.565 42.185 4-15
Camshaft outside diameter mm 49.925 – 49.950 49.890 4-15
Gear side Bushing inside diameter mm 49.990 – 50.055 50.130 4-15
Clearance mm 0.040 – 0.130 0.240 4-15
Intermediate Block inside diameter mm 50.000 – 50.025 50.100 4-15
Clearance mm 0.065 – 0.115 0.225 4-15
Flywheel side Block inside diameter mm 50.000 – 50.025 50.100 4-15
Clearance mm 0.050 – 0.100 0.210 4-15
(2-2) Idle gear shaft and bushing
Reference
page
Shaft outside diameter mm 45.950 – 49.975 45.900 4-16
Bushing inside diameter mm 46.000 – 46.025 46.075 4-16
Clearance mm 0.025 – 0.075 0.175 4-16
(2-3) Backlash of each gear
Reference
page
Crank gear, cam gear, idle gear, fuel injection pump
mm 0.08 – 0.14 0.16 4-13
gear and PTO gear
Lubricating pump gear mm 0.09 – 0.15 0.17 4-13
11-4 4D92E, 4D94LE, 4D98E

(3) Cylinder block

(3-1) Cylinder block
Reference
page
4D92E mm 92.000 – 92.030 92.130 4-21
Inner diameter 4D94LE mm 94.000 – 94.030 94.130 4-21
Cylinder bore 4D98E mm 98.000 – 98.030 98.130 4-21
Roundness mm 0.01 or less 0.03 4-21
Cylindricity mm 0.01 or less 0.03 4-21
(3-2) Crankshaft
Reference
page
Bending (1/2 the dial gauge reading) mm — 0.02 4-22
Pin outside diameter mm 57.952 – 57.962 57.902 4-23
Metal thickness mm 1.492 – 1.500 — 4-23
Crank pin
US 0.25 mm mm 1.617 – 1.625 — 4-23
Clearance mm 0.038 – 0.074 0.150 4-23
Journal outside diameter mm 64.952 – 64.962 64.902 4-23
Metal thickness mm 1.995 – 2.010 — 4-23
Crank journal
US 0.25 mm mm 2.125 – 2.130 — 4-23
Clearance mm 0.038 – 0.068 0.150 4-23
(3-3) Thrust bearing
Reference
page
Crankshaft end play mm 0.11 – 0.21 — 4-19
mm 1.930 – 1.980 1.850 4-24
Thrust bearing thickness
OS 0.25 mm mm 2.055 – 2.105 — 4-24
4D92E, 4D94LE, 4D98E 11-5

(3-4) Piston and ring
Reference
page
4D92E mm 91.945 – 91.955 91.900 4-24
OS 0.25 mm mm 92.195 – 92.205 — 4-24
OS 0.50 mm mm 92.445 – 94.705 — 4-24
OS 1.00 mm mm 92.945 – 92.955 — 4-24
Piston outside diam- 4D94LE mm 93.945 – 93.955 93.900 4-24

eter OS 0.25 mm mm 94.195 – 94.205 — 4-24
OS 0.50 mm mm 94.445 – 94.455 — 4-24
4D98E mm 97.945 – 97.955 97.900 4-24
OS 0.25 mm mm 98.195 – 98.205 — 4-24
OS 0.50 mm mm 98.445 – 98.455 — 4-24
Clearance with cylinder bore
Note) Measure at 22 mm above the piston bottom mm 0.050 – 0.080 0.120 4-24
face in vertical direction to the piston pin.
Piston outside diameter mm 29.989 – 30.000 29.959 4-25
Piston pin Hole inside diameter mm 30.000 – 30.009 30.039 4-25
Clearance mm 0.000 – 0.020 0.080 4-25
Piston ring groove width mm 2.040 – 2.060 — 4-25
Piston ring width mm 1.940 – 1.960 1.920 4-25
Top ring
Piston side clearance mm 0.080 – 0.120 — 4-25
Piston end clearance mm 0.250 – 0.450 0.540 4-25
Piston ring groove width mm 2.080 – 2.095 2.195 4-25
Second ring
Piston side clearance mm 0.090 – 0.125 0.245 4-25
Piston ring groove width mm 3.015 – 3.030 3.130 4-25
Oil ring
Piston side clearance mm 0.025 – 0.060 0.180 4-25
11-6 4D92E, 4D94LE, 4D98E

