29402-00120 - Service Manual S6A3 December 2017

SERVICE MANUAL
Issued: December 2017
Pub. No. 29402-00120

Foreword
This service manual describes the maintenance and adjustment procedures, and specifi-
cations for Mitsubishi diesel engines.
To maintain the performance of the engine for many years and to ensure safe operation,
it is important to use the engine correctly and conduct scheduled inspection and mainte-
nance, and it may also be necessary to take appropriate measures which involve disassem-
bly, inspection, repair and assembly works of the engine and engine parts.
Read through this manual carefully and understand the work procedures fully before dis-
assembling, inspecting, repairing or assembling the engine.
The contents of this manual are based on the engine model produced at the time of publi-
cation. Please note that the contents of this manual may change due to improvements made
thereafter.
29402-00120
I
Foreword
HOW TO USE THIS MANUAL

This service manual consists of several chapters, which will give you quick references to specifications, maintenance standards,
adjustment and service procedures including practices to disassemble, inspect, repair and assemble the Mitsubishi diesel
engines.
A short summary describing the contents of each chapter is given in the CHAPTER INDEX page, and there is also a detailed
table of contents at the beginning of each chapter.
Regarding the procedures for operation and scheduled maintenance of the engine, refer to the Operation and Maintenance Man-
ual. For information on the engine components and ordering of service parts, refer to the Parts Catalogue. Structure and func-
tion of the engine are described in the relevant training manuals.
If you have an inquiry, please check the engine model and serial number, and contact our service department.
Description format
(1) Index numbers allotted to parts in exploded views are not only a call-out of part names listed in the text but also an indica-
tion of the sequence of disassembly.
(2) Inspections to be conducted during disassembly process are indicated in boxes in the relevant exploded views.
(3) Maintenance standards required for inspection and repair works are indicated in the appropriate positions in the text. They
are also collectively indicated in the Chapter 2.
(4) The tightening torque with engine oil applied on the thread is specified as [Wet]. Unless otherwise specified, the tightening
torque is of dry condition.
(5) In this manual, important safety or other cautionary instructions are emphasized with the following head marks.
Indicates an immediately hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
Indicates a potentially hazardous situation which, if not avoided, may result in property
damage.
NOTICE Emphasizes important matter, or indicates information useful for operation or maintenance
of the engine.
II 29402-00120
Foreword
Terms used in this manual

Nominal value
means the basic nominal size of a part to be measured.
Standard value
means the quantitative requirement for dimension of a part, clearance between parts or standard performance of engine. The
values are rounded off for the inspection job, and do not necessarily conform to the design values.
Limit value
means the value, which the measured value reaches, the part needs repair or replacement with a new one.
Abbreviations and Standards
BTDC: Before Top Dead Center
ATDC: After Top Dead Center
BBDC: Before Bottom Dead Center
ABDC: After Bottom Dead Center
TIR: Total Indicator Reading
API: American Petroleum Institute
ASTM: American Society for Testing and Materials
JIS: Japanese Industrial Standards
LLC: Long Life Coolant
MIL: Military Specifications and Standards (U.S.A.)
MSDS: Material Safety Data Sheet
SAE: Society of Automotive Engineers (U.S.A.)
P/N: Part Number
Unit of Measurement
Measurements are based on the International System of Units (SI), and their converted metric values are indicated in { } and
U.S. customary values are in [ ]. For the conversion, the following rates are used.
Pressure: 1 MPa = 10.197 kgf/cm2
Torque: 1 N•m = 0.10197 kgf•m
Force: 1 N = 0.10197 kgf
Output power: 1 kW = 1.341 HP = 1.3596 PS
Pressure (mercury column): 1 kPa = 0.7 cmHg
Pressure (water column): 1 kPa = 10.197 cmH2O (cmAq)
Rotational speed: 1 min-1 = 1 rpm
29402-00120
III
Foreword
Safety Cautions
Fire and Explosion Protection
Keep Flames Away Be Alert for Leaking Fuel, Oil, or Exhaust

Do not use flames near the engine (in Gas
the engine room). The flame is dan- If any fuel, oil or exhaust gas leakage is found, imme-
gerous as it ignites combustibles and diately take corrective measures to stop it. Such leak-
cause a fire. Wipe off spilled fuel, oil ages, if left uncorrected, can cause fuel or engine oil to
and LLC immediately and thoroughly. reach hot engine surfaces or hot exhaust gas to con-
Spilled fuel, oil and LLC may ignite and cause a fire. tact flammable material, may results in a fire, personal
Store the fuel and engine oil in a well ventilated area. injury and damage to the equipment.
Make sure that the fuel and engine oil container caps
Use Explosion-Proof Light
are tightly fastened.
When inspecting fuel, engine oil, coolant, battery elec-
Tidy Up Around the Engine trolyte, etc., use an explosion-proof light. If the lighting
Do not place combustible or explosive material, such is not an explosion-proof type, it may ignite and cause
as fuel, engine oil, LLC or explosive powder near the an explosion.
engine. Such substances can cause a fire or explo-
Prevention of Electric Short Circuit
sion. Thoroughly remove dust, dirt, and other foreign
Avoid inspecting or servicing the electrical system with
material accumulated on the engine and the area
the battery cable connected to the battery. Otherwise,
around the engine. Such material can cause a fire or
a fire could result from a short circuit. Be sure to dis-
the engine to overheat. In particular, clean the top sur-
connect the battery cable from the negative (-) termi-
face of the battery thoroughly. Dust can cause a short
nal before starting work. A loose terminal and a
circuit. Always place the engine at a position at least 1
damaged cable or wire may result in a short circuit and
m [3.28 ft.] apart from buildings and other facilities to
a fire. Inspect, and if any defect is found, repair or
prevent a possible fire caused by engine heat.
replace it before starting work.
Do Not Open Side Covers Until Engine
Keep Fire Extinguishers and First-Aid Kit
Cools
Handy
Do not try to open the side cover of crankcase before
Keep fire extinguishers handy, and
the engine cools down. Wait at least 10 minutes after
become familiar with their usage.
stopping the engine. Opening the cover when the
Keep a first-aid kit at the designated
engine is hot allows fresh air to flow into the crank-
place to be ready for use in an emer-
case, which can cause oil mist to ignite and explode.
gency. Make counteract procedures
against a fire or an accident. Provide the contact per-
son and means of communication in case of emer-
gency.
IV 29402-00120
Foreword
Stay Away From Rotating and Moving Parts
Install Protective Covers Over Rotating Lockout and Tagout

Parts After Inspection and Maintenance Be sure to lockout and tagout before starting inspec-
Work tion and maintenance. Lockout and tagout are effec-

tive methods of cutting off machines and equipment
Check the covers over engine rotating
from energy sources. To accomplish the lockout/
parts for correct installation. Repair
tagout, remove the starter switch key, set the battery
any damaged or loosed covers. Never
switch to the OFF position and attach a DO NOT RUN
remove the protective covers around
or equivalent caution tag to the starter switch. The
rotating parts during operation. When
starter switch key must be kept by the person who per-
the engine is coupled to a radiator or other equipment,
forms inspection and maintenance work.
install protective covers over the exposed connecting
belt and coupling. Be Sure to Stop Engine Before Inspection/
Check Work Area for Safety Before Starting Maintenance
Before starting the engine, make sure that no one is Be sure to stop the engine before proceeding to
near the engine and that tools are not left on or near inspection and maintenance work. Never try to make
the engine. Verbally notify persons within the immedi- adjustments on the engine parts while the engine is
ate area when starting the engine. When the starter running. Rotating parts such as belt can reel in your
device is tagged with the warning sign saying DO NOT body and cause serious injuries.
RUN, never start the engine. Always Put Turning Tool Back in Place After
Stay Away From Moving Parts During Oper- Use
ation Be sure to remove the turning tool used for inspection
Keep away from the rotating parts and maintenance work. Make sure to pull back the
during operation. Do not leave any turning gear to the engine running position before
objects that may get caught in rotating starting the engine. If the engine is started with a turn-
parts. If clothes or a tool gets caught ing tool inserted or left in the turning condition, it can
in rotating parts, serious injury will not only cause a damage to the engine, but also lead
result. to a personal injury.
29402-00120
V
Foreword
Prevention of Exhaust Gas Poi- Fall Prevention

soning
Lift Engine Carefully
Pay Attention to Ventilation When Operat- Use slings or wire ropes strong
ing Engine enough to lift the load considering the
If the engine is installed in an engine weight. To lift the engine,
enclosed area, and the exhaust gas is attach the proper slings to the lifting
ducted outside, make sure that duct hangers prepared on the engine. To
joints are free from gas leak. Exhaust lift the engine, keep the engine in a
gas from the engine sometimes con- well-balanced position, thinking carefully of the engine
tains harmful components. Operating the engine in an center of gravity.
ill-ventilated area can cause gas poisoning. The hangers prepared on the engine are designed for
lifting the weight of engine only. In the case where the
Prevention of Hearing Loss
generator, marine gear, and others are installed to the
engine, consider that the additional weight will not
Wear Ear Plugs
affect the hangers of the engine.
Always wear ear plugs when entering
Keep the angle formed by slings attached to hangers
the machine room (engine room).
within 60°. If the angle exceeds this limit, excessive
Combustion sound and mechanical
load may be applied to the hangers and damage the
noise of engine can cause hearing
hangers. If the wire rope contacts the engine part
loss.
directly, place a cloth or other soft pad to avoid dam-
age to the part and wire rope. Remove the engine part
if necessary.
Do Not Climb Onto the Engine

Do not climb onto the engine, nor step on any engine
parts on the engine sides. To work on parts located
high on the engine, use a ladder, footing, and others to
prevent from slipping and falling. Climbing onto the
engine may result in engine part damage and your
injury by falling down.
Always Prepare a Stable Footing

When working on the upper part of
the engine and other hard-to-reach
places, use a stable footing. Stand-
ing on an old footstool or parts box
may result in personal injury. Do not
put any unnecessary objects on the footing.
VI 29402-00120
Foreword
Be Careful When Handling Fuel, Burn Protection

Engine Oil or Coolant
Do Not Touch the Engine During or Immedi-
Use Specified Fuel, Engine Oil and Coolant ately After Operation
Only Do not touch any parts of the engine
Use the fuel, oil and coolant specified in this manual during or immediately after operation.
only, and handle them carefully. Use of material other You can get burned. Before starting
than the specified one, or improper handling may the maintenance and inspection work,
cause various engine defects and malfunctions. Get check the water temperature meter to make sure that
the MSDS issued from the fuel, oil and coolant suppli- the engine is cooled down.
ers, and follow the directions in the MSDS for proper Be Careful to Open and Close the Radiator
handling. Cap
Be Careful with Coolant Never open the radiator cap while the engine is run-
When handling coolant, wear rubber gloves and a pro- ning or immediately after the engine stops. Stop the
tective face mask. If the coolant contacts your skin, or engine and give a sufficient time to allow the coolant to
get into your eyes or mouth, it may cause injury of skin cool down before opening the cap. When opening the
or eyes, or poisoning. If coolant is accidentally swal- radiator cap, slowly open the cap so as to release
lowed, induce vomiting immediately and seek medical internal pressure. To prevent hot steam scald, wear
attention. If coolant enters your eyes, flush them thick rubber gloves, or cover the cap with a cloth.
immediately with plenty of water and seek medical When closing the radiator cap, tightly close the cap.
attention. If coolant contacts your skin or clothing, Do not open the radiator cap during engine running or
wash it away immediately with plenty of water. Keep immediately after engine stop. Otherwise hot steam
flames away from coolant. Coolant can catch flames and coolant gush out and can cause burns.
and cause a fire. Drained coolant is a hazardous mate- Refill Coolant Only After the Coolant Tem-
rial. Do not discard it in an unauthorized procedure.
perature Dropped
Obey the applicable laws and regulations to dispose of
Refill the coolant after the coolant temperature drops
drained coolant.
to a room temperature. Replacement job immediately
Proper Procedure to Discard Waste Oil and after the engine stop may cause burns.
Coolant Do Not Remove Heat Shields
Do not dispose of waste engine oil or coolant in an
The exhaust system, which becomes extremely hot
unauthorized procedure. Such a way of disposal is
while the engine is running, is provided with various
strictly prohibited by laws and regulations. Discard
heat shields. Never remove the heat shields. If any of
waste oil, coolant and other environmentally hazard-
these heat shields were inevitably removed for the
ous waste in accordance with the applicable laws and
inspection and maintenance, be sure to install them
regulations.
after the work.
Burn Prevention When Changing Oil

Wear gloves when draining oil or changing oil filters. If
your skin contacts hot oil or hot parts, you get burn
injury.
29402-00120
VII
Foreword
Battery Safety Precautions When Abnormality Occurs
Be Careful When Handling Battery Do Not Add Coolant Immediately After a

Never use flames or generate Sudden Stop Due to Overheating
sparks near the battery. The bat- If the engine stops suddenly due to overheating, or
tery gives off highly flammable you suddenly stop the engine by any reason, do not
hydrogen gas and oxygen gas. add coolant immediately. If coolant is added immedi-
Any flame or spark near a battery ately, parts such as cylinder heads can be damaged
may cause an explosion.
due to the sudden drop of temperature. Add coolant
Do not use the battery if its fluid level is below the
slowly after the engine becomes cool.
lower limit line. Wrong use of the battery may result
in an explosion. Be Careful When Starting After an Abnor-
Do not short the battery terminals with a tool or other mal Stop
metal object. If the engine stops abnormally, do not restart the
When disconnecting battery cables, always remove engine immediately after the stopping. If the engine
the negative (-) terminal first. When reconnecting the stops or is stopped, inspect the engine to clarify the
cables, always connect the positive (+) terminal first. cause of the defect and correct the cause before
Charge the battery in a well-ventilated area with all
restarting. If the engine is kept operating in such a
battery cables removed.
condition, it can result in serious engine failure.
Make sure the cable clamps are securely fastened to
the battery terminals. A loose terminal can cause When the Engine Oil Pressure Decreases,
sparks that may result in an explosion. Stop the Engine Immediately
Before servicing electrical components or conducting If the engine oil pressure drops significantly, stop the
electric welding, set the battery switch to the [Open/ engine immediately, and inspect the lubrication sys-
OFF] position or disconnect the cable from the nega- tem to find the cause. Continuous engine operation
tive (-) battery terminal to cut off the electrical cur- with low oil pressure may cause bearings and other
rent.
parts to seize.
Electrolyte (battery fluid) contains dilute sulfuric acid.
Careless handling of the battery may lead to the loss
Stop the Engine Immediately When the Belt
of sight and/or skin burns. Also, do not swallow bat- Break
tery fluid. If the belt breaks, stop the engine immediately. Contin-
Wear protective goggles and rubber gloves when uous engine operation with the broken belt can cause
working with the battery (such as adding water or the engine to overheat. Steam of boiled coolant may
charging). gush out from the reserve tank or radiator, and results
If battery electrolyte is spilled onto the skin or cloth- in burns.
ing, immediately wash it away with lots of water. Use
soap to clean thoroughly.
Battery fluid can make you blind if splash into your
eyes. Immediately flush it away with plenty of clean
water, and seek immediate medical attention.
If battery fluid is accidentally swallowed, gargle with
plenty of water, then drink lots of water, and seek
immediate medical attention.
VIII 29402-00120
Foreword
Other Precautions
Do Not Tamper Never Break the Seals

If tampered, the warranty is totally void even in the To ensure the proper engine operation, the fuel injec-
warranty period. Tampering with the engine can not tion pump, governor, handle and fuel control link are
only damage the engine but also may lead to personal provided with seals that protect the fuel injection vol-
injury. ume and rotation speed settings against tampering. If
the engine is operated with the seal tampered, no
Performance of Pre-Operation Inspection
guarantee will be provided. The defects shown below
and Periodic Inspections
may occur if the seal is tampered.
Conduct the daily inspection and periodic inspection/
Rapid wear of moving and rotating parts
maintenance as described in this manual.
Failures such as seizure and damage of engine parts
Failure to conduct the specified inspections may cause
Sudden increase of fuel and lubricating oil consump-
various engine problems, damage to parts, and a seri-
tion
ous accident. Poor engine performance due to improper balance
Wear Proper Work Clothing and Protective between fuel injection volume and governor control,
Gears or a serious accident due to overrunning of the

engine
Wear a hard hat, a face shield, safety shoes, a dust
mask, gloves, ear plugs and other protective gears as Check the Engine After Operation
needed. When using compressed air, wear ear plugs, After the engine operation, check each part of engine
safety goggles, a hard hat, gloves and other neces- once again. If any defect is found, correct immediately.
sary protective gears. Works without wearing proper Engine Break-in
protective gears may result in serious injury. To break-in a new engine or an overhauled engine,
operate the engine at a speed lower than the rated
speed in a light load condition during the first 50 hours
of operation. Operating a new engine or an overhauled
engine in a severe condition during the break-in period
shortens the service life of the engine.
29402-00120
IX
Foreword
Warming Up Engine First Do Not Splash Water on Engine

After starting the engine, run the engine at a low idling Use care to protect engine from water such as rain
speed for warming-up, Start the work after the coolant entering through the air inlet or exhaust openings. Do
temperature is raised. Warm-up operation circulates not wash the engine while it is running. Cleaning fluid
lubricant in the engine, and works for the longer ser- or water can be sucked into the engine. Starting the
vice life and economical operation. Do not continue engine with water inside the combustion chamber can
the warm-up operation for a longer time than neces- cause the water hammering, and may result in engine
sary. Long warm-up operation causes carbon deposits inner parts damage and serious accident.
in the cylinders, and may lead to incomplete combus- Air cleaner or
tion.
Pre-cleaner is to be properly maintained
Do Not Operate the Engine in an Over- With foreign material in the intake air, excessive wear
loaded Condition of the engine can result. Worn parts produce many
If the engine shows an overloaded condition such as problems such as increase of oil consumption,
black exhaust smoke, reduce the load immediately to decrease of output and starting difficulties. For effec-
an appropriate load condition. Overloading causes not tive removal of dust from intake air, maintain the air
only high fuel consumption but also excessive carbon cleaner/pre-cleaner according to the following instruc-
deposits inside the engine. Carbon deposits cause tions.
various problems and will shorten the service life of the Never perform maintenance of the air cleaner or pre-
engine. cleaner during operation. Foreign material enters the
turbocharger and may result in a serious failure.
Cool Down the Engine Before Stopping
When removing the air cleaner or pre-cleaner, be
Cool down the engine at a low idling for five to six min-
careful to prevent dust and foreign material collected
utes before stopping it. Stopping the engine immedi-
on the cleaner from entering the engine. After
ately after a high-load operation will cause local heat
removing the air cleaner or pre-cleaner, immediately
up of engine parts and shorten the service life of the cover the opening (inlet port of engine or turbo-
engine. During the cooling operation, check the engine charger silencer) with plastic sheet or similar means
for abnormalities. to prevent foreign materials from entering the
Do not operate engine continuously under engine.
An air cleaner with a dust indicator gives an alarm
low load
when it is clogged. Conduct the maintenance when
When operating the engine at a load less than 30 % of
the rated load, limit the operation within one hour. the alarm is given.
Accumulated carbon in the cylinder may cause defec-

tive combustion.
Operate the engine at a load of 50 % or higher for 30
minutes after continuous low load operation to prevent
carbon from accumulating in the cylinder.
X 29402-00120
Foreword
Obey Safety Rules at Work Site Engine Transportation Precautions

Obey the safety rules established at the workplace To road-transport the engine, consider the engine
when operating and maintaining the engine. Do not weight, width and height, and obey applicable laws
operate the engine if you are in bad health. Consult and regulations such as road traffic laws, vehicle road
your supervisor about your condition. Operation of the acts and vehicle restriction ordinances.
engine with decreased attention may cause improper Pay Attention to Engine Room Ventilation
operation and results in an accident. When working in Always keep the engine room well-ventilated. Insuffi-
a team of two or more people, use specified hand sig- cient intake air amount of the engine can cause an
nals to communicate among workers. increase in the engine temperature, and could result in
Use Proper Tools for Maintenance Work a decrease in the output power and poor performance.
Always keep in mind to select most appropriate tools It is highly recommended to calculate the required
for the work, and use them correctly. If a tool is dam- amount of air supply to the engine and install an ade-
aged, replace it with a new one. quate ventilation system before installing the engine.
Do Not Operate Starter Continuously Do Not Touch High-Pressure Fuel Spray

Do not use the starter for more than 10 seconds at a Do not touch fuel jet leaked or sprayed from the high
time. If the engine does not start, wait for at least 1 pressure injection pipe. Fuel in the fuel injection pipe is
minute before starting again. Continuous operation of under high pressure and if the fuel impinges your skin,
the starter to start a stubborn engine may lead to a flat it goes through the skin and can cause serious injury.
battery or starter burning out.
Do Not Turn Off the Battery Switch During

Operation
Do not turn off the battery switch during operation. If
the battery switch is turned OFF when the engine is
running, not only various indicators will stop working
but also the diodes and transistors in the starter can
be damaged.
29402-00120
XI
Foreword
Warning Labels
Maintenance of Warning Labels

Make sure all warning/caution labels are legible.
Clean or replace the warning or caution label when the description or illustration is not clear to read.
For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvent, gasoline or other
chemicals to prevent the label from fading and peering.
Replace a damaged or missing label with a new one.
If any engine part stuck with a warning label is replaced with a new one, attach a new identical warning label to the
new part.
To get new warning labels, contact your MHI dealer.
Common Warning Labels
XII 29402-00120
Foreword
Points on Disassembling and Assembling

This service manual contains the recommended practices to Points on Assembling
service the engine. The manual also contains dedicated spe-  Wash all engine parts, except such parts as oil seals, O-
cial tools made for the work, and the basic safety cautions to rings and rubber seats, in cleaning oil, and dry them with
obey when working. Note that this manual does not cover compressed air.
all potential hazards that could occur during maintenance,  Use correct tools and instruments.
inspection and service works of the engine. Use only high-quality lubricating oil and grease of the
appropriate type. Be sure to apply oil, grease or adhesive
When working on the engine, follow the related instructions
to specified surfaces.
in this manual and also pay attention to the following:
Use a torque wrench to tighten parts correctly when their
Points on Disassembling tightening torques are specified. Refer to "Tightening
 Use correct tools and instruments. Otherwise, serious
torque table."
damage or accident may result.
Replace gaskets, packings and O-rings with new ones.
Do not use jack bolts having sharp edge, as they may cause
Apply adhesive as required. Do not apply adhesive too
damage to the surface.
much.
Use a footing or workbench to place disassembled parts as
Use protective gloves when you touch overheated or fro-
required, and obey the disassembly procedure in this
zen parts. Touching such a part with a bear hand can
manual. Do not place the parts on the floor directly. Place
cause burns.
them on a workbench or the like.
Place the engine parts in good order to prevent from miss-
ing. Also, place the parts in the serial order for reassem-
bling.
When reusing the engine parts, unless there are special rea-
sons, install them to their original positions.
Pay attention to assembling marks. Put your marks on the
parts, if necessary, to ensure correct assembling.
Carefully check each part for defects during disassembling
or cleaning. Do not miss symptoms which cannot be
found after finishing the disassembling or cleaning.
Pay attention to the safety, especially for the balancing of
disassembled parts and carrying of heavy parts. (Get the
help, and use jacks, chain blocks and guide bolts as neces-
sary.)
Use protective gloves when you touch overheated or fro-
zen parts. Touching such a part with a bear hand can
cause burns.
29402-00120
XIII
GENERAL CONTENTS
Chapter 1 GENERAL
1. External View
2. Outline of Systems
3. Indications of Plate and Label
4. Specifications
Chapter 2 SERVICE DATA

1. Maintenance Service Data
2. Tightening Torque Table
Chapter 3 SERVICE TOOLS

1. Special Tools
Chapter 4 OVERHAUL INSTRUCTIONS

1. Determining Overhaul Timing
2. Compression Pressure - Measure
Chapter 5 DISASSEMBLY OF BASIC ENGINE

1. Cylinder Head and Valve Mechanism - Disassemble and Inspect
2. Rear Mechanism - Disassemble and Inspect
3. Front Mechanism - Disassemble and Inspect
4. Cylinder Liner, Piston, and Connecting Rod - Disassemble and Inspect
5. Crankcase, Crankshaft, and Main Bearing - Disassemble and Inspect
Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

1. Cylinder Head and Valve Mechanism - Inspect and Repair
2. Rear Mechanism - Inspect and Repair
3. Front Mechanism - Inspect and Repair
4. Piston and Connecting Rod - Inspect and Repair
5. Crankcase and Crankshaft - Inspect and Repair
Chapter 7 ASSEMBLY OF BASIC ENGINE

1. Crankshaft and Main Bearing - Install
2. Cylinder Liner, Piston, and Connecting Rod - Assemble
3. Front Mechanism - Assemble
4. Rear Mechanism - Assemble
5. Cylinder Head and Valve Mechanism - Assemble
Chapter 8 FUEL SYSTEM

1. Fuel System - Remove and Inspect
2. Fuel System - Disassemble, Inspect, and Assemble
3. Fuel System - Install
Chapter 9 LUBRICATION SYSTEM

1. Lubrication System - Remove and Inspect
2. Lubrication System - Disassemble, Inspect, and Assemble
3. Lubrication System - Install
Chapter 10 COOLING SYSTEM

1. Cooling System - Remove and Inspect
2. Cooling System - Disassemble, Inspect, and Assemble
3. Cooling System - Install
Chapter 11 INLET AND EXHAUST SYSTEMS

1. Inlet and Exhaust Systems - Remove and Inspect
2. Inlet and Exhaust Systems - Disassemble, Inspect, and Assemble
3. Inlet and Exhaust Systems - Install
Chapter 12 AIR START SYSTEM

1. Air Start System - Remove and Inspect
2. Air Start System - Disassemble, Inspect and Assemble
3. Air Start System - Install
Chapter 13 ADJUSTMENT AND OPERATION

1. Engine - Adjust
2. Break-In Operation
3. Engine - Test and Adjustment
Chapter 1 GENERAL
1. External View ........................................................................................................... 1-3
2. Outline of Systems ................................................................................................ 1-17
2.1 Outline of Fuel System ........................................................................................................... 1-17
2.2 Outline of Lubrication System................................................................................................. 1-17
2.3 Outline of Cooling System ...................................................................................................... 1-18
2.4 Outline of Inlet and Exhaust System....................................................................................... 1-20
3. Indications of Plate and Label .............................................................................. 1-22
3.1 Name Plate ............................................................................................................................. 1-22
3.2 Caution Plate .......................................................................................................................... 1-22
3.3 Emission Certification Label ................................................................................................... 1-22
4. Specifications ........................................................................................................ 1-23
29402-00120
3-1
Chapter 1 GENERAL
1. External View
Chapter 1 GENERAL
S6A3-PTA
Thermostat case
Water pump
Alternator
Damper
Note: Configuration varies depending on the destination and specifications.

Engine Front View
S6A3-PTA
Timing gear case
Rotation direction
Flywheel
Oil pan
Note: Configuration may differ depending on the customization and specifications.
Engine Rear View
29402-00120
1-3
Chapter 1 GENERAL
Exhaust pipe, exhaust outlet S6A3-PTA

Turbocharger
Air inlet
Oil cooler
Rear hanger
Water drain cock
Front Rear
Fan
Starter
Water drain cock
Coolant inlet
Oil filter
Bypass oil filter
Left Side View
S6A3-PTA
Air cooler Governor Stop solenoid
Fuel injection pump Coolant outlet
Breather and oil filler Front hanger
Rear Front
Fuel feed pump
Oil level gauge
Fuel return port

Fuel inlet Fuel filter

Right Side View
1-4 29402-00120
Chapter 1 GENERAL
S6A3-PTK
Thermostat case
Coolant outlet port
Coolant inlet port
Water pump
Alternator
Damper

Engine Front View
S6A3-PTK
Timing gear case
Rotation direction
Flywheel
Oil pan

Engine Rear View
29402-00120
1-5
Chapter 1 GENERAL
S6A3-PTK
Exhaust pipe, exhaust outlet Turbocharger
Air inlet
Oil cooler
Rear hanger
Water drain cock
Front Rear
Starter
Water drain cock
Oil filter
Bypass oil filter
Left Side View
S6A3-PTK
Air cooler Governor
Stop solenoid
Fuel injection pump
Front hanger
Breather and oil filler
Rear Front
Fuel feed pump
Oil level gauge
Fuel return port

Right Side View
1-6 29402-00120
Chapter 1 GENERAL
Engine coolaant inlet S6A3-PTAA

(To radiator) Air inlet
(To air cooler)
Thermostat case
Air outlet
(To air cooler)
Water pump
Damper
Engine coolant outlet

(From radiator)
Alternator
Note: Configuration may differ depending

on the customization and specifications.
Engine Front View
S6A3-PTAA
Timing gear case
Rotation direction
Flywheel
Note: Configuration may differ depending Oil pan

Engine Rear View
29402-00120
1-7
Chapter 1 GENERAL
S6A3-PTAA
Exhaust outlet
Turbocharger
Air inlet
Radiator
Oil cooler
Exhaust manifold Rear hanger
Water drain cock
Front Rear
Starter
Fan
Water drain cock Oil filter

Bypass oil filter
Left Side View
S6A3-PTAA
Actuator
Fuel injection pump
Front hanger
Breather and oil filler
Stop solenoid
Rear Front
Air cooler
Fuel feed pump
Oil level gauge
Fuel return port Fuel filter

Fuel inlet

Right Side View
1-8 29402-00120
Chapter 1 GENERAL
S6A3-Y2TAA
Engine coolant inlet
(To radiator)

(From engine)
Air outlet
(From air cooler)
Thermostat case
Water pump
Tension pulley
Damper
Air inlet
(To air cooler)
Alternator
Note: Configuration may differ depending

on the customization and specifications. Engine coolant outlet (From radiator)
Engine Front View
S6A3-Y2TAA
Timing gear case
Rotation direction
Flywheel

Engine Rear View
29402-00120
1-9
Chapter 1 GENERAL
Exhaust outlet
S6A3-Y2TAA
Turbocharger
Muffler
Air inlet
Radiator
Exhaust manifold
Rear hanger
Oil cooler
Front Rear
Starter
Fan
Water drain cock
Water drain cock Oil filter

Bypass oil filter
Left Side View
S6A3-Y2TAA
Actuator
Fuel injection pump

Front hanger
Breather
Stop solenoid
Rear Front
Fuel return port Air cooler
Fuel feed pump
Fuel inlet
Oil level gauge

Fuel filter Oil filler
Right Side View
1-10 29402-00120
Chapter 1 GENERAL
S6A3-E2PTAA
Engine coolant inlet
Air inlet
(To radiator) (To air cooler)
Thermostat case
Air outlet
(From air cooler)
Water pump
Tension pulley Damper
Alternator

Note: Configuration may differ depending (From radiator)
Engine Front View
S6A3-E2PTAA
Timing gear case
Rotation direction
Flywheel

Engine Rear View
29402-00120
1-11
Chapter 1 GENERAL
S6A3-E2PTAA
Exhaust outlet
Turbocharger
Radiator
Exhaust manifold
Oil cooler
Rear hanger
Front Rear
Starter
Fan
Water drain cock Water drain cock

Bypass oil filter Oil filter
Left Side View
S6A3-E2PTAA
Actuator
Fuel injection pump

Front hanger
Stop solenoid
Rear Front
Air cooler
Fuel feed pump
Fuel return port
Fuel inlet
Oil level gauge Fuel filter Oil filler Breather
Right Side View
1-12 29402-00120
Chapter 1 GENERAL
Exhaust gas outlet S6A3-T2MTK3

Expansion tank cap
Heat exchanger
Rotation
Oil pan

Engine Front View
S6A3-T2MTK3
Sea water pump
Marine gear oil cooler
Marine gear oil level gauge
Marine gear oil filler cap

Marine gear oil drain pipe
Marine gear oil drain plug

Engine Rear View
29402-00120
1-13
Chapter 1 GENERAL
S6A3-T2MTK3
Oil lfilter Exhaust maniford Oil cooler
Turbocharger alarm switch
Rear hanger
Pre cleaner Inter cooler
Sea water inlet
Marine gear
Rear Front
Water pump
Water pump
coolant drain cock
Bypass oil filter Engine body

Oil filter Starter
coolant drain cock
Left Side View
S6A3-T2MTK3
Stop lever Fuel injection pump Fuel filter

Governor Front hanger
Expansion tank
Governor oil filter level gauge
Sea water pump Sea water inlet

6723
Rear Front
Priming pump
Alternator
Breather
Oil level gauge Fuel feed pump Fuel inlet Oil filler

Right Side View
1-14 29402-00120
Chapter 1 GENERAL
S6A3-Y3MPTK
Expansion tank cap

Exhaust gas outlet
Heat exchanger
Rotation
Oil pan

Engine Front View
S6A3-Y3MPTK
Sea water inlet
(from Marine gear)
Rotation
Sea water outlet
(from Marine gear)
Sea water pump

Engine Rear View
29402-00120
1-15
Chapter 1 GENERAL
S6A3-Y3MPTK
Exhaust manifold Turbocharger Silencer
Oil cooler
Rear hanger
Water pump
Front Rear
Flywheel housing
Starter
By-pass oil filter Oil filter

Left Side View
S6A3-Y3MPTK
Fuel injection pump Governor Breather
Fuel feed pump Front hanger

Air cooler
Stop solenoid
OP
ST
Rear Front
Oil level gauge
Oil filler Alternator


Right Side View
1-16 29402-00120
Chapter 1 GENERAL
2. Outline of Systems
2.1 Outline of Fuel System
Leak-off pipe
Fuel injection nozzle
Return pipe
Fuel injection pump
Fuel feed pump
From fuel tank
Fuel filter
To fuel tank
Outline of Fuel System
2.2 Outline of Lubrication System
Turbocharger
Hydraulic governor spec
Oil cooler Valve mechanism
Camshaft
Oil jet
Bypass valve
Fuel injection pump
Governor
Governor oil filter
Water pump Timing gear
Crankshaft
Safety valve
Oil filter alarm
Oil pump
Bypass oil filter
Relief valve Oil filter Oil strainer
Outline of Lubrication System
29402-00120
1-17
Chapter 1 GENERAL
Turbocharger Electronic governor spec

Oil cooler
Valve mechanism
Bypass valve Camshaft
Oil jet
Fuel injection pump
Rear accesory drive
Timing gear
Water pump
Crankshaft
Oil filter alarm Safety valve

Oil pump
Bypass oil filter
Relief valve Oil filter Oil strainer
Outline of Lubrication System
2.3 Outline of Cooling System
PTA spec
Cooling fan Thermostat Air cooler
Radiator
Water pump
Oil cooler
Outline of Cooling System
1-18 29402-00120
Chapter 1 GENERAL
Thermostat TAA spec
Cooling Fan
Air cooler
Fan belt
Radiator
Water pump
Oil cooler
Engine PTK spec

coolant outlet
Thermostat
Air cooler
coolant outlet
Oil cooler
Air cooler
coolant inlet
Water pump
Engine
coolant inlet
Air cooler
29402-00120
1-19
Chapter 1 GENERAL
Heat exchanger MTK spec
Thermostat Exhaust manifold
Air cooler
Seawater pump
Seawater
Water pump
Oil cooler
2.4 Outline of Inlet and Exhaust System
Internal air cooler spec

Intake Exhaust
Exhaust
From pre-cleaner
or air cleaner
Turbocharger
Air cooler
Outline of Inlet and Exhaust System
1-20 29402-00120
Chapter 1 GENERAL
Intake External air cooler spec

Exhaust
Exhaust
From pre-cleaner
or air cleaner
Turbocharger
Air heater
Piston
Air cooler (air to air type)
Outline of Inlet and Exhaust System
29402-00120
1-21
Chapter 1 GENERAL
3. Indications of Plate and Label

3.1 Name Plate
The name plate is located on the lateral side of the engine,
and indicates the following information:
Engine serial number Right
Manufactured date
Total displacement
Front 1 2 3 4 5 6 Rear
Engine output
Rated speed
Cylinder No. Left
Name Plate
3.2 Caution Plate
The caution plate is located on the top face of the rocker
cover of No. 1 cylinder and indicates the following informa-
tion:

Valve clearance
Firing order
Fuel injection timing VA LV E C L E A R A N C E ( C O L D )
Connecting rod weight rank INLET 0.4 mm EXHAUST 0.5 mm
FIRING ORDER
1-5-3-6-2-4
㼻
BTDC
FUEL INJECTION TIMING
CON-ROD RANK
Caution Plate
3.3 Emission Certification Label
The emission certification label that shows compliance with
emission requirements is attached to the engine.
1-22 29402-00120
Chapter 1 GENERAL
4. Specifications
Engine model S6A3
Type Water cooled, four stroke cycle diesel, turbo charged
No. of cylinders - Arrangement 6 cylinders, in-line
Combustion system Direct injection system
Valve mechanism Overhead
Cylinder bore × stroke 150×175 mm [5.91 × 6.89 in.]
Total displacement 18.56 L [1132.77 cu.in.]
Firing order 1-5-3-6-2-4
Direction of rotation Counterclockwise as viewed from flywheel side
Engine oil Class CF or CH-4 (API service classification)
Specification table
The mark "○" in the table represents the installed equipment of each engine type.
Note:(a) This table shows the general information. The installation of equipment differs in accordance with the customization
and specifications.
(b) The specification and part number may be changed with the design progress without prior notice.
E2PTAA-1
T2MTKM
Y3MPTK
Y2MPTK
Y1MPTK
Y1MPTA
T2MTK3
Y2TAA1
Equipment name Specification name
MPTK
MPTA
MTK2
MTK
PTK
PTA
Overlap 110°(32505-50101) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Camshaft Overlap 110°advanced by 4°(35A05-50101) ○
Overlap 108°(35A05-20101) ○ ○ ○
Standard (32513-40100) 70 L [18.49 U.S. gal] ○ ○ ○ ○
Deep type (45721-52400) ○ ○
Oil pan Aluminum made (35A13-20100) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Deep type (35A13-00401) 60 to 90 L [15.9 to 23.8 U.S. gal] ○ ○
For wheel loader (35A13-24100) 82.5 L [ 21.8 U.S. gal] ○
Overlap 110° Compression ratio 14.5 (35A17-30101) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Overlap 108° Compression ratio 15 (35A17-00600) ○
Piston
Overlap 108° Compression ratio 14.5 (35A17-00700) ○
Overlap 110° Compression ratio 14.5 (35A17-30200) ○ ○
(35A20-02400) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
(35A20-02600) ○ ○ ○ ○ ○
Crankshaft pulley (35A20-12500) ○ ○ ○ ○ ○ ○ ○
(45685-60600) ○
(45780-23100) ○ ○
(32521-20015) ○
(35A21-00031) ○ ○ ○ ○ ○ ○
18in. I/D6.4 (35A21-10022) ○ ○ ○
Flywheel
18in. I/D10 (35A21-10013) ○ ○ ○ ○
14in. (35A21-01052) ○
14in. (35A21-11031) ○ ○
V-belt (35A25-03201) ○ ○ ○
For turning (45685-60600) ○ ○
Front pulley Ribbde belt (35A20-13100) ○ ○
(45681-97800) ○
Without pulley ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
29402-00120
1-23
Chapter 1 GENERAL
E2PTAA-1
T2MTKM
Y3MPTK
Y2MPTK
Y1MPTK
Y1MPTA
T2MTK3
Y2TAA1
MPTK
MPTA
MTK2
MTK
PTK
PTA
Screw adjusting type (35A61-00010) ○ ○ ○ ○ ○ ○ ○
Screw adjusting type (35A61-10030) ○
Screw adjusting type (35A61-01060) ○
Fuel injection Shim adjusting type (35A61-11050) ○

nozzle Shim adjusting type (35A61-11030) ○ ○ ○ ○
Shim adjusting type (35A61-70030) ○
Shim adjusting type (35A61-71030) ○
Shim adjusting type (32661-11060) ○
"A" diesel oil 1 unit (32562-60010) ○ ○ ○ ○ ○ ○
Diesel oil (32562-61010) ○ ○ ○ ○ ○ ○ ○ ○
Fuel filter "A" diesel oil 2 units (32562-60500) ○ ○
Diesel oil, change over type (37562-70800) ○ ○
Water separator (ME158-071) ○
Woodward make PSG type governor ○ ○ ○ ○
Woodward make TS750, PSG type governor ○ ○
TOHO SEISAKUSHO Co., LTD.
○ ○
Governor SG4017 model two wire type actuator
TOHO SEISAKUSHO Co., LTD.
○ ○
SG4017 model five wire type actuator
Woodward make PROACT type actuator ○
RUN ON ○ ○ ○ ○ ○
Stop solenoid
RUN OFF ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
TD10L-36F-28 ○
TD13L-51F-55 ○ ○ ○
TD10L-42F-43 ○
TD13L-42F-40 ○ ○
TD13L-48F-47 ○ ○
TD10L-42F-34 ○
TD13L-58VRC-55 ○
TD13L-43QRC-40 ○
TD13L-43QRC-47 ○
TD10L-51VRC-34 ○
Turbocharger TD13L-42F-40 ○
TD13L-48QRC-55 ○
TD10L-51V-43 ○ ○
TD13M-44QRC-40 ○
TD13M-48QRC-40 ○
TD09-45MRC-34 ○
TD13L-42F-34 ○ ○
TD10L2-45VRC-34 ○
TD13L4-50QRC-47 ○
TD13M1-45QHRC-47 ○
TD13M1-48QH23.5VRCN-40 ○
Water cooled exhaust manifold (35A-20020) ○ ○ ○
Fresh water cooling (32530-90010) ○ ○ ○
(32530-16010) ○
Air cooler
(35A55-20012) ○ ○ ○
(35A55-02030) ○ ○
(35A55-05300) ○
1-24 29402-00120
Chapter 1 GENERAL
E2PTAA-1
T2MTKM
Y3MPTK
Y2MPTK
Y1MPTK
Y1MPTA
T2MTK3
Y2TAA1
MPTK
MPTA
MTK2
MTK
PTK
PTA
D1010 PUSH (46648-02700) ○ ○
D1010 PUSH (33748-04200) ○
Fan
D1016 PUSH (46648-22601) ○ ○ ○
D800 PUSH (46648-00400) ○
Land use 6 kW body earth (04301-36100) ○ ○ ○
Land use 6 kW (37566-20101) ○ ○
Starter
Marine use 6 kW floating ground (04301-37010) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
8 kW body earth (36266-11801) ○
35A (04343-35500) ○ ○ ○ ○ ○ ○ ○ ○
30A (04343-38000) ○ ○
35A (04344-05101) ○ ○ ○ ○
Alternator
30A (04343-37000) ○ ○
70A (04344-05001) ○
110A (04344-07001) ○
29402-00120
1-25
1. Maintenance Service Data ...................................................................................... 2-3
1.1 General Maintenance Service Data of Engine.......................................................................... 2-3
1.2 Maintenance Service Data of Engine Body .............................................................................. 2-4
1.3 Maintenance Service Data for Fuel System ............................................................................. 2-9
1.4 Maintenance Service Data of Lubrication System .................................................................. 2-11
1.5 Maintenance Service Data of Cooling System ....................................................................... 2-12
1.6 Maintenance Service Data of Electrical System ..................................................................... 2-14
1.7 Air start system maintenace service data ............................................................................... 2-19
2. Tightening Torque Table....................................................................................... 2-20
2.1 Tightening Torque for Engine Body ........................................................................................ 2-20
2.2 Tightening Torque Spec for Fuel System ............................................................................... 2-21
2.3 Tightening Torque Specifications for Lubrication System....................................................... 2-21
2.4 Tightening Torque Specifications for Cooling System ............................................................ 2-21
2.5 Tightening Torque Specifications for Inlet and Exhaust System ............................................ 2-22
2.6 Tightening Torque Specifications for Electrical System.......................................................... 2-23
2.7 Tightening Torque Spec for Air Start System ......................................................................... 2-24
2.8 Tightening Torque for Standard Bolts..................................................................................... 2-25
2.9 Tightening Torque for Standard Union Bolts .......................................................................... 2-26
2.10 Tightening Torque for Standard Union Nuts ........................................................................... 2-26
2.11 Tightening Torque for Fuel Injection Pipe............................................................................... 2-26
2.12 Tightening Torque for Standard Plug...................................................................................... 2-26
29402-00120
2-1
1. Maintenance Service Data

1.1 General Maintenance Service Data of Engine
Nominal
Item Standard value Limit value Remarks
value
2.45 MPa 1.96 MPa
Cranking
Compression pressure {24.47 kgf/cm2} {20 kgf/cm2}
(approx 120 min-1)
[355 psi] [284 psi]
0.49 to 0.64 MPa 0.29 MPa
(at rated) {5 to 6 kgf/cm2} {3 kgf/cm2}
[71 to 93 psi] [42 psi] When oil temperature is
Engine oil pressure
0.20 to 0.29 MPa 0.15 MPa 90 to 100º C [194 to 212ºF]
When idling: {2 to 3 kgf/cm2} {1.5 kgf/cm2}
[29 to 42 psi] [22 psi]
Open BTDC 55º
Inlet
Close ABDC 65° Valve clearance 0 mm
Open BBDC 65° (Standard Value)
Exhaust
Overlap 110°Camshaft P/N : Close ATDC 55º
32505-50101 (part No. stamp) Open BTDC 11º
Inlet
Close ABDC 21° ± 2º Valve clearance 2 mm
Open BBDC 21° (crank angle) [0.08 in.]
Exhaust
Close ATDC 11º
Open BTDC 59º
Inlet
Close ABDC 61° Valve clearance 0 mm
Open BBDC 69° (Standard Value)
Overlap 110° Exhaust
advanced by 4°Camshaft Close ATDC 51º
Valve timing
Camshaft P/N : 35A05-10301 Open BTDC 15º
(part No. stamp) Inlet
Close ABDC 17° ± 2º Valve clearance 2 mm
Open BBDC 25° (crank angle) [0.08 in.]
Exhaust
Close ATDC 7º
Open BTDC 63º
Inlet
Close ABDC 34º Valve clearance 0 mm
Open BBDC 52º (Standard Value)
Exhaust
Overlap 108º Camshaft P/N : Close ATDC 45º
35A05-20101 (blue paint color) Open BTDC 21º
Inlet
Close ABDC 0º ± 2º Valve clearance 2 mm
Open BBDC 18º (crank angle) [0.08 in.]
Exhaust
Close ATDC3º
0.4 mm
Inlet
[0.016 in.]
Land use engine
0.5 mm
Exhaust
[0.020 in.]
Valve clearance (when cold)
0.7 mm
Inlet
[0.028 in.]
Marine engine
0.8 mm
Exhaust
[0.031 in.]
Check the caution plate on
Fuel injection timing
No. 1 rocker cover.
29402-00120
2-3
1.2 Maintenance Service Data of Engine Body

Unit: mm [in.]
Nominal
value
ø32 32.055 to 32.080 32.100
Rocker bushing inside diameter
[ø1.26] [1.2620 to 1.2630] [1.2638]
Rockers
ø32 31.975 to 31.991 31.950
Rocker shaft outside diameter
[ø1.26] [1.2589 to 1.2595] [1.2579]
ø10 9.940 to 9.960 9.910
Inlet valve
[ø0.39] [0.3913 to 0.3921] [0.3902]
Valve stem outside diameter
ø10 9.910 to 9.930 9.880
Exhaust valve
[ø0.39] [0.3902 to 0.3909] [0.3890]
ø10 10.000 to 10.015 10.060 Same for both inlet and
Valve Valve guide inside diameter
[ø0.39] [0.3937 to 0.3943] [0.3961] exhaust valves.
Adjusting screw
Clearance between bottom 2.6 [0.098]
side
face of valve bridge and top
face of valve rotator Non adjusting
1.6 [0.063]
side
Valve seat angle 30º
- 0.1 to 0.1 0.5
Valve sinkage 0
[-0.004 to 0.104] [0.020]
Seat width
2.08 1.98 to 2.18 2.5
Inlet valve
[0.0819] [0.0780 to 0.0858] [0.098]
Seat width
1.85 1.75 to 1.95 2.3
Exhaust valve
[0.0728] [0.0689 to 0.0768] [0.091] Valve
seat angle Valve
Valve margin
2.9 2.7 to 3.1 sinkage
Inlet valve 2.0
[0.114] [0.106 to 0.122]
Valve margin [0.079]
3.0 2.8 to 3.2 after refacing
Exhaust valve
[0.118] [0.110 to 0.126]
58.000 to 58.030 58.09
Inlet valve
Inside diameter of valve seat [2.2835 to 2.2846] [2.2870]
counterbore 54.000 to 54.030 54.09
Valve seat and Exhaust valve
[2.1260 to 2.1272] [2.1295]
valve
58.100 to 58.130
Standard 2pcs, yellow
[2.2874 to 2.2886]
58.130 to 58.160
Inlet valve 0.03 [0.012] 3pcs, yellow
[2.2886 to 2.2898]
58.160 to 58.190
Valve seat 0.06 [0.024] 4pcs, yellow
[2.2898 to 2.2909]
outside
diameter 54.100 to 54.130
Standard Double blue lines
[2.1299 to 2.1311]
Exhaust 54.130 to 54.160
0.03 [0.012] Triple blue lines
valve [2.1311 to 2.1323]
54.160 to 54.190
0.06 [0.024] Quadruple blue lines
[2.1323 to 2.1335]
0.070 to 0.130
Valve seat interference
[0.0028 to 0.0051]
66.2
Free length 67.5 [2.6575]
[2.606]
A=1.5º or less
B=2.3 [0.091] A
Squareness B=1.76 [0.069] or less at whole B
Valve spring
length Lf
Lf=67.5 [2.658]
60.0 [2.362]/259 to 286
Set length/load (mm [in.]/N {kgf} [lbf]) {26.43 to 29.19}
[58.27 to 64.35]
0.50
Push rod Runout TIR
[0.0197] or less
2-4 29402-00120
Unit: mm [in.]
Nominal
value
0.03 0.07
Distortion of bottom surface
[0.0012] or less [0.0028]
Cylinder head
134.9 to 135.1
Height (reference)
[5.311 to 5.319]
ø150 150.000 to 150.040 150.140
Inside diameter
[ø5.91] [5.9055 to 5.9071] [5.9110]
0.02
Roundness
[0.0008] or less
0.02
Cylindricity
[0.0008] or less
P/N: 0.10 to 0.19
35A07-32500 [0.0039 to 0.0075]
Cylinder liner Flange protrusion
P/N: -0.01 to -0.10
35A07-22500 [-0.00039 to - 0.0039]
P/N: 15.15 to 15.19
35A07-32500 [0.5965 to 0.5980]
Flange thickness
P/N: 14.95 to 14.99
35A07-22500 [0.5886 to 0.5902] T2MTK3
P/N: 0.16 to 0.24

Top ridge height
35A07-32500 [0.0063 to 0.0094]
P/N:
("00600"stamp)
35A17-00600
P/N: At a height of 90.5 mm
("00700" stamp)
Outside 35A17-00700 ø150 149.71 to 149.75 149.68 [3.563 in.] from the
diameter P/N: [ø5.91] [5.8941 to 5.8957] [5.8929] piston lower end in the
("30101" stamp) right angle to piston pin
35A17-30101
P/N:
("30200" stamp)
35A17-30200
P/N:
("00600"stamp)
35A17-00600
Piston
P/N:
Weight ("00700" stamp)
35A17-00700
difference in Within ± 15 g [0.53 oz]
one engine P/N:
("30101" stamp)
35A17-30101
P/N:
("30200" stamp)
35A17-30200
ø58 58.002 to 58.012 58.040
Piston pin bore inside diameter
[ø2.28] [2.2835 to 2.2839] [2.2850]
0.229 to 0.839
Protrusion
[0.0090 to 0.0330]
Cylinder head 1.8 1.77 to 1.83
Thickness when tightened
gasket [0.071] [0.0697 to 0.0720]
0.26 to 0.32 MPa
Piston cooling
Valve opening pressure {2.65 to 3.26 kgf/cm2}
nozzl
[37.69 to 46.36 psi]
Piston and 1.191 to 2.031
Top clearance
cylinder head [0.0469 to 0.0800]
0.6 to 0.8 2.0
No. 1 compression
[0.024 to 0.032] [0.08]
0.5 to 0.7 2.0
Piston ring End gap No. 2 compression
[0.0197 to 0.0276] [0.08]
0.5 to 0.7 2.0
Oil
[0.0197 to 0.0276] [0.08]
ø58 57.987 to 58.000 57.970
Piston pin Outside diameter
[ø2.28] [2.2829 to 2.2835] 2.2823
29402-00120
2-5
Unit: mm [in.]
Nominal
value
ø58 58.020 to 58.040 58.070
Inside diameter of connecting rod bushing
[ø2.28] [2.2842 to 2.2850] [2.2862]
0.05/100
Bend and twist
[0.0020/3.94] or less
0.4 to 0.6 1.0
End play
[0.0157 to 0.0236] [0.04]
Minimum:
109.950
Connecting rod
ø110 110.000 to 110.022 [4.3287]
Inside diameter of big end bore
[ø4.33] [4.3307 to 4.3316] Maximum:
110.050
[4.3327]
0.100
Circularity for inside diameter of big end bore
[0.0039]
60.7 to 60.8
Big end side (width)
[2.3898 to 2.3937]
3.000 2.987 to 3.000 2.950
Standard
[0.1181] [0.1176 to 0.1181] [0.1161]
3.125 3.112 to 3.125 3.075
0.25 [0.0098]
[0.1230] [0.1225 to 0.1230] [0.1211]
Connecting rod Thickness at 3.250 3.237 to 3.250 3.200
0.50 [0.0197]
Bearing center [0.1280] [0.1274 to 0.1280] [0.1260]
Under size
3.375 3.362 to 3.375 3.325
0.75 [0.0295]
[0.1329] [0.1324 to 0.1329] [0.1309]
3.500 3.487 to 3.500 3.450
1.00 [0.0394]
[0.1378] [0.1373 to 0.1378] [0.1358]
Face runout (reference) 0.285 [0.0112] or less
Flywheel
Radial runout (reference) 0.127 [0.0050] or less
0.11 to 0.18 0.50
Backlash between crank gear and rear idler gear
[0.0043 to 0.0071] [0.0197]
Backlash between injection pump gear 0.12 to 0.18 0.50
and camshaft gear [0.0047 to 0.0071] [0.0197]
Backlash between idler gear 0.12 to 0.18 0.50
and injection pump gear [0.0047 to 0.0071] [0.0197]
Rear Backlash between crankshaft gear 0.12 to 0.18 0.50
mechanism and oil pump gear [0.0047 to 0.0071] [0.0197]
ø50 50.000 to 50.025 50.060
Rear idler bushing inside diameter
[ø1.97] [1.9685 to 1.9695] [1.9709]
ø50 49.950 to 49.975 49.900
Rear idler shaft outside diameter
[ø1.97] [1.9665 to 1.9675] [1.9646]
0.2 to 0.4 0.6
Rear idler gear end play
[0.0079 to 0.0157] [0.0236]
7.54 to 7.64 6.79
Cam lift (major diameter - minor diameter)
[0.2968 to 0.3008] [0.2673]
0.05 0.08
Runout TIR
[0.0020] or less [0.0031]
ø68 67.920 to 67.940 67.870
Cam shaft Journal diameter
[ø2.68] [2.6740 to 2.6748] [2.6720]
Cam shaft bushing inside diameter ø68 68.000 to 68.030 68.090
(as installed in crankcase) [ø2.68] [2.6772 to 2.6783] [2.6807]
0.20 to 0.30 0.40
End play
[0.0079 to 0.0118] [0.0157]
2-6 29402-00120
Unit: mm [in.]
Nominal
value
103.880 to 103.900 103.840
Standard
[4.0898 to 4.0905] [4.0882]
103.630 to 103.650 103.590
0.25 [0.0098]
[4.0799 to 4.0807] [4.0783]
Crankpin
ø104 103.380 to 103.400 103.340
outside 0.50 [0.0197]
[ø4.09] [4.0701 to 4.0709] [4.0685]
diameter Under size
103.130 to 103.150 103.090
0.75 [0.0295]
[4.0602 to 4.0610] [4.0587]
102.880 to 102.900 102.840
1.00 [0.0394]
[4.0504 to 4.0512] [4.0488]
139.930 to 139.950 139.900
Standard
[5.5090 to 5.5098] [5.5079]
139.680 to 139.700 139.640
0.25 [0.0098]
[5.4992 to 5.5000] [5.4976]
Crankshaft
main journal ø140 139.430 to 139.450 139.390
0.50 [0.0197]
outside [ø5.51] [5.4894 to 5.4901] [5.4878]
diameter Under size
139.180 to 139.200 139.140
0.75 [0.0295]
[5.4795 to 5.4803] [5.4779]
138.930 to 138.950 138.890
1.00 [0.0394]
[5.4697 to 5.4705] [5.4681]
Deviation 0.01
0.03
Parallelism of journal and crankpin [0.0004] or less over
[0.0012]
entire pin length
Diameter difference 0.03
Circularity of journal and crankpin
0.01 [0.0004] or less [0.0012]
Diameter difference 0.03
Cylindricity of journal and crankpin
0.01 [0.0004] or less [0.0012]
Crank shaft R7 6.8 to 7.0
Fillet radius of pin
[R0.28] [0.268 to 0.276]
R7 6.8 to 7.0
Fillet radius of journal
[R0.28] [0.268 to 0.276]
Hardness of journal and crankpin Hv > 620
Finishing surface roughness Ra 0.2 μm [7.87 µin.]
Angular deviation between pins ±20'
61 61.20 to 61.30
Crankpin width
[2.40] [2.4094 to 2.4134]
58.00 to 58.03
Standard
[2.2835 to 2.2846]
58.25 to 58.28
0.25 [0.0098]
[2.2933 to 2.2945]
58.50 to 58.53
0.50 [0.0197]
[2.3031 to 2.3043]
Rearmost
58 58.75 to 58.78
crank journal 0.75 [0.0295]
[2.28] [2.3130 to 2.3142 ]
width Over size
59.00 to 59.03
1.00 [0.0394]
[2.3228 to 2.3240]
59.25 to 59.28
1.25 [0.0492]
[2.3327 to 2.3339]
59.50 to 59.53
1.50 [0.0591]
[2.3425 to 2.3437]
0.04 0.10
Runout TIR
[0.002] or less [0.0039]
0.300 to 0.765 0.500
End play (width between web and thrust bearing)
[0.0118 to 0.0301] [0.0197]
29402-00120
2-7
Unit: mm [in.]
Nominal
value
3.500 3.467 to 3.480 3.425
Standard
[0.1378] [0.1365 to 0.1370] [0.1348]
3.625 3.592 to 3.605 3.550
0.25 [0.0098]
[0.1427] [0.1414 to 0.1419] [0.1398]
Thickness at 3.750 3.717 to 3.730 3.675
Main bearing 0.50 [0.0197]
center [0.1476] [0.1463 to 0.1469] [0.1447]
Under size
3.875 3.842 to 3.855 3.800
0.75 [0.0295]
[0.1526] [0.1513 to 0.1518] [0.1496]
4.000 3.967 to 3.980 3.925
1.00 [0.0394]
[0.1575] [0.1562 to 0.1567] [0.1545]
5.00 4.78 to 4.85 4.76
Standard
[0.1969] [0.1882 to 0.1909] [0.1874]
5.25 5.03 to 5.10 5.01
0.25 [0.0098]
[0.2067] [0.1980 to 0.2008] [0.1972]
Thrust plate Thickness
5.50 5.28 to 5.35 5.26
Over size 0.50 [0.0197]
[0.2165] [0.2079 to 0.2106] [0.2071]
5.75 5.53 to 5.60 5.51
0.75 [0.0295]
[0.2264] [0.2177 to 0.2205] [0.2169]
0.1 0.2
Distortion of top surface
[0.004] or less [0.0079]
ø147 147.000 to 147.025 147.045
Inside diameter of main bearing housing
[ø5.79] [5.7874 to 5.7884] [5.7892]
Crank case
15.00 to 15.05
Depth of counterbore in crankcase
[0.5906 to 0.5925]
468.95 to 469.05
Height from journal center to top face (reference)
[18.4626 to 18.4665]
2-8 29402-00120
1.3 Maintenance Service Data for Fuel System

Unit: mm [in.]
Item Nominal value Standard value Limit value Remarks
P/N: 35A61-00010 ("-"mark)
P/N: 35A61-01060 ("-"mark) 21.6 MPa 22.1 to 22.6 MPa
{220 kgf/cm2} {225 to 230 kgf/cm2}
P/N: 35A61-10030 ("E"mark) [3133 psi] [3205 to 3278 psi]
Fuel
injection P/N: 35A61-11050 ("-"mark)
starting P/N: 35A61-11030 ("J"mark)
pressure 29.4 MPa 29.9 to 30.7 MPa
P/N: 35A61-70030 ("C"mark)
{300 kgf/cm2} {305 to 313 kgf/cm2}
P/N: 35A61-71030 ("R"mark) [4264 psi] [4337 to 4453 psi]
P/N: 32661-11060 ("2M"mark)
Orifice cone angle 158º
0.25
P/N: 32661-11060 ("2M"mark)
[0.0098]
0.26
P/N: 35A61-11030 ("J"mark)
[0.0102]
0.27
P/N: 35A61-10030 ("E"mark)
[0.0106]
Fuel
injection Orifice P/N: 35A61-00010 ("-"mark)
nozzle diameter 0.28
P/N: 35A61-01060 ("-"mark)
[0.0110]
P/N: 35A61-71030 ("R"mark)
0.29
P/N: 35A61-70030 ("C"mark)
[0.0114]
0.31
P/N: 35A61-11050 ("-"mark)
[0.0122]
7
P/N: 35A61-11050 ("-"mark)
[0.28]
P/N: 35A61-11030 ("J"mark)
P/N: 35A61-10030 ("E"mark)
Number of 8
P/N: 35A61-00010 ("-"mark)
orifices [0.32]
P/N: 35A61-01060 ("-"mark)
P/N: 32661-11060 ("2M"mark)
P/N: 35A61-70030 ("C"mark) 10
P/N: 35A61-71030 ("R"mark) [0.39]
79.988 to 80.018
ø80 [ø3.15]
[3.1491 to 3.1503]
Inside diameter of case bearing housing
99.987 to 100.022
ø100 [ø3.94]
[3.9365 to 3.9379]
79.987 to 80.000
Small ø80 [ø3.15]
Outside [3.1490 to 3.1496]
diameter 99.985 to 100.000
Large ø100 [ø3.94]
Fuel injection pump Injection pump drive [3.9364 to 3.9370]
accessory drive shaft bearing 39.988 to 40.000
Small ø40 [ø1.57]
Inside [1.5743 to 1.5748]
diameter 44.988 to 45.000
Large ø45 [ø1.77]
[1.7712 to 1.7717]
40.002 to 40.013
ø40 [ø1.57]
[1.5749 to 1.5753]
Drive shaft bearing outside diameter to fit
45.002 to 45.013
ø45 [ø1.77]
[1.7717 to1.7722]
29402-00120
2-9
Unit: mm [in.]
99.987 to 100.022
Inside diameter of drive case bearing housing ø100 [ø3.94]
[3.9365 to 3.9379]
89.955 to 89.990
Inside diameter of drive gear bearing housing ø90 [ø3.54]
[3.5415 to 3.5429]
79.988 to 80.018
Inside diameter of bearing case bearing housing ø80 [ø3.15]
[3.1491 to 3.1503]
46.989 to 47.014
Inside diameter of driven gear bearing case bearing housing ø47 [ø1.85]
[1.8500 to 1.8509]
46.989 to 47.000
Outside diameter ø47 [ø1.85]
[1.8500 to 1.8504]
Driven gear bearing
19.990 to 20.000
Inside diameter ø20 [ø0.79]
[0.7870 to 0.7874]
20.002 to 20.011
Outside diameter of driven gear to fit bearing ø20 [ø0.79]
[0.7875 to 0.7878]
79.987 to 80.000
Small ø80 [ø3.15]
[3.1491 to 3.1496]
Governor Outside 89.985 to 90.000
Middle ø90 [ø3.54]
drive diameter [3.5427 to 3.5433]
99.985 to 100.000
Large ø100 [ø3.94]
[3.9364 to 3.9370]
Drive case cover bearing
39.988 to 40.000
Small ø40 [ø1.57]
[1.5743 to 1.5748]
Inside 54.985 to 55.000
Middle ø55 [ø2.17]
diameter [2.1648 to 2.1654]
44.988 to 45.000
Large ø45 [ø1.77]
[1.7712 to 1.7717]
45.002 to 45.013
ø45 [ø1.77]
[1.7717 to 1.7722]
54.993 to 55.012
Outside diameter of drive shaft bearing fit ø55 [ø2.17]
[2.1651 to 2.1658]
40.002 to 40.013
ø40 [ø1.57]
[1.5749 to 1.5753]
0.10 to 0.20 0.50
Backlash between drive gear and driven gear
[0.004 to 0.008] [0.0197]
2-10 29402-00120
1.4 Maintenance Service Data of Lubrication System

Unit: mm [in.]
0.087 to 0.316 0.400
Backlash between oil pump gear and idler gear
[0.0034 to 0.0124] [0.00157]
0.087 to 0.316 0.400
Backlash between drive gear and driven gear
[0.0034 to 0.0124] [0.00157]
0.200 to 0.296 0.350
Clearance between drive/driven gears and case
[0.0079 to 0.0117] [0.0138]
0.039 to 0.114 0.250
Side clearance between gear width and case depth
[0.0015 to 0.0045] [0.0098]
24.947 to 24.960 24.900
Drive shaft outside diameter
ø25 [0.9822 to 0.9827] [0.9803]
[ø0.98 in.] 25.000 to 25.021 25.100
Bushing inside diameter
[0.9843 to 0.9851] [0.9882]
Oil pump
24.947 to 24.960 24.900
Driven shaft outside diameter
ø25 [0.9822 to 0.9827] [0.9803]
[ø0.98 in.] 25.000 to 25.021 25.100
Bushing inside diameter
[0.9843 to 0.9851] [0.9882]
Backlash between oil pump idler gear 0.120 to 0.180
and crankshaft gear [0.0047 to 0.0071]
1.4 ± 0.1 MPa
Safety valve opening pressure {14 ± 1 kgf/cm2}
[203.1 ± 14.5 psi]
65.3[2.571]/436 ± 17.7 N
Safety valve spring installed length/load {44.46 ± 1.8 kgf}
[98.02 ± 3.98 lbf]
0.42 ± 0.02 MPa
Relief valve Valve opening pressure {4.3 ± 0.2 kgf/cm2}
[60.92 ± 2.9 psi]
0.165 ± 0.015 MPa
Oil filter alarm Differential pressure to activation the alarm {1.68 ± 0.15 kgf/cm2}
[21 ± 4.3 psi]
0.42 MPa 0.44 ± 0.05 MPa
Oil cooler bypass valve Valve opening pressure {4.3 kgf/cm2} {4.5 ± 0.5 kgf/cm2}
[61 psi] [64 ± 7 psi]
115
Relief valve spring Free length
[4.53]
29402-00120
2-11
1.5 Maintenance Service Data of Cooling System

Unit: mm [in.]
Nominal Limit
Item Standard value Remarks
value value
ø62 61.988 to 62.018 62.025
[ø2.44] [2.4405 to 2.4416] [2.4419]
ø72 71.988 to 72.018 72.025
[ø2.83] [2.8342 to 2.8353] [2.8356]
ø62 61.987 to 62.004
Outside [ø2.44] [2.4404 to 2.4411]
diameter ø72 71.987 to 72.004
Bearing
[ø2.83] [2.8341 to 2.8348]
Fresh water pump
Inside ø30 29.985 to 30.003
diameter [1.18] [1.1805 to 1.1812]
ø30 30.002 to 30.011 29.995
Outside diameter of shaft fit to bearing
[1.18] [1.1812 to 1.1815] [1.1809]
0.5 to 1.3
Impeller front clearance
[0.0197 to 0.0512]
1.0
Impeller back clearance
[0.039]
Tension pulley bearing inside diameter of ø52 51.970 to 51.995
housing [ø2.05] [2.0461 to 2.0470]
Outside ø52 51.987 to 52.000
Tension pulley water pump diameter [ø2.05] [2.0467 to 2.0472]
Bearing
side Inside ø20 19.990 to 20.000
diameter [ø0.79] [0.7870 to 0.7874]
ø20 19.987 to 20.000
Outside diameter of bracket bearing fit
[ø0.79] [0.7869 to 0.7874]
Tension pulley bearing inside diameter of ø90 89.972 to 89.994
housing [ø3.54] [3.5422 to 3.5431]
Outside ø90 89.985 to 90.000
diameter [ø3.54] [3.5427 to 3.5433]
Tension pulley fan side Bearing
Inside ø40 39.988 to 40.000
diameter [ø1.57] [1.5743 to 1.5748]
ø40 39.982 to 40.000
[ø1.57] [1.5741 to 1.5748]
69 to 73 ºC Opening temperature
Primary
[156 to 163 ºF] marking: 71ºC [160 ºF]
Valve opening temperature
P/N: 72 to 76ºC
Secondary
35C46-05500 [162 to 169ºF]
Temperature at which valve lift becomes 85 ºC
10 mm [0.39 in.] or more [185 ºF]
74.5 to 78.5 ºC Opening temperature
Primary
[166 to 173 ºF] marking: 76.5 ºC [170 ºF]
P/N: 77.5 to 81.5 ºC
Thermostat Secondary
35C46-05600 [172 to 179 ºF]
10 mm [0.39 in.] or more [194 ºF]
80 to 84 ºC Opening temperature
Primary
[176 to 183 ºF] marking: 82 ºC [180 ºF]
P/N: 83 to 87 ºC
Secondary
35C46-05700 [181 to 189 ºF]
10 mm [0.39 in.] or more [203 ºF]
2-12 29402-00120
Unit: mm [in.]
Nominal Limit
value value
ø90 89.825 to 90.175
[ø3.54] [3.5364 to 3.5502]
Outside ø90 89.985 to 90.000
diameter [ø3.54] [3.5427 to 3.5433]
ø30 29.990 to 30.000
Bearing
Inside [1.18] [1.1807 to 1.1811]
diameter ø40 39.988 to 40.000
Sea water pump
[ø1.57] [1.5743 to 1.5748]
ø30 30.002 to 30.015
[1.18] [1.1812 to 1.1817]
ø40 40.002 to 40.018
[ø1.57] [1.5749 to 1.5755]
Sea water pump gear and PTO gear 0.095 to 0.353
backlash [0.0037 to 0.0139]
ø80 79.988 to 80.018
[ø3.15] [3.1491 to 3.1503]
Outside ø80 79.987 to 80.000
diameter [ø3.15] [3.1491 to 3.1496]
Fan drive Bearing
Inside ø40 39.988 to 40.000
diameter [ø1.57] [1.5743 to 1.5748]
ø40 40.002 to 40.013
[ø1.57] [1.5749 to 1.5753]
29402-00120
2-13
1.6 Maintenance Service Data of Electrical System

Unit: mm [in.]
Nominal Limit
value value
ø19 19 19.2
Pinion case
[ø0.75] [0.75] [0.756]
Inside diameter of bearing
ø28 28 28.2
Center bracket
[ø1.10] [1.10] [1.110]
ø52 51.97 to 51.995 52.1
Inside diameter of gear case bearing housing
[ø2.05] [2.0461 to 2.0470] [2.051]
ø32 31.995 to 32.02 32.1
Inside diameter of rear bracket bearing housing
[ø1.26] [1.2596 to 1.2606] [1.26]
ø40 40 38
Outside diameter
[ø1.57] [1.5748] [1.50]
0.02
Commutator Runout [0.0008] TIR
or less
0.5 to 0.8 0.2
Undercut depth
[0.0197 to 0.0315] [0.008]
19 13
Brush length Replace
[0.75] [0.51]
13.7 N 12.7 to 14.7 N 9.8 N
Brush spring load {1.4 kgf} {1.3 to 1.5 kgf} {1.0 kgf} With brush installed
P/N: [3.08 psi] [2.86 to 3.30 psi] [2.20 psi]
04301-36100 P coil resistance 0.15 Ω
h coil resistance 0.786 Ω
Contactor spring 1.5 1.0 to 2.0
deflection [0.059] [0.039 to 0.07]
Magnetic switch
Thickness of fixed 7 6.9 to 7.1 6.7
contact [0.28] [0.272 to 0.280] [0.264]
Thickness of mov- 5 4.9 to 5.1 4.7
ing contact [0.20] [0.1929 to 0.2008] [0.185]
Starter
Outside diameter at ø28 28 27.95
the center [ø1.10] [1.10] [1.1004]
Outside diameter of ø19 19 18.95
pinion [ø0.75] [0.75] [0.7461]
Pinion shaft Outside diameter at ø19 19 18.95
front [ø0.75] [0.75] [0.7461]
0.02
Runout [0.0008] TIR
or less
Armature field 100 MΩ or more
Insulating resistance
Brush holder 100 MΩ or more
ø19 19 19.2
Pinion case
[ø0.75] [0.75] [0.7559]
ø19 19 19.2
Center bracket
[ø0.75] [0.75] [0.7559]
ø52 51.97 to 51.995 52.1
[ø2.05] [2.0461 to 2.0470] [2.051]
ø32 32 32.1
[ø1.26] [1.26] [1.264]
P/N:
04301-37010 ø40 40 38
Outside diameter
[ø1.57] [1.57] [1.496]
0.02
or less
0.5 to 0.8 0.2
Undercut depth
[0.020 to 0.032] [0.008]
18 17 to 19 12
[0.7087] [0.67 to 0.75] [0.47]
2-14 29402-00120
Unit: mm [in.]
Nominal Limit
value value
13.7 N 12.7 to 14.7 N 8.8 N
[3.08 psi] [2.86 to 3.30 psi] [1.98 psi]
P coil resistance 0.248 Ω 0.236 to 0.26 Ω
h coil resistance 2Ω 1.9 to 2.1 Ω
deflection [0.059] [0.039 to 0.079]
Magnetic switch
Thickness of fixed 7 6.9 to 7.1 6.7
contact [0.28] [0.271 to 0.280 ] [0.263]
Thickness of 5 4.9 to 5.1 4.7
P/N: moving contact [0.20] [0.193 to 0.201] [0.185]
04301-37010 Outside diameter at ø19 19 18.8
the center [ø0.75] [0.75] [0.740]
pinion [ø0.75] [0.75] [0.740]
Pinion shaft Outside diameter at ø19 19 18.8
front [ø0.75] [0.75] [0.740]
0.02
Runout [0.0008] TIR
or less
ø19 19.07 to 19.1 19.2
Pinion case
[ø0.75] [0.7508 to 0.7520] [0.756]
ø19 19.07 to 19.1 19.2
Center bracket
[ø0.75] [0.7508 to 0.7520] [0.756]
ø58 57.97 to 57.995 58.1
[ø2.28] [2.2823 to 2.2833] [2.287]
Starter
ø35 34.995 to 35.02 35.1
[ø1.38] [1.3778 to 1.3787] [1.381]
ø44 44 42
Outside diameter
[ø1.73] [1.73] [1.65]
0.02
or less
0.5 to 0.8 0.2
Undercut depth
[0.020 to 0.032] [0.008]
22 15
[0.87] [0.591]
P/N:
04301-38000 17.7 N 15.7 to 19.6 N
Brush spring load {1.8 kgf} {1.6 to 2.0 kgf} With brush installed
[3.98 psi] [3.53 to 4.41 lbf]
h coil resistance 2.207 Ω 2.097 to 2.317 Ω
deflection [0.059] [0.04 to 0.079]
Magnetic switch
Thickness of MB 7 6.7
contact [0.28] [0.264]
Thickness of main 5 4.7
contact [0.20] [0.185]
Outside diameter at ø19 19.073 to 19.04 18.8
the center [ø0.75] [0.7509 to 0.7496] [0.740]
Outside diameter of ø19 19.073 to 19.04 18.8
Pinion shaft
pinion [ø0.75] [0.7509 to 0.7496] [0.740]
Outside diameter at ø19 19.073 to 19.04 18.8
front [ø0.75] [0.7509 to 0.7496] [0.740]
29402-00120
2-15
Unit: mm [in.]
Nominal Limit
value value
0.02
Pinion shaft Runout [0.0008] TIR
P/N: or less
04301-38000
Front shaft outside ø19 18.90 to 18.94
diameter [ø0.75] [0.7441 to 0.7457]
Rear shaft outside ø30 30.002 to 30.011
diameter [ø1.18] [1.1812 to 1.1815]
Pinion shaft Inside diameter of
ø55 55 55.1
center bracket
[ø2.17] [2.17] [2.169]
bearing housing
0.2 to 0.8
End play
[0.008 to 0.032]
20 to 21 13
[0.79 to 0.83] [0.51]
44.13 N 39.23 to 49.03 N 39.23 N
[9.92 lbf] [8.82 to 11.02 lbf] [8.82 lbf]
Front shaft outside ø25 25.002 to 25.011
diameter [ø0.98] [0.9843 to 0.9847]
P/N:
Front bearing fit ø52 52 52.1
37566-20101
diameter [ø2.05] [2.05] [2.051]
Rear shaft outside ø10 10.001 to 10.007
Armature
diameter [ø0.39] [0.3937 to 0.3940]
Rear bearing fit ø30 30 30.1
diameter [ø1.18] [1.18] [1.185]
Starter 0.2 to 0.8 Adjust with the

End play
[0.008 to 0.032] adjust washer
ø39 39 48
Outside diameter
[ø1.54] [1.54] [1.89]
0.06 0.1
Commutator Runout TIR
[0.0024] [0.004]
0.7 to 0.9 0.2
Undercut depth
[0.028 to 0.035] [0.008]
Resistance between
Magnetic switch M terminal and the 1.16 Ω
case
ø20 20.07 to 20.1 20.2
Inside diameter of bearing Front
[ø0.79] [0.7902 to 0.7913] [0.795]
ø62 61.965 to 61.995 62.1
[ø2.44] [2.4396 to 2.4407] [2.445]
ø35 35 to 35.025 35.2
[ø1.38] [1.3780 to 1.3789] [1.386]
ø44 44 42
Outside diameter
[ø1.73] [1.7323] [1.654]
P/N: 0.02
36266-11801 Commutator Runout [0.0008] TIR
or less
0.5 to 0.8 0.2
Undercut depth
[0.020 to 0.032] [0.008]
22 15
[0.87] [0.591]
27.5 N
Brush spring load {2.8 kgf} With brush installed
[6.18 lbf]
2-16 29402-00120
Unit: mm [in.]
Nominal Limit
value value
h coil resistance 0.488 Ω 0.464 to 0.512 Ω
deflection [0.098] [0.08 to 0.12]
Magnetic switch
Thickness of 7 6.7
MB contact [0.28] [0.264]
Thickness of main 5 4.7
contact [0.20] [0.185]
P/N:
Starter Outside diameter at ø35 35 34.95
36266-11801
the center [ø1.38] [1.38] [1.3760]
Pinion shaft pinion [ø0.79] [0.79] [0.7854]
0.02
Runout [0.0008] TIR
or less
64 A or more (when
Rotation 2500
Output current the engine is warm)
speed
(at 27 V) 78 A or more (when
(min-1) 5000
the engine is warm)
Separate Regulator adjusting voltage

exci- (Alternator 5000 min-1, load at 5 A or 28.5 ± 0.5 V
P/N: tation lower)
ME049164 type 41 40.4
(with Outside diameter of rotor slip ring
[1.61] [1.591]
brush)
23 8.0 The part shows a
Height of brush
[0.91] [0.32] limit line.
3.7 N 3.1 to 4.3 N 1.8 N
Pressure of brush spring {0.38 kgf} {0.32 to 0.44 kgf} {0.18 kgf}
[0.83 lbf] [0.70 to 0.97 lbf] [0.4 lbf]
Rotation 25 A or more
Output current
speed 5000 (when the engine is
(at 28 V)
(min-1) hot)
Alternator Regulator adjusting voltage
Separate (Alternator 5000 min-1, load at 5 A or 28.5 ± 0.5 V
exci- lower)
P/N: tation
04344-25000 type 33 32
Outside diameter of rotor slip ring
(with [1.30] [1.26]
brush) 13 3
Height of brush
[0.51] [0.12]
2.7 N 1.5 to 3.8 N
Pressure of brush spring {0.28 kgf} {0.15 to 0.39 kgf}
[0.61 lbf] [0.34 to .85 lbf]
30 A or more (when
Rotation 2500
Output current the engine is cold)
Initial speed
exci- (min-1) 5000
P/N: tation the engine is warm)
04343-35500 type Regulator adjusting voltage
(brush- (Alternator 5000 min-1, load at 5 A or 28.5 ± 0.5 V
less) lower)
Field coil resistance (20 ºC [68 ºF]) 7.3 to 8.5 Ω
29402-00120
2-17
Unit: mm [in.]
Nominal Limit
value value
26 A or more (when
Rotation 2500
Output current the engine is warm)
speed
(min-1) 5000
the engine is warm)
Regulator adjusting voltage
Self (Alternator 5000 min-1, load at 5 A or 28.5 ± 0.5 V
exciting lower)
P/N:
type
04343-38000 33 32.8 to 33.2 32.4
(with Outside diameter of rotor slip ring
brush) [1.30] [1.291 to 1.307] [1.276]
21.5 8.0 The part shows a
Height of brush
[0.847] [0.315] limit line.
3.7 N 3.1 to 4.3 N 1.8 N
[0.83 lbf] [0.83 to 0.97 lbf] [0.4 lbf]
Rotation
Output current 35 A or more (when
speed 5000
Self (at 28 V) the engine is warm)
(min-1)
exciting
P/N:
type Regulator adjusting voltage
04344-05100
(brush- (Alternator 5000 min-1, load at 5 A or 28.5 ± 0.5 V
less) lower)
Field coil resistance (20 ºC [68 ºF]) 12 to 13 Ω
Rotation
Output current 24 A or more (when
speed 2500
(at 26 V) the engine is cold)
(min-1)
Separate (Alternator 5000 min-1, load at 5 A or 28.5 ± 0.5 V
exci- lower)
P/N: tation
04343-37000 type 46 45.4
(with [1.81] [1.787]
Alternator
brush) 18 8.0 The part shows a
Height of brush
[0.71] [0.315] limit line.
3.6N 3.0 to 4.2 N 2.1 N
[0.81 lbf] [0.67 to 0.94 lbf] [0.47 lbf]
Rotation
Self Output current 70 A or more (when
speed 5000
exciting (at 28 V) the engine is warm
P/N: (min-1)
type
04344-05001 Regulator adjusting voltage
(with
brush) (Alternator 5000 min-1, load at 5 A or 28.5 ± 0.5 V
lower)
Rotation 110 A or more
Output current
speed 5000 (when the engine is
(at 28 V)
(min-1) warm)
Separate (Alternator 5000 min-1, load at 5 A or 29 ± 0.5 V
exci- lower)
P/N: tation
04344-07001 type 37.5 35.5
(with [1.476] [1.398]
brush) 18 13
Height of brush
[0.71] [0.51]
4.2 N 3.5 to 4.9 N 2.9 N
[0.94 lbf] [0.79 to 1.10 lbf] [0.65 lbf]
When the center of
the belt is pushed
10 to 15 with a force of
Belt tension (cogged type)
[0.39 to 0.59] approx 98 to 147 N
{10 to 15 kgf}
[22 to 33 lbf]
2-18 29402-00120
1.6.1 Belt tension

Unit: N {kgf} [lbf]
Belt straight distance (mm) [in.]
Number
Item 300 [11.81] or more than 300 to 400 more than 400 to 500 more than 500 to 600 more than 600
of ribs
below [11.81 to 15.75] [15.75 to 19.69] [19.69 to 23.62] [23.62]
3 74 {7.55} [16.64] 49 {5.00} [11.02] 37 {3.77} [8.32] 29 {2.96} [6.52] 25 {2.55} [5.62]
4 88 {8.97} [19.78] 59 {6.02} [13.26] 44 {4.49} [9.89] 35 {3.57} [7.87] 29 {2.96} [6.52]
5 103 {10.50} [23.16] 69 {7.04} [15.51] 51 {5.20} [11.47] 41 {4.18} [9.22] 34 {3.47} [7.64]
6 118 {12.03} [26.53] 79 {8.06} [17.76] 59 {6.02} [13.26] 47 {4.79} [10.57] 39 {3.98} [8.77]
When a new belt 7 132 {13.46} [29.67] 88 {8.97} [19.78] 66 {6.73} [14.84] 53 {5.40} [11.91] 44 {4.49} [9.89]
is installed: 8 147 {14.99} [33.05] 98 {9.99} [22.03] 74 {7.55} [16.64] 59 {6.02} [13.26] 49 {5.00} [11.02]
9 162 {16.52} [36.42] 108 {11.01} [24.28] 81 {8.26} [18.21] 65 {6.63} [14.61] 54 {5.51} [12.14]
10 176 {17.95} [39.57] 118 {12.03} [26.53] 88 {8.97} [19.78] 71 {7.24} [15.96] 59 {6.02} [13.26]
11 191 {19.48} [42.94] 127 {12.95} [28.55] 96 {9.79} [21.58] 76 {7.75} [17.09] 64 {6.53} [14.39]
12 206 {21.01} [46.31] 137 {13.97} [30.80] 103 {10.50} [23.16] 82 {8.36} [18.43] 69 {7.04} [15.51]
3 51 {5.20} [11.47] 34 {3.47} [7.64] 26 {2.65} [5.85] 21 {2.14} [4.72] 17 {1.73} [3.82]
4 62 {6.32} [13.94] 41 {4.18} [9.22] 31 {3.16} [6.97] 25 {2.55} [5.62] 21 {2.14} [4.72]
5 72 {7.34} [16.19] 48 {4.89} [10.79] 36 {3.67} [8.09] 29 {2.96} [6.52] 24 {2.45} [5.40]
6 82 {8.36} [18.43] 55 {5.61} [12.36] 41 {4.18} [9.22] 33 {3.37} [7.42] 27 {2.75} [6.07]
When 7 93 {9.48} [20.91] 62 {6.32} [13.94] 46 {4.69} [10.34] 37 {3.77} [8.32] 31 {3.16} [6.97]
re-adjusted: 8 103 {10.50} [23.16] 69 {7.04} [15.51] 51 {5.20} [11.47] 41 {4.18} [9.22] 34 {3.47} [7.64]
9 113 {11.52} [25.40] 75 {7.65} [16.86] 57 {5.81} [12.81] 45 {4.59} [10.12] 38 {3.87} [8.54]
10 123 {12.54} [27.65] 82 {8.36} [18.43] 62 {6.32} [13.94] 49 {5.00} [11.02] 41 {4.18} [9.22]
11 134 {13.66} [30.12] 89 {9.08} [20.01] 67 {6.83} [15.06] 54 {5.51} [12.14] 45 {4.59} [10.12]
12 144 {14.68} [32.37] 96 {9.79} [21.58] 72 {7.34} [16.19] 58 {5.91} [13.04] 48 {4.89} [10.79]
The force when the middle of belt straight line is pushed and deflected by 15 mm [0.5906 in.]
1.7 Air start system maintenace service data