(3-5) Connecting rod
Reference
page
Thrust clearance mm 0.20 – 0.40 — 4-18
Bushing inside diameter mm 30.025 – 30.038 30.068 4-26
Small end of
Piston pin outside diameter mm 29.987 – 30.000 29.959 4-26
connecting rod
Clearance mm 0.025 – 0.051 0.109 4-26
(3-6) Tappet
Reference
page
Tappet stem outside diameter mm 11.975 – 11.990 11.955 4-27
Tappet hole (block) inside diameter mm 12.000 – 12.018 12.038 4-27
Clearance mm 0.010 – 0.043 0.083 4-27
11-3 Lubricating oil system (trochoid pump)
Reference
page
Clearance between outer rotor and gear case mm 0.100 – 0.155 0.25 5-4
Side clearance between outer rotor and gear case mm 0.05 – 0.10 0.15 5-4
Shaft outer diameter mm 12.925 – 12.990 12.915 5-4
Rotor shaft and
Bearing inside diameter mm 12.980 – 13.020 13.050 5-4
gear case
Clearance mm 0.010 – 0.065 0.125 5-4
4D92E, 4D94LE, 4D98E 11-7

11-4 Tightening torques for main parts

Nm {kgm}
Nominal Reference
Tightening position Tightening torque
size page
Thermostat case M8 22.5 – 28.4 {2.3 – 2.9} 6-3
Intake manifold M8 22.5 – 28.4 {2.3 – 2.9} 4-3
Exhaust manifold M8 22.5 – 28.4 {2.3 – 2.9} 4-3
Cylinder head Bonnet M8 22.5 – 28.4 {2.3 – 2.9} 4-3
Valve arm support M10 44.1 – 53.9 {4.5 – 5.5} 4-3
(*1) Fuel injection nozzle M6 6.9 – 8.8 {0.7 – 0.9} 4-3
Engine hoisting hook M8 22.5 – 28.4 {2.3 – 2.9} 4-3
(*2) Cylinder head M11 102. 9 – 112.7 {10.5 – 11.5} 4-5
Gear case M8 22.5 – 28.4 {2.3 – 2.9} 4-12
Idle gear shaft M8 22.5 – 28.4 {2.3 – 2.9} 4-12
Camshaft thrust bearing M8 22.5 – 28.4 {2.3 – 2.9} 4-12
Oil pan M8 22.5 – 28.4 {2.3 – 2.9} 4-16
M10 44.1 – 53.9 {4.5 – 5.5}
Cylinder block Flywheel housing 4-18
M8 22.5 – 28.4 {2.3 – 2.9}
(*2) Bearing cap M11 107. 8 – 117.6 {11.0 – 12.0} 4-19
Lubricating oil suction pipe M8 22.5 – 28.4 {2.3 – 2.9} 4-17
PTO lubrication pipe M8 12.7 – 16.7 {1.3 – 1.7} 4-12
Fuel injection pump inlet pipe M8 12.7 – 16.7 {1.3 – 1.7} 4-12
Fuel injection pump rear stay M8 22.5 – 28.4 {2.3 – 2.9} 4-12
Cooling water pump M8 17.6 – 22.5 {1.8 – 2.3} 6-3
Alternator M10 44.1 – 53.9 {4.5 – 5.5} 4-3
Gear case cover M8 17.6 – 22.5 {1.8 – 2.3} 4-12
Fuel injection pump M10 34.3 – 44.1 {3.5 – 4.5} 4-12
Gear case Oil pan M8 17.6 – 22.5 {1.8 – 2.3} 4-19
Lubricating oil pump ass’y M8 17.6 – 22.5 {1.8 – 2.3} 5-3
Fuel injection pump drive gear
M8 17.6 – 22.5 {1.8 – 2.3} 4-12
cover
PTO Lubrication pipe M8 12.7 – 16.7 {1.3 – 1.7} 4-12
(*2) Flywheel M14 186. 2 – 205.8 {19 – 21} 4-12
Crankshaft
(*2) Crankshaft pulley M14 107. 8 – 127.4 {11 – 13} 4-13
Connecting rod (*2) Connecting rod bolt M10 53.9 – 58.8 {5.5 – 6.0} 4-18
Mounting flange Starting motor M12 78.4 – 98.0 {8.0 – 10.0} 4-12
Main bearing cap Lubricating oil suction pipe stay M8 22.5 – 28.4 {2.3 – 2.9} 4-17
Intake manifold Fuel filter M10 34.3 – 44.1 {3.5 – 4.5} 4-3
11-8 4D92E, 4D94LE, 4D98E