Unit: mm [in.]
12.973 to 12.984
Starter valve outside diameter ø13 [ø0.51]
[0.5107 to 0.5112]
13.000 to 13.018
Starter valve inside diameter ø13 [ø0.51]
[0.5118 to 0.5125]
Starter valve
0.016 to 0.045 0.100
Clearance between valve and valve guide
[0.0006 to 0.0018] [0.0039]
30 28
Valve spring free length
[1.81] [1.10]
22 21.8 to 21.9 21.5
Distributer valve height
[0.87] [0.858 to 0.862] [0.847]
19.959 to 19.980
Distributer shaft outside diameter ø20 [ø0.79]
[0.7886 to 0.7866]
Distributer valve
20.030 to 20.050
Bushing inside diameter ø20 [ø0.79]
[0.7874 to 0.7894]
0.050 to 0.091 0.150
Clearance between shaft and bushing
[0.0019 to 0.0036] [0.0059]
29402-00120
2-19
2. Tightening Torque Table

2.1 Tightening Torque for Engine Body
Dia × Pitch Tightening torque

Description Remarks
(M-thread) N·m kgf·m lbf·ft
M 20 × 2.5 MTK3 except [Wet]
Cylinder head bolt Note (a)
M 18 × 2.5 MTK3 [Wet]
Rocker cover M 12 × 1.25 15 ± 2 1.5 ± 0.2 11 ± 1.5
Rocker shaft bracket M 12 × 1.75 49 ± 2.5 5 ± 0.25 36 ± 1.8
Rocker arm (lock nut) M 12 × 1.25 64 ± 6.4 6.5 ± 0.65 47 ± 4.7
Bridge (lock nut) M 10 × 1.25 55 ± 5.5 5.6 ± 0.56 41 ± 4
Camshaft gear M 30 × 1.5 392 ± 20 40 ± 2 289 ± 15 Left-hand thread
Main bearing cap M 24 × 3.0 588 ± 29 60 ± 3 434 ± 21 [Wet], Note (b)
Main bearing cap (side bolt) M 16 × 1.5 147 ± 7.4 15 ± 0.8 108 ± 5.5 [Wet], Note (b)
Piston cooling nozzle M 12 × 1.75 34 ± 3.4 3.5 ± 0.35 25 ± 2.5 Note (c)
Timing gear case M 12 × 1.25 108 ± 5.4 11 ± 0.55 80 ± 4
Rear plate M 12 × 1.25 108 ± 5.4 11 ± 0.55 80 ± 4
Front mounting bracket M 18 × 1.5 245 ± 12 25 ± 1.3 180 ± 9
Rear mounting bracket M 16 × 1.5 216 ± 11 22 ± 1.1 159 ± 8
Connecting rod cap M 18 × 1.5 Note (e) [Wet]
Flywheel M 22 × 1.5 539 ± 27 55 ± 2.8 398 ± 20 [Wet]
Damper, Pulley M 22 × 1.5 392 ± 20 40 ± 2 289 ± 14.8
Idler shaft M 12 × 1.25 54 ± 2.7 5.5 ± 0.28 40 ± 2
Idler gear M 10 × 1.25 59 ± 5.9 6 ± 0.6 43 ± 4.4
Injection pump gear M 30 × 1.5 392 ± 20 40 ± 2 289 ± 14.8
Oil pump gear M 27 × 1.5 294 ± 15 30 ± 1.5 217 ± 11.1
Note:(a) For torque-angle tightening methods of cylinder head bolts, follow the steps in sequence given below:
Torque-angle tightening methods (S6A3-T2MTK3L except)
Part name Torque method (2-time tightening method) Angle method (2-time tightening method)
Cylinder head bolt (short) 11 8± 5.9 N·m {12 ± 0.6 kgf·m} [87 ± 4.4 lbf·ft] →75 ± 3°
392 ± 20 N·m {40 ± 2 kgf·m}[289 ± 14.8 lbf·ft]
Cylinder head bolt (long) 196 ± 9.8 N·m {20 ± 1 kgf·m} [145 ± 7.2 lbf·ft]→ 60 ± 3°
Torque tightening method (S6A3-T2MTK3L)

Part name Torque method (2-time tightening method)
Cylinder head bolt (short)
343 ± 17 N·m {35 ± 1.7 kgf·m} [253 ± 12.5 lbf·ft]
Cylinder head bolt (long)
(b) For tightening of main bearing cap bolts and main bearing cap side bolts, follow the specified sequence. Snug tighten
all the bolts to the half of specified torque, and after the snug tightening of all the bolts, then tighten them to the specified
torque.
For the tightening procedure, refer to "Main bearing cap - Install" of "ASSEMBLY OF BASIC ENGINE."
(c) Tighten the piston cooling nozzle check valve to the specified torque. Do not over-tighten. If the tightening torque ex-
ceeds the specified torque, it can cause malfanction of the check valve, which may result in piston seizure.
(d) When [Wet] is indicated, apply engine oil to the threads and bolt seat surface.
(e) Tighten connecting rod cap bolts as shown below.
Torque method (2-time tightening method) Angle controlled method (2-time tightening method)
343 ± 17 N·m {35 ± 1.8 kgf·m} [253 ± 12.5 lbf·ft] Snug torque 147 ± 7.4 N·m {15 ± 0.8 kgf·m} [108 ± 5.5 lbf·ft] → 45±3°
(f) Parts (bolts/nuts) indicated by 2-time tightening method are to be tightened as follows: tighten to the specified torque,
and loosen, then retighten to the specified torque.
2-20 29402-00120
2.2 Tightening Torque Spec for Fuel System

Description Remarks
M 12 × 1.75 88 ± 5 9 ± 0.5 65 ± 3.7
Coupling shaft
M 14 × 1.5 172 ± 5 17.5 ± 0.5 216 ± 3.7 S6A3-MTK2,MTK3
M 12 × 1.75 88 ± 5 9 ± 0.5 65 ± 3.7 Bosch PE(S)-P type pump
Laminated plate
M 12 × 1.25 118 ± 5 12 ± 0.5 87 ± 3.7 MHI PS6 type pump
Fuel injection
pump Pump mounting bolt M 12 × 1.25 108 ± 5.4 11 ± 0.55 80 ± 4 S6A3-MTK2
Bracket M 10 × 1.25 60 ± 6 6.1 ± 0.61 44 ± 4.4 10.9 material bolt
Dedicated bolt with width
Stay (pump back face) M 14 × 1.5 34 ± 3.4 3.5 ± 0.35 25 ± 2.5
across flats 19
Stay (installing crankcase) M 10 × 1.25 60 ± 6 6.1 ± 0.61 44 ± 4.4 10.9 material bolt
Fuel rack control lever M 8 × 1.25 25 ± 2.5 2.5 ± 0.25 18 ± 1.8 2-time tightening method
Fuel filter air vent plug M 8 × 1.25 9±1 0.9 ± 0.1 7 ± 0.7
Nozzle tip retaining nut M 19 × 1.0 68.5 ± 9.5 7±1 50 ± 7
Nozzle inlet connector M 14 × 1.5 74 ± 5 7.5 ± 0.5 55 ± 3.7
Nozzle holder cap nut M 14 × 1.0 44 ± 5 4.5 ± 0.5 32 ± 3.7
Nozzle holder eye bolt M 10 × 1.0 17.5 ± 2.5 1.75 ± 0.25 13 ± 1.8
Nozzle gland (nut) M 12 × 1.25 59 ± 2.9 6 ± 0.3 44 ± 2
S7S feed pump inlet M 14 × 1.5 27 ± 2 2.75 ± 2.5 20 ± 1.5
2.3 Tightening Torque Specifications for Lubrication System

Description Remarks
Oil pump idler gear (nut) M 12 × 1.25 68 ± 6.8 7 ± 0.7 51 ± 7.4 Apply LOCTITE 262 to threads
Oil pump cover M 10 × 1.25 33 ± 6.7 3.4 ± 0.68 24 ± 5
Governor oil filter air vent plug M 8 × 1.25 9.8 ± 2 1 ± 0.2 7 ± 1.5
Governor oil filter drain plug M 8 × 1.25 9.8 ± 2 1 ± 0.2 7 ± 1.5
Governor oil filter center bolt M 14 × 1.5 34.3 ± 6.9 3.5 ± 0.7 25 ± 55
Oil pan M 10 × 1.25 39 ± 3.9 4 ± 0.4 29 ± 3
2.4 Tightening Torque Specifications for Cooling System

Description Remarks
(M-thread) N·m kgf·m lbf·
Pump impeller M 22 × 1.5 210 ± 10 21 ± 1 155 ± 7.4
Water pump Pump shaft pulley M 24 × 1.5 260 ± 12 26 ± 1.2 192 ± 9
Pump cover M 10 × 1.5 32 ± 6.67 3.3 ± 0.68 24 ± 5
Sea water pump drive gear M 24 × 2.0 220 ± 10 22.4 ± 1 162 ± 7.4
Drive pulley M 30 × 1.5 441± 22 45 ± 2.3 325 ± 16 Apply LOCTITE 262
Fan drive
Spacer M 12 × 1.25 108 ± 10.8 11 ± 1.1 80 ± 8
Cooling water outlet pipe M 10 × 1.25 54 ± 5 5.5 ± 0.5 40 ± 3.7
29402-00120
2-21
2.5 Tightening Torque Specifications for Inlet and Exhaust System

Description Remarks
Exhaust manifold mounting bolt M 10 × 1.5 54 ± 5 5.5 ± 0.5 40 ± 3.7
Exhaust manifold coupling nut M 6 × 1.0 8.4 ± 0.5 0.85 ± 0.05 6.2 ± 0.4
Exhaust pipe V-clamp M 6 × 1.0 6±1 0.6 ± 0.1 4.4 ± 0.7
+5 +0.5 +3.7
Air cooler tank mounting bolt M 10 × 1.5 29 0 2.9 0 21 0 S6A3-MTK2
Air cooler tank mounting nut M 8 × 1.25 22 ± 2 2.2 ± 0.2 16 ± 1.5
2-22 29402-00120
2.6 Tightening Torque Specifications for Electrical System

Description Remarks
Connect bar M 10 × 1.25 19 ± 3 1.94 ± 0.31 14 ± 2.21
Battery cable M 10 × 1.25 19 ± 3 1.94 ± 0.31 14 ± 2.21
P/N: Through bolt - 14.7 ± 1 1.5 ± 0.1 10.8 ± 0.74

04301-36100 Gear case bolt - 14.7 ± 1 1.5 ± 0.1 10.8 ± 0.74
Engage mounting bolt - 7.2 ± 1.4 0.73 ± 0.14 5.3 ± 1.03
Brush holder - 4.2 ± 0.6 0.43 ± 0.06 3.1 ± 0.44
Connect bar M 10 × 1.25 19 ± 3 1.94 ± 0.31 14 ± 2.21
Battery cable M 10 × 1.25 19 ± 3 1.94 ± 0.31 14 ± 2.21
P/N: Through bolt - 11.1 ± 1.4 1.13 ± 0.14 8.2 ± 1.03
04301-37010
Starter
04301-38000 Gear case bolt - 11.1 ± 1.4 1.13 ± 0.14 8.2 ± 1.03
Engage mounting bolt - 7.2 ± 1.4 0.73 ± 0.14 5.3 ± 1.03
Brush holder - 4.2 ± 0.6 0.43 ± 0.06 3.1 ± 0.44
P/N:
B terminal M 10 × 1.25 22.6 ± 2.9 2.3 ± 0.3 16.7 ± 2.14
37566-20101
M terminal M 10 × 1.25 19 ± 3 1.94 ± 0.31 14 ± 2.21
Through bolt - 16.7 ± 1 1.70 ± 0.1 12.3 ± 0.74
P/N:
Gear case bolt - 14.7 ± 1 1.5 ± 0.1 10.8 ± 0.74
36266-11801
Engage mounting bolt - 14.7 ± 1 1.5 ± 0.1 10.8 ± 0.74
Brush holder - 4.2 ± 0.6 0.43 ± 0.06 3.1 ± 0.44
Pulley nut M 20 × 1.5 147 ± 15 15 ± 1.53 108 ± 11.06
Retainer tightening screw M 5 × 0.8 3.7 ± 0.7 0.38 ± 0.07 2.7 ± 0.52
Through bolt M 5 × 0.8 5.1 ± 0.6 0.52 ± 0.06 3.8 ± 0.44
P/N: Regulator assembly tightening
ME049164 M 5 × 0.8 3.7 ± 0.7 0.38 ± 0.07 2.7 ± 0.52
screw
Rectifier assembly tightening
M 5 × 0.8 3.7 ± 0.7 0.38 ± 0.07 2.7 ± 0.52
screw
B terminal nut M 10 × 1.5 21 ± 2.4 2.14 ± 0.24 15 ± 1.77
R terminal nut M 5 × 0.8 2.65 ± 0.29 0.27 ± 0.03 1.95 ± 0.21
P/N:
B terminal nut M 5 × 0.8 2.65 ± 0.29 0.27 ± 0.03 1.95 ± 0.21
04344-25000
E terminal nut M 5 × 0.8 2.65 ± 0.29 0.27 ± 0.03 1.95 ± 0.21
Pulley nut M 20 × 1.5 147 ± 15 14.99 ± 1.53 108 ± 11.06
Alternator
Retainer tightening screw M 5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.74
Through bolt M 6 × 1.0 5.4 ± 1.5 0.55 ± 0.15 4.0 ± 1.11
Regulator assembly tightening
M 5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.74
screw
M 5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.74
P/N: screw
04343-35500 B terminal nut M 5 × 0.8 6.9 ± 0.9 0.7 ± 0.09 5.1 ± 0.66
E terminal nut M 5 × 0.8 6.9 ± 0.9 0.7 ± 0.09 5.1 ± 0.66
Coil assembly tightening screw M 5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.74
Screw connecting field coil and
M 5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.74
regulator
Connector assembly tightening
M 6 × 1.0 5.4 ± 1.5 0.55 ± 0.15 4.0 ± 1.11
bolt
29402-00120
2-23

Description Remarks
Pulley nut M 20 × 1.5 147 ± 29 15 ± 2.95 108 ± 21.39
Retainer tightening screw M 5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.74
Through bolt M 5 × 0.8 4.4 ± 1 0.45 ± 0.1 3.3 ± 0.74
P/N: Regulator assembly tightening
04343-38000 screw M 5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.74

M 5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.74
screw
B terminal nut M 5 × 0.8 6.9 ± 1.9 0.7 ± 0.19 5.1 ± 1.40
Pulley nut - 112 ± 15.7 11.4 ± 1.6 83 ± 11.58
Through bolt - 7.8 ± 1.0 0.8 ± 0.1 5.8 ± 0.74
P/N:
Heat sink tightening bolt - 2.16 ± 0.29 0.22 ± 0.03 1.59 ± 0.21
04344-05100
Terminal nuts M 5 × 0.8 2.16 ± 0.29 0.22 ± 0.03 1.59 ± 0.21
Coil assembly mounting bolt - 4.22 ± 0.59 0.43 ± 0.06 3.11 ± 0.44
Alternator
Pulley nut - 117 ± 19 11.9 ± 1.9 86 ± 14.01
Retainer tightening screw M 5 × 0.8 3.7 ± 0.7 0.38 ± 0.07 2.7 ± 0.52
P/N:
04343-37000 Rectifier assembly tightening M 5 × 0.8 3.7 ± 0.7 0.38 ± 0.07 2.7 ± 0.52
screw
B terminal nut M 5 × 0.8 3.7 ± 0.7 0.38 ± 0.07 2.7 ± 0.52
P/N: F, N terninal nut M 5 × 0.8 2.16 ± 0.29 0.22 ± 0.03 1.59 ± 0.21
04344-05001 B, E terminal nut - 8.83 ± 0.98 0.9 ± 0.1 6.51 ± 0.72
Pulley nut - 129 ± 17 13.2 ± 1.7 95.1 ± 12.54
Through bolt - 15.7 ± 2.9 1.6 ± 0.3 11.6 ± 2.14
P/N: Retainer tightening screw - 2.16 ± 0.29 0.22 ± 0.03 1.59 ± 0.21
04344-07001 A terminal nut - 8.83 ± 0.98 0.9 ± 0.1 6.51 ± 0.72
Heat sink tightening bolt - 2.94 ± 0.59 0.3 ± 0.06 2.17 ± 0.44
Diode tightening screw - 2.65 ± 0.20 0.27 ± 0.02 1.95 ± 0.15
2.7 Tightening Torque Spec for Air Start System

Description Remarks
Starter valve nut M 8 × 1.25 19 ± 0.95 1.94 ± 0.1 14 ± 0.7
Starter valve cap nut M 30 × 1.5 147 ± 7.35 15 ± 0.75 108 ± 5.4
2-24 29402-00120
2.8 Tightening Torque for Standard Bolts

Thread size Width across Strength classification
Threads Dia. × Pitch flats
(M-thread) (mm) [in.] 7T 10.9
7 10
N·m kgf·m lbf·ft N·m kgf·m lbf·ft
8 × 1.25 12 [0.47] 17 1.7 12.3 30 3.1 22.4
10 × 1.25 14 [0.55] 33 3.4 24.6 60 6.1 44.1
Metric automobile 12 × 1.25 17 [0.67] 60 6.1 44.1 108 11.0 79.6
screw thread 14 × 1.5 22 [0.87] 97 9.9 71.6 176 17.9 129.5
16 × 1.5 24 [0.94] 145 14.8 107.1 262 26.7 193.1
18 × 1.5 27 [1.06] 210 21.4 154.8 378 38.5 278.5
20 × 1.5 30 [1.18] 291 29.7 214.8 524 53.4 386.2
22 × 1.5 32 [1.26] 385 39.3 284.3 694 70.8 512.1
24 × 1.5 36 [1.42] 487 49.7 359.5 878 89.5 647.4
27 × 1.5 41 [1.61] 738 75.3 544.7 1328 135.5 980.1
N·m kgf·m lbf·ft N·m kgf·m lbf·ft

10 × 1.5 14 [0.55] 32 3.3 23.9 58 5.9 42.67
12 × 1.75 17 [0.67] 57 5.8 42.0 102 10.4 75.2
Metric course screw
14 × 2 22 [0.87] 93 9.5 68.7 167 17.0 123.0
thread
16 × 2 24 [0.94] 139 14.2 102.7 251 25.6 185.2
18 × 2.5 27 [1.06] 194 19.8 143.2 350 35.7 258.2
20 × 2.5 30 [1.18] 272 27.7 200.4 489 49.9 361.0
22 × 2.5 32 [1.26] 363 37.0 267.6 653 66.6 482.0
24 × 3 36 [1.42] 468 47.7 345.0 843 86.0 622.0
27 × 3 41 [1.61] 686 70.0 506.3 1236 126.0 911.4
Note:(a) The tightening torque listed in this table is for standard bolts and nuts.
(b) The numerical values in the table are the values when spring washers are used.
(c) The table shows the standard values with a maximum tolerance value of ±10%.
(d) Use the tightening torque in this table unless otherwise specified.
(e) Do not apply oil to threaded portions. (Dry)
29402-00120
2-25
2.9 Tightening Torque for Standard Union Bolts

Strength classification
Thread size
Width across flats
Dia. × Pitch 4T
(mm) [in.]
(M-thread)
N·m kgf·m lbf·ft
8 × 1.25 12 [0.47] 8±1 0.8 ± 0.1 5.90 ± 0.73
10 × 1.25 14 [0.55] 15 ± 2 1.5 ± 0.2 11.06 ± 1.47
12 × 1.25 17 [0.67] 25 ± 3 2.5 ± 0.3 18.44 ± 2.21
14 × 1.5 19 [0.75] 34 ± 4 3.5 ± 0.4 25.08 ± 2.95
16 × 1.5 22 [0.87] 44 ± 5 4.5 ± 0.5 32.45 ± 3.68
18 × 1.5 24 [0.94] 74 ± 5 7.5 ± 0.5 54.58 ± 3.68
20 × 1.5 27 [1.06] 98 ± 10 10.0 ± 1.0 72.28 ± 7.37
24 × 1.5 32 [1.26] 147 ± 15 15.0 ± 1.5 108.42 ± 11.06
27 × 1.5 41 [1.61] 226 ± 20 23.0 ± 2.0 166.69 ± 14.75
(Dry)
2.10 Tightening Torque for Standard Union Nuts

Cap nut thread size
Width across flats
Nominal Dia. × Pitch N·m kgf·m lbf·ft
(mm) [in.]
(M-thread)
63 14 × 1.5 19 [0.75] 39 4 28.76
80 16 × 1.5 22 [0.87] 49 5 36.14
100 20 × 1.5 27 [1.06] 78 8 57.53
120 22 × 1.5 30 [1.18] 98 10 72.28
150 27 × 1.5 32 [1.26] 157 16 115.80
180 30 × 1.5 36 [1.42] 196 20 144.56
200 30 × 1.5 36 [1.42] 196 20 144.56
220 33 × 1.5 41 [1.61] 245 25 180.70
254 36 × 1.5 41 [1.61] 294 30 216.84
(Maximum tolerance value: ±10%, dry condition)
2.11 Tightening Torque for Fuel Injection Pipe

Cap nut thread size
N·m kgf·m lbf·ft
Dia. × Pitch
12 × 1.5 39 ± 5 4 ± 0.5 28.8 ± 3.68
14 × 1.5 49 ± 5 5 ± 0.5 36.1 ± 3.68
18 × 1.5 59 ± 10 6 ± 1.0 43.5 ± 7.37
(Dry)
2.12 Tightening Torque for Standard Plug

Nominal Tighten to aluminum material Tighten to iron material
R,G,NPTF N·m kgf·m lbf·ft N·m kgf·m lbf·ft
1/16 6.4 ± 1.5 0.65 ± 0.15 4.7 ± 1 9.8 ± 2 1 ± 0.2 7.2 ± 1.5
1/8 9.8 ± 2 1 ± 0.2 7.2 ± 1.5 18.1 ± 3.4 1.85 ± 0.35 13.3 ± 2.5
1/4 24.5 ± 4.9 2.5 ± 0.5 18 ± 3.6 39.2 ± 4.9 4 ± 0.5 28.9 ± 3.6
3/8 46.6 ± 7.4 4.75 ± 0.75 34.4 ± 5.5 63.7 ± 9.8 6.5 ± 1 46.9 ± 7.2
2-26 29402-00120
1. Special Tools............................................................................................................ 3-3
29402-00120
3-1
1. Special Tools
Maintenance Tool name Part No. Illustration Usage

item
Basic engine Rocker bushing puller 32591-02600 Rocker bushing - replace
Bushing inside × outside diam :
ø32 × 36 mm [ø1.26 × 1.42 in.]
Idler bushing puller 32591-02500 Idler bushing - replace

Bushing inside × outside diam :
ø50 × 55 mm [ø1.97 × 2.17 in.]
Eye bolt 45815-32301 Piston - lift
M10 × 1.5
Eye nut 08014-00003 Cylinder head assembly - install/

remove
M12 × 1.25
Jack bolt 64362-68500 Flywheel - Remove
M12 × 1.25㨺95
Front seal 35A91-04012 Front oil seal - install

installer assembly
Rear seal installer assembly 32591-07012 Rear oil seal - install
35A91-12011 Rear oil seal - install

(double lip spec)
29402-00120
3-3

item
Basic engine Rear slinger installer 35A91-02020 Rear slonger - install
(double lip spec)
Nozzle remover 36291-00900 Fuel injection nozzle, main bearing

cap and starter valve- remove
M18×1.5
Valve spring pusher 33591-04500 Valve spring - install/remove
Valve guide remover 36291-04200 Valve guide - remove

Applicable valve guide inside ×
outside diam :
ø10 × 18 mm [ø0.39 × 0.71 in.]
ø17.5 × L60
ø9.85 × L45
Guide and seal installer 32591-10300 Valve guide and stem seal - install
Guide height : 27.5 mm [1.08 in.]
Stem seal height : 30.3 mm [1.19 in.]
Socket 32591-02800 Camshaft connector - install/remove
Adapter 32591-04300 Main bearing cap - remove

M10 × 1.25
M18 × 1.5
Ring expander 37191-03200 Piston ring - install/remove

Applicable diam :
ø101.6 to 177.8 mm [ø4.00 to 7.00 in.]
Cylinder liner remover 32591-14100 Cylinder liner - remove

Applicable cylinder liner inner diam :
ø150 mm [ø5.91 in.]
3-4 29402-00120

item
Basic engine Installer 32591-01800 Cylinder liner - install
Projection plate 37598-09201 Depth of counterbore in ???????

- measure
L230 × W50 × T15 mm
[L9.06 × W1.97 × T0.59 in.]
Connecting rod 32591-18010 Connecting rod bushing -

bushing installer install/remove
Valve lapper 30091-08800 Valve lapping

Suction cup diam :
ø40 mm [ø1.57 in.]
Valve seat cutter shaft Valve seat - reface

37591-06400 Width across flats : 32 mm [1.26 in.]
Applicable seat inside/outside
ø10 mm diameter : ø45 to 66 [ø1.77 to 2.60 in.]
[ø0.39 in.]
W1 1/8 -18
Cutter
37591-06430
W1 1/8 -18
θ㧩30°
Socket wrench 32591-01100 Cylinder head bolt - install/remove
Inlet valve seat caulking 35A91-05010 Inlet valve seat - press-in

tool
Exhaust valve 35A91-05020 Exhaust valve seat - press-in

seat caulking tool
29402-00120
3-5

item
Basic engine Valve seat puller 32591-04200 Valve seat - remove
Piston installer 37191-07100 Piston - install

Applicable piston diam : ø89 to 178
mm [ø3.50 to 7.01 in.]
??????? 32591-04050 Depth of counterbore in ???????

grinder - reface
Turning bar 32091-01500 Engine turning
Fuel system Nozzle tester 04239-00050 Fuel injection nozzle opening pressure
- measure
Socket 58309-73100 Fuel injection pump gear - install/

remove
Injection coupling gauge 37591-06100 Fuel injection pump coupling clear-

ance - adjust
GO : 48.75 mm [1.9193 in.]
NO GO: 49.25 mm [1.9390 in.]
3-6 29402-00120

item
Cooling system Thread cover 37191-06600 Water pump Shaft - press-in
Bearing installer 32591-03600 Water pump bearing - press-in
Seal ring installer guide 45B91-02100 Seal ring of sea water pump - install
Cooling system Mating ring installer guide 45B91-02200 Mting ring of sea water pump - install
Air start system Starter valve adapter 32691-01300 Starter valve - remove
Inspection and Compression gauge 33A91-01700 Compression pressure - measure

measurement Measurement range : 0 to 7 MPa
{0 to 71 kgf/cm2} [0 to 1015 psi]
Gauge adapter 36291-02200 Compression pressure - measure

U5/8-18
Belt gauge 32591-09100 Belt tension - measure

29402-00120
3-7
1. Determining Overhaul Timing ................................................................................ 4-3
1.1 Definition of Overhaul ............................................................................................................... 4-3
1.2 Determining Overhaul Timing ................................................................................................... 4-3
2. Compression Pressure - Measure.......................................................................... 4-4
29402-00120
4-1
1. Determining Overhaul Timing

1.1 Definition of Overhaul

Overhaul is to disassemble the engine and replace parts within a specified period to keep the engine in good conditions until the
next overhaul.
When the soundness of a part may not be maintained until next overhaul even if the part is in the standard condition at the
moment, the part must be replaced.
1.2 Determining Overhaul Timing
In most cases, the engine should be overhauled when the compression pressure of the engine decreases. An increase in engine
oil consumption and blow-by gas should be considered when evaluating the engine condition.
Such symptoms as the output decrease, fuel consumption increase, oil pressure decrease, engine starting difficulty, and noise
increase should be considered to evaluate overhaul timing, although these symptoms are often affected by various causes and
are not always effective to consider overhaul timing.
Decreased compression pressure shows a variety of symptoms and engine conditions, thus making it difficult to accurately
determine when the engine needs an overhaul.
Typical symptoms are:
(1) Decrease in output power
(2) Increase in fuel consumption
(3) Increase in engine oil consumption
(4) Increased blow-by gas through the breather due to worn cylinder and piston (Visually check the blow-by amount.)
(5) Increase in gas leaks due to poor seating of inlet and exhaust valves
(6) Worsened start ability
(7) Increase in noise of engine parts
(8) Abnormal exhaust color after engine warm-up
The engine shows above symptoms in various combinations.
Some of those symptoms are directly caused by worn engine parts, while others are not.
Symptoms of items (2) and (6) are affected by improper fuel injection volume and timing of the fuel injection pump, worn
plunger, faulty nozzles, and also faulty conditions of electrical devices such as battery and starter.
The most valid reason to overhaul an engine is a decrease in compression pressure due to worn cylinder and piston, as
described in item (4), and once this is determined, it is reasonable to take other problems into consideration for making a final
evaluation.
29402-00120
4-3
2. Compression Pressure - Measure
(a) Be sure to measure the compression pressure of Compression gauge

P/N: 33A91-01700
all cylinders. It is not a clever way to measure
the compression pressure of only two or three
cylinders, and assume the compression pres-
sure of all other cylinders. Cylinders are all inde-
pendent.
(b) Also be sure to check the engine speed when
Gauge adapter
measuring the compression pressure, as the P/N: 36291-02200
compression pressure varies depending on the Compression pressure - measure
engine speed.
(c) It is important to measure the compression pres-
sure at regular intervals, and know the change of
the pressure.
(1) Remove the injection nozzle from the cylinder head
where the compression pressure is to be measured.
(2) Attach the compression gauge adapter to the fuel injec-
tion nozzle hole and connect the compression gauge.
Note: To attach the gauge adapter, use a nozzle gland.
(3) Place the fuel injection pump rack at the no-injection
position (rack "0" position), and crank the engine with
the starter.
Read the engine speed and compression pressure while
the engine is running at a stable speed.
Note: Ensure the battery being fully charged when cranking
the engine with the starter.
If the battery voltage is low, the proper compression
pressure can not be measured because of a low crank-
ing speed.
(4) If the measured value exceeds the limit, overhaul the
engine.
Standard Rotation speed at

Item Limit value
value standard pressure
2.45 MPa 1.96 MPa
Compression
{25 kgf/cm2} {20 kgf/cm2} 120 min-1
pressure
[355 psi] [284 psi]
4-4 29402-00120
1. Cylinder Head and Valve Mechanism - Disassemble and Inspect ...................... 5-3
1.1 Fuel Pipe - Remove .................................................................................................................. 5-4
1.2 Nozzle Assembly - Remove...................................................................................................... 5-4
1.3 Valve Clearance - Inspect......................................................................................................... 5-4
1.4 Fuel Injection Timing - Inspect.................................................................................................. 5-5
1.5 Rocker Shaft Assembly - Remove............................................................................................ 5-5
1.6 Clearance Between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect... 5-5
1.7 Valve Bridge - Remove............................................................................................................. 5-6
1.8 Cylinder Head Assembly - Remove.......................................................................................... 5-6
1.9 Valve Sinkage - Measure.......................................................................................................... 5-6
1.10 Valve and Valve Spring - Remove............................................................................................ 5-7
1.11 Nozzle Gland Stud Bolt and Bridge Guide - Remove ............................................................... 5-7
1.12 Fuel Connector - Remove......................................................................................................... 5-7
2. Rear Mechanism - Disassemble and Inspect ........................................................ 5-8
2.1 Flywheel Face and Radial Runouts - Measure......................................................................... 5-9
2.2 Flywheel - Remove ................................................................................................................... 5-9
2.3 Timing Gear Case - Remove .................................................................................................... 5-9
2.4 Timing Gear Backlash - Measure ........................................................................................... 5-10
2.5 Idler Gear End Play - Measure ............................................................................................... 5-10
2.6 Camshaft End Play - Measure................................................................................................ 5-10
2.7 Idler Gear - Remove ............................................................................................................... 5-11
2.8 Fuel Injection Pump Accessory Drive - Remove .................................................................... 5-11
2.9 Camshaft Gear - Remove....................................................................................................... 5-11
2.10 Camshaft - Remove................................................................................................................ 5-12
2.11 Idler Shaft - Remove............................................................................................................... 5-12
2.12 Rear Plate - Remove .............................................................................................................. 5-12
3. Front Mechanism - Disassemble and Inspect..................................................... 5-13
3.1 Fan, Fan Bracket Assembly, and Belt - Remove.................................................................... 5-14
3.2 Front Pulley, Damper, and Crankshaft Pulley - Remove ........................................................ 5-14
3.3 Front Cover - Remove ............................................................................................................ 5-15
4. Cylinder Liner, Piston, and Connecting Rod - Disassemble and Inspect ........ 5-16
4.1 Piston Protrusion - Measure ................................................................................................... 5-17
4.2 Connecting Rod End Play - Measure ..................................................................................... 5-17
4.3 Hard Carbon Deposits on the Upper Part of Cylinder Liner - Remove ................................... 5-17
4.4 Connecting Rod Cap - Remove.............................................................................................. 5-17
4.5 Piston - Remove ..................................................................................................................... 5-18
4.6 Piston Ring - Remove............................................................................................................. 5-19
4.7 Piston Pin and Piston - Remove ............................................................................................. 5-19
4.8 Cylinder Liner Inside Diameter - Measure .............................................................................. 5-19
4.9 Cylinder Liner Flange Protrusion - Measure ........................................................................... 5-19
4.10 Cylinder Liner - Remove ......................................................................................................... 5-20
5. Crankcase, Crankshaft, and Main Bearing - Disassemble and Inspect............ 5-21
5.1 Crankcase - Turn Over (Upend) ............................................................................................. 5-22
5.2 Crankshaft End Play - Measure.............................................................................................. 5-22
5.3 Piston Cooling Nozzle - Remove ............................................................................................ 5-22
5.4 Main Bearing Cap - Remove .................................................................................................. 5-22
5.5 Crankshaft - Remove.............................................................................................................. 5-23
29402-00120
5-1
1. Cylinder Head and Valve Mechanism - Disassemble and Inspect

Understanding of the current engine condition before disassembling is very important to find the cause of trouble and to per-
form efficient maintenance work.
Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with
any job.
Valve Clearance - Inspect
Fuel Injection Timing - Inspect
Clearance Between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect
Valve Sinkage - Measure
10
Replace
9 3
Check,Replace
1
Replace 2
Crack, oil leak,
settling Check, Replace:
13 8 4 nozzle tip
5
Replace 6
Replace Replace
12
7
Wear 11 Wear, oil hole 17

clogging Replace
14 Wear
Wear at both 18
15
Flaw ends, bend
19
Wear, oil hole clogging
20 16
21
Settling, crack
22 25 Crack, carbon deposit,
flaw, scale deposit
Corrosion
Cam contact face and outer
23 Contact, wear
peripheral contact face wear
Crack, flaw, settling,

Stem/face portion wear, corrosion, rubber portion crack
crack, flaw, carbon deposit
24
Replace
Cylinder Heads and Valve Mechanisms - Disassemble and Inspect

Disassembling Sequence
1 Rocker cover 10 Cylinder head bolt (long) 19 Valve cotter
2 Fuel injection pipe 11 Rocker arm 20 Valve rotator
3 Fuel leak-off pipe 12 Rocker shaft 21 Valve spring
4 Washer, nut 13 Rocker shaft bracket 22 Stem seal
5 Nozzle gland 14 Bridge cap 23 Valve
6 Fuel injection nozzle 15 Valve bridge 24 Cylinder head gasket
7 Gasket 16 Push rod 25 Tappet
8 Adjusting screw 17 Cylinder head bolt (short)
9 Rocker bracket bolt 18 Cylinder head (Approx 29 kg [64 lb])
29402-00120
5-3
1.1 Fuel Pipe - Remove

(1) Remove the clamp, and remove the fuel injection pipe.
Union bolt Clamp
(2) Remove the union bolt of fuel injection nozzle, and
Sealing
remove the fuel leak-off pipe. washers
When removing the pipes, be sure to remove the seal-
ing washers so as not to lose them.
Fuel Fuel
injection leak-off
pipe pipe
Fuel Pipe - Remove
1.2 Nozzle Assembly - Remove
Nozzle remover
P/N:36291-00900
When removing the nozzle assembly with nozzle Gasket
remover, be careful not to get caught your fingers
between the nozzle remover weight, bar, and plate.
Before removing the nozzle assembly, clean the noz-

zle assembly to prevent foreign material from getting
into the cylinder head. Store the nozzle and the fuel
pipe together, and handle with care to avoid damage Nozzle Assembly - Remove
to the nozzle tip.
(1) Remove the nozzle gland.
(2) Remove the nozzle holder with nozzle remover.
(3) Remove the gasket that is left inside the cylinder head.
1.3 Valve Clearance - Inspect

Inspect the valve clearance to check the current condition.
For the inspection procedure, see "Valve Clearance - Inspect
Valve clearance
and Adjust" of "ENGINE BODY - ASSEMBLE."
Valve Clearance - Inspect
5-4 29402-00120
1.4 Fuel Injection Timing - Inspect

Inspect the fuel injection timing to check the current condi-
tion.
For the inspection procedures, refer to "Fuel Injection Tim-
ing - Check and Adjust" of "ENGINE BODY - ASSEM-
BLE."
Fuel injection
timing mark
Pointer
Fuel Injection Timing - Inspect
1.5 Rocker Shaft Assembly - Remove
(1) Loosen the adjusting screw of rocker arm.
(2) Remove the rocker bracket bolt. Cylinder head bolt (long)
Loosen
(3) Remove the cylinder head bolt (long), which also fixing adjusting Rocker bracket bolt
screw
the rocker bracket.
(4) Remove the rocker shaft assembly from the cylinder
head.
Note: Store the removed rocker shaft assembly and bolts as a
set.
Rocker Shaft Assembly - Remove

(5) Remove the push rod.
(6) Disassemble the rocker shaft assembly. Rocker shaft
Note: DO NOT remove the rocker bushing unless it is defec- Rock nut
tive or its inside diameter exceeds the limit. Rocker arm
Washer
Rocker shaft
bracket
Adjusting screw
Rocker Shaft Assembly - Disassemble

1.6 Clearance Between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect
Inspect the clearance between the bottom face of valve
Hold down the top
bridge and the top face of valve rotator to check the current Bridge cap of bridge by hand.
Clearance between
condition. valve bridge bottom
Valve bridge face and valve
For the inspection procedure, see "Clearance Between Bot- rotator top face
tom Face of Valve Bridge and Top Face of Valve Rotator - Valve rotator
Inspect" of "ENGINE BODY - ASSEMBLE".
Clearance Between Valve Bridge Bottom Face and

Rotator Top Face - Inspect Clearance
29402-00120
5-5
1.7 Valve Bridge - Remove

Remove the valve bridge and bridge cap.
Bridge cap
Note: Be careful not to drop the bridge cap into the cylinder
Valve bridge
head.
Valve Bridge - Remove

1.8 Cylinder Head Assembly - Remove
Eye nut
P/N:08014-00003
When removing the cylinder head gasket, be careful (M12 × 1.25)
not to damage the cylinder head and crankcase sur-
face with a screwdriver or the like.
(1) Remove the cylinder head bolt.
Dowel pin
(2) Remove the cylinder head by lifting with a hoist.
Note: Dowel pins are used to retain the cylinder head in a po-
sition. Therefore, pull the cylinder head vertical to the
mounting surface when lifting.
(3) Remove the cylinder head gasket. Cylinder Head Assembly - Remove
1.9 Valve Sinkage - Measure

Measure the valve sinkage to check the current condition.
For the measurement procedure, refer to "Valve Sinkage -
Measure" of "ENGINE BODY - ASSEMBLE."
5-6 29402-00120
1.10 Valve and Valve Spring - Remove

Using a valve spring pusher, compress the valve spring
evenly, and remove the valve cotters. Valve spring pusher
Note: If valves are reusable, mark the each valve seat and the P/N : 33591-04500
mating valve to identify their original positions. Do not
change the combination of the valve seat and the valve
when reassembling.
Valve Spring - Compress
Valve cotter
Valve rotator
Valve spring
Stem seal
Valve and Valve Spring - Remove

1.11 Nozzle Gland Stud Bolt and Bridge Guide - Remove
Do not remove the nozzle gland stud bolt and the bridge
guide from the cylinder head unless they are defective.
Bridge guide
If they are removed, see "Nozzle Gland Stud Bolt and
Bridge Guide - Inspect and Replace" of "ENGINE BODY -
INSPECT AND REPAIR." Nozzle gland
stud bolt
Nozzle Gland Stud Bolt and Bridge Guide - Remove

1.12 Fuel Connector - Remove
Do not remove the fuel injection connector and fuel leak-off
connector from the cylinder head unless they are defective.
Fuel leak-off connector
Fuel injection
connector
Fuel Connector - Remove
29402-00120
5-7
2. Rear Mechanism - Disassemble and Inspect

any job.
Flywheel Face and Radial Runout - Measure
Timing Gear Backlash - Measure
Idler Gear and Camshaft End Play - Measure
Hydraulic pressure Mechanical governor,

Flaw, wear governor spec electronic governor spec Replace: O-ring, gasket
9
12
Flaw, wear
11
10
Peeling, wear
Clogging, wear Marine PTO

Hour meter spec Non- 13 spec
attachment spec Crack, dowel hole
14
Replace 6 defect, gear flaw,
abnormal wear
Replace 8 7
Crack, dowel
hole defect 14inch flywheel, PTO spec
5
NO.0-UNF 2
NO1.W/L
Wear,
flaw, aging 4
1 NO1-M
Flaw
18inch flywheel spec
18inch flywheel spec 14inch flywheel, PTO spec

Rear Mechanism - Disassemble and Inspect
Disassembling sequence
1 Pick up (electronic governor spec) 9 Accessory drive (mechanical and electronic governor spec)
2 Flywheel (18 inch approx 50 kg [110 lb] and others) Governor drive (Hydraulic governor spec)
3 Timing gear case (approx 65 kg [143 lb] and others) (Refer to the chapter "FUEL SYSTEM" for disassembly, in-
4 Oil seal spection and assembly.)
5 Oil seal slinger 10 Camshaft gear
6 PTO gear 11 Thrust plate
7 Thrust plate 12 Camshaft (STD approx 22.7 kg [50 lb] and others)
8 Idler gear 13 Idler shaft
14 Rear plate (approx 9.6 kg [21 lb.])
5-8 29402-00120
2.1 Flywheel Face and Radial Runouts - Measure

Measure the face and radial runouts of the flywheel to check
the current condition.
For the measurement procedure, see "Flywheel Face and Face runout
measuring plane
Radial Runout - Measure" of "ENGINE BODY - ASSEM-
BLE." Radial runout
measuring plane
Flywheel Face and Radial Runouts - Measure

2.2 Flywheel - Remove
Sling
(a) Be careful not to drop or hit the flywheel. It can,
not only cause damage, but also may cause per-
sonnel injury.
(b) Be careful not to cut your hands with the ring gear
when pulling-out the flywheel.
Guide bolt
Be sure to remove the pickups before removing the P/N:64362-68500
Flywheel (M12 × 1.25)
flywheel. Flywheel - Remove
(1) Attach a sling to the flywheel to prevent it from falling
off.
(2) Screw two jack bolts evenly into the bolt holes, and
remove the flywheel.
2.3 Timing Gear Case - Remove
Sling
Be careful not to drop or hit the timing gear case. It
can, not only cause damage, but also may cause per-
sonnel injury.
(1) Attach a sling to the timing gear case to prevent it from
falling off.
Timing gear
(2) Lift the timing gear case to disengage the dowel pins, case
and remove the timing gear case.
Oil seal
(3) Remove the oil seal from the timing gear case.
Note: Replace the removed oil seal with a new one. Oil seal Timing Gear Case - Remove
cannot be re-used.
29402-00120
5-9
2.4 Timing Gear Backlash - Measure

Measure the timing gear backlash to check the current con-
dition.
Camshaft gear
For measurement procedure, see "Timing Gear Backlash -
Measure" of "ENGINE BODY - ASSEMBLE". Fuel injection
pump gear
Idler gear
Crankshaft gear
Timing Gear Backlash - Measure

2.5 Idler Gear End Play - Measure
Measure the idler gear end play to check the current condi-
tion.
For measurement procedure, see "Idler Gear End Play -
Measure" of "ENGINE BODY - ASSEMBLE".
Idler gear
Idler Gear End Play - Measure

2.6 Camshaft End Play - Measure
Measure the camshaft end play to check the current condi-
tion.
For measurement procedure, see "Camshaft End Play - Camshaft gear
Camshaft End Play - Measure
5-10 29402-00120
2.7 Idler Gear - Remove
Camshaft gear
The camshaft gear mounting nuts are left-hand Loosen nut before
removing idler gear
threaded. Be sure to turn them clockwise to loosen
[Left-hand thread]
them. Idler gear
If the idler gear is removed first, the nut that fixes the cam- Thrust
shaft gear cannot be loosened because the camshaft gear plate
rotates. Thus, loosen the camshaft gear mounting nut before
removing the idler gear.
(1) Remove the oil seal slinger from the crankshaft. Be
careful not to scratch the crankshaft. Idler Gear - Remove
(2) Using a socket, loosen the camshaft gear mounting nut
(left-hand thread).
(3) Remove the thrust plate.
(4) Remove idler gears.
2.8 Fuel Injection Pump Accessory Drive - Remove

Remove the fuel injection pump accessory drive from the
Mechanical and Hydraulic governor
rear plate. electronic governor spec
spec
(See FUEL SYSTEM for disassembly, inspection, and
assembly.)
Fuel injection pump

accessory drive
Fuel Injection Pump Accessory Drive - Remove

2.9 Camshaft Gear - Remove
(1) Remove the camshaft gear mounting nut with the
socket. Socket wrench
P/N:32591-02800
(2) Remove the camshaft gear from the camshaft.
Camshaft gear
Camshaft Gear - Remove
29402-00120
5-11
2.10 Camshaft - Remove
Remove the camshaft from crankcase by lifting so that

the crankcase and camshaft bushing do not get dam-
aged.
(1) Remove thrust plate.
(2) Support the camshaft with a sling from the top of the
crankcase and remove the camshaft from the crankcase. Camshaft
Thrust plate
Camshaft - Remove
2.11 Idler Shaft - Remove
Screw two jack bolts evenly into the jack bolt holes, and
remove the idler shaft.
Idler shaft
Idler Shaft - Remove

2.12 Rear Plate - Remove
Remove the rear plate from the crankcase.
.
Dowel pin
Rear Plate - Remove
5-12 29402-00120
3. Front Mechanism - Disassemble and Inspect

any job.
Damper Face and Radial Runouts - Measure
Oil
pipe
Replace
8 (Slinger)
2
7
1
3
With fan spec
PTA,MPTA,
With pulley (Ribbed belt) MPTK spec
4 Belt groove wear 9
6
Replace Crackࠊknock
8 hole abnormality
(Seal lip)
MTK,MTK2, E2PTAA-1, MTK,MTK2,
MPTA,MPTK, Y2TAA1 spec MPTA,MPTK spec
With pulley (㹔-belt) Y1MPTK,
Y2MPTK spec
With cranking pulley
Crack, oil leakage Belt groove wear
The front slinger is a cassette (assembling) type including the oil seal.
When removing front cover, change front oil seal with a new one.
Front Mechanism - Disassemble and Inspect

1 Fan (with fan spec) 6 Crankshaft pulley
2 Fan bracket assembly (with fan spec) 7 Oil seal case
3 Belt (with fan spec) 8 Oil seal
4 Front pulley 9 Front cover
5 Damper (Approx 28.5 kg [63 lb])
Note:(a) The configurations of fan, fan drive assembly, belt and pulley differ depending on the customization and specification.
(b) The consisting parts of the damper differ in accordance with the customization and specification.
29402-00120
5-13
3.1 Fan, Fan Bracket Assembly, and Belt - Remove

(Fan equipped type)
Remove the fan, fan bracket assembly, and belt.
3.2 Front Pulley, Damper, and Crankshaft Pulley - Remove
Be careful not to drop or bump the pulley and

Front pulley
damper. It can, not only cause damage to parts, but
also lead to personnel injury.
(1) Loosen several of the front cover pulley mounting
bolts, and install the guide bolts.
(2) Unscrew the remaining mounting bolts and remove the
front pulley with the guide bolts as support.
(3) Loosen several of the damper mounting bolts, and Guide bolt
install the guide bolts. Front Pulley - Remove

(4) Unscrew the remaining mounting bolts and install two
jack bolts.
(5) Screw two jack bolts evenly into the jack bolt holes, Guide bolt
and remove the damperwith the guide bolts as support.
Damper
Jack bolt (M10 × 1.25)

Damper - Remove
(6) Remove the crankshaft pulley from the crankshaft.
Crankshaft
Crankshaft pulley
Dowel pin
Crankshaft Pulley - Remove
5-14 29402-00120
3.3 Front Cover - Remove
When removing the oil seal (slinger portion), be careful

not to damage the crankshaft. If the crankshaft has a
flaw, oil will leak from its flaw even if a new oil seal is
installed.
Slinger
(1) Loosen the front cover mounting bolts, and remove the
front cover. Front cover
(2) Dismount the oil seal case from the front cover and Oil seal case
Oil seal
remove the oil seal (seal lip portion).
(3) Remove the oil seal (slinger portion) from the crank- Front Cover - Remove
shaft by tapping lightly or prying it.
29402-00120
5-15
4. Cylinder Liner, Piston, and Connecting Rod - Disassemble and Inspect

any job.
Piston Protrusion - Measure
Connecting Rod End Play - Measure
Cylinder Liner Inside Diameter - Measure
Cylinder Liner Flange Protrusion - Measure
Wear, flaw
5
6
Outside scar, crack, flaw,
7 wear, carbon adhesion
10
8 Inner surface scratch, wear,

Wear 12
outer surface/O-ring groove
Inner face wear, rust, cavitation
flaw, discoloration
Crack, oil hole clogging
11
4 Replace
3
flaw
Inner and outer surface flaw,

1 seizure, peeling
2
Serrated portion wear,

crack
Cylinder Liner, Piston, and Connecting Rod - Disassemble and Inspect

Disassembly sequence
1 Connecting rod cap bolt 7 Oil ring
2 Connecting rod cap 8 Snap ring
3 Lower connecting rod bearing 9 Piston pin
4 Upper connecting rod bearing 10 Piston
5 No. 1 compression ring 11 Connecting rod
6 No. 2 compression ring 12 Cylinder liner (approx. 16 kg [35 lb])
5-16 29402-00120
4.1 Piston Protrusion - Measure

Measure the piston protrusion to check the current condi-
tion.
For measurement procedure, see "Piston Protrusion - Mea- Piston protrusion
sure" of "ENGINE BODY - ASSEMBLE".
Piston Protrusion - Measure

4.2 Connecting Rod End Play - Measure
Measure the connecting rod end play to check the current
condition. Connecting rod
For measurement procedure, see "Connecting Rod End Play
- Measure" of "ENGINE BODY - ASSEMBLE".
Connecting rod end play
Connecting Rod End Play - Measure

4.3 Hard Carbon Deposits on the Upper Part of Cylinder Liner - Remove
Be sure to remove hard carbon deposits from the Cylinder liner Hard carbon
upper part of the cylinder liner before removing the pis-
ton. Hard carbon deposits, if not removed, cause dam-
age to the piston and piston rings.
Remove hard carbon deposits from the upper part of cylin-
der liner with carbon remover (scraper, sandpaper, etc.)
Note: Be careful not to damage the inner surface of the cyl-
inder liner.
Hard Carbon Deposits on the Upper Part of Cylinder
Liner - Remove
4.4 Connecting Rod Cap - Remove

Using a socket wrench, remove the connecting rod bolts
Socket wrench
through the inspection window on the side of the crankcase Connecting rod
P/N:32591-01100
, and remove the connecting rod cap and connecting rod cap
bearings.
Note: Make marks, such as cylinder number and distinction
between upper and lower, on the removed connecting
rod bearings to ensure the correct reassembly.
Connecting Rod Cap - Remove
29402-00120
5-17
4.5 Piston - Remove
When holding the connecting rod with your hand to prevent it from swinging, be very careful, as you may suffer
hand injuries from accidental movement of the connecting rod.
(a) When pulling-out the piston, be careful not to drop the upper connecting rod bearing.
(b) When removing the piston, be careful not to damage the cylinder liner with connecting rod movement.
(c) When only a few pistons remain in the cylinders, the crankshaft tends to turn by weight imbalance. Be sure to
hold the crankshaft to prevent it from rotating while removing pistons.
(d) Make sure that the connecting rod does not damage the piston cooling nozzle when removing the piston.
(e) When pulling the piston out of the cylinder liner, hold the piston by hand so that the piston does not rock. If the
piston rocks, the piston inner surface collides against the connecting rod, results in the damage of piston.
4.5.1 Removing the Piston With Chain Block Lifting

Eye bolt
(1) Remove the connecting rod cap and turn the crankshaft P/N:45815-32301
(M10 × 1.5)
to bring the piston to the top dead center position.
(2) Install the eye bolt to the threaded hole on the piston
top, and support the piston to prevent it from falling
down.
(3) Rotate the crankshaft to place the crank pin slightly
near to the inspection window so that the connecting
Crankpin
rod big end will not contact the cylinder liner.
(4) Carefully pull-out the piston by making sure that the
Removing the Piston With Chain Block Lifting
connecting rod big end moves into the cylinder liner.
4.5.2 Removing the Piston With Pushing-up the Con-

Eyebolt
necting Rod Big End P/N: 45815-32301
(1) Remove the connecting rod cap and turn the crankshaft (M10 × 1.25)
to bring the piston to the top dead center position.

(2) Install the eye bolt to the threaded hole on the piston
top, and support the piston to prevent it from falling
down.
(3) Rotate the crankshaft carefully until the crankpin is dis-
Crankpin
placed from the connecting rod and the lower bolt hole
can be seen through the inspection window.
Crankshaft - Rotate
(4) Insert a bar wrapped with cloth, and push up the bottom
of connecting rod carefully, with the crankpin as a ful-
crum.
Note: Protect the crankpin and connecting rod big end with
cloth or rubber to prevent them from damage with the
bar.
Wrap in cloth
(5) Push-up the connecting rod and piston while adjusting
the fulcrum position. Turning bar
When the oil ring is slid out of the cylinder liner, care-
fully place the piston on the top face of cylinder liner.
(6) Lift the piston with eye bolt on the piston top, and pull- Connecting Rod Big End - Push-Up
out the piston from cylinder liner.
5-18 29402-00120
4.6 Piston Ring - Remove
Ring expander
When removing the piston ring, be careful not to be P/N : 37191-03200
pinched your hand between the piston and connecting
rod by the piston tilt movement.
A free swing of piston and its bump to connecting rod

may result in piston damage.
Hold the piston and connecting rod in a vise, and remove
the piston rings with ring expander. Piston Ring - Remove
4.7 Piston Pin and Piston - Remove

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

4.8 Cylinder Liner Inside Diameter - Measure
Measure the cylinder liner inside diameter to check the cur-
rent condition.
For measurement procedure, see "Cylinder Liner Inside
Diameter - Measure" of "ENGINE BODY - ASSEMBLE".
Cylinder liner
Cylinder Liner Inside Diameter - Measure

4.9 Cylinder Liner Flange Protrusion - Measure
Measure the cylinder liner flange protrusion to check the
current condition. Cylinder liner
flange protrusion
For measurement procedure, see "Cylinder Liner Flange Liner pusher
Protrusion - Measure" of "ENGINE BODY - ASSEMBLE". Bolt
Cylinder Liner Flange Protrusion - Measure
29402-00120
5-19
4.10 Cylinder Liner - Remove

(1) Install the cylinder liner remover to the cylinder liner.
Nut
Note: Use care not to hit the piston cooling nozzle when in-
Removing stroke
60 mm [2.36 in.]
stalling the remover plate to the bottom of cylinder lin- Cylinder liner
er. remover
P/N:32591-14100
(2) Screw the nuts, and remove the cylinder liner.
Cylinder liner
Cylinder Liner - Remove
5-20 29402-00120
5. Crankcase, Crankshaft, and Main Bearing - Disassemble and Inspect

any job.
Crankshaft End Play - Measure
Local contact and crack on

counterbore, fretting and
corrosion on cylinder liner
Water scale, flaw
fitting face
crack and oil hole
clogging
11
Wear
Oil jet pipe bend
diformation 8
2 7
Valve movement 10
oil hole clgging
9
Flaking, wear,
local contact
Wear, flaw, crack 6
Inside and outside

5 Flaw, corrosion,
spalling
Flaw
4
1
3
Crack
Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect

1 Main bearing cap bolt 7 Upper main bearing
2 Side bolt 8 Upper thrust plate
3 Main bearing cap 9 Check valve
4 Lower main bearing 10 Piston cooling nozzle
5 Lower thrust plate 11 Crankcase (Approx 440 kg [970 lb])
6 Crankshaft (Approx 235 kg [518 lb])
29402-00120
5-21
5.1 Crankcase - Turn Over (Upend)

Using a turnover machine, turn over the crankcase. When
Weight of crankcase
the turnover machine is not available, attach slings to the and crankshaft assembly:
Approx 675 kg [1488 lb]
crankcase using wood pieces and cloth pads, and raise the
Crankcase
crankcase with a hoist or crane. Then lay it on the wooden
block with its side face downward. Then, change the posi-
tions of the slings, and turn over to upend the crankcase.
.
Wood pieces
Crankcase - Turn Over (Upend)
5.2 Crankshaft End Play - Measure
Measure the crankshaft end play to check the current condi-
tion.
For measurement procedure, see "Crankshaft End Play -
Crankshaft End Play - Measure

5.3 Piston Cooling Nozzle - Remove
Remove the piston cooling nozzle from the crankcase.
.
5.4 Main Bearing Cap - Remove
When removing the main bearing cap, be careful not to damage the main bearing or the thrust plate attached to the
cap. Also be careful not to drop those parts from the cap, which may result in crankshaft damage.
(1) Remove the main bearing cap bolts and side bolts.
Sliding hammer
(2) Install the adapter to main bearing cap. Cap remove
P/N:36291-00900
Install the nozzle remover to adapter. adapter
P/N:32591-04300
(3) Remove the main bearing cap from the crankcase.
(4) Remove the lower main bearing from the main bearing
cap.
(5) Remove the lower thrust plate from the rearmost main
bearing cap.
Main Bearing Cap - Remove
5-22 29402-00120
5.5 Crankshaft - Remove
(a) When removing the crankshaft, remove the front upper thrust plates first, and be careful not to drop into the
crankcase.
(b) When placing the crankshaft onto a pallet or other stands, be careful not to damage the crankshaft. Once
placed on a pallet, place some support to prevent the crankshaft from rolling.
(1) Push a mating face of upper and lower of the front

upper thrust plate, and remove while rotating.
(2) Lift the crankshaft in a horizontal position, and slowly
remove the crankshaft upward. Crankshaft
Weight: approx.
Note: Do not attach a chain directly onto crankshaft, as it will 235 kg [518 lb]
damage the crankshaft. Place cloth belts or pads in the
positions before lifting the crankshaft.
(3) Remove the upper main bearing from crankcase, pay-
ing attention to the lug position, and remove the upper
thrust plate on the rear side.
Crankshaft - Remove
29402-00120
5-23
1. Cylinder Head and Valve Mechanism - Inspect and Repair................................. 6-3

1.1 Rocker Bushing Inside Diameter and Rocker Shaft Outside Diameter - Measure ................... 6-3
1.2 Rocker Bushing - Replace ........................................................................................................ 6-3
1.3 Valve Stem Outside Diameter and Valve Guide Inside Diameter - Measure ........................... 6-4
1.4 Valve Guide - Replace.............................................................................................................. 6-4
1.5 Valve Face - Inspect ................................................................................................................. 6-5
1.6 Valve Face - Reface ................................................................................................................. 6-5
1.7 Valve Seat Ring - Reface ......................................................................................................... 6-6
1.8 Valve Seat Ring - Replace........................................................................................................ 6-6
1.9 Valve and Valve Seat Ring - Lap.............................................................................................. 6-8
1.10 Valve Bridge, Bridge Cap, Valve Cotter, and Valve Rotator - Inspect ...................................... 6-8
1.11 Squareness and Free Length of Valve Spring - Measure......................................................... 6-8
1.12 Tappet - Inspect........................................................................................................................ 6-9
1.13 Pushrod Runout - Measure....................................................................................................... 6-9
1.14 Nozzle Gland Stud Bolt and Bridge Guide - Inspect and Replace............................................ 6-9
1.15 Distortion of Cylinder Head Bottom Surface - Measure.......................................................... 6-10
1.16 Water Director - Inspect and Replace..................................................................................... 6-10
2. Rear Mechanism - Inspect and Repair................................................................. 6-11
2.1 Idler Bushing Inside Diameter and Idler Shaft Outside Diameter - Measure .......................... 6-11
2.2 Idler Bushing - Replace .......................................................................................................... 6-11
2.3 Cam Lift of Cam Shaft Lobe - Measure .................................................................................. 6-11
2.4 Camshaft Runout - Measure................................................................................................... 6-12
2.5 Camshaft Journal Outside Diameter - Measure ..................................................................... 6-12
2.6 Camshaft Bushing - Inspect.................................................................................................... 6-12
2.7 Camshaft Bushing - Replace .................................................................................................. 6-13
3. Front Mechanism - Inspect and Repair................................................................ 6-14
3.1 Damper - Inspect Visually....................................................................................................... 6-14
3.2 Pulley - Inspect ....................................................................................................................... 6-14
4. Piston and Connecting Rod - Inspect and Repair .............................................. 6-15
4.1 Piston - Inspect Visually.......................................................................................................... 6-15
4.2 Piston Weight ......................................................................................................................... 6-15
4.3 Piston Outside Diameter - Measure........................................................................................ 6-15
4.4 Piston Ring Groove - Inspect.................................................................................................. 6-15
4.5 Piston Pin Hole Inside Diameter - Measure............................................................................ 6-16
4.6 Piston Ring - Inspect Visually ................................................................................................. 6-16
4.7 Piston Ring End Gap - Measure ............................................................................................. 6-16
4.8 Piston Pin Outside Diameter - Measure ................................................................................. 6-16
4.9 Connecting Rod Bushing Inside Diameter - Measure............................................................. 6-17
4.10 Connecting Rod Bushing - Replace........................................................................................ 6-17
4.11 Connecting Rod Assembly Weight Rank................................................................................ 6-20
4.12 Inside Diameter and Roundness of Connecting Rod Big-End Bore - Measure ...................... 6-20
4.13 Side Face Width of Connecting Rod Big End - Measure........................................................ 6-21
4.14 Connecting Rod Big End Serration and Bolt Holes - Inspect.................................................. 6-21
4.15 Connecting Rod Bearing - Inspect.......................................................................................... 6-21
4.16 Connecting Rod Bearing Thickness - Measure ...................................................................... 6-21
4.17 Connecting Rod Bend and Twist - Inspect ............................................................................. 6-22
29402-00120
6-1
5. Crankcase and Crankshaft - Inspect and Repair ................................................ 6-23

5.1 Crankcase Top Surface Distortion - Measure......................................................................... 6-23
5.2 Inside Diameter of Main Bearing Housing Bore - Measure .................................................... 6-23
5.3 Cylinder Liner Fitting Bore in Crankcase - Inspect ................................................................. 6-23
5.4 Counterbore in Crankcase - Repair ........................................................................................ 6-24
5.5 Crank Pin and Journal Outside Diameters - Measure ............................................................ 6-25
5.6 Width of Crankpin and Rearmost Crank Main Journal - Measure .......................................... 6-27
5.7 Crankshaft Runout - Measure................................................................................................. 6-27
5.8 Crankshaft Gear - Inspect....................................................................................................... 6-28
5.9 Crankshaft Gear - Replace ..................................................................................................... 6-28
5.10 Oil Seal Slinger - Inspect ........................................................................................................ 6-29
5.11 Oil Seal Slinger - Replace....................................................................................................... 6-29
5.12 Main Bearing - Inspect............................................................................................................ 6-31
5.13 Thickness of Main Bearing - Measure .................................................................................... 6-31
5.14 Thrust Plate - Inspect.............................................................................................................. 6-31
5.15 Thickness of Thrust Plate - Measure ...................................................................................... 6-32
5.16 Piston Cooling Nozzle - Inspect.............................................................................................. 6-32
6-2 29402-00120
1. Cylinder Head and Valve Mechanism - Inspect and Repair

1.1 Rocker Bushing Inside Diameter and Rocker Shaft Outside Diameter - Measure
Measure the inside diameter of the rocker bushing and the
outside diameter of the rocker shaft. If the measurement Measuring
direction
exceeds the limit, replace the rocker bushing or rocker shaft
Measuring
with a new one. position
Measuring
Nominal
Item Standard value Limit value direction
value
32.055 to
Rocker bushing inside ø32 mm 32.080 mm 32.100 mm
diameter [ø1.26 in.] [1.2620 to [1.2638 in.]
1.2630 in.]
31.975 to
Rocker shaft outside ø32 mm 31.991 mm 31.950 mm Bushing Inside Diameter and Shaft Outside Diameter
diameter [ø1.26 in.] [1.2580 to [1.2579 in.] of Rocker - Measure
1.2595 in.]
1.2 Rocker Bushing - Replace
Removal
If the rocker bushing notch direction is not aligned with
the center axis of screw hole, oil will not feed from the Rocker bushing puller
P/N:32591-02600
rocker arm to valve, resulting in wear of the rocker arm
and the bridge, or seizure of the valve.
(1) Pull out the rocker bushing using the rocker bushing
Rocker arm
puller.
Rocker bushing
Rocker Bushing - Remove

(2) Install a new rocker bushing using the rocker bushing Bushing inside surface
roughness Turn up
puller. the notch.
Ra0.8μm{‫ۃ‬3.2S
‫ۃۃ‬
}
Face the notch of the rocker bushing upward, and align
Rocker bushing puller
the position indicated in the right figure. Press-in the P/N:32591-02600
rocker bushing from the chamfered side of the rocker Press-fit it from
chamfered side
bushing hole. Rocker bushing
(3) Make sure rocker arm is in the specified relational posi-

Press-fit
tion to rocker bushing.
(4) Measure inside diameter of installed rocker bushing. Rocker arm
If the value is smaller than the standard, ream the inside
Rocker Bushing - Insert
diameter to the standard.
Rocker bushing
notch Oil hole Rocker arm
Rocker
bushing 8r
3 °
joint
Inner peripheral groove

Rocker bushing
Press-fit so that the rocker bushing notch is aligned
parallel to the center axis of screw hole.
Rocker Bushing - Position
29402-00120
6-3
1.3 Valve Stem Outside Diameter and Valve Guide Inside Diameter - Measure
Measure the outside diameter of valve stem and the inside
diameter of valve guide at the top and bottom sliding ends in Measuring
mutually right-angle directions, as the sliding surfaces tend directions
to wear at the top and bottom ends. If the measurement

exceeds the limit, replace the valve guide or the valve with a
new one.
Note: Lap the valve and valve seat ring whenever a new Measuring
positions
valve is installed.
Nominal Standard
Item Limit value
value value
Valve Stem Outside Diameter - Measure
9.940 to
ø10 mm 9.960 mm 9.910 mm
Inlet
[0.39 in.] [0.3913 to [0.3902 in.]
0.3921 in.] Measurement
Valve stem out- direction
side diameter 9.910 to
ø10 mm 9.930 mm 9.880 mm
Exhaust Measurement
[0.39 in.] [0.3902 to [0.3890 in.]
point
0.3909 in.]
10.000 to
Valve guide inside diame- ø10 mm 10.015 mm 10.060 mm
ter [0.39 in.] [0.3937 to [0.3961 in.]
0.3943 in.]
Valve Guide Inside Diameter - Measure

1.4 Valve Guide - Replace
Valve guide
Be sure to use the guide and seal installer to install remover
P/N:36291-04200
the valve guide to the specified height.
(1) Remove the valve guide with the valve guide remover.
Valve Guide - Remove

(2) Install a new valve guide slowly with the guide and seal
installer.
Guide & seal installer
P/N:32591-10300
Valve guide
27.5 ± 0.1 mm
[1.083 ± 0.004 in.] Cylinder head
Valve Guide - Press Fit
6-4 29402-00120
1.5 Valve Face - Inspect

Inspect the valve face after the valve guide is inspected or
replaced. Lap the valve and valve seat whenever the valve is Seat width
refaced or replaced.
Valve seat angle

Valve margin
Valve sinkage
Valve Face - Inspect

1.5.1 Valve Margin - Inspect
Measure the valve margin. If the value exceeds the limit,
reface or replace the valve with a new one.
1.5.2 Seat Width - Inspect
Apply a thin lead-free coloring paste on the valve face, and
Valve lapper
tap the valve face against valve seat with the valve lapper to P/N:30091-08800
check the contact condition. If the contact is not even, or
any defects are found, or if the value exceeds the specified
Lapping
limit, reface or replace the valve or valve seat. compound
Note: Do not rotate the valve when pressing valve face coat-
ed with lead-free coloring paste against valve seat.
Item Standard value Limit value

Valve seat angle 30° - Seat Width - Inspect
1.98 to 2.18 mm 2.5 mm
Valve Inlet
Seat [0.0780 to 0.0858 in.] [0.098 in.]
seat
width 1.75 to 1.95 mm 2.3 mm
Exhaust
[0.0690 to 0.0768 in.] [0.091 in.]
2.7 to 3.1 mm
Inlet
[0.106 to 0.122 in.] 2.0 mm
Valve margin
2.8 to 3.2 mm [0.079 in.]
Exhaust
[0.1102 to 0.1260 in.]
Good Bad
Contact condition between valve seat and valve

1.6 Valve Face - Reface
When refacing valve face to reuse, use the valve refacer.
Note:(a) Grind the valve face with valve refacer adjusted to Valve refacer
the specified angle.

(b) The valve margin should be within the specified
limit. If the dimensions after refacing do not meet
the specified values, replace the valve with a new
Grind valve face
one. at the specified angle.
Valve Face - Reface
29402-00120
6-5
1.7 Valve Seat Ring - Reface

If any damage or inclusions are found, grind the seat face.
(1) Reface the valve seat with valve seat cutter or valve
Socket
seat grinder. After refacing, insert sand paper of approx (width across flats
400 grit between cutter and valve, and grind valve seat 32 mm [1.26 in.])
lightly.
If the seat width exceeds the standard, grind the valve Valve seat cutter
P/N:37591-06400
inner seat with a valve seat cutter having the angle of 37591-06430
44°50′.
(2) Lap valve and valve seat ring.
Note:(a) Keep the valve seat refacing depth to the minimum.
Valve Seat Ring - Reface
(b) If the seat width cannot be corrected to the standard
value, or a line contact on valve seat outer periphery
is presented, replace the valve seat ring with a new
one.
(c) If the valve sinkage exceeds the specified limit after
refacing, replace the valve seat ring with a new one.
1.8 Valve Seat Ring - Replace
Select the valve seat with the appropriate interference.

Improper interference can result in dropping out of the
valve seat or crack on the cylinder head.
Be careful not to damage the machined surface of cylinder
head when removing the valve seat.
1.8.1 Valve Seat - Remove With Valve Seat Puller

Remove the valve seat with the valve seat puller. Valve seat puller
P/N:32591-04200
Valve Seat - Remove With Valve Seat Puller

1.8.2 Valve Seat - Remove by Welding
To remove the valve seat, weld a stud to the valve seat as
shown. Then, insert a shaft into the valve guide hole from Welding
Shaft
the top of cylinder head, and punch out the valve seat with
shaft. Valve seat ring
Note: Be careful not to allow spatters to adhere to the ma-
chined surface of the cylinder head during welding.
Stud, etc.
Valve Seat - Remove by Welding
6-6 29402-00120
1.8.3 Valve Seat - Install
[0.472+0.004 ]
(1) Before installing the valve seat, measure the inside
0
diameter of valve seat counterbore in the cylinder head
12+0.1
and the outside diameter of valve seat to make sure that
0
9 [0.35]
the interference is within the range of standard value. If
3 [0.118]
the value exceeds the standard, use the oversize valve
seat. If the inside diameter of valve seat counterbore in
cylinder head exceeds the limit, replace the cylinder 60°± 15' Valve seat fitting
bore inside diameter
head with a new one.
Valve seat
Note: Oversized valve seats are available in 0.03 and 0.06 outside diameter Unit: mm [in.]
Valve seat counterbore
mm [0.0012, 0.0024 in.] sizes.

58.000 to 58.030 mm 58.09 mm
Inside diameter of valve seat counterbore
[2.2835 to 2.2846 in.] [2.2870 in.]
58.100 to 58.130 mm
Standard - 2pcs, yellow
[2.2874 to 2.2886 in.]
Inlet
0.03 mm 58.130 to 58.160 mm
Valve seat outside diameter - 3pcs, yellow
[0.0012 in.] [2.2886 to 2.2898 in.]
0.06 mm 58.160 to 58.190 mm
- 4pcs, yellow
[0.0024 in.] [2.2898 to 2.2909 in.]
54.000 to 54.030 mm 54.09 mm
Inside diameter of valve seat counterbore
[2.1260 to 2.1272 in.] [2.1295 in.]
54.100 to 54.130 mm
Standard - Double blue lines
[2.1299 to 2.1311 in.]
Exhaust
0.03 mm 54.130 to 54.160 mm
Valve seat outside diameter - Triple blue lines
[0.0012 in.] [2.1311 to 2.1323 in.]
0.06 mm 54.160 to 54.190 mm
- Quadruple blue lines
[0.0024 in.] [2.1323 to 2.1335 in.]
0.070 to 0.130 mm
Valve seat interference -
[0.0028 to 0.0051 in.]
Inside diameter of valve seat counterbore Applicable valve seat

58.030 mm [2.2846 in.] or less Standard
Inlet More than 58.030 mm [2.2846 in.] 0.03 mm [0.0012 in.]
More than 58.060 mm [2.2858 in.] 0.06 mm [0.0024 in.]
54.030 mm [2.1272 in.] or less Standard
Exhaust More than 54.030 mm [2.1272 in.] 0.03 mm [0.0012 in.]
54.060 mm [2.1283 in.] or more 0.06 mm [0.0024 in.]
(2) Cool the valve seat at least for 4 minutes in liquid nitro-
Valve seat caulking tool
gen and keep the cylinder head in a room temperature.
P/N:35A91-05010(Inlet)
(3) Install the valve seat into the cylinder head with the 35A91-05020(Exhaust)
valve seat caulking tool.
Valve Seat - Install
29402-00120
6-7
1.9 Valve and Valve Seat Ring - Lap

Lap the valve and valve seat ring whenever the valve seat
ring is refaced or the valve is replaced, or the contact sur-
faces fail to keep a pressure in the pressure test after assem-
bling.
(1) Apply a thin coat of lapping compound evenly on valve
seat face.
Note:(a) Do not allow the compound to adhere to the valve
stem. Compound
(b) The compound spreads more evenly when it is
mixed with a small amount of engine oil.
(c) Use a medium-grain compound (125 to 150 mesh)
for initial lapping, then use the fine-grain com- Compound - Apply
pound (200 mesh) for finishing.
(2) Use a valve lapper for lapping. Tap the valve against Valve lapper
P/N:30091-08800
the valve seat while rotating the valve little by little.
(3) Wash off the compound using diesel fuel.
(4) Apply engine oil on mating surfaces, and lap for finish-
ing.
(5) Apply a thin coat of lead-free coloring paste on the
valve face, and tap the valve face against the valve seat
using a valve lapper to check the contact condition.
Valve and Valve Seat Ring - Lap
1.10 Valve Bridge, Bridge Cap, Valve Cotter, and Valve Rotator - Inspect
(1) Inspect the contact surfaces between the valve bridge
Bridge cap
and the valve stem, and the sliding surfaces between the
Bridge guide
valve bridge and the bridge guide. If significant wear or Valve bridge
uneven contact is found, replace them with new ones. Valve rotator
Valve stem
(2) Check the bridge cap for wear. If significant wear is
found, replace the bridge cap with a new one. Valve cotter
(3) Check the valve rotator for rotation. If any defect is
found, replace the valve rotator with a new one.
(4) Inspect the contact surfaces between valve cotter and
valve stem, and valve cotter and valve rotator. If uneven
wear or significant dent is found, replace with new
ones. Valve Bridge, Bridge Cap, Valve Cotter, and Valve
Rotator - Inspect
1.11 Squareness and Free Length of Valve Spring - Measure
Measure the squareness and the free length of valve spring.
If the free length or squareness exceeds the specified limit, Spring squareness
replace the valve spring with a new one.
Nominal
Standard value Limit value
value
66.2 mm
Free length 67.5 mm [2.658 in.]
[2.606 in.]
A = 1.5° Free length
A At the whole
B B = 1.76 mm
length
Squareness [0.0693 in.]
Lf B = 2.3 mm
Lf = 67.5 mm
[0.091 in.]
[0.266 in.]
Set length /
60.0 mm [2.362 in.] / 259 to 286 N Squareness and Free Length of Spring - Measure
{26.43 to 29.19 kgf} -
load
[58.27 to 64.35 lbf]
6-8 29402-00120
1.12 Tappet - Inspect

Inspect the tappet sliding face to cam for local wear. If
defective, replace the tappet with a new one. Flaw, local wear
Flaw, local wear
Good Bad Bad
Tappet Sliding Face to Cam - Inspect

1.13 Pushrod Runout - Measure
Measure the runout of pushrod in the total indicator reading
(TIR). If the runout exceeds the standard, replace the push-
rod with a new one.
Measurement V-block
Standard value Remark Push rod
item
Pushrod runout 0.50 mm [0.0197in.] or less TIR
1/2 1/2
Surface plate
Pushrod Runout - Measure

1.14 Nozzle Gland Stud Bolt and Bridge Guide - Inspect and Replace
Inspect the nozzle gland stud bolt for bending or damage at
the threaded portion.
Bridge guide
Inspect the bridge guide for uneven wear and damage on the Approx.84 mm
[3.31 in.]
sliding surfaces.
(48 mm 37 mm
1.14.1 Nozzle Gland Stud - Install Nozzle ground [1.89 in.]) [1.46 in.]
Tighten the nozzle gland stud bolt until it comes to the bot- stud
tom end.
1.14.2 Bridge Guide - Install
Press fit the bridge guide to the specified dimension.
Nozzle gland stud bolt and Bridge guide - Install
29402-00120
6-9
1.15 Distortion of Cylinder Head Bottom Surface - Measure
Keep the grinding amount of cylinder head to the

minimum. Excessive grinding of the cylinder head
may result in defects such as contact between piston
and valve.
With a straight edge placed on the bottom face of cylinder
head, measure the bottom face distortion with feeler gauges.
If the value exceeds the limit, replace the cylinder head with
Cylinder head
a new one, or correct by grinding.
Distortion of Cylinder Head Bottom Surface - Measure
After the grinding, record the maximum depth of grinding.
The maximum amount of total grinding, which includes Cylinder head top face
roughness:
both grinding amount of the top of crankcase and the bottom 134.9 to 135.1 mm
Ra 3.2 μ m{12.5S
‫ۃۃۃ‬
} [5.311 to 5.319 in.]
of cylinder head, must be 0.50 mm [0.020 in.] or less.

Distortion of cylinder 0.03 mm 0.07 mm
head bottom surface [0.0012 in.] or less [0.0028 in.]
Height of cylinder head 134.9 to 135.1 mm
-
(reference value) [5.311 to 5.319 in.]
Height of Cylinder Head - Measure

1.16 Water Director - Inspect and Replace
(1) Inspect the water director, and if corrosion or damage is
found, replace the water director with a new one. Water director
(2) Orient the pipe and the opening of the water director as
shown in the illustration, and tap the water director
lightly with a soft head mallet.
A 35° B B
1.0 mm 1.0 mm [0.039 in.]

[0.039 in.]
Section AA Section BB
Water Director Mounting Orientation
6-10 29402-00120
2. Rear Mechanism - Inspect and Repair

2.1 Idler Bushing Inside Diameter and Idler Shaft Outside Diameter - Measure
Measure the idler bushing inside diameter and the idler shaft
outside diameter. If the value exceeds the limit, replace the Measurement
direction
idler gear assembly or the idler shaft with a new one.
Measurement
Note: When replacing the idler bushing only, finish the bush- point
ing inside diameter by reaming.
Nominal
value Measurement
direction
Idler bushing ø50 mm 50.000 to 50.025 mm 50.060 mm
inside diameter [1.97 in.] [1.9690 to 1.9695 in.] [1.971 in.]
Idler shaft ø50 mm 49.950 to 49.975 mm 49.900 mm
diameter [1.97 in.] [1.9665 to 1.9675 in.] [1.9646 in.] Idler Bushing Inside Diameter and Idler Shaft Outside
Diameter - Measure
2.2 Idler Bushing - Replace

(1) Using the removing side of the idler bushing puller,
remove the idler bushing.
Idler bushing puller
(2) Using the installing side of the idler push puller, press- P/N:32591-02500
in the idler bushing from the large gear side until it
becomes flush with the end face of gear boss. Idler bushing B
(3) After installing, ream the bore of idler bushing to the ▲
specified dimension as shown.
Note: Reaming after press-fit is necessary, as the idler bush-
A
▲
ing is supplied in a semi-finished condition.
[0.16 in.]
4 mm
Idler gear
Ra 0.8μm
▽▽▽
3.2S
ø0.05 S A
ø0.05 S B
Φ50H7( +0.025
0 )mm
Idler bushing replacement

2.3 Cam Lift of Cam Shaft Lobe - Measure
Measure the major diameter and the minor diameter of cam
lobe to calculate the cam lift. If the value exceeds the limit,
replace the camshaft with a new one.
Major diam

Cam lift of camshaft 7.54 to 7.64 mm 6.79 mm
(major dia - minor dia) [0.2969 to 0.3008 in.] [0.2673 in.] Minor diam
Cam Lift of Cam Shaft Lobe - Measure
29402-00120
6-11
2.4 Camshaft Runout - Measure

Measure the runout of camshaft in TIR. If the value exceeds
the limit, correct the camshaft using a press, or replace the
V-block
camshaft with a new one.
Note: With a dial gauge set on the camshaft, rotate the cam-
shaft one turn and read the gauge indication.
Item Standard value Limit value Remark Surface plate

0.05 mm 0.16 mm 1/2 1/2
Camshaft runout TIR
[0.0019 in.]or less [0.0063 in.]
Camshaft Runout - Measure

2.5 Camshaft Journal Outside Diameter - Measure
Measure the diameter of each camshaft journal in two direc-
tions at right angles to each other. If the value exceeds the
limit, replace the camshaft with a new one.
Nomi-
Item nal Standard value Limit value
value
Measuring
Camshaft journal ø68 mm 67.920 to 67.940 mm 67.870 mm directions
outside diameter [ø2.68 in.] [2.6740 to 2.6748 in.] [2.6720 in.]
Camshaft Journal Outside Diameter - Measure

2.6 Camshaft Bushing - Inspect
(1) Check the inside surface of each bushing for damage,
corrosion, flaking and other abnormalities. If any defect
is found, replace the camshaft bushing with a new one.
(2) Measure the camshaft bushing inside diameter with
bushing installed in the crankcase. If the value exceeds
the limit, replace the camshaft bushing with a new one. Measuring
Note: Be careful not to damage the inner surface of camshaft directions
bushing when measuring the inside diameter.
Nominal Limit
Item Standard value
value value
Camshaft Bushing Inside Diameter - Measure
Camshaft bushing ø68 mm 68.000 to 68.030 mm 68.090 mm
inside diameter [ø2.68 in.] [2.6772 to 2.6783 in.] [2.6807 in.]
6-12 29402-00120
2.7 Camshaft Bushing - Replace
Before tightening the set bolt, be sure to check that Oil holes
the set bolt is in alignment with the set bolt hole in the
camshaft bushing.
Make sure that the oil hole in the camshaft bushing is Set bolt
in alignment with the oil hole from the oil gallery.

(1) Remove the camshaft bushing set bolt and remove the
camshaft bushing. Set bolt hole
(2) Before inserting the camshaft bushing to the bushing Sealing washer
hole on the crankcase, be sure to check the position of Camshaft Bushing - Install
oil hole and set bolt hole.
(3) Before securing the set bolt, be sure to check that the
set bolt is in alignment with the oil hole.
29402-00120
6-13
3. Front Mechanism - Inspect and Repair

3.1 Damper - Inspect Visually
Check the damper for cracks around the outer periphery,
swelling in the end plate, silicone oil leakage, and discolor-
ation and peeling of the coating due to overheating. If any
defect is found, replace the damper with a new one.
Damper - Inspect Visually

3.2 Pulley - Inspect
Check the belt groove of pulley for wear.
(1) Check the sinkage of belt.
(2) Fit a new belt tightly in the pulley groove.
(3) If the belt sinks 1.6 mm [0.063 in.] or more below the
1.6 mm [0.063 in.]
pulley rim, replace the pulley with a new one.
or less
Pulley Wear - Inspect
6-14 29402-00120
4. Piston and Connecting Rod - Inspect and Repair

4.1 Piston - Inspect Visually
Check the combustion surface, piston pin bore, ring groove,
sliding surface, and bottom surface of the piston. If any
defect is found, replace the piston with a new one.
Piston - Inspect Visually

4.2 Piston Weight
Check the piston weight punch mark on the top face of pis-
ton. Engine Front
Piston weight mark Direction mark㺀㹄㺁
When replacing pistons, be sure that the weight difference
in one engine is within the permissible range.
Item Standard value

)
Piston weight difference Within ±15 g [0.53 oz]
ID mark
(Last 5 digits of PN)
Piston weight punch mark
4.3 Piston Outside Diameter - Measure
Measure the piston outside diameter of piston skirt in the
[1.18 in.]
30 mm
right angle to the piston pin. If the value exceeds the limit,
replace the piston with a new one.
Measuring
positions
Nominal
value
Piston outside ø150 mm 149.71 to 149.75 mm 149.68 mm
diameter [ø5.91 in.] [5.8941 to 5.8957 in.] [5.8929 in.]
Piston Outside Diameter - Measure

4.4 Piston Ring Groove - Inspect
Remove carbon deposits from the piston and inspect

Ring groove insert
the whole circumference of piston.
No.1 compression ring
(1) Remove all deposits such as carbon from each ring groove
groove.
No.2 compression ring
(2) Visually check each ring groove for wear or damage. If groove
defective, replace the piston with a new one. Inspect the
Oil ring groove
ring trager of No. 1 compression ring groove by dye
penetration test for cracks and separation.
Piston Ring Groove - Inspect
29402-00120
6-15
4.5 Piston Pin Hole Inside Diameter - Measure

Measure the piston pin bore inside diameter. If the value
exceeds the limit, replace the piston with a new one.
Nominal
value
Measuring
Piston pin bore ø58 mm 58.002 to 58.012 mm 58.040 mm direction Measuring
inside diameter [ø2.28 in.] [2.2835 to 2.2839 in.] [2.2850 in.] posion
Piston Pin Bore Inside Diameter - Measure

4.6 Piston Ring - Inspect Visually
Check the sliding surface, the top and bottom surfaces for
seizing, wear, foreign material inclusion, and plating flak-
ing. If any defect is found, replace the piston ring with a
new one.
4.7 Piston Ring End Gap - Measure

Place the piston ring in the gauge or a new cylinder liner,
and measure the end gap. If the value exceeds the limit,
replace the piston rings with a new set of rings. Thickness gauge
Note: With a piston, push the piston ring squarely into the
gauge or the cylinder liner.