Nm {kgm}
Nominal Reference
Tightening position Tightening torque
size page
Cooling water
Cooling fan M8 17.6 – 22.5 {1.8 – 2.3} 4-3
pump
Fuel injection pipe M12 19.6 – 24.5 {2.0 – 2.5} 4-3
Delivery valve holder — 58.8 – 68.6 {6.0 – 7.0} 7-3
(*1) Drive gear M14 63.7{6.5} 4-13
Fuel pipe (inlet) M14 19.6 – 24.5 {2.0 – 2.5} 7-3
Fuel injection pump
Fuel pipe (return) M14 19.6 – 24.5 {2.0 – 2.5} 7-3
Fuel feed pump M6 7.8 – 9.4 {0.8 – 0.96} 7-3
Oil inlet pipe M10 9.8 – 12.7 {1.0 – 1.3} 4-12
Rear stay M10 44.1 – 53.9 {4.5 – 5.5} 4-12
Fuel injection noz- Fuel injection pipe M12 19.6 – 24.5 {2.0 – 2.5} 4-3
zle Nozzle holder — 39.2 – 44.1 {4.0 – 4.5} 3-5
Fuel pipe (inlet) M14 19.6 – 24.5 {2.0 – 2.5} 7-8
Fuel pipe (outlet) M14 19.6 – 24.5 {2.0 – 2.5} 7-8
Fuel feed pump
Priming pump M16 39.2 – 44.1 {4.0 – 4.5} 7-8
Plug M26 78.4 – 88.2 {8.0 – 9.0} 7-8
Fuel pipe M12 24.5 – 34.3 {2.5 – 3.5} 4-3
Fuel filter
Fuel return pipe M14 39.2 – 44.1 {4.0 – 4.5} 4-3
Alternator Stay M8 22.5 – 28.4 {2.3 – 2.9} 4-3
Marked (*1): Important bolt

(*2): Apply lubricating oil.
4D92E, 4D94LE, 4D98E 11-9

4D94E-BE3
4D92E, 4D94LE, 4D98E DIESEL ENGINE

4d92e, 4d94le, 4d98e
diesel engine
APPLICABLE MACHINE SERIAL NO. APPLICABLE ENGINE

FD10/15/18-20 650001 and up 4D92E
FD20/25/30-16 700001 and up 4D94LE
FD20N/25N/30N-16 700001 and up 4D94LE
BE3
FD20H/25H/30H/35A-16 700001 and up 4D98E
Printed in Japan
01-05(01)

Engine 4d94e Be3

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Engine 4d94e Be3

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4D94E-BE3

2. TROUBLESHOOTING ......................................................................................... 2-1

3. INSPECTION AND ADJUSTMENT ..................................................................... 3-1

4. ENGINE BODY .................................................................................................... 4-1

5. LUBRICATION SYSTEM ..................................................................................... 5-1

6. COOLING SYSTEM ............................................................................................. 6-1

7. FUEL INJECTION PUMP, GOVERNOR ............................................................. 7-1

8. STARTING MOTOR............................................................................................. 8-1

10. SPECIAL SERVICE TOOLS.............................................................................. 10-1

11. SERVICE STANDARDS .................................................................................... 11-1

00-2 4D92E, 4D94LE, 4D98E

4D92E, 4D94LE, 4D98E 1-1

Engine name — 4D92E 4D94LE 4D98E

Engine specification class — For standard forklift truck

Type — Vertical, in-line, 4-cycle, water-cooled diesel engine

Combustion chamber — Swirl chamber type

Cylinder bore x stroke mm x mm 92 x 100 94 x 110 98 x 110

Displacement l 2.659 3.053 3.318

Revolving speed rpm 2,450 2,450 2,400

Fuel injection timing (A.T.D.C.) deg 4 6

MPa 12.3 – 13.3

Ignition order — 1–3–4–2 (No.1 cylinder on flywheel side)

Power take off — Flywheel

Direction of rotation — Counterclockwise (viewed from flywheel)

Cooling system — Radiator

Lubrication system — Forced lubrication with trochoid pump

Starting system — Electric

Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2

Applicable lubricant — API grade class CC or higher

Battery capacity V-AH 12–64 (5HR) or above

Lubricant capacity Total l 7.5

Cooling water capacity (engine only) l 4.2

Overall length mm 700 (fan – flywheel)

Engine dimensions Overall width mm 508 (fuel filter – alternator)

Overall height mm 706 (oil pan – rocker cover upper surface)

Dry engine weight kg 225

1-2 4D92E, 4D94LE, 4D98E

1-2 Fuel oil, lubricating oil and cooling water

4D92E, 4D94LE, 4D98E 1-3

1-3 Engine performance curve

1-4 4D92E, 4D94LE, 4D98E

4D94LE [Applicable machine: FD20/25/30-16, FD20N/25N/30N-16]

4D92E, 4D94LE, 4D98E 1-5

4D98E [Applicable machine: FD20H/25H/30H/35A-16]

1-6 4D92E, 4D94LE, 4D98E

1-4 Engine external views

1) Starting motor 7) Fuel injection pump

1-8 4D92E, 4D94LE, 4D98E

12) Crankshaft pulley

4D92E, 4D94LE, 4D98E 1-9

1-5 Structural description

1) Exhaust manifold 9) Tappet

1-10 4D92E, 4D94LE, 4D98E

16) Water pump 20) Flywheel housing

4D92E, 4D94LE, 4D98E 1-11

1-6 How to read this manual

(2) How to Read the Explanations

• Disassembly procedure • Operation Points

Operation point to be explained on a later page.

1-12 4D92E, 4D94LE, 4D98E

• Contents omitted in this manual

(3) Definition of Terms

A.T.D.C. after top dead center