No.1 0.6 to 0.8 mm
compression [0.024 to 0.032 in.]
No.2 0.5 to 0.7 mm 2.0 mm Gauge diameter:
Piston ring end gap
compression [0.020 to 0.028 in.] [0.079 in.] 150 ± 0 mm [5.91 ± 0 in.] End gap
0.5 to 0.7 mm Piston Ring End Gap - Measure
Oil
[0.020 to 0.028 in.]
4.8 Piston Pin Outside Diameter - Measure

Measure the piston pin outside diameter.
Measuring
If the value exceeds the limit, replace the piston pin with a directions
new one.
Nominal
value
Piston pin ø58 mm 57.987 to 58.000 mm 57.970 mm
outside diameter [ø2.28 in.] [2.2829 to 2.2835 in.] [2.2823 in.]
Measuring
positions
Piston Pin Outside Diameter - Measure
6-16 29402-00120
4.9 Connecting Rod Bushing Inside Diameter - Measure

Measure the inside diameter of the connecting rod bushing.
If the value exceeds the limit, replace the connecting rod Measuring
directions
bushing with a new one.
Measuring
Nominal positions
value
Inside diameter
ø58 mm 58.020 to 58.040 mm 58.070 mm
of connecting rod
[ø2.28 in.] [2.2842 to 2.2850 in.] [2.2862 in.]
bushing
Connecting Rod Bushing Inside Diameter - Measure

4.10 Connecting Rod Bushing - Replace
Replace the connecting rod bushing using the connecting
rod bushing installer.
4.10.1 Installer Base and Connecting Rod - Fix
Connecting rod bushing installer
(1) Align the match mark on the base with the match mark P/N:32591-18010
Base match mark
on the plate, and install the plate. Base match mark (red ø4 mm [0.16 in.])
(red line mark)
(2) Align the match mark on the adapter with the match
mark on the base, and install the adapter.
Adapter Plate
Adapter match mark Base Plate match marks
(red line mark) (red ø4 mm [ø0.16 in.])
Connecting Rod Bushing Installer - Use (1)
(3) With the connecting rod bearing removed from the con-
necting rod, install the connecting rod cap to the plate. Connecting rod cap
Connecting rod Plate
(4) Align the match mark, and install the connecting rod to
the plate.
(5) Tighten the connecting rod bolts to the specified torque.
(6) Secure the connecting rod with the bracket.
Base
Mark on the plate
Adapter
Bracket Oil hole of connecting rod
29402-00120
6-17
4.10.2 Connecting Rod Bushing - Remove

(1) Apply engine oil on inner surface of connecting rod
bushing.
(2) Attach the collar A to the mandrel and insert the assem- Mandrel
bly into the connecting rod bushing while aligning the Mark on collar A
(red stamp mark)
match mark (red scribed line) on the collar A with that Collar A
on the adapter.
(3) Using a pressing machine, apply pressure slowly on the
mandrel head to push-out the connecting rod bushing.
Connecting rod
bushing
Mark on adapter
(red line mark)
Adapter
Base
6-18 29402-00120
4.10.3 Connecting Rod Bushing - Press-In
(a) Make sure that the match marks (red lines) on col-
Connecting rod bushing
lars A and B are aligned. oil hole
(b) Make sure that the oil hole of connecting rod
Collar A
bushing is in alignment with match mark (red φ4 match mark
(ø4 mm [ø0.16 in.] red)
mm [φ0.16 in.]) on collar A.
(1) Align the oil hole with the match mark on collar A (ø4
mm [0.16 in.] red), and install the new connecting rod
bushing on the collar A. Connecting Rod Bushing Installer - Use (4)
(2) Install the combination of collar A and collar B to the
mandrel, and fix them with the nut.
Mandrel
Match mark on
collar A and B
(red stamp marks)
Collar B
Connecting rod
bushing
Nut Collar A
Match mark on adapter

(red line marks)
Adapter
Base
(3) Apply engine oil to the outer surface of connecting rod
Collar A match mark
bushing. Align the match mark (red line) on collar A (ø4 mm [ø0.16 in.] red) Connecting rod oil hole
with the mark of collar B to align the oil hole of con-
necting rod bushing and the oil hole of connecting rod.
Press-in the bushing into the connecting rod with a
pressing machine.
Connecting rod
oil hole
29402-00120
6-19
(4) Measure the inside diameter of the connecting rod

Bushing inner surface
bushing. 1.6S
roughness ‫ۃ‬ ‫ۃۃ‬
If the value is not within the standard value, ream the Inside diameter of
connecting rod bushing
inside diameter to the standard.
Connecting rod
Item Standard value bushing
58.020 to 58.040 mm
Inside diameter of connecting rod bushing
[2.2842 to 2.2850 in.]
Connecting rod
Connecting Rod Bushing Inside Diameter - Measure
4.11 Connecting Rod Assembly Weight Rank
When replacing a connecting rod, be sure to check the
weight rank of the connecting rod, and use the connecting
rod having the same weight rank mark. All the connecting
rods in one engine must have the same weight rank mark.
Weight rank list

Allowable
Part No. Weight rank Weight
value
7220 g
32519-81110 A
[254.7 oz]
7320 g Weight rank mark location
32519-81210 B
[258.2 oz]
7420 g Connecting Rod Weight Rank Mark Location
32519-81310 C
[261.7 oz]
7520 g
32519-81410 D
[265.3 oz] ±20g
7620 g [0.7 oz]
32519-81510 E
[268.8 oz]
7720 g
32519-81610 F
[272.3 oz]
7820 g
32519-81710 G
[275.8 oz]
7920 g
32519-81810 H
[279.4 oz]
Note: The weight rank of connecting rod assembled in the

engine is also stamped on the caution plate.
4.12 Inside Diameter and Roundness of Connecting Rod Big-End Bore - Measure
Measure the connecting rod bore diameter at the front and
rear ends respectively in the directions A, B and C as shown
in the illustration. The roundness is determined by subtract-
A
ing the minimum value from the maximum value among B
measurements of A, B and C.
C Front Rear
If the value exceeds the limit, replace the connecting rod
with a new one. Measuring
Measuring positions
directions
Limit value
Nominal Standard
Item Limit value of
value value
roundness
Minimum:
Connect-
ø110 mm
110.000 to 109.950 mm Connecting Rod Big-End Bore Diameter - Measure
ing rod big- 110.022 mm [4.3287 in.] 0.100 mm
[ø4.33
end bore [4.3307 to Maximum: [0.0039 in.]
in.]
diameter 4.3316 in.] 110.050 mm
[4.3327 in.]
6-20 29402-00120
4.13 Side Face Width of Connecting Rod Big End - Measure

(1) Visually inspect the side face of the connecting rod big-
end. If there is any defect such as wear or flaw, replace
the connecting rod with a new one.
(2) Measure the side face width of connecting rod big-end.
Connecting rod big end side face (width)
If the measured value does not meet the standard,
replace the connecting rod with a new one.
Item Standard value

60.7 to 60.8 mm
Side face width of connecting rod big-end
[2.390 to 2.394 in.]
Side Face Width of Connecting Rod Big-End -Measure

4.14 Connecting Rod Big End Serration and Bolt Holes - Inspect
Inspect the connecting rod big-end serration and the bolt
holes with the magnetic particle inspection. If there is any
defect such as cracks, fretting, and foreign material inclu-
sion, replace the connecting rod with a new one.
4.15 Connecting Rod Bearing - Inspect
Inspect the sliding surface, back surface, and end surfaces of
the connecting rod bearing. If there is any defect such as
local contact, sliding scratches, corrosion, and foreign mate-
rial inclusion, replace the bearing with a new one.
Scratches
Flaking
Seizure
End face
Connecting Rod Bearing - Inspect

4.16 Connecting Rod Bearing Thickness - Measure
Measure the thickness of the connecting rod at its center
position.
If the value exceeds the limit, replace both upper and lower
Measure
connecting rod bearing shells with new ones as a set. When at the center
the crankshaft is re-ground due to wear of the crank pin, use of bearing.
the undersize bearing.
For the crankshaft grinding procedure, refer to "Crankpin
and Crank Journal - Grind" of "INSPECTION AND
REPAIR OF BASIC ENGINE."
Note: Replacement shells for undersized connecting rod
bearing are available in sizes of 0.25, 0.50, 0.75 and
1.00 mm [0.0098, 0.0197, 0.0295 and 0.0394 in.]. Bearing thickness - Measure
Item Size Nominal value Standard value Limit value
Standard 3.000 mm [0.1181 in.] 2.987 to 3.000 mm [0.1176 to 0.1181 in.] 2.950 mm [0.1161 in.]
0.25 mm
3.125 mm [0.1230 in.] 3.112 to 3.125 mm [0.1225 to 0.1230 in.] 3.075 mm [0.1211 in.]
[0.0098 in.]
0.50 mm
Connecting rod bearing 3.250 mm [0.1280 in.] 3.237 to 3.250 mm [0.1274 to 0.1280 in.] 3.200 mm [0.1260 in.]
[0.0197 in.]
thickness Under size
0.75 mm
[0.0295 in.]
1.00 mm
[0.0394 in.]
29402-00120
6-21
4.17 Connecting Rod Bend and Twist - Inspect

(1) Measure the dimensions of C and L as shown in the
illustration to check bend and twist of the connecting C C 0.05 [ 0.0020 ]
L 100 3.94
rod. Correct the connecting rod with a press machine so L C 0.05 [ 0.0020 ]
that the measured value meets the standard. Piston pin L 100 3.94 L
If the value exceeds the limit, replace with a new one.
C
Note: Tighten the connecting rod cap to the specified torque
and check bend and twist. Connecting rod bend Connecting rod twist
Torque
(2) To inspect the connecting rod in the piston installed
343 ± 17.7 N·m
condition, turn the piston upside down and place it on a {35 ± 1.8 kgf·m} [253 ± 13.0 lbf·ft]
surface plate. Insert a round bar having the same diame- 2-Step tightening [wet] Unit: mm [in.]
Connecting Rod Bend and Twist - Inspect
ter as the crankpin into the big-end bore, and measure
the height of the bar with a dial gauge. D Unit: mm [in.]
Item Standard value
C
Connecting rod bend and twist 0.05/100 mm
(C/L and C/D) [0.0020/3.94 in.] or less
C 0.05 [0.002]
D 100 [3.937]
Surface plate
Bend of Connecting Rod - Measure
6-22 29402-00120
5. Crankcase and Crankshaft - Inspect and Repair

5.1 Crankcase Top Surface Distortion - Measure
Straight edge
The refacing depth of the crankcase is to be minimum.
An excessive grinding of the crankcase may result in
defects such as the defective combustion and stamp-
ing between the piston and the valve.
Apply a straight edge to the top surface of the crankcase and
measure its distortion with thickness gauges. If the value
exceeds the limit, replace the cylinder head with a new one,
or repair by grinding.
After the grinding, record the maximum depth of grinding. Crankcase Top Surface Distortion - Measure
Note that the total grinding amount, which includes the
grinding depth of the bottom surface of the cylinder head, Cylinder head top face roughness:
Ra 1.6 μ m{‫}ۃۃۃ‬
must be 0.50 mm [0.0197 in.] or less.
Standard
Item Limit value 468.95 to
value
469.05 mm
0.1 mm 0.2 mm [18.4626 to
Crankcase top surface distortion
[0.004] or less [0.008 in.]
18.4665 in.]
468.95 to
Height from the crank journal center
469.05 mm
to the crankcase top surface (refer- -
[18.4626 to
ence value)
18.4665 in.]
From the center of crank journal to the crankcase top

surface
5.2 Inside Diameter of Main Bearing Housing Bore - Measure
(1) Assemble the main bearing cap in the crankcase in
588 ± 29 N·m
accordance with the specified method. {60 ± 3 kg f·m}
Note: For the tightening procedure of the main bearing cap, [434 ± 21.4 lbf·ft]
[Wet]
refer to "Main Bearing Cap - Install" of "ASSEMBLY
OF BASIC ENGINE."
(2) Measure the housing diameter in the vertical and the
two diagonal directions.
147 ± 7.4 N·m ]
{15 ± 0.75 kgf·m}
Nominal Standard [108 ± 5.46 lbf·ft]
Item Limit value
value value [Wet]
147.000 to
Inside diameter of ø147 mm 147.025 147.045 mm
main bearing housing [ø5.79 in.] [5.7874 to [5.7892 in.] Inside Diameter of Main Bearing Housing Bore -
5.7884 in.] Measure
5.3 Cylinder Liner Fitting Bore in Crankcase - Inspect
(1) Inspect the counterbore in the crankcase. Check for
cracks in edges, uneven contact between the counter- Counterbore in crankcase
bore and the bottom face of the cylinder liner flange. If
any defect is found, reface the counterbore in the crank-
case.
(2) Inspect the cylinder liner fitting section in the crank-
case. Check for the defects such as fretting and corro-
sion.
Fitting bore of
cylinder liner
in crankcase
Cylinder Liner Fitting Bore in crankcase- Inspect

29402-00120
6-23
5.4 Counterbore in Crankcase - Repair

If a local contact is found on the counterbore in the crank-
Grinder
case, grind and repair. Grind the counterbore with the crank-
case grinder to correct the depth differences at four
directions in circumference to be 0.05 mm [0.0020 in.] or
less.
After the grinding of counterbore in the crankcase is com-
pleted, measure the cylinder liner flange protrusion. Crankcase
counterbore
Crankcase grinder
P/N:37591-07010
Counterbore in Crankcase - Repair
6-24 29402-00120
5.5 Crank Pin and Journal Outside Diameters - Measure

(1) Measure the outside diameter of crankpins and crank
journals. Measuring Measuring
directions positions
If the value exceeds the limit, use the undersize bearing,
and grind the crankshaft to fit the undersize bearing. If
the value exceeds the limit even when the -1.00 mm [-
0.0394 in.] undersize bearing is used, replace the crank-
shaft with a new one.
(2) Calculate the roundness and cylindricity based on the
measured values.
Crankpin Outside Diameter - Measure

5.5.1 Crankpin and Crank Journal - Grind
When using the undersize bearing, grind to the standard
Measuring Measuring
value corresponding to the undersize bearing to be used. Do directions positions
not change the fillet radius and the bearing journal width
when grinding. If a remarkable decrease in hardness is
found, quench the crankshaft again and inspect it with the
magnetic particle inspection.
After the grinding, measure the width of crankpins and the
rearmost crank main journal.
Crank Journal Outside Diameter - Measure
29402-00120
6-25
Nominal
Item Size Standard value Limit value
value
Standard 103.880 to 103.900 mm [4.0898 to 4.0905 in.] 103.840 mm [4.0882 in.]
0.25 mm
103.630 to 103.650 mm [4.0799 4.0807 in.] 103.590 mm [4.0783 in.]
[0.0098 in.]
0.50 mm
ø104 mm 103.380 to 103.400 mm [4.0701 to 4.0709 in.] 103.340 mm [4.0685 in.]
Crankpin outside diameter [0.0197 in.]
[4.09 in.] Under
size 0.75 mm
103.130 to 103.150 mm [4.0602 to 4.0610 in.] 103.090 mm [4.0587 in.]
[0.0295 in.]
1.00 mm
102.880 to 102.900 mm [4.0504 to 4.0512 in.] 102.840 mm [4.0488 in.]
[0.0394 in.]
Standard 139.930 to 139.950 mm [5.5090 to 5.5098 in.] 139.900 mm [5.5079 in.]
0.25 mm
139.680 to 139.700 mm [5.4992 to 5.5000 in.] 139.640 mm [5.4976 in.]
[0.0098 in.]
0.50 mm
Crankshaft main journal ø140 mm 139.430 to 139.450 mm [5.4894 to 5.4901 in.] 139.390 mm [5.4878 in.]
[0.0197 in.]
outside diameter [5.51 in.] Under
size 0.75 mm
139.180 to 139.200 mm [5.4795 to 5.4803 in.] 139.140 mm [5.4779 in.]
[0.0295 in.]
1.00 mm
138.930 to 138.950 mm [5.4697 to 5.4705 in.] 138.890 mm [5.4681 in.]
[0.0394 in.]
Deviation of 0.01 [0.0004] or less
Parallelism - - 0.03 mm [0.0012 in.]
over the whole pin length
Roundness - - Diameter difference 0.01 [0.0004] or less 0.03 mm [0.0012 in.]
Cylindricity - - Diameter difference 0.01 [0.0004] or less 0.03 mm [0.0012 in.]
R7 mm
Pin [R0.28 - 6.8 to 7.0 mm [0.268 to 0.276 in.] -
Pin and
Fillet in.]
journal
radius R7 mm
Journal [R0.28 - 6.8 to 7.0 mm [0.268 to 0.276 in.] -
in.]
Hardness - - Hv > 620 -
Finishing surface
- - Ra 0.2 μm [8 μin.] -
roughness
Angular deviation between pins - - ±20' -
6-26 29402-00120
5.6 Width of Crankpin and Rearmost Crank Main Journal - Measure

(1) Inspect the ends of crankshaft for harmful flaw and
wear. Crankpin
(2) Measure the crankpin and rearmost crank journal width
width. Rearmost crank
When using oversize thrust plates due to wear of rear- journal width
most crank journal width, grind the crankshaft for use
with oversize thrust plates.
5.6.1 Rearmost Crank Journal Width - Grind
When using the oversize thrust plates, grind the rearmost
crank journal width to the standard value for use with over-
size thrust plates.
Width of Crankpin and Rearmost Crank Main Journal -
Do not change the fillet radius when grinding. Quench the Measure
crankshaft if its surface hardness is significantly decreased,
and after quenching do the magnetic particle inspection.
Ensure that the finishing surface roughness after grinding is 3.2S
‫ۃۃۃ‬
in the standard value.
3.2S
Note: The difference between the front and the rear thrust ‫ۃۃۃ‬
plate in thickness must be 0.25 mm [0.0098 in.] or less.
‫ۃۃۃۃ‬
Fillet radius Fillet radius

R7 mm[R0.28 in.] R7 mm[R0.28 in.]
Rearmost Crank Journal Width - Grind
Item Nominal value Size Standard value

Crankpin width 61 mm [2.40 in.] - 61.20 to 61.30 mm [2.4094 to 2.4134 in.]
Standard 58.00 to 58.03 mm [2.2835 to 2.2846 in.]
0.25 mm [0.0098 in.] 58.25 to 58.28 mm [2.2933 to 2.2945 in.]
0.50 mm [0.0197 in.] 58.50 to 58.53 mm [2.3031 to 2.3043 in.]
Rearmost crank journal width 58 mm [2.28 in.] 0.75 mm [0.0295 in.] 58.75 to 58.78 mm [2.3130 to 2.3142 in.]
Over size
1.00 mm [0.0394 in.] 59.00 to 59.03 mm [2.3228 to 2.3240 in.]
1.25 mm [0.0492 in.] 59.25 to 59.28 mm [2.3327 to 2.3339 in.]
1.50 mm [0.0591 in.] 59.50 to 59.53 mm [2.3425 to 2.3437 in.]
5.7 Crankshaft Runout - Measure

Support the crankshaft at the front and the rear main jour-
nals with V-blocks, and measure the crankshaft runout at the
V-block
center journal with a dial gauge. If the runout deviates
slightly outside of the standard values, correct the crank-
shaft by grinding. If the value exceeds the standard values
considerably, straighten the crankshaft with a pressing
machine.
If the value exceeds the limit, replace the crankshaft with a Surface plate
new one. 1/2 1/2
If the crankshaft is repaired by grinding or pressing, inspect
the crankshaft for cracks and other harmful damages with
the magnetic particle inspection. Crankshaft Runout - Measure

0.04 mm 0.10 mm
Crankshaft runout TIR
[0.0016 in.] or less [0.0039 in.]
29402-00120
6-27
5.8 Crankshaft Gear - Inspect

If there is any defect on the crankshaft gear tooth, such as
flaking, wear, or local contact, replace the crankshaft gear
with a new one.
5.9 Crankshaft Gear - Replace
Use protective gloves when you touch hot parts.

Crankshaft gear
Handling with bear hands could result in burns.
5.9.1 Crankshaft Gear - Remove

Remove the gear from the crankshaft with a gear puller.
Note: When removing the crankshaft gear by heating, the
heating temperature shall be 180°C [356 °F] or less.
Crankshaft Gear - Remove
5.9.2 Crankshaft Gear - Install

Engaged
position
(a) Make sure the correct orientation and position of
crankshaft gear when installing.
(b) To shrinkage-fit the crankshaft gear to the crank-
shaft, heat the crankshaft gear evenly at the spec-
ified temperature or below.
(1) Measure the outside diameter of crankshaft and the

Matching mark
inside diameter of crankshaft gear, and check the inter- stamped side
ference. Crankshaft Gear - Install
(2) Heat the crankshaft gear evenly at the specified tem-
Shrink fit temperature: 180䉝 [356䉣] or below
perature or below. After checking gear orientation and
Crankshaft gear
position, install the crankshaft gear.
Dowel pin
Interference standard:
0.106 to 0.171 mm
[0.0042 to 0.0067 in.]
Crankshaft Gear Installation Orientation
6-28 29402-00120
5.10 Oil Seal Slinger - Inspect

If any defect such as dent, damage, wear and backlash that
Front Rear
could lead to oil leakage is found on the rear oil seal slinger,
Timimg
replace the rear oil seal slinger with a new one. Oil seal gear case
case
Note: Whenever the front cover is replaced, the front side
slinger must be replaced with a new one, as the front
slinger is a cassette (assembling) type including the oil Oil seal
seal.
Oil seal
slinger
Oil seal
Oil Seal Slinger - Inspect
Timimg
gear case
Oil seal
Oil seal
slinger
Rear Oil Seal Slinger - Inspect (double lip spec)

5.11 Oil Seal Slinger - Replace
Oil seal slinger

5.11.1 Oil Seal Slinger - Remove
(1) With a gear puller, pull out the rear side oil seal slinger
from the crankshaft.
(2) Remove the front side oil seal slinger with a screw-
driver by prying it out.
Note: When removing the oil seal slinger by heating, the
heating temperature is 100°C [212°F] or less. Oil Seal Slinger (Rear) - Remove
Double lip spec
When making a cut in the oil seal slinger, be very care-

ful not to damage the crankshaft with the chisel.
Tap a chisel with a hammer on the periphery of the oil seal

slinger at three locations by holding the chisel in the radial
direction to reduce the slinger tension. When the slinger is
loosened, remove the slinger.
Note: If the oil slinger can not be removed by the above pro-
cedure, hold the chisel in the axial direction and tap the
slinger end to loosen, then remove the slinger.
29402-00120
6-29
5.11.2 Oil Seal Slinger - Install

(1) Measure the outside diameter of crankshaft and the ID mark
(32511-05200)
inside diameter of oil seal slinger, and check the inter-
ference.
(2) Heat the rear side oil seal slinger evenly to 110ºC [230
°F] or below. After checking the correct direction and
Crankshaft
position of slinger, install the slinger. rear end
Note: The front side slinger is a cassette type with the inte- Tight contact with gear
Interference standard value:
grated oil seal, therefore, the front slinger must be in- 0.210 to 0.294 mm
[0.0083 to 0.0116 in.]
stalled together with the oil seal after the front cover is
Oil Seal Slinger - Install (1)
mounted.
For installation, refer to "Front Oil Seal - Install" of
Installer
"ASSEMBLY OF BASIC ENGINE."
Oil seal
slinger
Oil Seal Slinger - Install (2)

Double lip spec
Be flush with the edge of
crankshaft when installing
oil seal slinger.
Pay attention not to dent or damage the outer surface
Dowel pin
of oil seal slinger.
Installer
When installing the oil seal slinger, apply oil to the inside of P/N:32591-00500
Rear
oil seal slinger, and drive it to the crankshaft with the rear oil seal
slinger
slinger installer.
Rear slinger guide Rear slinger
Installer
P/N:35A91-02200 P/N:35A91-02020
Rear Oil Seal Slinger - Install
(double lip spec)
6-30 29402-00120
5.12 Main Bearing - Inspect

Inspect the sliding surface, back surface and end surfaces of
the main bearing. If any defect such as local contact, sliding
scratches, corrosion and foreign material inclusion is found,
replace the main bearing with a new one.
Flaw, corrosion, flaking
End face
Main Bearing - Inspect

5.13 Thickness of Main Bearing - Measure
Measure the thickness of main bearing shell at the center
position.
If the value exceeds the limit, replace both upper and lower Measure
main bearing shells with new ones as a set. at the center
of bearing.
When the crankshaft is re-ground due to wear of crank jour-
nal, use the undersize bearings.
For the crankshaft grinding procedure, see "Crankpin and
Crank Journal - Grind" of "INSPECTION AND REPAIR
OF BASIC ENGINE."
Note: Replacement shells for undersized main bearing are
available in sizes of 0.25, 0.50, 0.75 and 1.00 mm Thickness of Main Bearing - Measure
[0.0098, 0.0197, 0.0295 and 0.0394 in.].

3.500 mm 3.467 to 3.480 mm 3.425 mm
Standard
[0.1378 in.] [0.1365 to 0.1370 in.] [0.1348 in.]
0.25 mm 3.625 mm 3.592 to 3.605 mm 3.550 mm
[0.010 in.] [0.1427 in.] [0.1414 to 0.1419 to in.] [0.1398 in.]
0.50 mm 3.750 mm 3.717 to 3.730 mm 3.675 mm
Main bearing thickness at the center position
[0.020 in.] [0.1476 in.] [0.1463 to 0.1469 in.] [0.1447 in.]
Undersize
0.75 mm 3.875 mm 3.842 to 3.855 mm 3.800 mm
[0.030 in.] [0.1526 in.] [0.1513 to 0.1518 in.] [0.1496 in.]
1.00 mm 4.000 mm 3.967 to 3.980 mm 3.925 mm
[0.039 in.] [0.1575 in.] [0.1562 to 0.1567 in.] [0.1545 in.]
5.14 Thrust Plate - Inspect

Inspect the sliding surface, back surface, and end surfaces of
the thrust plate. If any defect such as local contact, sliding
scratches, corrosion, and foreign material inclusion is
End face
found, replace the thrust plate with a new one.
Flaw, corrosion, peeling

Thrust Plate - Inspect
29402-00120
6-31
5.15 Thickness of Thrust Plate - Measure

Measure the thickness of thrust plate.
If the value exceeds the limit, replace the thrust plate with a
new one. When the crankshaft is re-ground due to wear, use
the oversize thrust plates.
For crankshaft grinding procedure, see "Rearmost Crank
Journal Width - Grind" of "ENGINE BODY - INSPECT
AND REPAIR."
Note:(a) Replacement thrust plates are available in three
oversizes of 0.25, 0.50, and 0.75 mm [0.0098,
0.0197, 0.0295 in.].
Thickness of Thrust Plate - Measure
(b) Because the oversize thrust plate can be used in
only one side (a set of upper and lower plates), the
end play can be adjusted with a minimum depth of
the crankshaft grinding.

Standard 5.00 mm [0.1969 in.] 4.78 to 4.85 mm [0.1882 to 0.909 in.] 4.76 mm [0.1874 in.]
0.25 mm [0.0098 in.] 5.25 mm [0.2067 in.] 5.03 to 5.10 mm [0.1980 to 0.2008 in.] 5.01 mm [0.1972 in.]
Thickness of thrust plate
Oversize 0.50 mm [0.0197 in.] 5.50 mm [0.2165 in.] 5.28 to 5.35 mm [0.2079 to 0.2106 in.] 5.26 mm [0.2071 in.]
0.75 mm [0.0295 in.] 5.75 mm [0.1506 in.] 5.53 to 5.60 mm [0.2177 to 0.2205 in.] 5.51 mm [0.2169 in.]
5.16 Piston Cooling Nozzle - Inspect
Spray hole
If the oil jet pipe of piston cooling nozzle is bent or
deformed, it will reduce the cooling performance, and
can lead to the piston seizure.
Inspect the piston cooling nozzle.
If there is any defect such as valve malfunction and oil hole
clogging, replace the piston cooling nozzle with a new one.
Valve
Item Standard value
0.26 to 0.32 MPa
Valve opening pressure of piston Piston Cooling Nozzle - Inspect
{2.65 to 3.26 kgf/cm2}
cooling nozzle
[37.7 to 46.4 psi]
6-32 29402-00120
1. Crankshaft and Main Bearing - Install ................................................................... 7-3
1.1 Crankcase - Turn Over (Upend) ............................................................................................... 7-3
1.2 Piston Cooling Nozzle - Install .................................................................................................. 7-3
1.3 Upper Main Bearing - Install ..................................................................................................... 7-4
1.4 Crankshaft - Install.................................................................................................................... 7-4
1.5 Upper Trust Plate - Install ......................................................................................................... 7-5
1.6 Lower Main Bearing Shell and Lower Thrust Plate - Install ...................................................... 7-5
1.7 Main Bearing Cap - Install ........................................................................................................ 7-6
1.8 Crankshaft End Play - Measure................................................................................................ 7-7
1.9 Crankcase - Turn Over ............................................................................................................. 7-7
2. Cylinder Liner, Piston, and Connecting Rod - Assemble .................................... 7-8
2.1 Cylinder Liner Protrusion - Measure ......................................................................................... 7-8
2.2 Cylinder Liner Flange Protrusion - Calculate (When Cylinder Liner Not Installed) ................... 7-8
2.3 Cylinder Liner - Install ............................................................................................................. 7-10
2.4 Cylinder Liner Flange Protrusion - Measure (When Cylinder Liner Installed)......................... 7-10
2.5 Cylinder Liner Inside Diameter - Measure .............................................................................. 7-11
2.6 Piston and Connecting Rod - Assemble ................................................................................. 7-11
2.7 Piston Ring - Install................................................................................................................. 7-12
2.8 Engine - Turning ..................................................................................................................... 7-12
2.9 Piston Installation - Preparation.............................................................................................. 7-13
2.10 Upper Connecting Rod Bearing - Install ................................................................................. 7-13
2.11 Piston - Install ......................................................................................................................... 7-14
2.12 Connecting Rod Cap - Install.................................................................................................. 7-16
2.13 Connecting Rod End Play - Measure ..................................................................................... 7-17
2.14 Piston Protrusion - Measure ................................................................................................... 7-17
3. Front Mechanism - Assemble............................................................................... 7-18
3.1 Front Cover - Install ................................................................................................................ 7-18
3.2 Front Oil Seal - Install ............................................................................................................. 7-18
3.3 Crankshaft Pulley, Damper, and Front Pulley - Install ............................................................ 7-19
3.4 Pointer - Install and Adjust...................................................................................................... 7-19
4. Rear Mechanism - Assemble ................................................................................ 7-20
4.1 Rear Plate - Install .................................................................................................................. 7-20
4.2 Idler Shaft - Install................................................................................................................... 7-20
4.3 Camshaft - Install.................................................................................................................... 7-21
4.4 Camshaft Gear - Install........................................................................................................... 7-21
4.5 Camshaft End Play - Measure................................................................................................ 7-21
4.6 Fuel Injection Pump Accessory Drive - Install ........................................................................ 7-22
4.7 Idler Gear - Install ................................................................................................................... 7-22
4.8 Idler Gear End Play - Measure ............................................................................................... 7-22
4.9 Timing Gear Backlash - Measure ........................................................................................... 7-23
4.10 Timing Gear Case - Install ...................................................................................................... 7-23
4.11 Rear Oil Seal - Install.............................................................................................................. 7-24
4.12 Flywheel - Install ..................................................................................................................... 7-25
4.13 Flywheel Face and Radial Runouts - Measure....................................................................... 7-25
4.14 Pickup - Install ........................................................................................................................ 7-25
5. Cylinder Head and Valve Mechanism - Assemble .............................................. 7-26
5.1 Cylinder Head - Assemble ...................................................................................................... 7-26
5.2 Valve Sinkage - Measure........................................................................................................ 7-27
5.3 Liquid Gasket - Apply.............................................................................................................. 7-27
29402-00120
7-1
5.4 Cylinder Head Gasket - Install ................................................................................................ 7-27

5.5 Cylinder Head Assembly - Install............................................................................................ 7-28
5.6 Cylinder Head Bolt - Tighten................................................................................................... 7-28
5.7 Bridge and Bridge Cap - Install............................................................................................... 7-29
5.8 Tappet and Push Rod - Install ................................................................................................ 7-29
5.9 Valve Bridge and Adjusting Screw - Adjust ............................................................................ 7-29
5.10 Clearance Between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect. 7-30
5.11 Rocker Shaft Assembly - Assemble ....................................................................................... 7-30
5.12 Rocker Shaft Assembly - Install.............................................................................................. 7-31
5.13 Valve Clearance - Check and Adjust ...................................................................................... 7-32
5.14 Fuel Injection Timing - Check and Adjust ............................................................................... 7-32
5.15 Valve Timing - Inspect ............................................................................................................ 7-34
5.16 Fuel Injection Nozzle Assembly - Install ................................................................................. 7-37
5.17 Fuel Pipe - Install .................................................................................................................... 7-37
7-2 29402-00120
1. Crankshaft and Main Bearing - Install

1.1 Crankcase - Turn Over (Upend)

the turnover machine is not available, attach slings to the Crankcase
weight:440 kg
crankcase using wood pieces and cloth pads, and raise the [970 lb]
crankcase with a hoist or crane. Then lay it on the wooden Crankcase
block with its side face downward. Then, change the posi-
tions of the slings, and turn over to upend the crankcase.
Wood block
Crankcase - Turn Over (Upend)
1.2 Piston Cooling Nozzle - Install
34 ± 3.4 N·m
Be sure to tighten the piston cooling nozzle to the {3.5 ± 0.35 kgf·m}
[25 ± 2.5 lbf·ft]
specified torque using a torque wrench. If excessively
Piston cooling nozzle
tightened, piston seizure may occur due to check
valve malfunction.
Install the piston cooling nozzle onto the crankcase and
tighten the check valve to the specified torque.
Piston Cooling Nozzle - Install
29402-00120
7-3
1.3 Upper Main Bearing - Install
(a) Do not apply engine oil on the back face of the main bearing shell and the main bearing housing in the crank-
case when installing the main bearing. Wash those surfaces to remove foreign material, oil, and grease using
a washing solvent before installing the main bearing.
(b) When installing main bearings, be careful not to confuse the upper shell with the lower shell.
The upper main bearing shell can be identified by a machined oil hole, and the lower main bearing shell has
no oil hole nor groove. Be careful not to install the main bearings upside down.
(c) Be careful not to damage the bearing when installing.
(1) Clean the main bearing housing and the main bearing
cap mating surfaces using cleaning solvent, and make
sure that these surfaces are free from any foreign mate-
rial.
(2) Make sure that the main bearing is free from damage or
contamination.
(3) Fit the upper main bearing shell in the crankcase bore Oil holes
by aligning the lug on the shell with the lug slot in the
crankcase.
Note:(a) Make the main bearing crush heights even at both
Lug groove Upper main bearing
ends.
Upper Main Bearing - Install
(b) The oil hole in the upper main bearing shell is
aligned with the oil hole in the crankcase by align-
ing the lug on the upper shell with the lug slot in the
crankcase.
(4) Apply an even coat of clean engine oil on the sliding
surface of upper main bearing shell.
1.4 Crankshaft - Install

(1) After installation, make sure that the sliding surfaces of
the upper main bearing shells in the crankcase are Apply engine oil to
the crank journal
evenly coated with clean engine oil.
after cleaning.
(2) Thoroughly clean the crankshaft with cleaning oil, and
blow off the oil with compressed air. Then, apply an
even coat of clean engine oil on the crankshaft journals.
Note: When cleaning the crankshaft, be sure to thoroughly Blow compressed
clean the crank journals, crankpins, and oil holes, and air after cleaning.
make sure that the crankshaft is free from foreign ma-
terial such as machining chips and dirt. Make sure that
oil holes are free from burrs.
Crankshaft - Clean
(3) Lift the crankshaft by keeping it in a horizontal attitude,
and slowly install into the crankcase.
Note: When lifting the crankshaft, use fiber slings or pads to
avoid any damages to the crankshaft.
Crankshaft
(4) Slowly rotate the crankshaft to verify a smooth rotation Weight: approx.
of the crankshaft. 235 kg [518 lb]
Crankshaft - Install
7-4 29402-00120
1.5 Upper Trust Plate - Install
Upper
thrust plate
Carefully install the thrust plate to avoid damage to Oil groove
thrust plate.
(1) Apply engine oil evenly on sliding surface of the upper
thrust plate.
(2) Install the upper thrust plates onto the front and back
faces of the rearmost journal through the clearances
between crankcase and crankshaft. Oil groove
Note: When installing, orient the thrust plate so that its oil
groove faces outward. Upper Thrust Plate - Install
1.6 Lower Main Bearing Shell and Lower Thrust Plate - Install
(1) Install the lower main bearing shell by aligning the lug
with the lug slot in the main bearing cap. Lower main
bearing
Note: Make the crush heights even.
(2) Apply an even coat of clean engine oil on sliding sur- Lower thrust
face of lower main bearing shell. plate
Lug slot
(3) Install the lower thrust plates by aligning with the Lower thrust
dowel pins on the rearmost main bearing cap. plate
Note: Install the lower thrust plates so that the oil grooves
faces outward. Main bearing cap
Oil Dowel pin
groove
Lower Main Bearing and
Lower Thrust Plates - Install
29402-00120
7-5
1.7 Main Bearing Cap - Install
Be sure to follow the specified tightening sequence

when tightening the main bearing cap bolts and side
bolts.
(1) Make sure that the main bearings and the thrust plates
Soft-head
installed on the main bearing caps are evenly coated hammer
with clean engine oil.
(2) Install the main bearing caps so that their number
stamps line up in numerical order from the front to rear
of the engine, and also the sides of the raised part num-
ber face toward the engine front (so that all rug grooves Main bearing
cap
are aligned on the same side).
(3) Apply oil to the main bearing cap bolts and washers,
and hand tighten them.
Main Bearing Cap - Install
(4) Tap the main bearing caps with a soft-head hammer
evenly to install them in position.
(5) Apply oil to the side bolts with O-rings and hand
tighten them.
(6) Tentatively tighten the main bearing cap bolts and side Tighten to the specified First time:
bolts except the rearmost ones, to the half of the speci- torque in the numerical Main bolt12:294 ± 15 N·m
order in two steps. {30 ± 1.5 kgf·m}
fied torque in the specified tightening sequence as [Wet] [217 ± 11 lbf·ft]
Side bolt 3, 4:74 ± 3.7 N·m
shown in the illustration. {7.5 ± 0.4 kgf·m}
Lower 1 2
(7) Then tighten the main bearing cap bolts and side bolts side
[55 ± 2.7 lbf·ft]
Second time:
except the rearmost ones to the specified torque in the Main bolt12:588 ± 29 N·m
specified sequence shown in the illustration. 3 4 {60 ± 3 kgf·m}
[434 ± 21.4 lbf·ft]
(8) Hand tighten the rearmost cap bolts and side bolts to Side bolt 3, 4:147 ± 7.4 N·m
Upper {15 ± 0.8 kgf·m}
make the rearmost main bearing be lightly seated. side [108 ± 5.5 lbf·ft]
Measure the crankshaft end play in this condition. Right side Left side View from engine rear side
Tightening Sequence of Main Bearing Cap Bolts
Cap bolt
588 ± 29 N·m
{60 ± 3 kgf·m}
[434 ± 21 lbf·ft]
[Wet]
Side bolt
147 ± 7.4N·m
{15 ± 0.8kgf·m}
[108 ± 5.5 lbf·ft]
[Wet]
Main Bearing Cap Bolts - Install
7-6 29402-00120
1.8 Crankshaft End Play - Measure

(1) Verify the smooth rotation of the crankshaft.
(2) Apply a dial gauge probe to the rear end face of the
crankshaft.
(3) With a bar, move the crankshaft fully to the front and
the rear, and read the each measurement. The end play
is the difference between the front and rear measure-
ments.
If the value exceeds the standard, inspect the thrust
plates and the crankshaft.
If the end play is less than the standard value, loosen
Crankshaft End Play - Measure
the rear most bearing cap bolts and move the crankshaft
back and forth, and measure the end play again.
(4) After tightening the rearmost main bearing cap to the
specified torque, measure the end play again to verify.
(5) Again, verify the crankshaft smooth rotation.
(6) Verify again all the main bearing cap bolts and side
bolts to make sure that they are tightened properly.

0.300 to 0.765 mm 0.500 mm
Crankshaft end play
[0.0118 to 0.0301] [0.0197 in.]
1.9 Crankcase - Turn Over

the turnover machine is not available, attach slings to the Weight of crankcase and
crankshaft assembly:
crankcase using wood pieces and cloth pads, and raise the Approx 675kg [1488 lb]
crankcase with a hoist or crane. Then lay it on the wooden Crankcase
block with its side face downward. Then, change the sling
positions. Turn over the crankcase on the wooden blocks to
turn it to the normal position.
Wooden
blocks
Crankcase - Turn Over
29402-00120
7-7
2. Cylinder Liner, Piston, and Connecting Rod - Assemble

2.1 Cylinder Liner Protrusion - Measure
(1) Place a dial gauge probe on the top surface of cylinder
Height of protrusion
liner flange, and adjust the dial to zero.
(2) Place the probe to measure the protrusion of the cylin-
der liner at four places.
(3) If the value exceeds the limit, or if the ridge is cracked,
Cylinder liner
replace the cylinder liner with a new one. top face
Item Part No. Standard value

0.16 to 0.24 mm
Cylinder liner protrusion 35A07-32500
[0.0063 to 0.0094 in.]
Cylinder Liner Protrusion - Measure

2.2 Cylinder Liner Flange Protrusion - Calculate (When Cylinder Liner Not Installed)
If the amount of protrusion is not enough, the contact

pressure of cylinder head gasket is low, and it can
result in gas and water leakages.
(1) Inspect the cylinder liner contact surface of the crank-
case. If uneven contact is shown, reface the counterbore
with the crankcase grinder to correct the depth differ- Projection plate
P/N:37598-09201
ence at four places in circumference to be less than 0.05
mm [0.0020 in.].
Counterbore depth
For the repair procedure, refer to "Counterbore in
crankcase - Repair" of "INSPECTION AND REPAIR
OF BASIC ENGINE."
(2) Make sure that the top and bottom faces of cylinder
liner flange, the top surface of crankcase, and the fitting
Depth of Counterbore in Crankcase - Measure
surfaces of cylinder liner and the crankcase are clean
before measurement.
(3) Measure the depth of counterbore in crankcase.
Item Standard value

Depth of counterbore in 15.00 to 15.05 mm
crankcase [0.5906 to 0.5925 in.]
(4) Measure the thickness of cylinder liner flange.

15.15 to 15.19 mm
35A07-32500
Thickness of [0.5964 to 0.5980 in.]
cylinder liner flange Cylinder liner
35A07-22500 14.95 to 14.99 mm
(T2MTK3) [0.5886 to 0.5902 in.]
Thickness of Cylinder Liner Flange
7-8 29402-00120
(5) Calculate the cylinder liner flange protrusion by sub-

tracting the depth of counterbore in crankcase from the Crankcase
Shim
thickness of the cylinder liner flange.
Cylinder liner
If the value exceeds the limit, insert a shim under the
cylinder liner flange. Select a shim which makes the
cylinder liner flange protrusion the largest within the
tolerance of the standard.
Note:(a) Shims are available in thicknesses of 0.05, 0.10,
0.15, 0.20, 0.25, 0.30, 0.35, 0.40 mm [0.0020,
0.0039, 0.0059, 0.0079, 0.0098, 0.0118, 0.0138,
and 0.0157 in.]. Shim - Insert
(b) Do not double the shims.

0.10 to 0.19 mm
35A07-32500
Cylinder liner flange [0.0039 to 0.0075 in.]
protrusion -0.01 to -0.1 mm
35A07-22500
[-0.0004 to -0.0039 in.]
Shim thickness Part No.

0.05 mm [0.0020 in.] 35A07-17500
0.10 mm [0.0039 in.] 35A07-17100
0.15 mm [0.0059 in.] 35A07-17600
0.20 mm [0.0079 in.] 35A07-17200
0.25 mm [0.0098 in.] 35A07-17700
0.30 mm [0.0118 in.] 35A07-17300
0.35 mm [0.0138 in.] 35A07-17800
0.40 mm [0.0157 in.] 35A07-17400
29402-00120
7-9
2.3 Cylinder Liner - Install
Apply engine oil on O-ring sliding surface in the crankcase to prevent O-rings from twisting.
DO NOT apply engine oil on O-ring grooves on cylinder liner.
(1) Install the O-rings on the cylinder liner.
(2) Insert the shim into the cylinder which needs the adjust-
ment of the cylinder liner flange protrusion.
(3) Apply engine oil on O-ring sliding surface in the crank-
Apply
case and on the cylinder liner O-rings. engine oil
Cylinder Liner O-Rings - Install

(4) Slowly insert the cylinder liner into the bore in the
crankcase. With a proper cylinder liner installer, lightly
tap the cylinder liner until its flange contacts snugly on
the seating surface of the crankcase. And then, lightly Installer
tap the liner several times to verify the stable seating. P/N:32591-01800
Note: To verify the correct O-rings installation, measure the
roundness of inside diameter of the cylinder liner (es- Cylinder liner
pecially at installed position of O-ring).
Cylinder Liner - Install

2.4 Cylinder Liner Flange Protrusion - Measure (When Cylinder Liner Installed)
(1) Remove dust and dirt from the crankcase top face and
the cylinder liner top face. Cylinder liner
flange protrusion
(2) Place the liner pushers on 4 equally-spaced locations of Liner pusher
the cylinder liner upper rim, and tighten the pusher Bolt
bolts evenly to make a close contact of the cylinder
liner and the crankcase.
(3) Apply a dial gauge probe to the top face of the crank-
case, and adjust the gauge to zero.
(4) Slide the probe to measure the flange protrusion at four
places on the top of the cylinder liner, and obtain the
Cylinder Liner Flange Protrusion - Measure
mean value.
(5) If the mean value of the protrusion is smaller than the
standard, insert a shim under the cylinder liner flange.
For the shim and the standard value, see "Cylinder
Liner Flange Protrusion - Calculate (When Cylinder
Liner Not Installed)" of "ENGINE BODY - ASSEM-
BLE."
7-10 29402-00120
2.5 Cylinder Liner Inside Diameter - Measure

Measure the inside diameter of the cylinder liner at three
levels, i.e., the upper position (the position of No.1 com-
pression ring when the piston is at the top dead center), the
liner middle position, and the O-ring installed position, in
both parallel and perpendicular directions to the piston pin
Cylinder liner
direction.
Replace the cylinder liner if the value exceeds the limit. If
the liner is distorted, pull-out and re-install the liner.
Nominal
value
Cylinder Liner Inside Diameter - Measure
Inside ø150 mm 150.000 to 150.040 mm 150.140 mm
diameter [ø5.91 in.] [5.9055 to 5.9071 in.] [5.9110 in.] Direction travers to piston pin
0.02 mm Direction parallel
Roundness - -
[0.0008 in.] or less
[1.18 in.]
to piston pin
[3.93 in.]
100 mm
30 mm
0.02 mm
250 mm [9.84 in.]

Cylindricity - -
[0.0008 in.] or less
Cylinder liner dimension measuring positions

2.6 Piston and Connecting Rod - Assemble
(1) Apply engine oil on the piston pin, and assemble the
A
piston and the connecting rod. The orientation of the Piston weight
P/N
piston and the connecting rod is as shown in the illus-
tration.
Note: The piston and the piston pin are made for a clearance Camshaft
fit. However, the piston pin is more easily inserted into Matching
the piston if the piston is warmed up with a heater or mark
Engine front direction mark
with hot water.
View from A
(2) Install the snap ring with ring pliers. Make sure that the
snap ring is fully engaged in the ring groove.
Assembling Orientation of Piston and Connecting Rod
Snap ring
Piston and Connecting Rod - Assemble
29402-00120
7-11
2.7 Piston Ring - Install
Ring expander
P/N: 37191-03200
Every piston ring has an upper face mark near the end
gap. Install the piston ring with the mark facing Up mark
upward. No.1
compression ring
Be careful not to install the piston rings upside down. If
the piston rings are assembled incorrectly, it results in No.2
compression ring
defects such as engine seizure.
Oil ring
(1) Install the piston rings on the piston with a ring
expander. Coil spring
(2) Install the oil ring with its end gap 180° away from the Combination of Piston and Piston Ring
joint of the coil spring, as shown in the illustration.
Coil spring joint
180°
Oil ring gap
Combination of Oil Ring and Coil Spring

2.8 Engine - Turning
(1) Install two bolts in flywheel mounting holes of crank-
shaft.
(2) Using the bolts, turn crankshaft with a bar.
Turning bar
P/N:32091-01500
M22 × 1.5
Engine - Turning
7-12 29402-00120
2.9 Piston Installation - Preparation

(1) When installing the piston, turn the crankshaft to a
position where the connecting rod big end does not hit
the crankpin.
Position where the
connecting rod big-end
does not hit crankpin
Crankpin
Position of Crankpin - Adjust

(2) Clean the cylinder liner inner surface and the crankpin,
and apply engine oil to the cylinder liner.
Piston Installation - Preparation

2.10 Upper Connecting Rod Bearing - Install
Upper connecting rod bearing

Be careful not to get engine oil on the back face of
Lug slot
upper connecting rod bearing.
Install the upper connecting rod bearing on the connecting
rod big end by aligning the lug and the lug slot. Apply
engine oil on sliding surface. Make sure the oil hole of con-
necting rod is aligned with the oil hole of bearing.
Oil hole
Upper Connecting Rod Bearing - Install
29402-00120
7-13
2.11 Piston - Install
Eye bolt
When installing the piston, install the eye bolt to the P/N:45815-32301
(M10 × 1.5)
threaded hole on the piston top, and lift the piston with
chain block. When the installation work is inevitably
)
done by hand, be sure to take preventive measures so
Engine front
that the piston does not falling down, and be very care- ࠕFࠖmark
ful not to hurt your hands and fingers or not to damage
Position so that
the parts. connecting rod
Camshaft big-end does not
hit crankpin.
Piston and Connecting Rod - Install
(a) Make sure that the "F" mark on the top of piston
faces the front of engine.
No. 1 compression ring gap
(b) Checking through the inspection window on the Coil spring gap
side of crankcase, make sure that the connecting

rod does not hit the piston cooling nozzle when
installing the piston. Piston pin
(c) To prevent the oil ring from impact damaging,

slowly insert the piston.
(1) Insert the connecting rod into the cylinder liner care- No. 2 compression ring gap Oil ring gap
fully not to damage the liner, and slowly lower the pis-
ton to the upper surface of crankcase. Piston Ring End Gaps - Place
(2) Apply engine oil to the piston rings.

Place the end gaps equally spaced each other, avoiding
Compression ring
piston pin and thrust/anti-thrust directions.
(3) Hold the compression ring position of piston with
hands, and slowly insert the piston skirt into the cylin-
der liner.
Piston Skirt - Insert

(4) Verify again the positions of piston ring gaps.
Apply engine oil to the piston rings. Piston installer
P/N:37191-07100
Apply engine oil to the inner surface of the piston
installer.
Verify that the oil ring is placed in the groove. Then,
compress the piston rings with the piston installer.
Note: For the piston ring placing, see above (2).
Piston Ring - Compress
7-14 29402-00120
(5) Install the piston into the cylinder liner by tapping the
piston top with a soft-head hammer.
Note: Make sure that the piston does not get stuck in the cyl-
inder liner, or the connecting rod big end does not hit
Use of a soft-head
the crank pin. hammer handle
Tap Piston Top to Insert.

(6) Check the proper placing of the upper connecting rod
bearing shell through the inspection window on the Check connecting rod bearing position
crankcase side face. If the bearing shell is not placed
properly, push the bearing upward by hand to correct
the position.
Connecting Rod Bearing - Installation Check

(7) If the upper connecting rod bearing is displaced from
the connecting rod big end, rotate the crankshaft to
make a space between the connecting rod big end and
the crankpin. Then, insert the connecting rod bearing,
sliding on the crankpin, and make sure that the lug on
the bearing shell is correctly positioned in the lug slot
of the connecting rod.
Upper connecting
rod bearing
Connecting Rod Bearing - Reinstall
29402-00120
7-15
2.12 Connecting Rod Cap - Install
Lower connecting rod

(a) Make sure that the matching numbers on the con- Connecting rod bolt bearing
necting rod and the connecting rod cap are on the Lug slot
same side and in alignment.
(b) When installing the connecting rod cap, make sure
that dust or metal particles are not caught in the
Serration
serrations, bolt seating surfaces, and the bolt
threads. Connecting rod cap
(1) Install the lower connecting rod bearing, aligning its
lug with the lug slot of the connecting rod bearing cap. Connecting Rod Cap - Install (1)
(2) Apply engine oil on the connecting rod bolt threads and
seating surfaces, and the sliding surface of the lower
connecting rod bearing shell.
(3) Make sure the matching numbers on the connecting rod
cap and the connecting rod are on the same side and in
alignment, and then install the connecting rod cap to the
connecting rod.
(4) Hand tighten the connecting rod bolts.
Connecting Rod Cap - Install (2)

(5) Secure the rod end play by flushing the connecting rod
with rod cap side face.
Measure end play using
(6) Measure the connecting rod end play, and adjust the thickness gauge
end play within the standard value. 0.2 to 0.6 mm
[0.008 to 0.024 in.]
Connecting Rod Cap - Install (3)

(7) Tighten the connecting rod bolts to the specified torque.
After tightening to the specified torque, loosen the bolts
completely and tighten again to the specified torque. (2-
time tightening)
Measure the end play again.
Note: To tighten the connecting rod bolts with the angle con-
trol tightening method, follow the steps below.
(a)Tighten the bolt to a snug torque of 147 ± 7.4 343 ± 17N·m {35 ± 1.8kgf·m}
N•m {15 ± 0.8 kgf•m} [108 ± 5 lbf•ft]. [253 ± 12.5lbf·ft]
[Wet] 2-time tightening method
(b)Further rotate the bolt 45 ± 3 degrees.
(c)Loosen all bolts, and then tighten them again with Connecting Rod Cap - Install (4)
the angle method. (2-time tightening)
7-16 29402-00120
2.13 Connecting Rod End Play - Measure

Measure the end play of the connecting rod.
If the value exceeds the limit, find the causal parts, and Connecting rod
replace them with new ones.

0.4 to 0.6 mm 1.0 mm
[0.0157 to 0.0236 in.] [0.040 in.]
Connecting Rod End Play - Measure

2.14 Piston Protrusion - Measure
Piston protrusion must always meet the standard, as

Piston protrusion
the amount of protrusion not only influences engine
performance, but it also prevents the valves from
stamping.
Measure the protrusion of each piston, following the
instructions below. If the value exceeds the limit, inspect the
clearances between the concerned parts.
(1) Move the piston to the top dead center.
(2) Apply the dial gauge probe to the top face of crankcase, Piston Protrusion - Measure
and adjust the dial gauge to zero.
Top clearance
(3) Move the dial gauge to the top face of piston, measure Cylinder head gasket Piston protrusion
the maximum protrusion by turning the crankshaft near thickness
Cylinder head
the top dead center.
Note: The crankshaft position that indicates the maximum Cylinder liner
protrusion is defined as the correct top dead center.
(4) Measure the protrusions at four places on the piston top Cylinder liner flange
Crankcase Piston
face, and calculate the mean value. protrusion
Note: The top clearance (clearance between the piston top

and the cylinder head) can be calculated by the piston
Top Clearance
protrusion, the cylinder liner flange protrusion and the
cylinder head gasket thickness.
Top clearance = Cylinder head gasket thickness + Cyl-
inder liner flange protrusion - Piston protrusion
Item Standard value

0.229 to 0.839 mm
Piston protrusion
[0.0090 to 0.0330 in.]
0.10 to 0.19 mm
Cylinder liner flange protrusion
[0.0039 to 0.0075 in.]
1.77 to 1.83 mm
Thickness of cylinder head gasket
[0.0697 to 0.0720 in.]
1.191 to 2.031 mm
Top clearance
[0.0469 to 0.0800 in.]
29402-00120
7-17
3. Front Mechanism - Assemble

3.1 Front Cover - Install
(1) Install the oil seal case into the front cover.
(2) Apply sealant (ThreeBond 1211) on the packing
mounting surface of the crankcase, and install the pack-
ing.
(3) Apply sealant (ThreeBond 1211) on the front cover
mounting face of packing, and install the front cover.
(4) Tighten the bolts.
(5) Make sure that the lower face of front cover is flush
Oil seal
with the bottom face of crankcase. case
Cut off any excessive packing carefully. Front cover
Front Cover - Install
3.2 Front Oil Seal - Install

The font oil seal is a cassette type combining the seal lip and
Front seal Oil seal case
the slinger (assembled type). Do not forcibly separate the oil installer assembly
P/N:35A91-04012 Oil seal
seal from the slinger.
Using the front seal installer assembly, install the front oil Insert
seal. Socket bolt

(1) Apply clean engine oil evenly on the oil seal lip. Bolt
Note: Pay attention to the mounting orientation of the oil Guide flange
seal, and be careful not to damage the oil seal.
Swing washer
(2) Install the guide flange to the crankshaft front end, and
Insert bolt
secure with the insert bolts.
Front Oil Seal - Install (1)
(3) Set the oil seal to the insert, and install to the guide
flange.
(4) Tighten the bolt on the guide flange to insert the oil seal
Oil seal case
into the front cover.
(5) Remove the installer assembly. Oil seal
Crankshaft
Front Oil Seal - Install (2)
7-18 29402-00120
3.3 Crankshaft Pulley, Damper, and Front Pulley - Install

(1) Install guide bolt in damper mounting bolt hole on
crankshaft. Dowel pin
(2) Install the crankshaft pulley, damper, and front pulley 392 ± 20 N·m
through the guide bolt by aligning with dowel pins. {40 ± 2 kgf·m}
[289 ± 14.8 lbf·ft]
(3) Tighten the bolts to the specified torque.
Guide bolt
Crankshaft Pulley, Damper, and Front Pulley - Install

3.4 Pointer - Install and Adjust
(1) Install the pointer to the front cover.
(2) Turn the crankshaft to the top dead center of No. 1 cyl-
inder. Align the top dead center line of No. 1 cylinder
on the circumference of damper with the pointer.
(3) At the No.1 cylinder top dead center, the flywheel
punch mark is positioned at the same distance from the
two punch marks stamped on the timing gear case. Timing gear
Note: To check the top dead center by the piston movement, case
see "Piston Protrusion - Measure" of "ENGINE BODY
Flywheel
- ASSEMBLE."
Top Dead Center - Check with Punch Marks
29402-00120
7-19
4. Rear Mechanism - Assemble

4.1 Rear Plate - Install
(1) Check the plug that blocks the oil gallery of the crank-
case is installed (1 place).
(2) Apply sealant (ThreeBond 1211) to the packing mount- Plug
ing surface of the crankcase, and install the packing.
(3) Apply the same sealant (ThreeBond 1211) to the pack-
ing, and then install the rear plate.
(5) Make sure that the bottom face of the rear plate is flush
with the bottom face of the crankcase.Cut off excessive
packing carefully.
Plug Mounting Position
108 ± 5.4N·m
Dowel pin {11 ± 0.55kgf·m}
[80 ± 4 lbf·ft]
Rear Plate - Install
4.2 Idler Shaft - Install
(1) Install the idler shaft using bolt as a guide.
54 ± 2.7 N·m
{5.5 ± 0.28 kgf·m}
[40 ± 2 lbf·ft]
Idler Shaft - Install
7-20 29402-00120
4.3 Camshaft - Install
Install the camshaft by supporting with a lifting sling

through the push rod hole in the crankcase. Be careful
not to bump the camshaft to avoid the damage to cam
lobe and bushing.
(1) Apply engine oil to the inner surface of camshaft bush-
ing. Camshaft
(2) Apply engine oil to the camshaft oil galleries, journals
Thrust plate
and lobes.
(3) Slowly insert the camshaft into the crankcase while Camshaft - Install
supporting it with a lifting sling.
(4) Install the thrust plate.
(5) Make sure that the camshaft rotates.
4.4 Camshaft Gear - Install

(1) Install the camshaft gear by aligning it with the cam-
shaft Woodruff key.
(2) Using a socket wrench, tighten the nut (left-hand Socket wrench
P/N:32591-02800
thread) to the specified torque by turning it counter-
clockwise. >Left-hand thread@
392 ± 20 N·m
(3) Verify the camshaft smooth rotation. {40 ± 2 kgf·m}
[289 ± 15 lbf·ft]
3 3
3
Camshaft gear
Camshaft Gear - Install
4.5 Camshaft End Play - Measure
Measure the camshaft end play. If the value exceeds the
limit, find the causal parts, and replace them with new ones.

0.20 to 0.30 mm 0.40 mm
Camshaft end play
[0.0079 to 0.0118 in.] [0.0157 in.]
Camshaft gear
Camshaft End Play - Measure
29402-00120
7-21
4.6 Fuel Injection Pump Accessory Drive - Install

(1) Apply a thin coat of sealant (ThreeBond 1212) to the
Mechanical and Hydraulic governor
flange face of accessory drive case of fuel injection electronic governor spec
spec
pump.
(2) Install the fuel injection pump accessory drive to the
rear plate.
Fuel injection pump

accessory drive
Fuel Injection Pump Accessory Drive

- Install
4.7 Idler Gear - Install
(1) Turn crankshaft to bring No. 1 cylinder to the top dead
center.

(2) Apply engine oil on the idler shaft.

(3) Install the idler gear by aligning match marks.

(4) Install the thrust plate to the idler shaft.
59 ± 5.9 N·m
(6) Make sure match marks on timing gears are properly {6 ± 0.6 kgf·m}
aligned as shown in the illustration. [43 ± 4.4 lbf·ft]
Idler Gear - Install
Camshaft gear
Idler gear (Z51)
(Z70Z35) 3
33
Accessory Drive
gear
2 2
(Z51)
11
1
Crankshaft gear
(Z51)
Oil pump gear(Z63)
Timing Gear Train
4.8 Idler Gear End Play - Measure
Measure the end play of the idler gear. If the value exceeds
the limit, find the causal parts, and replace them with new
ones.

0.2 to 0.4 mm 0.6 mm
Idler gear end play
[0.0079 to 0.0157 in.] [0.024 in.]
Idler gear
Idler Gear End Play - Measure
7-22 29402-00120
4.9 Timing Gear Backlash - Measure

Measure the backlash of timing gears using either method:
measure the gear backlash with a dial gauge applying its
Camshaft gear
probe to a tooth flank on the pitch circle at a right angle to
the tooth axis, or measure the clearance between gears by Fuel injection
inserting thickness gauges between the engaging gear pump gear
teeth.If the value exceeds the limit, replace the gears with
new ones. Idler gear

Crankshaft gear
Backlash between crank gear 0.11 to 0.18 mm
and rear idler gear [0.0043 to 0.0071 in.]
Timing Gear Backlash - Measure
Backlash between injection
pump gear and camshaft gear 0.50 mm
Backlash between idler gear 0.12 to 0.18 mm [0.0197 in.]
and injection pump gear [0.0047 to 0.0071 in.]
Backlash between crank-
shaft gear and oil pump gear
4.10 Timing Gear Case - Install
Slings
Be careful not to drop or hit the timing gear case. It
may result in personnel injury as well as damage to
the timing gear case.
(1) Apply sealant (ThreeBond 1211) on the rear plate pack- 108 ± 5.4N·m
{11 ± 0.55kgf·m}
ing mating surface, and install the packing. [80 ± 4 lbf·ft]
(2) Apply sealant (ThreeBond 1211) on the packing mating
surface to timing gear case. Timing gear
case
(3) Attach the lifting equipment to the timing gear case,
align the case with the dowel pins, and install the case. Timing Gear Case - Install
(5) Carefully cut off excessive packing protruding from the
bottom of crankcase.
29402-00120
7-23
4.11 Rear Oil Seal - Install

Use the rear seal installer assembly to install the rear oil
Rear seal
seal. installer assembly
P/N:32591-07012
(1) Apply clean engine oil evenly to the oil seal lip.
Guide flange
Note: Pay attention to the installing side of the oil seal, and Socket bolt
be careful not to damage the oil seal.
Bolt
Place a white painted position upward in the case of
double lip oil seal.
Swing washer
(2) Install the guide flange to the crankshaft rear end face,
Insert
and fix it with insert bolts.
Insert bolt
(3) Set the oil seal to the insert and install them to the guide
Rear Oil Seal - Install (1)
flange.
(4) Tighten the bolt on the guide flange to insert the oil seal
12.5 mm
into the timing gear case. [0.492 in.]
(5) Remove the installer assembly. Timing gear case
Oil seal
Slinger
3.5 ± 0.1 mm
[0.138 ± 0.004 in.]
Rear Oil Seal - Install (2)
Rear seal
Installer assembly
P/N:35A91-12011
Socket bolt
Bolt
Swing washer
Guide flange
Insert
Insert bolt
Rear Oil Seal - Install (Double Lip Oill Seal 1)
Be flush with the edge of

22 mm crankshaft when installing
oil seal slinger.
[0.87 in.]
Timing gear White paint
case
Oil seal
(Double lip oil seal)
26 mm 1 mm Oil seal
[1.024 in.] [0.039 in.] slinger
Rear Oil Seal - Install (Double Lip Oill Seal 2)
7-24 29402-00120
4.12 Flywheel - Install
Sling
Be careful not to drop or bump the flywheel. It may
cause damage to the flywheel or may result in person-
nel injury.
(1) Check the mounting surfaces of flywheel and crank-
shaft to make sure that they are free from any foreign
material or damage. 539 ± 27N·m
{55 ± 2.8kgf·m}
(2) Attach sling to the flywheel. [398 ± 201lbf·ft]
(3) Install the flywheel by aligning its hole with the dowel Flywheel [Wet]
pin on the crankshaft. Flywheel - Install
(4) Apply engine oil on the bolt threads and bolt seat sur-
faces, then tighten the bolts to the specified torque.
4.13 Flywheel Face and Radial Runouts - Measure

Measure the face and radial runouts of the flywheel.
If the measured value significantly deviates from the stan-
dard, check the assembling condition such as loose bolt or Face runout
measuring plane
foreign material adhesion on the mounting faces.
Radial runout
measuring plane
Item Standard value
Face runout (reference) 0.285 mm [0.0112 in.] or less
Radial runout (reference) 0.127 mm [0.0050] or less
Flywheel Face and Radial Runout - Measure

4.14 Pickup - Install
(Electronic governor spec)
Timing gear case ձP/N:04410-29190
(1) Turn the crankshaft to align a top face of ring gear tooth ղP/N:04410-43410
to the center line of pickup installing hole.
(2) Insert the pickup into the hole slowly and carefully by Ring gear
hand.
Lock nut
(3) When the tip of pickup contacts with the ring gear tooth
Reverse by 3/4 to 4/4
top, loosen the pickup to adjust the clearance to the turn after contacting ձ1.
0
to a gear tooth ղ0. to 1.4 m
standard value. 7 to
1.0 m m [0.03
m [0 9
(4) Fix the pickup with the lock nut. Reverse by 1/2 to 3/4 .028 to 0.055
to 0.
turn after contacting 039 in.]
to a gear tooth in.]
Pickup - Install
29402-00120
7-25
5. Cylinder Head and Valve Mechanism - Assemble

5.1 Cylinder Head - Assemble
Guide and seal installer

(a) Be careful when inserting the valve through the Valve stem
P/N:32591-10300
stem seal, as the edge of stem groove can cause
Stem seal
damage to the stem seal lip.
(b) Do not apply oil or liquid sealant on the fitting
Valve guide
faces between the stem seal and the valve guide.
(c) Always replace the stem seal with a new one.
30.3 ± 0.1 mm
Stem seal cannot be re-used. [1.193 ± 0.04 in.] Cylinder head
(1) Apply engine oil on the valve stem, and insert the valve
into the valve guide. Stem Seal - Install
Note: The inlet valve and the exhaust valve are different
Valve cotter
parts. Make sure the correct assembled positions.
Valve rotator
(2) Install stem seal to valve guide with the guide and seal
installer.
Valve spring
Note: Place the valve in the valve guide before installing the
stem seal. The valve stem seal is centered with the
valve stem. Stem seal
(3) Apply engine oil on the lip of stem seal.
Valve and Valve Spring - Install

(4) Install valve spring and rotator to valve guide, and then
install valve cotters using the valve spring pusher. Valve spring pusher
P/N:33591-04500
Apply engine oil

Valve Cotter - Install
(5) Tap the top of valve stem lightly several times with a
soft-head hammer to slightly open the valve, and make Valve stem head
sure that the valve spring and the valve cotters are prop-
erly installed and seated firmly.
Valve - Install
7-26 29402-00120
5.2 Valve Sinkage - Measure

Measure the valve sinkage.
If the value exceeds the limit, replace the valve or valve seat Seat width
ring with a new one. Lap the valve and valve seat ring
whenever the valve or the valve seat ring is refaced or
Valve seat angle

replaced.

-0.1 to 0.1 mm Valve margin
Valve sinkage 0.5 mm [0.020 in.]
[-0.004 to 0.004 in.] Valve sinkage
Valve Sinkage - Measure

5.3 Liquid Gasket - Apply
(a) Do not apply the liquid gasket excessively. It

10 mm Never allow liquid
results in O-ring deformation. Be careful to apply [0.39 in.] gasket to adhere to
gasket to the portions A and B. The space to the this area.
O-ring is very narrow.
(b) Do not apply liquid gasket around the periphery of 5 to 8 mm A
[0.20 to
cylinder bore. It results in gas leaks. 0.32 in.]
Liquid gasket:
ThreeBond 1211
(1) Wipe off oil, grease, and other contaminants from the P/N:37594-01300
cylinder head gasket, cylinder head bottom surface, and Liquid gasket coating area
crankcase top surface. Liquid Gasket - Area of Application (Head Side)
(2) Apply a thin coat of liquid gasket on both sides of the
cylinder head gasket around tappet holes and oil pas-
sages. Beads of liquid gasket shall be 5 to 8 mm [0.20 10 mm Never allow liquid
to 0.31 in.] wide from the cylinder head gasket outer [0.39 in.] gasket to adhere to
this area.
edge and 0.2 to 0.5 mm [0.008 to 0.020 in.] thick. The
5 to 8 mm
area of application is as shown in the illustration. [0.20 to 0.32 in.]
B
Note: After the application of the liquid gasket on the cylin- Liquid gasket:
der head gasket, install the cylinder head before the ThreeBond 1211
P/N:37594-01300
liquid gasket dries.
Liquid gasket coating area
Liquid Gasket - Area of Application (crankcase Side)
5.4 Cylinder Head Gasket - Install
(1) Wipe off oil, grease, and other contaminants from the
cylinder head bottom surface and the crankcase top sur-
face.
(2) Install the cylinder head gasket coated with liquid gas-
ket onto the crankcase with the dowel pins and holes in
alignment.
Dowel pin
Cylinder Head Gasket - Install
29402-00120
7-27
5.5 Cylinder Head Assembly - Install

(1) Apply engine oil to the cylinder head bolt threads, bolt
Eye nut
seats and washer surfaces. P/N:08014-00003
(M12 × 1.25)
Note: Do not apply excessive amount of engine oil. Remove Apply engine oil
the excess before assembling. to threads of
head bolt (short).
(2) Install the eye nut to stud bolt, and lift the cylinder head
assembly.
(3) Slowly lower the cylinder head, and place the cylinder
head properly by aligning the holes with the dowel
pins, and hand tighten the cylinder head bolts except
long ones.
Cylinder Head Assembly - Install
5.6 Cylinder Head Bolt - Tighten
Because the long cylinder head bolts are used to tighten
Tightening torque of torque method(T2MTK3 except):
both the cylinder head and the rocker shaft bracket, the long 392 ± 20 N·m {40 ± 2 kgf·m} [289 ± 14.8 lbf·ft]
[Wet] 2-time tightening
bolts should be tightened after the rocker shaft bracket is
Snug torque of angle method (T2MTK3 except):
installed. Two methods of cylinder head bolt tightening, Short bolt: 4 2
torque tightening and angle controlled tightening, are avail- 118 ± 5.9 N·m
{12 ± 0.6 kgf·m}
able. [87 ± 4.4 lbf·ft]
Note: If a standard socket wrench interferes with the rocker Long bolt: 5
196 ± 9.8 N·m 6
bracket, use the special tool socket wrench. {20 ± 1 kgf·m} 1 3
5.6.1 Torque Tightening Method (all model) [145 ± 7.2 lbf·ft]
Cylinder head bolts (Long)
(1) Tighten the cylinder head bolts progressively to the
Cylinder Head Bolts - Tightening Sequence
specified torque in the sequence shown in the illustra- (T2MTK3L except)
tion.
Tightening torque of torque method:(T2MTK3)
(2) Tighten all the bolts, and then loosen them, and tighten 343 ± 17 N·m {35 ± 1.7 kgf·m} [253 ± 12.5 lbf·ft]
them again according to this torque method. (2-time [Wet] 2-time tightening
4 2
tightening)
5.6.2 Angle Controlled Tightening Method (T2MTK3L
except)
(1) Tighten the cylinder head bolts to the specified snug 6 5
torque in the sequence shown the illustration. 1 3
(2) Tighten the cylinder head bolts by the specified angle in
the sequence shown in the illustration. Cylinder head bolts (Long)
(3) Loosen all bolts, and then angle controlled tighten them Cylinder Head Bolts - Tightening Sequence
(T2MTK3L)
again. (2-time tightening)
Tightening position Snug torque Angle method

118 ± 5.9 N·m
Cylinder head bolt (short) {12 ± 0.6 kgf·m} 75 ± 3°
[87 ± 4.4 lbf·ft]
196 ± 9.8 N·m
Cylinder head bolt (long) {20 ± 1 kgf·m} 60 ± 3°
[145 ± 7.2 lbf·ft]
Socket wrench
P/N:32591-01100
Cylinder Head Bolt - Tighten
7-28 29402-00120
5.7 Bridge and Bridge Cap - Install

Note: Cover the pushrod hole to prevent the bridge cap from
falling into the crankcase through the pushrod hole. Apply engine oil to
bridge guide.
(1) Apply engine oil on the bridge guide.
Screw
(2) Orient the screw-fitted end of the bridge on the exhaust
manifold side, and install the bridge on the bridge
guide. Apply engine oil
to bridge guide.
(3) Apply engine oil on the contact face of bridge cap , and
install the cap on the bridge.
Bridge and Bridge Cap - Install
5.8 Tappet and Push Rod - Install

(1) Apply engine oil to the tappet outside face, insert the
tappet into the tappet hole and place the tappet softly on Apply engine oil
the camshaft.
(2) Insert the push rod into the tappet.
Tappet and Push rod - Install

5.9 Valve Bridge and Adjusting Screw - Adjust
Adjust the contact of valve stem top faces to ensure the
Hold down the top of
smooth sliding of bridge on the guide and the balanced bridge by hand. 55 ± 5.5 N·m
pushing to valves. {5.6 ± 0.56 kgf·m}
[41 ± 4 lbf·ft]
Tighten an
(1) Loosen the adjusting screw so that the screw top face additional 10゜
protrudes from the top face of nut by 6 to 7 mm [0.23 to
0.27 in.].
Valve
(2) Press the top of bridge by hand so that the bridge solid bridge-valve
side (without the screw) contacts firmly to the valve contact
stem top face.

(3) Turn the adjusting screw slowly until the screw comes
Valve Bridge and Adjusting Screw - Adjust
into contact with the top face of valve stem. Then, turn
the screw further by 10 degrees, and tighten the lock
nut to the specified torque.
29402-00120
7-29
5.10 Clearance Between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect
Hold down the top
Bridge cap of bridge by hand.
Be sure to keep the standard clearance between the Clearance between
valve bridge bottom
valve bridge and the valve rotator. If the clearance is Valve bridge face and valve
rotator top face
smaller than the standard, the valve cotter may
Valve rotator
come off or get damage.
Press the valve bridge by hand to make the close contact of
top end face of valve stems. Then, check the clearance
between the bottom face of valve bridge and the top face of
valve rotator. If the clearance deviates from the standard,
find the causal parts, and replace them with new ones. Clearance Between Bottom Face of Valve Bridge
and Top Face of Valve Rotator - Inspect
Item Standard value
Adjusting screw 2.6 mm
Clearance between bottom face of side [0.102 in.]
valve bridge and top face of valve
rotator Solid side 1.6 mm
(without the screw) [0.063 in.]
5.11 Rocker Shaft Assembly - Assemble

(1) Insert the rocker shaft into the rocker shaft bracket.
Rocker shaft bracket
Align the rocker shaft cutoff and the head bolt hole of
rocker shaft bracket.
Notch Rocker shaft

Rocker Shaft - Assemble
(2) Install the rocker arm to the rocker shaft, and tighten
Rocker shaft bracket
them with the washer and the snap ring. Rocker shaft
Rock nut
Snap ring
Rocker arm
Cylinder head
bolt (long)
Washer Adjusting screw

Rocker Shaft Assembly - Assemble
7-30 29402-00120
5.12 Rocker Shaft Assembly - Install

(1) Install the push rods into the tappet holes from the cyl-
Cylinder head bolt (long)
inder head.
(2) Install a new O-ring to the cylinder head bolt (long), Rocker bracket bolt
and tentatively install the rocker shaft assembly to the 49 ± 2.5 N·m
{5 ± 0.25 kgf·m}
cylinder head.
[36 ± 1.8 lbf·ft]
(3) Insert the rocker bracket bolt to the rocker shaft
bracket.
(4) By loosely tightening the bracket mounting bolt, adjust
the bracket position so that the ends of both rockers O-ring
come into contact equally with the respective bridge
Rocker Shaft Assembly - Install
cap tops.
(5) Tighten the cylinder head bolts.
For tightening procedure, see "Cylinder Head Bolt -
Tighten" of "ENGINE BODY - ASSEMBLE".
(6) Tighten the rocker bracket bolts to the specified torque.
29402-00120
7-31
5.13 Valve Clearance - Check and Adjust

Adjust the valve clearance when the engine is cold.
Note:(a) The inlet valves are located on the left side and the

8#.8'%.'#4#0%'
%1.&
exhaust valves are located on the right when the +0.'6 OO ' : * # 7 5 6 OO
( + 4 + 0 ) 1 4 & ' 4
cylinder head is viewed from the camshaft side.
q
(7'.+0,'%6+106+/+0) $6&%
(b) The valve clearance standard values are indicated
%1041&4#0-
on the caution plate on the No. 1 cylinder rocker

cover.
Item Standard value

Inlet 0.4 mm [0.016 in.]
Land use engine Valve Clearance Plate - Location
Exhaust 0.5 mm [0.020 in.]
Valve clearance
Inlet 0.7 mm [0.028 in.]
Marine engine
Exhaust 0.8 mm [0.031 in.]
Pointer
(1) According to the firing order, adjust the valve clearance
at the top dead center (TDC) of compression stroke by
turning the crankshaft in the normal direction.
(2) On each cylinder, the piston is at the top dead center on
compression stroke, when the corresponding cylinder
number stamped on the damper is aligned with the
pointer, and the inlet valve and the exhaust valve are
Firing order㸸1-5-3-6-2-4
not pushed with the push rods. No. 1 Cylinder Compression Top Dead Center - Check
(3) Insert a feeler gauge between the rocker arm and the
bridge cap to measure the clearance. Tighten or loosen Lock nut
64 ± 6.4 N·m
the screw to adjust the clearance where the movement {6.5 ± 0.65 kgf·m}
Screw [47 ± 4.7 lbf·ft]
of feeler gauge is slightly restricted.
(4) After adjustment, tighten lock nut firmly to the speci-
fied torque. Then, check the clearance again.
Valve Clearance - Adjust

5.14 Fuel Injection Timing - Check and Adjust
5.14.1 Specified Value of Fuel Injection Timing - Check
The fuel injection timing varies depending on the engine

8#.8'%.'#4#0%'
%1.&
output, speed, and specifications. Be sure to check the plate +0.'6 OO ' : * # 7 5 6 OO
( + 4 + 0 ) 1 4 & ' 4
on the No. 1 rocker cover for the fuel injection timing.
q
(7'.+0,'%6+106+/+0) $6&%
%1041&4#0-
Specified Value of Fuel Injection Timing - Check
7-32 29402-00120
5.14.2 Fuel Injection Timing - Check

(1) Turn the crankshaft in normal direction, and stop the
turning when the No. 1 cylinder is positioned approx Pointer
10° before the specified fuel injection timing.
Also, make sure that the line stamped on the fuel injec-
tion pump coupling is positioned before and close to the
pointer.
Note: In this condition, if the clearances of inlet and exhaust
valves are as specified, the valves are not pushed
down. Firing order㸸1-5-3-6-2-4
No. 1 Cylinder Compression Top Dead Center - Check
In case of the exhaust stroke top dead center, the valves
are pushed down.
(2) Turn the crankshaft progressively to the normal direc-
tion, and align the fuel injection timing mark on damper
with the engine pointer.
The fuel injection timing is adjusted to the specified
timing if the line stamped on the fuel injection pump
coupling (or timer) aligns with the pointer.
If the line does not align with the pointer, adjust the fuel Fuel injection
timing mark
injection timing. Pointer
Fuel Injection Timing - Check
5.14.3 Fuel Injection Timing - Adjust

(1) Turn the crankshaft progressively to the normal direc-
tion, and align the fuel injection timing mark on damper
with the engine pointer.
(2) Loosen the bolts of the drive coupling, and align the
line with the pointer by rotating the fuel injection pump 88 ± 5 N㺃m
only. Then tighten the bolts. {9 ± 0.5 kgf㺃m}
[65 ± 3.7 lbf㺃ft
Note: Tighten the bolts evenly and progressively.
Line mark of fuel
The laminates will be shifted and decentered if the injection pump
Pointer
bolts are firmly tightened on one side.
Fuel Injection Timing - Adjust
(3) Check the bulge of laminate coupling.
(4) Turn the crankshaft in the reverse direction by approx
10°from the specified fuel injection timing.
(5) Turning the crankshaft progressively to the normal
direction again, and align the line mark of fuel injection
timing with the pointer.
Then, make sure that the line on the fuel injection pump
coupling (or timer) aligns with the pointer.
Repeat the steps (1) through (4) until the proper align-
ment is made.
29402-00120
7-33
5.15 Valve Timing - Inspect

The specified valve timing is automatically made, when
gears are assembled by aligning match marks and valve
clearances are adjusted to the specified value. To make sure,
check the valve timing as follows:
5.15.1 Valve Timing at Standard Valve Clearance (No
Rocker arm
thickness gauge insertion)
(1) Check that the valve clearance is adjusted to the specifi-
cation.
Standard valve clearance
(2) Insert the thickness gauge, which has the same thick-
ness as the specified valve clearance, between the
bridge cap and the rocker arm. (Valve clearance 0 mm)
(3) Turn the crankshaft in the normal direction little by lit-
tle, and find a position where the thickness gauge is
Bridge cap Feeler gauge
tightly gripped (valve open position) and a position
Valve clearance 0 mm (Standard value)
where the thickness gauge is released (valve closed
position).
(4) Verify the valve timing to the specification.
5.15.2 Valve Timing When Valve Clearance Is 2 mm

Rocker arm
[0.08 in.] Valve timing
Adjust the clearance to 2.5 mm [0.098 in.] to check the tim-
ing where the valve moves rapidly and the measurement is
Valve clearance 2 mm [0.08 in.]
more accelerate.
0.5 mm [0.020 in.]
(1) Insert a thickness gauge of 0.5 mm [0.020 in.] between
the bridge cap and the rocker arm. (Valve clearance 2
mm [0.08 in.])
(2) Turn the crankshaft in the normal direction little by lit-
Bridge cap Feeler gauge
tle, and find a position where the thickness gauge is
Valve clearance 2 mm [0.08 in.]
tightly gripped (valve open position) and a position
where the thickness gauge is released (valve closed
position).
(3) Verify the valve timing to the specification.
(4) Readjust the valve clearance to the normal value.
7-34 29402-00120
Overlap 110° Spec

Top dead center Top dead center 11°11°
r 55
5 5 r Inlet valve Exhaust valve
Inlet valve Exhaust valve
open closes
open close
Direction of
Direction of
rotation
rotation
Inlet valve Exhaust valve

close open Inlet valve Exhaust valve
65
r 6 5r closes 21° 21°open
Bottom dead center Bottom dead center
Overlap 110° Spec Overlap 110° Spec
Valve timing when valve clearance is 0 mm Valve timing when valve clearance is 2 mm [0.08 in.]
(Standard value)
Item Specification Valve clearance Measuring position Nominal value Standard value
Open BTDC 55°
Inlet
0 mm [0.00 in.] Close ABDC 65°
-
(Standard value) Open BBDC 65°
Standard Exhaust
Overlap 110° Close ATDC 55°
Valve timing
Camshaft P/N : 32505-50101 Open BTDC 11°
(part No. stamp) Inlet
Close ABDC 21°
2 mm [0.08 in.] ± 2°
Open BBDC 21°
Exhaust
Close ATDC 11°
Overlap 110° Advanced by 4° Spec
TDC TDC
r 51
59 r Inlet valve open 15° 7° Exhaust valve
closed
Inlet valve open Exhaust valve
closed
Rotation direction Rotation direction
Exhaust valve
open
Inlet valve closed
Inlet valve closed Exhaust valve
61r r open
69 17° 25°
BDC BDC
(Standard value)
Open BTDC 59°
Inlet
-
Exhaust
Overlap 110° Advanced by 4° Close ATDC 51°
Valve timing Camshaft P/N : 35A05-10301
(part No. stamp) Open BTDC 15°
Inlet
Close BBDC 17°
2 mm [0.08 in.] ± 2°
Open BBDC 25°
Exhaust
Close BTDC 7°
29402-00120
7-35
Overlap 108° Spec
TDC TDC
r 51
59 r
Inlet valve open 21° 3°Exhaust valve closed
Inlet valve open Exhaust valve
closed
Rotation direction Rotation direction
Exhaust valve
open
Inlet valve closed
r 18°Exhaust valve open
61r 69 Inlet valve closed 0°
BDC BDC
(Standard value)
Open BTDC 63°
Inlet
-
Exhaust
Overlap 108° Close ATDC 45°
Valve timing Camshaft P/N :
35A05-20101(blowe color paint) Open BTDC 21°
Inlet
Close ABBDC 0°
2 mm [0.08 in.] ± 2°
Open BBDC 18°
Exhaust
Close ABTDC 3°
7-36 29402-00120
5.16 Fuel Injection Nozzle Assembly - Install

(1) Apply a thin coat of grease on the gasket and install the 59 ± 2.9N·m 17.5 ± 2.5N·m
gasket to the fuel injection nozzle. {6 ± 0.3kgf·m} {1.75 ± 0.25kgf·m}
[44 ± 2.1lbf·ft] [12.9 ± 1.8lbf·ft]
(2) Insert the fuel injection nozzle to the cylinder head, and
hand tighten the nozzle gland.
(3) Tighten the nozzle gland nut to the specified torque so
that the inlet connector of fuel injection nozzle is not
interfered with the valve spring.
Note: Do not forget to install the gasket when installing the
fuel injection nozzle assembly. Gasket
If the fuel injection nozzle cannot be inserted, the gas-
Fuel Injection Nozzle - Install
ket is slipped off. Pull out the injection nozzle, and
check the gasket.
5.17 Fuel Pipe - Install

(1) Tighten the fuel injection pipe.
Union bolt
(2) Tighten the union bolt of fuel leak-off pipe to the speci- 17.5 ± 2.5 N·m Clamp
{1.75 ± 0.25 kgf·m}
fied torque. [13 ± 1.84 lbf·ft]
(3) Secure the fuel injection pipe and the fuel leak-off pipe Sealing
with the clamp. washer
Fuel injection Fuel

pipe leak-off
pipe
Fuel Pipe - Install
29402-00120
7-37
1. Fuel System - Remove and Inspect ....................................................................... 8-3
1.1 Fuel Injection Pipe - Remove and Inspect ................................................................................ 8-3
1.2 Fuel Leak-Off Pipe - Remove and Inspect................................................................................ 8-4
1.3 Fuel Filter and Fuel Pipe - Remove and Inspect ...................................................................... 8-5
1.4 Stop Solenoid - Remove and Inspect ....................................................................................... 8-6
1.5 Fuel Control Link - Remove and Inspect .................................................................................. 8-9
1.6 Governor and Actuator - Remove........................................................................................... 8-12
1.7 Fuel Injection Pump - Remove and Inspect............................................................................ 8-13
2. Fuel System - Disassemble, Inspect, and Assemble ......................................... 8-14
2.1 Fuel Filter (Wire Mesh Element) - Disassemble, Inspect and Assemble................................ 8-14
2.2 Water separator - Disassemble, Inspect and Assemble......................................................... 8-15
2.3 Fuel Filter (Paper Element) - Disassemble, Inspect and Assemble ....................................... 8-16
2.4 Fuel Injection Nozzle - Disassemble and Inspect ................................................................... 8-20
2.5 Fuel Injection Nozzle - Inspect and Adjust.............................................................................. 8-22
2.6 Fuel Injection Nozzle - Assemble ........................................................................................... 8-25
2.7 Fuel Injection Pump Accessory Drive - Disassemble and Inspect.......................................... 8-27
2.8 Outside Diameter and Inside Diameter of Accessory Drive Bearing Fitting Faces - Inspect.. 8-28
2.9 Fuel Injection Pump Accessory Drive - Assemble .................................................................. 8-29
2.10 Governor Drive - Disassemble and Inspect ............................................................................ 8-30
2.11 Outside Diameter and Inside Diameter of Bearing Fitting Faces............................................ 8-31
2.12 Governor Drive - Assemble .................................................................................................... 8-32
3. Fuel System - Install .............................................................................................. 8-34
3.1 Fuel Injection Pump - Install ................................................................................................... 8-34
3.2 Fuel Control Link - Install ........................................................................................................ 8-43
3.3 Stop Solenoid - Install............................................................................................................. 8-44
29402-00120
8-1
1. Fuel System - Remove and Inspect

1.1 Fuel Injection Pipe - Remove and Inspect
Standard injection pipe sepc SUS injection pipe spec

5
Leakage, crack, contact
4
5
1
Dual injection pipe spec
3 2
Replace
Replace
Replace: Sealing washer
Fuel Injection Pipe - Remove and Inspect

Removing sequence
1 Injection pipe stay 4 Clamp
2 Pipe 5 No.1 to 6 fuel injection pipes
3 Connector
Cover the openings on the fuel injection pump, nozzle inlet connectors and fuel injection pipes to prevent dust from
entering the fuel system.
Note: The consisting parts of fuel inlet and outlet differ depending on the customization and the specification.
29402-00120
8-3
1.2 Fuel Leak-Off Pipe - Remove and Inspect
5
Replace
Replace
3
2
4 Replace
Fuel Leak-Off Pipe - Remove and Inspect

Removing sequence
1 Leak-end pipe 4 Leak-off connector
2 Over-flow pipe 5 Leak-off pipe
3 Leak-end pipe
Cover the openings on the fuel injection pump, nozzle inlet connectors and fuel injection pipes to prevent dust from
entering the fuel system.
Note: The consisting parts of fuel inlet and outlet differ depending on the customization and the specification.
8-4 29402-00120
1.3 Fuel Filter and Fuel Pipe - Remove and Inspect
C Diesel oil, A diesel oil 2 units spec

E
D
C 1 B
A
2
4 E
D
B
Diesel, A dieasel 1 unit spec Diesel, change over A F

type spec
A 1
B
1
F
B 4 2
4
2 3
Fuel Filter and Fuel Pipe - Remove and Inspect

Removal sequence
1 Fuel pipe 3 Fuel filter assembly
2 Fuel pipe 4 Fuel filter bracket
29402-00120
8-5
1.4 Stop Solenoid - Remove and Inspect
Stop solenoid RUN ON spec

5
Rotation
7
Looseness, bend
2
3
PTA,PTAA spec
E2PTAA spec
6 PTA spec
6
6
Stop Solenoid - Remove and Inspect

Removing sequence
1 Link 5 Stop shaft
2 Ball joint 6 Stop solenoid
3 Ball joint 7 Solenoid bracket
4 Stop lever
8-6 29402-00120
Stop solenoid RUN OFF spec 1
PTA PTA,Y2TAA1
7
4 3
Rotation
2
1
5
4
Looseness,
bend
3
2
Looseness, bend

Removing sequence
1 Link 5 Shaft
2 Ball joint 6 Lever
4 Stop solenoid
29402-00120
8-7
Stop solenoid RUN OFF spec 2
MPTA,MPTK Y2MPTK
5
Looseness, bend
Looseness, bend 4
Rotation
3 Rotation
1
2

Removing sequence
1 Link 4 Stop solenoid
3 Ball joint
8-8 29402-00120
1.5 Fuel Control Link - Remove and Inspect
Oil pressure governor spec
3 Looseness, wear
1
Looseness, wear
2
4
Deterioration, deformation
Governor drive
*Wodward PSG governor

Fuel Control Link - Remove and Inspect
Removing sequence
1 Link 4 Stop lever
2 Governor lever 5 Lever
3 Link
29402-00120
8-9
Actuator spec
Looseness, wear
SG4017
3
※ TOHO SEISAKUSYO SG4017 type actuator

Removing sequence
1 Link 2 Connector 3 Stop lever
8-10 29402-00120
Actuator spec
Looseness, wear 1
4
2
Deterioration,
deformation
Looseness, wear
*Woodward ProAct actuator

Removing sequence
1 Link 4 Stop lever
2 Governor lever 5 Lever
3 Link
29402-00120
8-11
1.6 Governor and Actuator - Remove
Hydraulic pressure governor, actuator spec

Replace:rubber cushion
2 c. PROACT
1
a. PSG
Replace Replace:rubber cushion
b. SG4017
Replace:rubber cushion
a. Woodward PSG type governor 2

b. TOHO SEISAKUSYO SG4017 type actuator
c. Woodward PROACT type actuator
Governor and Actuator - Remove and Inspect

Removing sequence
1 Governor, Actuator 2 Bracket
8-12 29402-00120
1.7 Fuel Injection Pump - Remove and Inspect
PSG governor, MTK2 spec
1
3
PSG governor spec

1 actuator spec
2 1
2
3
Mechanical governor
spec
Fuel Injection Pump - Remove and Inspect

Removal sequence
1 Coupling cover 3 Bracket
2 Fuel injection pump (approx. 56 kg [123 lb]) 4 Bracket
29402-00120
8-13
2. Fuel System - Disassemble, Inspect, and Assemble

2.1 Fuel Filter (Wire Mesh Element) - Disassemble, Inspect and Assemble
Replace
Replace
2
10
Replace
Cracks, flaw 3
20 N·m
Replace
{2 kgf·m}
[14.7 lbf·ft]
5 6
1
4
Replace
Fuel Filter (Wire Element) - Disassemble, Inspect and Assemble

1 Plug, packing 6 Element
2 Bolt, spring washer, plain washer 7 Rod, O-ring
3 Flange, lower case, packing 8 Snap ring, washer, handle
4 Nut 9 Air vent plug
5 Plate, scraper, collar, O-ring 10 Cover
8-14 29402-00120
2.2 Water separator - Disassemble, Inspect and Assemble
Crack, damaged threads
Replace
Replace 7
Replace
6
2
5
Replace
4
Clog, cracks
Replace: Every 500 hrs.
3
1
Crack, damaged threads
Water Separator - Disassemble, Inspect and Assemble

1 Ring nut 5 Isolation plate
2 Case 6 Head
3 Baffle plate 7 Air vent plug
4 Screen assembly
29402-00120
8-15
2.3 Fuel Filter (Paper Element) - Disassemble, Inspect and Assemble
Standard fuel filter spec
Air bleed plug

9 ± 1 N·m
{0.9 ± 0.1 kgf·m}
[6.6 ±0.7 lbf·ft]
Filter wrench
Use the filter wrench to remove
the fuel filter.
(Use only when removing)
Crack, flaw
2
Dent
Fuel Filter (Paper Element) - Disassemble, Inspect and Assemble

1 Fuel filter cartridge 2 Fuel filter bracket
8-16 29402-00120
Dual spec
Air vent plug

9 ± 1 N·m
{0.9 ± 0.1 kgf·m}
[6.6 ± 0.7 lbf·ft]
Replace
Crack, flaw
Fuel filter bracket
Filter wrench
Fuel filter cartridge Use the filter wrench to remove
the fuel filter cartridge.
Dent
(Use only when removing)
29402-00120
8-17
Change over type fuel filter spec
Air bleed plug

9 ± 1 N·m
{0.9 ± 0.1 kgf·m}
Replace [6.6 ± 0.7 lbf·ft]
Filter wrench
Crack, flaw Use the filter wrench to remove
the fuel filter.
(Use only when removing.)
5
4 2
Replace
1
3
Dent

1 Fuel filter cartridge 4 Cock
2 Pin 5 Fuel filter bracket
3 Cover
8-18 29402-00120
2.3.1 Fuel Filter Cartridge - Install
(a) Make sure that there is no flame around the area before handling fuel.
(b) Wipe any spilled fuel to prevent a risk of fire.
(c) DO NOT use the fuel filter cartridge that has a dent on the case. If the case has a dented, it can cause the
damage to the fuel filter cartridge and the fuel leak during operation, and may cause a fire.
(a) When installing the fuel filter cartridge, DO NOT use a filter wrench. Hand-tighten the cartridge.
(b) Be careful not to dent or damage the surface of fuel filter cartridge.
(1) Remove dust and contaminants on the filter cartridge mating face.
(2) Apply clean fuel on the fuel filter gasket.
(3) After the fuel filter gasket comes into contact with the base, tighten the cartridge by 3/4 to 1 turn by the hand.
Note: After the installation, bleed air from the fuel system.
(4) Start the engine, and make sure that there is no fuel leak.
29402-00120
8-19
2.4 Fuel Injection Nozzle - Disassemble and Inspect

any job.
Fuel Injection Start Pressure - Inspect
Fuel Injection Nozzle Spray Pattern - Inspect
Shim adjust type spec
Deformation, deterioration, 9
flaw
8
1
6
7
Replace
5
4
Needle valve seat wear

10
3
Carbon deposit,
nozzle hole clogging,
needle valve sticking
Fuel Injection Nozzle - Disassemble and Inspect

1 Connector, Gasket 6 Pin
2 Retaining nut 7 Push rod
3 Nozzle tip 8 Nozzle spring
4 Pin 9 Shim
5 Spacer 10 Nozzle holder body
Note: Nozzle tip and nozzle spring must be replaced with new ones as a set.
8-20 29402-00120
Screw adjust type
1
2
Replace
Replace
3
Deformation, deterioration, flaw
4
7
5
Carbon deposit,
nozzle hole clogging,
needle valve sticking
Fuel Injection Nozzle - Disassemble and Inspect

1 Inlet connector, Gasket 5 Push rod
2 Cap nut, Gasket 6 Retaining nut
3 Adjusting screw 7 Nozzle tip
4 Nozzle spring 8 Nozzle holder
Note: Nozzle tip and nozzle spring must be replaced with new ones as a set.
29402-00120
8-21
2.5 Fuel Injection Nozzle - Inspect and Adjust

2.5.1 Fuel Injection Start Pressure - Inspect and
Nozzle tester
Adjust
P/N:04239-00050
Never touch the fuel spray during the fuel injection

nozzle test.
(Screw adjust type)
(1) Install the fuel injection nozzle to the nozzle tester.
(2) Push down the handle at a speed of one stroke a second
and measure the pressure when the injection starts. If
the pressure is out of the standard, adjust it to the stan- Fuel Injection Start Pressure - Inspect
dard.
44 ± 5 N·m
(3) To adjust the injection start pressure, remove the cap {4.5 ± 0.5 kgf·m}
[32 ± 3.7 lbf·ft]
nut on the nozzle holder, and turn the adjusting screw
Cap nut
with a screwdriver.
(4) After adjustment, tighten the cap nut to the specified
Pressure Pressure
torque. - decrease - increase
(5) After tightening, check if the injection start pressure is
within the standard again.
Adjusting screw
Item Nominal value Standard value
21.6 MPa 22.1 to 22.6 MPa Fuel Injection Start Pressure - Adjust
Fuel injection
{220 kgf/cm2} {225 to 230 kgf/cm2}
starting pressure
[3132 psi] [3205 to 3278 psi]
(Shim adjust type)

(1) Install the fuel injection nozzle to the nozzle tester. Pressure adjustment
by shim combinations
(2) Push down the handle at a speed of one stroke a second
and measure the pressure when the injection starts. If
the pressure is out of the standard, adjust it to the stan-
dard.
68.5 ± 9.5 N·m
(3) Adjust the injection start pressure by increasing or
{7 ± 1 kgf·m}
decreasing the number of shims. Shims are available in [50 ±7
[50.5 ± lbf·ft]
7.01 lbf·ft]
5 thicknesses from 0.40 to 0.70 mm [0.0157 to 0.0276
in]. The valve opening pressure difference of 0.1 MPa
Valve Opening Pressure of Fuel Injection Nozzle -
can be achieved by the change of shim thickness of
Adjust
approx 0.0045 to 0.0083 mm [0.0002 to 0.0003 in.].
(4) After the adjustment, tighten the retaining nut to the
specified torque.
(5) After tightening the retaining nut to the specified
torque, inspect again the injection start pressure to see
that it is as specified.

29.9 to 30.7 MPa
29.4 MPa
Fuel injection {304 to 313 kgf/cm2}
{300 kgf/cm2}
starting pressure [4337 to 4453 psi]
[4264 psi]
(the value when it is new)
8-22 29402-00120
2.5.2 Fuel Injection Nozzle Spray Pattern - Inspect

When adjusting the nozzle opening pressure with the nozzle
tester, inspect the nozzle orifice clogging, fuel spray pattern
Good Faulty spray
or check if fuel is dripping. If the spray pattern is faulty,
clean or replace the nozzle tip.
Checking points of the fuel spray pattern are as follows:
Injection spray shall be straight.
Large After Intermittent Whirling
The spray condition shall be of fine fuel droplets without angle dribble spray spray
big drops. spray
No dripping is after injection.
Fuel Injection Nozzle Spray Pattern - Inspect
2.5.3 Nozzle Tip - Clean and Replace
(a) Be careful not to hit the nozzle tip point.

(b) The needle valve and body are precision parts. Nozzle tip end
Handle them carefully, and do not change the
Retaining nut
original valve and body combination.
(1) Remove the retaining nut.
(2) Remove the nozzle tip.
Nozzle Tip - Remove

(3) Clean the needle valve and the body of nozzle tip.
When cleaning the needle valve and the nozzle tip
body, use clean wash oil. Assemble the needle valve
and the body in clean diesel fuel after cleaning.
(4) Tighten the nozzle tip retaining nut to the specified
torque.
Needle valve
(5) If the spray pattern is still faulty after cleaning and
Body
adjusting, change the nozzle tip with a new one.
New nozzle tips are coated with anti-corrosive agent.
Wash the nozzle tips before use. First wash them in
wash oil, and wash it again in clean diesel fuel before Nozzle Tip - Clean
installation.
2.5.4 Push Rod - Inspect

Shim adjust type Screw adjust type
Inspect the push rod visually. If its spring seat wears
Spring seating face
unevenly, or the needle valve contact surface wears remark- local wear
ably, or the cavitation occurs under the tapered area, replace
the push rod with a new one.
Cavitation
Needle valve
contact surface
wear
Push Rod - Inspect
29402-00120
8-23
2.5.5 Spacer - Inspect

High pressure
(Shim adjust type) seal face
Inspect the spacer visually. If its needle valve contact sur-
face or the high pressure seal surface wears remarkably,
replace the spacer with a new one.
Note: When the nozzle tip is replaced, replace the spacer and
the nozzle spring with new ones.
High pressure seal
face Needle valve seating face
ø3 mm [ø0.12 in.]
Spacer - Inspect
8-24 29402-00120
2.6 Fuel Injection Nozzle - Assemble
Shim adjust type
Do not hit with a hammer when

installing into cylinder head.
44 ± 5 N·m {4.5 ± 0.5 kgf·m}

[32 ± 3.7 lbf·ft]
Apply engine oil to gasket top

and bottom faces
68.5 ± 9.5 N·m {7 ± 1 kgf·m}

[50 ± 7 lbf·ft]
Fuel Injection Nozzle - Assemble
Be sure to tighten the retaining nut to the specified torque. The excessive tightening of retaining nut can harm
smooth movement of the needle valve and result in abnormal exhaust smoke or needle valve sticking.
Note: When assembling the nozzle tip on the nozzle holder, make sure to align the nozzle tip knock pin with the nozzle holder
hole.
29402-00120
8-25
Screw adjust type
Do not hit with a hammer,

when installing into cylinder head.
44 ± 5 N·m
{4.5 ± 0.5 kgf·m}
[32 ± 3.7 lbf·ft]
74 ± 5 N·m
{7.5 ± 0.5 kgf·m}
[55 ± 3.7 lbf·ft]
Apply engine oil to gasket top

and bottom faces
68.5 ± 9.5 N·m

{7 ± 1 kgf·m}
[50 ± 7 lbf·ft]
Fuel Injection Nozzle - Assemble
Be sure to tighten the retaining nut to the specified torque. The excessive tightening of retaining nut can harm
smooth movement of the needle valve and result in abnormal exhaust smoke or needle valve sticking.
8-26 29402-00120
2.7 Fuel Injection Pump Accessory Drive - Disassemble and Inspect
Deformation, wear on lip
Wear, scar
8
Rotation
7
9
Flaking, wear
5
Rotation
Replace
6
4
2 3
1
Fuel Injection Pump Accessory Drive - Disassemble and Inspect

1 Nut 4 Snap ring 7 Ball bearing
2 Washer 5 Drive shaft 8 Oil seal
3 Fuel injection pump gear 6 Ball bearing 9 Drive case
29402-00120
8-27
2.8 Outside Diameter and Inside Diameter of Accessory Drive Bearing Fitting Faces - Inspect
(1) Rotate the bearing and if the rotation is not smooth,
replace the bearing with a new one. Fuel injection pump gear
(2) Inspect the fitting faces of the drive shaft and the bear-
ing. If significant wear is found, replace the worn part
with a new one.
(3) Inspect the fitting faces of the drive case and the bear- Socket
ing. If significant wear is found, replace the worn part P/N:58309-73100
with a one.
(4) Inspect the drive shaft and the oil seal. If any defect is
found, replace the defective part with a new one.
Fuel Injection Pump Gear - Remove

ø80 mm [ø3.15 in.] 79.988 to 80.018 mm [3.1491 to 3.1503 in.]
ø100 mm [ø3.94 in.] 99.987 to 100.022 mm [3.9365 to 3.9379 in.]
Outside Small ø80 mm [ø3.15 in.] 79.985 to 80.000 mm [3.1490 to 3.1496 in.]
diameter Large ø100 mm [ø3.94 in.] 99.985 to 100.000 mm [3.9364 to 3.9396 in.]
Fuel injection pump drive shaft bearing
Inside Small ø40 mm [ø1.57 in.] 40.002 to 40.013 mm [1.5749 to 1.5753 in.]
diameter Large ø45 mm [ø1.77 in.] 45.002 to 45.013 mm [1.7717 to 1.7722 in.]
ø40 mm [ø1.57 in.] 39.988 to 40.000 mm [1.5743 to 1.5748 in.]
Outside diameter of drive shaft bearing fittting face
ø45 mm [ø1.77 in.] 44.988 to 45.000 mm [1.7712 to 1.7717 in.]
8-28 29402-00120
2.9 Fuel Injection Pump Accessory Drive - Assemble
Apply engine oil

392 ± 20 N·m to lip
{40 ± 2 kgf·m}
[289 ± 14.8 lbf·ft]
Apply engine oil
Fuel Injection Pump Accessory Drive - Assemble
29402-00120
8-29
2.10 Governor Drive - Disassemble and Inspect

1
Replace
5 Replace
Wear
22
Replace
Replace 8
12
Rotation
21 Replace
10
14
15
16
9
20 18 11
Rotation Rotation
7 13
6
Fatigue
17 19 Wear
* Woodward make PSG type governor
Governor Drive - Disassemble and Inspect
1 Bearing case 9 Bearing case 17 Pin
2 Snap ring 10 Snap ring 18 Ball bearing
3 Driven gear 11 Ball bearing 19 Drive gear
4 Snap ring 12 Oil seal 20 Snap ring
5 Ball bearing 13 Drive shaft 21 Ball bearing
6 Nut 14 Snap ring 22 Drive case
7 Fuel injection pump gear 15 Washer
8 Stay 16 Rubber
Note: Do not disassemble the idler gear and drive shaft unless it is absolutely necessary.
8-30 29402-00120
2.11 Outside Diameter and Inside Diameter of Bearing Fitting Faces

(Hydraulic governor spec)
Rotate the bearing and if the rotation is not smooth, replace
the bearing with a new one.
Inspect the fitting faces of the drive shaft, the idler shaft and
the bearing. If significant wear is found, replace the worn
part with a new one.
Inspect the fitting faces of the drive case and the bearing. If
significant wear is found, replace the worn part with a new
one.

Inside diameter of drive shaft case bearing housing ø100 mm [ø3.94 in.] 99.989 to 100.022 mm [3.9366 to 3.9379 in.]
Inside diameter of drive gear bearing housing ø90 mm [ø3.54 in.] 89.985 to 90.000 mm [3.5427 to 3.5433 in.]
Inside diameter of bearing case bearing housing ø80 mm [ø3.15 in.] 79.988 to 80.018 mm [3.1491 to 3.1503 in.]
Inside diameter of driven gear bearing case bearing housing ø47 mm [ø1.85 in.] 46.989 to 47.014 mm [1.8500 to 1.8509 in.]
Outside diameter ø47 mm [ø1.85 in.] 46.989 to 47.000 mm [1.8500 to 1.8504 in.]
Driven gear bearing
Inside diameter ø20 mm [ø0.79 in.] 20.002 to 20.011 mm [0.7875 to 0.7878 in.]
Outside diameter of driven gear to fit bearing ø20 mm [ø0.79 in.] 19.990 to 20.000 mm [0.7870 to 0.7874 in.]
Small ø80 mm [ø3.15 in.] 79.987 to 80.000 mm [3.1491 to 3.1496 in.]
Outside
Middle ø90 mm [ø3.54 in.] 89.955 to 89.990 mm [3.5415 to 3.5429 in.]
diameter
Large ø100 mm [ø3.94 in.] 99.985 to 100.000 mm [3.9364 to 3.9370 in.]
Drive case cover bearing
Small ø40 mm [ø1.58 in.] 40.002 to 40.013 mm [1.5749 to 1.5753 in.]
Inside
Middle ø55 mm [ø2.17 in.] 54.993 to 55.012 mm [2.1627 to 2.1658 in.]
diameter
Large ø45 mm [ø1.77 in.] 45.002 to 45.013 mm [1.7717 to 1.7722 in.]
ø45 mm [ø1.77 in.] 44.988 to 45.000 mm [1.7712 to 1.7717 in.]
Outside diameter of idler shaft to fit bearing ø55 mm [ø2.17 in.] 54.985 to 55.000 mm [2.1648 to 2.1654 in.]
ø40 mm [ø1.58 in.] 39.988 to 40.000 mm [1.5743 to 1.5748 in.]
*Woodward make PSG type governor
29402-00120
8-31
2.12 Governor Drive - Assemble
Hydraulic governor
Apply engine oil
Apply engine
oil to lips
392 ± 20 N·m
{40 ± 2 kgf·m}
[289 ± 14.8 lbf·ft]
Apply engine oil
* Woodward make PSG type governor

Governor Drive - Assemble
2.12.1 Drive Gear and Idler Gear Backlash - Measure

Measure the drive gear and idler gear backlash.If the value exceeds the limit, replace the drive gear or idler gear with a new
one.

Backlash between drive gear and 0.10 to 0.20 mm 0.50 mm
idler gear [0.0039 to 0.0079 in.] [0.0197 in.]
8-32 29402-00120
2.12.2 Governor Drive and Rubber - Install

Insert the drive gear to the drive shaft, then assemble the pin
and the rubber.
Governor Drive and Rubber - Install

2.12.3 Drive gear and Case - Assemble
Insert the drive shaft assembly to the drive case.
Governor Drive shaft - Insert
29402-00120
8-33
3. Fuel System - Install

To install, follow the removal sequence in reverse. (See the illustration for disassembly.)
Thoroughly clean fuel passages and dry them well.
3.1 Fuel Injection Pump - Install
108 ± 5.4 N·m PSG governor, MTK2 spec

{11 ± 0.55 kgf·m}
[80 ± 4 lbf·ft]
108 ± 5.4 N·m

{11 ± 0.55 kgf·m}
[80 ± 4 lbf·ft]
108 ± 5.4 N·m PSG governor spec

{11 ± 0.55 kgf·m} Actuator spec
[80 ± 4 lbf·ft]
Mechanical governor
60 ± 6 N·m spec
{6.1 ± 0.61 kgf·m}
[44 ± 4.4 lbf·ft]
Fuel Injection Pump - Install
8-34 29402-00120
3.1.1 Checking before installing fuel injection pump

(PE(S)-P Type)
(1) Confirm the type of nut for coupling between drive
coupling and laminated plate before installation. Oval Oval
nut A
nut A or hexagon nut B is used for the coupling.
(2) When installing the right bank fuel injection pump,
rotate the crankshaft so that No. 1 piston is at the top
dead center of compression stroke, and when installing Pointer
the left bank fuel injection pump, rotate the crankshaft Fuel injection pump
coupling line mark
so that No. 7 piston is at the top dead center of com-
Pointer and Line Mark Alignment (Oval nut A)
pression stroke.
Nut B
Pointer
Fuel injection pump

coupling line mark
Pointer and Line Mark Alignment (Hexagon nut B)
(3) Remove the tentatively installed drive coupling and
laminated plates set on the drive coupling from the fuel Fuel injection pump
injection pump. Install the coupling and the set to the accessory drive
accessory drive shaft with the woodruff key. Push the Drive coupling
drive coupling to the accessory drive as close as possi-
ble, and leave the tightening bolts loose. Laminated plate set
(4) Align the line mark on the fuel injection pump coupling
(or timer) with the pointer. (the injection start timings
of cylinder No. 1 and No. 7) Shaft tightening bolt
Drive coupling - Install (Oval nut A)
Fuel injection pump

accessory drive
Drive coupling
Laminated plate set
Shaft tightening bolt
Drive coupling - Install (Hexagon nut B)
29402-00120
8-35
(5) Make sure that the driving coupling and laminated plate
Laminated plate
are coupled as shown in the illustration.
Oval nut A
Coupling
tightening bolt
Drive side
Drive coupling
Connection of drive coupling and laminated plate
(Oval nut A)
Coupling key 19°30’±3
groove
Assembling Position of Fuel Injection Pump Coupling

that is viewed from Drive side (Oval nut A)
Laminated plate
Nut B
Coupling
tightening bolt
Drive side
Drive coupling
Connection of drive coupling and laminated plate
(Hexagon nut B)
Coupling key 19°30’±3
groove
Assembling Position of Fuel Injection Pump Coupling

that is viewed from Drive side (Hexagon nut B)
29402-00120
8-36
3.1.2 Fuel Injection Pump (PE(S)-P Type) - Install
(a) Wash the bolt, bushing and washer before using. Foreign material on the contact surface of drive coupling and
laminated plates can cause the slipping or damage of coupling.
(b) After the tightening of couplings check the laminated plates for distortion. If the plates are distorted loosen and
retighten the bolts.
(1) Lift the fuel injection pump. Slowly lower the fuel
injection pump, and install the pump aligning with the
dowel pin on bracket.
(2) Couple the drive coupling to the cross coupling and ten-
tatively tighten the bolt.
Then, make sure that the line mark on the fuel injection
pump coupling (or timer) is at a position close to the
pointer when the No. 1 and No. 7 cylinders are at the
top dead center on compression.
(3) Adjust the distance between couplings to the specified
value.
For adjustment procedure, refer to "Coupling Distance -
Adjust" of "FUEL SYSTEM."
(4) Tighten all bolts and nuts, which have been installed
tentatively to the couplings, to the specified torque. The
coupling procedure of drive coupling and laminated
plate ries according to the type of nut. Tighten the bolt
and the nut by following the instructions below.
Laminated plate
(a)For the oval nut A
(I)Tighten the bolts to the specified torque of 88 ±
5N·m (Four places right and left) Oval nut A
Coupling
tightening bolt
88 ± 5N·m
{9 ± 0.5kgf·m}
[65 ± 3.7 lbf·ft]
Drive side
Drive coupling
Couplings and laminated plates - assemble
(Oval nut A)
Torque wrench
Drive side 88 ± 5N·m
{9 ± 0.5kgf·m}
[65 ± 3.7 lbf·ft]
Couplings and laminated plates -assemble

(Oval nut A)
29402-00120
8-37
(b)For the hexagon nut B

Laminated plate
Tighten the bolt and nut from both directions by fol-
Nut B
lowing procedure. 88 ± 5N·m
{9 ± 0.5kgf·m}
(I)Tighten the bolts to the specified torque of 88 ± [65 ± 3.7 lbf·ft]
Coupling
5N·m with fixing the nut by using spanner. (Four tightening bolt
88 ± 5N·m
places right and left total) {9 ± 0.5kgf·m}
[65 ± 3.7 lbf·ft]
Drive side
Drive coupling
Couplings and laminated plates -assemble
(Hexagon nut B)
Drive side
Torque wrench
88 ± 5N·m
{9 ± 0.5kgf·m}
Spanner [65 ± 3.7 lbf·ft]
(nut fixation)
Couplings and laminated plates -with fixing the nut
(Hexagon nut B)
(II) Change over from the spanner to the torque wrench,

then tighten the nut to the specified torque of 88 ±
5N·m. (Four places right and left total)
Spanner
(bolt fixation)
Drive side Torque wrench
88 ± 5N·m
{9 ± 0.5kgf·m}
[65 ± 3.7 lbf·ft]
Couplings and laminated plates -with fixing the bolt

(Hexagon nut B)
(5) Install the stay in between the fuel injection pump case
and the crankcase.
(6) Refill engine oil through the oil drain pipe mounting
hole of cam chamber.
(7) Install the oil pipe and fuel pipe.
Refill the engine oil to the

intake hole on the oil drain
pipe.
Engine oil-Refill
8-38 29402-00120
3.1.3 Coupling Distance - Adjust (PE(S)-P Type)

Fuel injection pump side
Adjust the position of couplings so that the distance
64 mm [2.52 in.]
between couplings meet the specified value, and tighten the
Adjust so that the distance
bolts to the specified torque.
between the coupling end faces
meets the specified value.
Drive coupling
88 ± 5 N·m
{9 ± 0.5 kgf·m}
[65 ± 3.7 lbf·ft]
Coupling
Coupling Distance - Adjust (Oval nut A)
Fuel injection pump side
64 mm [2.52 in.]
Adjust so that the distance

between the coupling end faces
meets the specified value.
Drive coupling
88 ± 5 N·m
{9 ± 0.5 kgf·m}
[65 ± 3.7 lbf·ft]
Coupling
Coupling Distance - Adjust (Hexagon nut B)
29402-00120
8-39
3.1.4 Fuel Injection Pump (PS6 Type) - Check Before

Pointer
Install
Flywheel zero punch
mark position
Ensure the correct mounting position of the drive cou-

pling. If it is installed 180 degrees out of the position,
the fuel injection timing cannot be adjusted.
(1) Rotate the crankshaft to bring the No. 1 cylinder to the
compression top dead center.
(2) Install drive coupling temporary attached to the fuel
injection pump to the accessory drive shaft with a Pointer and Punch Mark - Align
woodruff key. Adjust the drive coupling position so that
Fuel injection pump
the coupling is not interfered with the bolt for fuel accessory drive
injection pump. Leave the shaft tightening bolts loose
Drive coupling
at this time.
(3) Align the "0" punch mark on the fuel injection pump Laminated plate set
flywheel with the pointer. (Injection start timing of cyl-
inder No. 1)
Shaft tightening bolt
Drive Coupling - Install

(4) Make sure that the camshaft stamped letter and the cou-
°
10
pling key groove are oriented as shown in the illustra-
ox
pr
tion.
Ap
Coupling key groove
Stamped characters
for camshaft
Fuel Injection Pump

Assembling Position of Camshaft and Drive Coupling
(View from rear/drive side)
29402-00120
8-40
3.1.5 Fuel Injection Pump (PS6 Type) - Install
(a) First, tighten the bolts (long) to connect the drive coupling and laminated plates to the specified torque, and then
loosen the bolts. Tighten again to the specified torque. (2-time tightening method)
(b) Wash the bolt, bushing and washer before using. Foreign material on the contact surfaces of the drive coupling
and the laminated plates can cause the slipping or the damage of couplings.
(c) After tightening the couplings, loosen and retighten the couplings if the laminated plates are distorted.
(1) Lift the fuel injection pump. Slowly lower the fuel Nut
137 ± 5 N·m Washer
injection pump, and install the pump aligning with the (Oil application is
{13 ± 0.5 kgf·m} Bushing
dowel pin on bracket. [101 ± 3.7 lbf·ft] strictly prohibited)
2-time tightening
(2) Connect the laminated plates and drive coupling, and
hand tighten the bolt.
Bolt (long)
Check that the "0" stamped line of the fuel injection
pump flywheel indicating the compression top dead Washer
(Oil application is
center of the No.1 cylinder is near the pointer. strictly prohibited)
Note: When installing coupling connecting bolts, be careful
Laminated plate
not to forget bushings and washers, and also pay atten-
tion to the mounting direction.
(3) Adjust the clearance between the drive coupling and Drive coupling
flywheel to the standard.

For the adjusting procedures, refer to "Clearance
Between Fuel Injection Pump Flywheel and Driving
Coupling - Adjust" of "FUEL SYSTEM."
(4) Tighten all bolts and nuts that have been hand tightened Bolt (short)
137 ± 5 N·m
to the couplings to the specified torque. {13 ± 0.5 kgf·m}
[101 ± 3.7 lbf·ft]
(5) Recheck the clearance between couplings and the tight-
ening condition of bolts and nuts. Drive Coupling and Laminated Plates - Connect
(6) Install the stay between the fuel injection pump case
and the crankcase.
.
(7) Refill engine oil through the oil drain pipe mounting
hole of cam chamber.
(8) Install the oil pipe and the fuel pipe.
34 ± 4 N·m
{3.5 ± 0.4 kgf·m}
Refill engine oil [25 ± 2.9 lbf·ft]
Engine Oil - Refill
29402-00120
8-41
3.1.6 Clearance Between Fuel Injection Pump

172 ± 5 N·m {17.5 ± 0.5 kgf·m} [127 ± 3.7 lbf·ft]
Flywheel and Drive Coupling - Adjust
Clearance
(PS6 Type) 49 ± 0.25 mm
Adjust the clearance between the fuel injection pump fly- [1.929 ± 0.0098 in.]
wheel and the drive coupling with the fuel injection pump
coupling gauge.
(1) Insert the GO side of gauge into the clearance between
the fuel injection pump flywheel and the drive cou-
Injection coupling
pling. And adjust the clearance. gauge
(2) Tighten the bolts to the specified torque. P/N:37591-06100
Clearance Between Fuel Injection Pump Flywheel
(3) Verify that the NO GO side of gauge cannot be inserted
and Drive Coupling - Adjust
in the clearance while the GO side can be inserted. In
this condition, the clearance between the fuel injection
pump flywheel and the drive coupling is adjusted to the
specified value.
(4) If the specified value cannot be made by inserting the
gauge, loosen the bolts, and readjust the clearance.
29402-00120
8-42
3.2 Fuel Control Link - Install

3.2.1 Control Link Lever - Install
(1) Install the link lever with the ball bearing, snap ring, and end plate to the bracket.
(2) Set the governor output shaft at the "0" angle (fuel decreasing side) and the governor lever at the specified angle, then
engage the serration.
3.2.2 Fuel Control Link - Install and Adjust
672
M
3
ax
129.5 mm [5.09 in.] End plate
40
°
117 mm [4.6 in.]
Ball bearing
672
Link lever
3
Stop lever
Control link
Rack control lever
Fuel injection pump rack
Snap ring
Bracket
Toho Seisakusho SG4017 actuator spec
Woodward PSG governor spec (PE(S)-P) Woodward ProAct actuator spec
117 mm Stop lever

[4.6 in.] 108.6 mm Rack control lever
Governor lever Control link [4.3 in.]
Actuator lever
Stop lever Fuel injection 12

15
0 pump rack [4.82.7 m
[5. mm in.] m
9 in Control link
.]
25°
6723 Link lever
30° Fuel injection
pump rack
20.7°
Control link
145mm
[5.7 in.] Stop lever
Rack control lever 62.5mm
[2.5 in.] 30°
78mm 6723 Rack control lever
[3.1 in.]
Control link
13.5°
Governor lever
Control link 103mm

[4.1 in.] 66.5mm
Woodward PSG governor spec(PS6) Fuel injection pump rack [2.6 in.]
Fuel Control Link - Install and Adjust
29402-00120
8-43
(1) Adjust the control link between the fuel injection pump rack and the rack control lever to the specified length, and install
the link.
(2) Install the control link between the rack control lever and the governor lever.
(3) Adjust the length of control link so that the distance between the end face of fuel injection pump and the end of rack
becomes the specified value.
Note: Make sure that the length of thread engagement between the rod and the ball joint screw is 8 mm [0.32 in.] or more.
(4) Verify the distance between the end of fuel injection pump and the fuel injection pump rack is as specified and the play is 3
mm [0.12 in.] when the stop lever is fully pulled to the stop position (rack "0").
3.3 Stop Solenoid - Install

3.3.1 Stop Solenoid (RUN ON) - Adjust
RUN ON stop system spec
Flexible length
control link
Follower
53.5mm
[0.39 in.]
Stop solenoid ON OFF
(RUN ON)
0.5 to 1.0mm
[0.02 to 0.04 in.]
Stop solenoid OFF: 78 ± 0.5 mm [3.07 ± 0.02 in.]

Play: approx 3 mm [0.12 in.]
Stop Solenoid (RUN ON) - Adjust
(1) Turn off the stop solenoid (engine stop).

(2) Fine adjust the flexible length control link so that the distance between the end face of the fuel injection pump and the end
of the control rack becomes 78±0.5 mm [3.07±0.02 in.] (stop position).
Note: Secure the approx 3 mm [0.12 in.] play when the stop solenoid is in the OFF condition so that the control rack does not
move to the "0" position.
29402-00120
8-44
3.3.2 Stop Solenoid (RUN OFF) - Adjust
RUN OFF stop system sepc 1
Flexible length
control link
Follower
Stop solenoid 15 mm
(RUN OFF) [0.59 in.]
ON OFF
10.5 mm
[0.413 in.] ON
OFF
Stop solenoid ON position : 78 ± 0.5 mm [3.071 ± 0.0197 in.]
Play : Applox 3 mm [0.118 in.]
Stop Solenoid (RUN OFF) - Adjust
(1) Push the stop solenoid manually to the stop solenoid ON position (engine stop).
Note: Secure the approx 3 mm [0.12 in.] play when the stop solenoid is in the ON condition so that the control rack does not
29402-00120
8-45
RUN OFF stop system spec 2
ON OFF
10.5 mm Follower
[0.4134 in.]
15 mm
[0.59 in.] Stop solenoid
ON OFF
(RUN OFF)
Stop solenoid Flexible

ON position : 78 ± 0.5 mm [3.071 ± 0.019 in.] control link
Play : Approx 3 mm [0.118 in.]
Note: Secure the approx 3 mm [0.12 in.] play when the stop solenoid is in the ON condition so that the control rack does not
29402-00120
8-46
RUN OFF stop system spec 3
ON OFF
26 mm [1.024 in.]
Flexible length
Stop solenoid
control link (RUN OFF)
(2) Turn the stop solenoid to the OFF position (engine run). Adjust the variable-length control lint to bring the stroke to 26 mm
[1.02 in.].
29402-00120
8-47
3.3.3 Solenoid Function - Verify

Make sure the solenoid functions of start, running and emergency stop of the engine and check the fuel injection pump rack
positions.
Stop solenoid
Specification Item Engine starting Engine running Engine emergency stop
Plunger position (spring condition) Compressed Stretched
Stop solenoid Activation ON OFF
RUN ON
Distance from the fuel injection pump end face 78 ± 0.5 mm
-
to the control rack end [3.07 ± 0.02 in.]
Plunger position (spring condition) Stretched Compressed
Stop solenoid Activation OFF ON
RUN OFF
Distance from the fuel injection pump end face 78 ± 0.5 mm
-
to the control rack end [3.07 ± 0.02 in.]
Note:(a) If the distance of the fuel rack end of fuel injection pump is 78.5 mm [3.091 in.] (3.5 mm [0.138 in.] play to the rack
"0" position) or more, the engine may not be stopped.
(b) If the distance of fuel injection pump rack end is 76 mm [2.99 in.], the fuel injection pump rack stopper may be dam-
aged. Ensure the correct play of 2 to 3 mm [0.08 to 0.12 in.]
29402-00120
8-48
1. Lubrication System - Remove and Inspect ........................................................... 9-3
1.1 Oil Pipe - Remove..................................................................................................................... 9-3
1.2 Oil Pipe for Fan Drive - Remove............................................................................................... 9-4
1.3 Oil Cooler and Oil Filter - Remove and Inspect ........................................................................ 9-5
1.4 Breather - Remove and Inspect................................................................................................ 9-6
1.5 Oil Level Gauge and Oil Filler - Remove and Inspect............................................................... 9-7
1.6 Governor Oil Filter - Remove and Inspect ................................................................................ 9-8
1.7 Oil Pan, Oil Strainer, and Oil Pump - Remove and Inspect ...................................................... 9-9
2. Lubrication System - Disassemble, Inspect, and Assemble ............................. 9-10
2.1 Oil strainer - Disassemble and Inspect ................................................................................... 9-10
2.2 Oil Pump and Safety Valve - Disassemble and Inspect ......................................................... 9-11
2.3 Oil Pump and Safety Valve - Assemble.................................................................................. 9-14
2.4 Oil Cooler and Relief Valve - Disassemble and Inspect ......................................................... 9-15
2.5 Oil Cooler and Relief Valve - Assemble.................................................................................. 9-16
2.6 Oil Filter - Disassemble and Inspect ....................................................................................... 9-17
2.7 Bypass Oil Filter - Disassemble and Inspect .......................................................................... 9-19
2.8 Governor Oil Filter - Disassemble and Inspect ....................................................................... 9-20
2.9 Governor Oil Filter - Assemble ............................................................................................... 9-22
2.10 Oil Filter - Inspect.................................................................................................................... 9-23
2.11 Oil Filter Alarm - Inspect ......................................................................................................... 9-23
2.12 Oil Filter - Assemble ............................................................................................................... 9-23
3. Lubrication System - Install.................................................................................. 9-24
3.1 Oil Pump - Install .................................................................................................................... 9-24
3.2 Oil Pan - Install ....................................................................................................................... 9-24
29402-00120
9-1
1. Lubrication System - Remove and Inspect

1.1 Oil Pipe - Remove
MTK2, MPTA, Y1MPTA,Y1MPTK, PTA, MPTA, Y3MPTK spec

Y2MPTK,T2MTK3 spec
5
4
5
4
E2PTAA-1 spec
5 4
3
1
2
1 Replace: packing,
2 O-ring
*Woodward PSG type governor
Oil Pipe - Remove
Removing sequence
1 Oil drain pipe 4 Oil pipe
2 Oil pipe 5 Oil drain pipe
3 Oil pipe
29402-00120
9-3
1.2 Oil Pipe for Fan Drive - Remove
E2PTAA-1 spec
Crankcase
2
Side cover
Crankcase
1
Replace: O-ring
Side cover sealing washer
Oil Pipe for Fan Drive - Remove

Removing sequence
1 Flexible pipe 2 Oil pipe 3 Flexible pipe
9-4 29402-00120
1.3 Oil Cooler and Oil Filter - Remove and Inspect
5 Change over type oil filter spec
Replace: packing, O-ring
Oil Cooler and Oil Filter - Remove and Inspect

Removing sequence
1 Bypass oil filter element 4 Oil filter bracket
2 Oil filter element 5 Oil cooler assembly
3 Bypass oil filter bracket
29402-00120
9-5
1.4 Breather - Remove and Inspect
PTA, MPTA spec

T2MTK3 spec
1
1
2 Replace
2
Replace
3
3 Replace
Replace
MTK2,Y3MPTK spec E2PTAA-1 spec MPTA, MPTK, Y1MPTA,

Y2MPTK spec
Y3MPTK
1 1
Air cooler
1
1
2
2 2
MTK2
Replace Replace
Replace
3 3
Y3MPTK
MTK2
3 3
Replace
Breather - Remove and Inspect (for Land Use)

Removing sequence
1 Breather pipe 2 Breather 3 Breather pipe
9-6 29402-00120
1.5 Oil Level Gauge and Oil Filler - Remove and Inspect
PTA, MPTA,T2MTKM,Y3MPTK spec
MPTA,
MPTK spec
E2PTAA-1 spec
1
Replace 2
PTA, E2PTAA-1 spec
Replace
1
2
T2MTK3 spec
2
Replace 2
Replace
Oil Level Gauge and Oil Filler - Remove and Inspect

Removal sequence
1 Oil level gauge 2 Oil filler
29402-00120
9-7
1.6 Governor Oil Filter - Remove and Inspect
Hydraulic pressure governor MPTA, MPTK, Y1MPTK spec

Hydraulic pressure governor MTK2 spec
Replace 2
Replace 3
MTK2、T2MTK3
Replace
C
5
2
A Replace 4
1 C
Crankcase
B
1
Replace Replace
Replace
5
3
A
B
4
Replace
※Woodward PSG type governor
Governor Oil Filter - Remove and Inspect (PSG Governor Spec)
Removing sequence
1 Oil pipe, Flexible pipe (MTK2) 4 Governor oil filter assembly
2 Oil pipe 5 Oil filter bracket, Control bracket (MTK2)
3 Oil pipe
9-8 29402-00120
1.7 Oil Pan, Oil Strainer, and Oil Pump - Remove and Inspect
Y2TAA1 spec
(TCM)
3
Y2TAA1 spec PTA,E2PTAA spec
2 2
3 3 1
Deep type oil pan spec Standard oil pan spec
PTA,E2PTAA spec MTK,MTK2,T2MTK3, MPTA,MPTK spec
T2MTKM,Y3MPTK spec
1 1 1
Replace: packing, O-ring, sealing washer, gasket
Oil Pan, Oil Strainer and Oil Pump - Remove and Inspect
Removing sequence
1 Oil pan 2 Oil pump assembly 3 Oil strainer
29402-00120
9-9
2. Lubrication System - Disassemble, Inspect, and Assemble

2.1 Oil strainer - Disassemble and Inspect
Replace
Crack
Replace
Clogged strainer hole:

Wash with diesel fuel
Crack
2
Oil strainer - Disassemble and Inspect

1 Oil strainer 2 Oil pipe
9-10 29402-00120
2.2 Oil Pump and Safety Valve - Disassemble and Inspect
Crack, flaw 8 Wear

10
Contact, peeling, wear
7
5
Contact,
peeling, wear
6 4
2
Crack, flaw 1
Settling, break, wear
Oil Pump and Safety Valve - Disassemble and Inspect

1 Safety valve assembly 6 Pump driven gear
2 Oil pump cover 7 Nut
3 Pump drive gear 8 Spindle
4 Oil pump gear 9 Idler gear
5 Pump driven gear 10 Oil pump case
29402-00120
9-11
2.2.1 Oil Pump Gear Backlash - Measure

Measure the backlash between the oil pump gear and the
idler gear. If the value exceeds the limit, replace the gears
with new ones.

Backlash between oil pump 0.087 to 0.316 mm 0.400 mm
gear and idler gear [0.0034 to 0.0124 in.] [0.0157 in.]
Backlash between drive gear 0.087 to 0.316 mm 0.400 mm
and driven gear [0.0034 to 0.0124 in.] [0.0157 in.]
2.2.2 Clearance Between the Gear Teeth and Case -

Measure
Measure the top clearance between drive/driven gear teeth
and case housing. If the value exceeds the limit, replace the
gear or the case with a new one.

Top clearance between 0.200 to 0.296 mm 0.350 mm
gear teeth and case [0.0079 to 0.0117 in.] [0.0138 in.]
Clearance Between the Gear Teeth and Case -

Measure
2.2.3 Side Clearance Between Gear Width and Case
- Measure
Measure the side clearance between the gear width and case
depth. Remove the cover mounting packing (0.04 mm
[0.0016 in.] thick) to measure the clearance. If the value
exceeds the limit, replace the gear or the case with a new
one.

Side clearance between 0.039 to 0.114 mm 0.250 mm
gear width and case depth [0.0015 to 0.0045 in.] [0.0098 in.]
Side Clearance Between Gear Width and Case -
Measure
2.2.4 Drive and Driven Gear Shaft Outside Diameters
and Bushing Inside Diameters - Measure
(1) Check the gear teeth. If any defect is found, replace the
gear with a new one.
(2) Measure the drive and driven gear shaft outside diame-
ters and bushing inside diameters. If any of the gear or
bushing exceeds the limit, replace the assembly with
new one.
Nomi-
Item nal Standard value Limit value
value
Drive shaft out- 24.947 to 24.960 mm 24.900 mm
side diameter [0.9822 to 0.9827 in.] [0.9803 in.]
Driven shaft
outside diame- ø25 mm 24.947 to 24.960 mm 24.900 mm
[0.98 in.] [0.9822 to 0.9827 in.] [0.9803 in.]
ter
Bushing inside 25.000 to 25.021 mm 25.100 mm
diameter [0.9843 to 0.9851 in.] [0.9882 in.]
9-12 29402-00120
2.2.5 Oil Pump Safety Valve - Inspect

(1) Check the valve spring fatque and wear. If significantly Safety valve spring
fatigued, worn or broken, replace the spring with a new

one.
Item Standard value

Safety valve spring 65.3 mm [2.571 in.]/ 436 ± 17.7 N
set length / load {44.46 ± 1.8kgf} [98.02 ± 3.98 lbf]
Stopper
Safety Valve - Inspect
29402-00120
9-13
2.3 Oil Pump and Safety Valve - Assemble
Wipe grease from nut and spindle,

and apply Locktite 262 to threads before tightening.
Tightening torque : 68 ± 6.8 N·m {7 ± 0.7 kgf·m} [50 ± 5 lbf·ft]
Shrinkage-fit each gear.

Shrinkage-fit temperature : 180 to 200°C
33 ± 6.7 N·m [356 to 392°F]
{3.4 ± 0.68 kgf·m} Used oil : Thermrex 55
[24 ± 4.9 lbf·ft] Heating period : Approx 5 min.
33 ± 6.7 N·m
{3.4 ± 0.68 kgf·m}
[24 ± 4.9 in.]
Backlash : 0.087 to 0.316 mm
[0.0034 to 0.0124 in.]
Oil Pump and Safety Valve - Assemble
Apply engine oil on each part when assembling. Apply a thick coat of engine oil on threads and seating surfaces of
the nuts and bolts before tightening them.
9-14 29402-00120
2.4 Oil Cooler and Relief Valve - Disassemble and Inspect
Spring fatigue,
break, wear
6
Clogging, blowout, crack
7
Replace 8
11 9
5
10
1
2
Replace 3
4
Replace Spring fatigue,
break, wear
Crack, deformation
Replace
Oil Cooler and Relief Valve - Disassemble and Inspect

1 Relief valve plug 7 Bypass valve spring
2 Relief valve spring 8 Bypass valve
3 Relief valve sleeve 9 Snap ring
4 Relief valve 10 Oil cooler cover
5 Side cover, packing 11 Oil cooler element
6 Bypass valve case
29402-00120
9-15
2.4.1 Oil Cooler - Inspect

Air
Check the oil passages of element for flaws or cracks by Leak, flaw, crack
applying compressed air of 1.5 MPa {15.3 kgf/cm2} [218
psi].
If any leak or damage is found, replace the element with a
new one.
Oil Cooler - Inspect

Inspect the bypass valve opening pressure. If limit is
exceeded, replace it with a new one.
Item Standard value

0.42 ± 0.02 MPa
Bypass valve opening pressure {4.3 ± 0.2 kgf/cm2}
[61 ± 3 psi]
2.4.2 Relief Valve - Inspect

(1) Inspect the relief valve spring, and if any deformation,
wear or damage is found, replace the spring with a new
one.
Item Standard value

Valve
Relief valve spring free length 115 mm [4.53 in.]
(2) Inspect the valve, and if any wear, flaw, or sliding mal- Spring
function is found, replace the valve with a new one.
Relief Valve - Inspect

2.5 Oil Cooler and Relief Valve - Assemble
To assemble, follow the disassembling sequence in reverse.
9-16 29402-00120
2.6 Oil Filter - Disassemble and Inspect
Replace 2
3 Crack, deformation
Clogging, crack, deformation
Oil Filter - Disassemble and Inspect

1 Oil filter element (cartridge type) 3 Oil filter bracket
2 Oil filter alarm
29402-00120
9-17
Change over type
Replace 6
7
Crack, deformation
Replace
3
4
2
1
Oil Filter (Changeover Type) - Disassemble and Inspect

1 Oil filter element (cartridge type) 5 Cock
2 Cover 6 Oil filter alarm
3 Straight pin 7 Oil filter bracket
4 Cover
9-18 29402-00120
2.7 Bypass Oil Filter - Disassemble and Inspect
Bypass oil filter
Crack, deformation
Bypass Oil Filter - Disassemble and Inspect

1 Oil filter element 2 Oil filter bracket
29402-00120
9-19
2.8 Governor Oil Filter - Disassemble and Inspect
Hydraulic pressure governor spec
1 Crack, deformation
* Woodward PSG type governor
Governor Oil Filter - Disassemble and Inspect

1 Oil filter element 2 Oil filter bracket
9-20 29402-00120
Hydraulic pressure governor spec
6 3
Replace
Clogging, crack
Replace

Governor Oil Filter - Disassemble and Inspect
1 Center bolt 3 Spring seat 5 Case
2 Element 4 Spring 6 Cover
29402-00120
9-21
2.9 Governor Oil Filter - Assemble
9.8 ± 2 N·m
{1 ± 0.2 kgf·m}
[7 ± 1.5 lbf·ft]
Replace
Clogging, crack
9.8 ± 2 N·m
{1 ± 0.2 kgf·m} 34.3 ± 6.9 N·m
[7 ± 1.5 lbf·ft] {3.5 ± 0.7 kgf·m}
[25 ± 5 lbf·ft]

Governor Oil Filter - Assemble
9-22 29402-00120
2.10 Oil Filter - Inspect

When replacing the oil filter, sample the oil (500 ml [0.13
US gal]) and check for metal and other particles. If metal or
other particles are found, cut and unfold the element, and
inspect the color and shape of metal particles trapped in ele-
ment to identify the cause.
Oil Filter - Inspect

2.11 Oil Filter Alarm - Inspect
(1) Use a tester to check the alarm for insulation and conti-
nuity. If the alarm is defective, disassemble and repair.
If the bakelite or rubber insulations are deteriorated or
Filter inlet
damaged, replace the alarm.
pressure
(2) If the filter alarm activation pressure is out of the stan-
dard, replace the alarm with a new one.
Item Standard value Filter

outlet pressure
Oil filter alarm differential
pressure to activate the alarm
0.165 ± 0.015 MPa
{1.65 ± 0.15 kgf/cm2} Ω
[23.93 ± 2.2 psi]
Oil Filter Alarm - Inspect
2.12 Oil Filter - Assemble
To assemble, follow the disassembly sequence in reverse.
Thoroughly clean oil passages with wash oil, and dry the
cleaned parts with compressed air.
(a) When installing the oil filter cartridge, tighten it

by hand. (Do not use a filter wrench.)
(b) Be careful not to dent or damage the surface of
cartridge.
(1) Remove dust and contamination on mating face of oil
filter cartridge.
(2) Apply clean engine oil on oil filter gasket.
(3) After the oil filter gasket contacts with the base surface,
tighten the cartridge by 3/4 to 1 turn by hand.
(4) Start the engine, and make sure that there is no fuel
leak.
29402-00120
9-23
3. Lubrication System - Install

Thoroughly clean oil passages and dry them well.
3.1 Oil Pump - Install

After installing the oil pump to the crankcase, measure the
backlash of crankshaft gear and oil pump gear.
Shim
If the backlash is out of the standard, insert shims to the oil Oil pump gear t = 0.1 mm [0.004 in.]
pump mounting faces to adjust the backlash. P/N : 32635-00900
Item Standard value

Backlash between oil pump gear 0.12 to 0.18 mm
and crankshaft gear [0.0047 to 0.0071 in.]
Oil
strainer
Oil pump
Backlash When Installing Oil Pump - Adjust
3.2 Oil Pan - Install

(1) Apply sealant (Heldite) on both surfaces of oil pan
packing joints (4 places), and attach the packing to the
oil pan. Apply Heldite
If the packing is pressed out, cut the protrusion care- to 4 joints
fully with a cutter or the like.
(2) Install two guide bolts into the crankcase and install the Packing
oil pan.
(3) Tighten the mounting bolts to the specified torque.
39 ± 3.9 N·m
Apply Heldite {4 ± 0.4 kgf·m}
to joint [29 ± 3 lbf·ft]
Oil Pan - Install
9-24 29402-00120
1. Cooling System - Remove and Inspect ............................................................... 10-3
1.1 Tension Pulley - Remove and Inspect (Water Pump Side) .................................................... 10-3
1.2 Tension Pulley - Remove and Inspect (Fan Side) .................................................................. 10-4
1.3 Thermostat Case and Water Pipe - Remove and Inspect ...................................................... 10-5
1.4 Heat Exchanger and Water Pipe - Remove and Inspect ........................................................ 10-9
1.5 Seawater Pump and Water Pipe - Remove and Inspect ...................................................... 10-10
1.6 Water Pump and Water Pipe - Remove and Inspect............................................................ 10-11
2. Cooling System - Disassemble, Inspect, and Assemble ................................. 10-12
2.1 Tension Pulley - Disassemble and Inspect (Water Pump Side) ........................................... 10-12
2.2 Tension Pulley (Fan Side) - Disassemble and Inspect ......................................................... 10-15
2.3 Thermostat - Disassemble and Inspect ................................................................................ 10-18
2.4 Thermostat - Inspect............................................................................................................. 10-19
2.5 Heat Exchanger - Disassemble and Inspect......................................................................... 10-20
2.6 Water Pump - Disassemble and Inspect .............................................................................. 10-21
2.7 Water Pump - Inspect ........................................................................................................... 10-23
2.8 Water Pump - Assemble....................................................................................................... 10-24
2.9 Seawater Pump - Disassemble and Inspect......................................................................... 10-26
2.10 Seawater Pump - Assemble ................................................................................................. 10-28
2.11 Fan Drive Assembly - Disassemble and Inspect .................................................................. 10-32
2.12 Fan Drive - Inspect ............................................................................................................... 10-33
2.13 Oil Seal Sleeve - Inspect ...................................................................................................... 10-33
2.14 Oil Seal Sleeve - Replace..................................................................................................... 10-33
2.15 Fan Drive Assembly - Assemble........................................................................................... 10-34
3. Cooling System - Install ...................................................................................... 10-37
3.1 Water Pipe (Air Cooler) - Install ............................................................................................ 10-37
3.2 Water Outlet Pipe - Install..................................................................................................... 10-37
29402-00120
10-1
1. Cooling System - Remove and Inspect

1.1 Tension Pulley - Remove and Inspect (Water Pump Side)
MTKMTK2,T2MTK3,T2MTKM,Y3MPTK spec
2
4
Crack, wear
Tension Pulley - Remove and Inspect (Water Pump Side)

Removing sequence
1 Tension bolt 3 Belt
2 Mounting bolt 4 Tension pulley assembly
29402-00120
10-3
1.2 Tension Pulley - Remove and Inspect (Fan Side)
E2PTAA-1 spec
1 4
Crack, wear
Tension Pulley - Remove and Inspect (Fan Side)

Removing sequence
1 Tension bolt 3 Belt
2 Mounting bolt 4 Tension pulley assembly
10-4 29402-00120
1.3 Thermostat Case and Water Pipe - Remove and Inspect
Air cooling exhaust manifold spec
Replace
9
8
Crankcase
PTA, MPTA spec Replace

TA, E2PTAA-1, TAA,
Replace
Replace MPTA, MPTK,
Y3MPTK spec
2 Replace 5
10
1
3
PTA, Y2MPTK spec Y2TAA-1 spec

4
10
10
Thermostat Case and Water Pipe - Remove and Inspect

Removing sequence
1 Coupling 6 Coupling
2 Water pipe 7 Water pipe
4 Coupling 9 Water pipe
5 Bypass pipe 10 Thermostat
29402-00120
10-5
Air cooling exhaust manifold E2PTAA-1 spec
8 10
Replace Replace
7
11
9 Replace
Replace

Removing sequence
1 Coupling 7 Rubber hose
2 Bypass pipe 8 Water pipe
3 Rubber hose 9 Rubber hose
5 Rubber hose 11 Thermostat
6 Water pipe
10-6 29402-00120
Water cooling exhaust manifold MPTA,Y1MPTA spec
6 Replace 2
Cylinder
head
1
Replace 7
Replace 14
13
15
Oil cooler
12
10
3
11
Replace
4
9
Replace
8 Replace

Removing sequence
1 Coupling 9 Bypass pipe
2 Water pipe 10 Cover
3 Coupling 11 Rubber hose
4 Water pipe 12 Thermostat
5 Rubber hose 13 Coupling
8 Coupling
29402-00120
10-7
Air cooling exhaust manifold PTK,Y2MPTK spec
Replace
9
Replace
PTK spec Y2MPTK spec

Replace
1 3
Replace Replace Replace
PTK spec Y2MPTK spec

7 6 6
8
5
Water pump

Removing sequence
3 Coupling 7 Thermostat
4 Connector 8 Water pipe
10-8 29402-00120
1.4 Heat Exchanger and Water Pipe - Remove and Inspect
Water cooling exhaust manifold MTK, MTK2, MPTKVSHF
7
Replace
Replace
5
13
6
Replace
11
3
12
4 Replace Crankcase
14
Cylinder Replace
head
Replace 8
10 9
Water
pump Replace
Heat Exchanger and Water Pipe - Remove and Inspect

Removing sequence
1 Coupling 8 Coupling
3 Rubber hose 10 Water pipe
4 Water pipe 11 Coupling
7 Water pipe 14 Heat exchanger (approx 68 kg [149 lb])
29402-00120
10-9
1.5 Seawater Pump and Water Pipe - Remove and Inspect
MTK,T2MTKM,Y1MPTK,Y3MPTK MTK,MTK2,T2MTK3,T2MTKM,Y1MPTK,Y3MPTK spec
Replace Replace 2
Replace
Heat exchanger
9 Replace
10 Aircooler
Replace 5
11
4
7
MTK2,T2MTK3
4
5 Heat exchanger
Replace Replace
2 6
Aircooler
9
Replace
8
10 1
11 3
7
Sea Water Pump and Water Pipe - Remove and Inspect
Removing sequence
1 Rubber hose 7 Rubber pipe
2 Sea water pipe 8 Sea water pipe
3 Sea water pipe 9 Sea water pipe
4 Rubber pipe 10 Sea water pipe
5 Sea water pipe 11 Sea water pump
6 Pipe assembly
10-10 29402-00120
1.6 Water Pump and Water Pipe - Remove and Inspect
Replace 1
Replace
Water Pump and Water Pipe - Remove and Inspect

Removing sequence
1 Connector 2 Water pump
29402-00120
10-11
2. Cooling System - Disassemble, Inspect, and Assemble

2.1 Tension Pulley - Disassemble and Inspect (Water Pump Side)
10
8
7
6
5 1
4 Crack, flaw,
deflection of shaft,
3 oil hole clogging
9
2
Belt groove wear

Rotation
Tension Pulley - Disassemble and Inspect (Water Pump Side)

1 Bracket 5 Snap ring 9 Tension pulley
2 Bolt 6 Ball bearing 10 Plate
3 Thrust plate 7 Spacer
4 Spacer 8 Ball bearing
2.1.1 Tension Pulley - Inspect

Measure the bearing fitting in the tension pulley and on the shaft. If abnormal wear or damage is shown, replace the bearing,
pulley or tension bracket.
Item Standard value Standard value

Inside diameter of tension pulley bearing housing ø52 [ø2.05] 51.987 to 52.000 mm [2.0467 to 2.0472 in.]
Outside diameter ø52 [ø2.05] 51.970 to 51.955 mm [2.0461 to 2.0455 in.]
Bearing
Inside diameter ø20 [ø0.79] 19.990 to 20.000 mm [0.7870 to 0.7874 in.]
Outside diameter of bracket bearing fittting ø20 [ø0.79] 19.987 to 20.000 mm [0.7869 to 0.7874 in.]
10-12 29402-00120
2.1.2 Tension Pulley - Assemble

(1) Apply engine oil to the fitting faces of bearing and ten-
sion pulley. ø52 [ø2.05]
Special jig
(2) Make the special jig and press-in the inner ball bearing
into the tension pulley using the jig and a hand-press. 34 ø20
[1.34] [ø0.8]
Note: The bearing is a grease sealed type. Do not wash the Bearing
bearing.
Tension pulley
Unit: mm [in.]
Inner ball bearing - Insert
(3) Press fit the bracket into the tension pulley with the
inner bearing using a hand-press.
Special jig
Bracket
Tension Pulley - Press-in

(4) Install the inside spacer.
Spacer
Inside spacer - Install

(5) Press-in the outer ball bearing into the tension pulley
using the special jig and a hand-press.
Special jig
Outer ball bearing - Insert
29402-00120
10-13
(6) Fit the snap ring in the groove on the inner periphery of
the tension pulley.
Snap ring
Snap Ring - Install

(7) Install the outside spacer.
Spacer
Outside Spacer - Install

(8) Install the thrust plate with bolt.
Thrust plate
Thrust plate - Install

(9) Tighten the bolt.
Note: After assembly, verify that the tension pulley rotates
Bolt 98 N·m
smoothly. {10 kgf·m}
[72 lbf·ft]
Bolt - Tighten
10-14 29402-00120
2.2 Tension Pulley (Fan Side) - Disassemble and Inspect
11
12
8 10
7
5 9 Crack, flaw,
Rotation deflection of shaft,
4 oil hole clogging
Flaw, wear
Rotation
Tension Pulley - Disassemble and Inspect (Fan side)

1 Tension bolt 5 End plate 9 Ball bearing
2 Bracket fix bolt 6 Tension pulley 10 Pointer
3 Tension bracket 7 Ball bearing 11 Tension plate
4 Bolt 8 Spacer 12 Tension bracket
2.2.1 Tension Pulley - Inspect

Measure the bearing fitting in the tension pulley and on the shaft. If abnormal wear or damage is shown, replace the bearing,
pulley or tension bracket.
Item Standard value Standard value

Inside diameter of tension pulley bearing housing ø90 [ø3.54] 89.985 to 90.000 mm [3.5427 to 3.5433 in.]
Bearing
Outside diameter of bracket bearing fittting ø40 [ø1.57] 39.982 to 40.000 mm [1.5741 to 1.5748 in.]
29402-00120
10-15
2.2.2 Tension Pulley - Assemble

(1) Apply engine oil to the fitting faces of bearing and ten-
sion pulley. ø 90 [ø 3.54] Special jig
(2) Make the special jig and press-in the inner ball bearing 34 ø 40
into the tension pulley using the jig and a hand-press. [1.34] [ø 1.57]
Bearing
Note: The bearing is a grease sealed type. Do not wash the
bearing.
Tension pulley
Unit: mm [in.]
Inner Ball Bearing - Insert 1
(3) Fit the inner ball bearing into the tension pulley using
the special jig and a hand-press.
Special jig
Bearing
Tension pulley
Inner Ball Bearing - Insert 2

(4) Place the inner ball bearing downside and assemble to
the shaft.
(5) Press-in the shaft into the tension pulley using a hand-
press.
Tension pulley
Bearing
Tension Pulley - Press-in

(6) Install the spacer.
(7) Press-in the outer ball bearing into the tension pulley
using the special jig and a hand-press. Special jig
Bearing
Spacer
Spacer and Outer Ball Bearing - Install
10-16 29402-00120
(8) Install the end plate with bolt.

Bolt,
Spring washer
End plate
End Plate - Install

Note: After assembly, verify that the tension pulley rotates
Bolt 235 N·m
smoothly. {24 kgf·m}
[182 lbf·ft]
Bolt - Tighten
29402-00120
10-17
2.3 Thermostat - Disassemble and Inspect
Y2TAA spec PTA, Y2PTK spec PTA, MPTA, MPTK, Y1MPTK,

Y3MPTK, E2PTAA-1 spec
30 ± 3 N·m
{3 ± 0.3 kgf·m}
[22 ± 2.2 lbf·ft]
1 1 1
2 2
2
Replace 3
Replace
Thermostat - Disassemble and Inspect

1 Thermostat cover 3 Thermostat
2 Packing 4 Thermostat case
10-18 29402-00120
2.4 Thermostat - Inspect
Stir water with a stick.

Pay attention to hot water and flames.
Or, you may get burned or cause a fire.
(1) Immerse the thermostat in a container filled with water.
(2) Heat the water while measuring water temperature.
Record the temperature at which the valve start to open,
and at which the valve lift becomes to the standard
value. Replace the thermostat if a deviation from the
standard temperature is significant.
Note:(a) Stir the water to maintain uniform temperature Thermostat Operation - Inspect
during the test.
(b) At assembling, be sure to check the valve opening
temperature marked on the side of thermostat valve.
Part No. Item Standard value

Temperature at which the valve 69 to 73 ºC
starts to open primarily [156 to 163 ºF]
Temperature at which the valve 72 to 76ºC
35C46-05500 starts to open secondarily [162 to 169ºF]
Temperature at which the valve
85 ºC
lift becomes 10 mm [0.39 in.]
[185 ºF]
or more
Temperature at which the valve 74.5 to 78.5 ºC
Temperature at which the valve 77.5 to 81.5 ºC
35C46-05600 starts to open secondarily [172 to 179 ºF]
90 ºC
[194 ºF]
or more
35C46-05700 starts to open secondarily [181 to 189 ºF]
95 ºC
[203 ºF]
or more
29402-00120
10-19
2.5 Heat Exchanger - Disassemble and Inspect
MTK, MTK2, MPTK,T2MTK3L,Y3MPTK spec
Replace: every 500 hours 6

or within 12 months
1
Replace
8
Replace
Replace
8 Replace
Replace
3
Replace
Clean: Every 2000 hours Replace
or within 24 months 5
4
Replace
Crack, corrosion 7
Replace
Replace: every 500 hours
or within 12 months
2
8
Replace
Heat Exchanger - Disassemble and Inspect

1 Connector 4 Cover 7 Expansion tank
2 Connector 5 Thermostat 8 Zink rod
3 Element 6 Pressure cap
2.5.1 Heat Exchanger Element - Clean

(1) Clean the pipe outside by pouring water and brushing
with wire brush or the like. Inspect the element for cor-
rosion and cracks.
(2) Remove deposits from the inside of pipes by inserting a Element
bar.
(3) Visually inspect the outside and inside of pipes for cav-
itation. If any defects are found, replace it with a new
one.
Heat Exchanger Element - Clean
10-20 29402-00120
2.6 Water Pump - Disassemble and Inspect
Replace
Replace Flaw, wear
10
3
5
4
Corrosion, crack,
flaw
Rotation
Corrosion, contact damage
9 11
8 Wear Corrosion, crack, flaw
6
7 Lip wear, flaw,
deterioration
2
1
Velt groove wear, damage
Water Pump - Disassemble and Inspect

1 Nut, washer 7 Ring
2 Water pump pulley 8 Water pump shaft
3 Water pump cover, O-ring 9 Ball bearing
4 Impeller 10 Oil seal
5 Unit seal 11 Water pump case
6 Oil seal
29402-00120
10-21
2.6.1 Water Pump Mounted on Engine - Inspect

With fingers, touch the drain pipe located at the bottom cen-
ter of the water pump case. If water is oozing out, determine
that the unit seal is defective. Disassemble, inspect, and cor-
rect the unit seal.
Water Pump Mounted on Engine - Inspect

2.6.2 Impeller - Remove
Socket wrench
width across flats
When removing the impeller from the water pump- 32 mm [1.26 in.] Impeller
shaft, be careful not to damage the water pump shaft

and the impeller.
(1) Install two nuts to the water pump

shaft on the opposite side of impeller to prevent the
shaft from rotating.
(2) Hold the two nuts with a wrench. Loosen the impeller
with a socket wrench (width across flats: 32 mm [1.26 Water pump
shaft
in.]) and remove it.
Lock with
double nuts
Impeller - Remove
2.6.3 Water Pump Shaft - Remove
(1) Remove the snap ring from the ball bearing on the
water pump pulley side. Ball bearing
(2) Remove the shaft and ball bearings by pushing the end
face of water pump shaft on the impeller side.
Water pump
shaft
Ball bearing
Water Pump Shaft - Remove
10-22 29402-00120
2.7 Water Pump - Inspect

Measure the bearing fitting diameters of water pump bearing housing and shaft, and the inside and outside diameters of the
bearings. If the measurement is out of the standard, replace the part with a new one.

ø62 mm [ø2.44 in.] 61.988 to 62.018 mm [2.4405 to 2.4416 in.]
ø72 mm [ø2.83 in.] 71.988 to 72.018 mm [2.8342 to 2.8353 in.]
Large
Bearing
Small
Outside diameter of shaft fitting to bearing ø30 mm [ø1.18 in.] 29.985 to 30.003mm [1.1805 to 1.1812 in.]
Impeller front clearance 0.5 to 1.3 mm [0.020 to 0.051 in.]
Impeller back clearance 1.0 mm [0.039 in.]
29402-00120
10-23
2.8 Water Pump - Assemble
Replace
210 ± 10 N·m
{21 ± 1 kgf·m}
[155 ± 7.4 lbf·ft]
260 ± 12 N·m
{26 ± 1.2 kgf·m}
[192 ± 9 lbf·ft]
Apply sealant 32 ± 6.67 N·m

{3.3 ± 0.68 kgf·m}
[24 ± 5 lbf·ft]
Apply sealant (ThreeBond 1102) to the outer circumference

of unit seal.
Apply engine oil to the oil seal lip, and fit it with the end
of case face.
Assemble shield plate to the oil seal side.
Apply engine oil to ball portion.
Water Pump - Assemble
10-24 29402-00120
2.8.1 Inner Oil Seal - Install

(1) Using the installer, press-in the oil seal, making sure Oil seal installer
that the oil seal surface is flush with the water pump
case face.
(2) Apply engine oil to the oil seal lip.
Apply engine
oil
Inner Oil Seal - Install

2.8.2 Unit Seal (Stationary Side) - Install
(1) Apply sealant (ThreeBond 1102) on the outer circum-
ference of unit seal (stationary side.) Unit seal installer
(2) Tap-in the unit seal into the water pump case with the
unit seal installer.
Apply ThreeBond 1102

to unit seal counterbore
Unit Seal (Stationary Side) - Install
2.8.3 Ball Bearing - Install
(1) Apply engine oil to the balls of the ball bearing. Apply
engine oil
(2) Press fit the ball bearing to the water pump shaft.
(3) Install the thread cover to the end of water pump shaft Bearing installer
P/N:32591-03600
with the ball bearings.
(4) Using a bearing installer, press-in the water pump shaft
gently until the end of ball bearing comes into contact
with the water pump case.
Thread cover
P/N: 37191-06600
Ball Bearing - Install
2.8.4 Outer Oil Seal - Install
(1) Apply engine oil to the oil seal lips. Apply engine oil
(2) Press fit the oil seal using the installer so that the oil
seal surface is flush with the water pump case face.
OIl seal installer
Outer Oil Seal - Install
29402-00120
10-25
2.9 Seawater Pump - Disassemble and Inspect
MTK, MTK2, MPTK, Y1MPTK spec
Lip surface wear, aging
Rotation
Spline wear
Rotation 11
14 1
Replace 15
13
Peeling, wear
2
3
8
12
10
4 Replace
9
Crack, wear
6
Wear deformation,
7 aging, crack, flaw
Replace
5
Replace
Replace
Seawater Pump - Disassemble and Inspect

1 Cover 9 Seawater pump gear
2 Seawater pump impeller, cover 10 Snap ring
3 Case 11 Sea water pump shaft
4 Plate 12 Ball bearing
5 Snap ring 13 Ball bearing
6 Unit seal 14 Oil seal
7 Housing 15 Bearing case
8 Nut, washer
10-26 29402-00120
2.9.1 Seawater Pump Assembled to Engine - Inspect

With fingers, touch the drain port at the bottom of pump
holder. If water is oozing out, the unit seal is thought to be
defective. Disassemble, check and correct the unit seal.
Clean the pipe inside with a thin stick or the like, in case of
the clogging with deposition salt.
Drain pipe
Seawater Pump Assembled to Engine - Inspect
2.9.2 Outside Diameter and Inside Diameter of
Bearing Fitting - Inspect
Turn the bearing and if the turning is not smooth, replace the bearing with a new one. Inspect the fitting of bearing case and
bearing. If significant wear is found, replace it with a new one. Inspect the fittin of shaft and bearing. If significant wear is
found, replace it with a new one.

Inside diameter of case bearing housing ø90 mm [ø3.54 in.] 89.825 to 90.175 mm [3.5364 to 3.5502 in.]
Bearing ø30 mm [ø1.18 in.] 30.002 to 30.015 mm [1.1812 to 1.1817 in.]
Inside diameter
ø40 mm [ø1.57 in.] 40.002 to 40.018 mm [1.5749 to 1.5755 in.]
ø30 mm [ø1.18 in.] 29.990 to 30.000 mm [1.1807 to 1.1811 in.]
Outside diameter of shaft fitting to bearing
ø40 mm [ø1.57 in.] 39.988 to 40.000 mm [1.5743 to 1.5748 in.]
2.9.3 Drive Gear - Inspect

　
Inspect the drive gear teeth. Replace the gear if flaking or wear is unusual.
29402-00120
10-27
2.10 Seawater Pump - Assemble
MTK, MTK2, MPTK, Y1MPTK,T2MTK3,T2MTKM,Y3MPTK spec
Fill the one-half of

lip with NOK Klueber grease NBU-12K.
Apply a small amount of

white petrolatum to sliding portion.
Apply lithium grease to
the rolling contact area.
220 ± 10 N·m
{22.4 ± 1 kgf·m}
[162 ± 7.4 lbf·ft]
Apply turbine oil to sliding surface.

Apply ThreeBond 1322 before press-fitting.
Seawater Pump - Assemble
10-28 29402-00120
2.10.1 Oil Seal - Install

(1) Press-in the oil seal into the bearing case with the Installer
installer.
Note: Always replace the oil seal with a new one.
Fill one-half of lip
Place the lip to face to the bearing. space with NOK Oil seal
(2) Apply grease to the oil seal groove and lip. Klueber grease
NBU-12K.
Oil Seal - Install

2.10.2 Unit Seal Ring - Install
Seal ring installer guide
Insert the unit seal ring slowly into the housing by hand Sliding surface P/N:45B91-02100
using the unit seal ring installer.
Note:(a) Replace the unit seal with a new one whenever it is
removed from the pump case.
(b) Do not use a hummer or mallet to install.
(c) Do not damage the sliding surface of the unit seal.
Housing
Seal ring portion
Unit Seal Ring - Install
2.10.3 Bearing - Install
(1) Press-in the bearing squarely along the shaft center line. Apply lithium grease to bearing rolling contact surface.
(2) Apply grease on the bearing rolling face.
Shaft
Bearing - Install
2.10.4 Shaft and Bearing - Install
(1) Press in the ball bearing and water pump shaft to the Installer
holder with the installer.
Bearing
(2) Press in the ball bearing to the water pump shaft with
the installer.
Holder
Shaft
Bearing
Shaft and Bearing - Install
29402-00120
10-29
2.10.5 Snap Ring - Install

Install the snap ring to the holder.
Snap ring
Snap Ring - Install

2.10.6 Housing - Install
(1) Install an O-ring to the shaft. Shaft
(2) Install the housing and unit seal assembly to the bearing
case. Clean the sliding faces of seal ring with ethyl Sliding surface
alcohol, and apply turbine oil. Holder Bushing
Note: Finally, check the sliding surfaces for flaw or dust.
Seal ring
portion
Housing - Install
2.10.7 Unit Seal Mating Ring - installing
(1) Clean the mating ring sliding face and the inside face of
unit seal with ethyl alcohol, and apply turbine oil.
Apply turbine oil
Unit Seal Mating Ring - Install (1)

(2) Install the mating ring and the snap ring to the shaft.
(3) Using the mating ring installer guide and the gear cou-
pler, slowly install the mating ring. Mating ring installer guide
Gear puller P/N: 45B91-02200
Note: Check the ring for square installation. If the ring is
slanted, the snap ring can not be assembled or it can
cause water leak. Shaft
(4) Press-in the mating ring until the installer guide con- Ring pliers
tacts to the shaft end face, fix the ring with a snap ring.
Snap ring
Note:(a) Do not over-tighten the gear puller.
(b) Use the ring prier through the opening of mating
Unit Seal Mating Ring - Install (2)
ring installer guide.
10-30 29402-00120
2.10.8 Body - Install

(1) Apply grease to O-rings and install them to the bearing
Body
case and the body.
(2) Attach the plate to the bearing case and install to the
body.
Plate Bearing
case
O-ring
Body - Install
2.10.9 Impeller - Install
(1) Tap-in the impeller to the shaft. Blade
Note: Place the impeller to bend its blades in the following Impeller
direction of the water pump rotation.
(2) Install the impeller cover.
Impeller
Apply a small amount
of white vaseline to
Rotation sliding portion.
direction
Impeller - Install
2.10.10Cover - Install
Install the O-ring to the body and install the cover.
Cover
Cover - Install
2.10.11Gear - Install
Install the drive gear and tighten the nut to the specified
torque. Bend the washer to lock.
220 ± 10 N·m
{22.4 ± 1 kgf·m}
[162 ± 7.4 lbf·ft]
Drive gear
Gear - Install
29402-00120
10-31
2.11 Fan Drive Assembly - Disassemble and Inspect
Fan ȭ1010,ȭ1016 spec Fan ȭ1010 spec

12
Rotation
11
Ribbed belt spec
3 Belt groove wear
10
9
Replace Crack, flaw

6
1 5
4
V-belt spec
3
2 Rotation
Replace
Wear
Fan Drive Assembly - Disassemble and Inspect

1 Fan spacer 5 Oil seal 9 Ball bearing
2 Cap nut 6 Snap ring 10 Spacer
3 Fan pulley 7 Cap 11 Ball bearing
4 Sleeve 8 Fan drive shaft 12 Drive shaft bracket
If one of fan blade is damaged, be sure to replace the fan with a new one. One blade damage may result in the
damage of other blades or abnormal wear of the bearing due to the vibration.
10-32 29402-00120
2.12 Fan Drive - Inspect

Inspect the fitting between the fan drive shaft and fan drive case bearing, and if unusual wear is found, replace it with a new
one.

Inside diameter of case bearing housing ø80 [ø3.15] 79.988 to 80.018 mm [3.1491 to 3.1503 in.]
Bearing
Outside diameter of shaft to fit bearing ø40 [ø1.57] 39.988 to 40.000 mm [1.5743 to 1.5748 in.]
2.13 Oil Seal Sleeve - Inspect

If any defects such as dents, scars, wear, or looseness that
can lead to oil leakage are found, replace the oil seal sleeve
with a new one.
2.14 Oil Seal Sleeve - Replace

2.14.1 Oil Seal Sleeve - Remove

Place a chisel vertically to the periphery of sleeve end and
tap three places with hammer. When the sleeve is loosened,
remove the sleeve.
If the sleeve can not be removed by the above procedure,
hold the chisel against the sleeve in the axial direction and
tap on it lightly to make the sleeve expand. Once the inter-
ference between crankshaft and sleeve is reduced, the sleeve
will be removed easily.
2.14.2 Oil Seal Sleeve - Install
Fan pully
Heat the oil seal sleeve at a temperature of 180 to 200 °C
[356 to 392 ºF] with a heater.
Insert the oil seal sleeve into the drive shaft.
Oil seal sleeve
Oil Seal Sleeve - Install
29402-00120
10-33
2.15 Fan Drive Assembly - Assemble
Apply engine oil to the oil seal lip.

Flush with the case face.
108 ± 10.8 N·m

{11 ± 1 .1 kgf·m}
[80 ± 8 lbf·t]
441 ± 22 N·m
{45 ± 2.3 kgf·m}
[325 ± 16 lbf·t]
Apply
LOCTITE 262 to threads.
108 ± 10.8 N·m

{11 ± 1.1 kgf·m} Apply engine oil to rolling surface
[80 ± 8 lbf·t]
Fan Drive Assembly - Assemble
10-34 29402-00120
2.15.1 Inner Ball Bearing - Press fit

(1) Apply engine oil on rolling surfaces of the ball bearing.
(2) Press fit the bearing into the drive shaft with the bearing
installer.
Bearing installer
Apply engine oil
Inner Ball Bearing - Press fit

2.15.2 Outer Ball Bearing - Press fit
(1) Apply engine oil on rolling surfaces of the ball bearing.
(2) Install the drive shaft in the fan drive case.
(3) Press fit the bearing into the drive shaft with the bearing
installer.
Bearing installer
Apply
engine oil
Outer Ball Bearing - Press fit

2.15.3 Oil Seal - Install
(1) Press fit the oil seal into the drive shaft bracket with the
oil seal installer.
(2) Apply engine oil on oil seal lips.
Oil seal installer
Apply engibe oil
Oil Seal - Install
29402-00120
10-35
2.15.4 Fan - Assemble

Fan pulley
Fan shall be mounted at the end of assembly work. 108 ± 10.8 N·m
Fan {11 ± 1 .1 kgf·m} Key
(1) Install the key to the fan end of fan drive shaft. [80 ± 8 lbf·ft]
(2) Install the fan pulley aligning to the key of fan drive
441 ± 22 N·m
shaft. 108 ± 10.8 N·m {45 ± 2.3 kgf·m}
{11 ± 1.1 kgf·m} [325 ± 16 lbf·ft]
(3) Tighten the cap nut to the specified torque. [79 ± 8 lbf·ft]
(4) Install the fan spacer to the fan pulley, and tighten the
bolts to the specified torque. Fan spacer
(5) Install the fan to the fan spacer, and tighten the bolts to Fan drive shaft
the specified torque.
Fan - Assemble
Note: Ensure the proper fan orientation (wind direction:
pusher) when installing. When using
pusher fan,
attach the
concave
face of the
blade forward.
Fan drive
Front (engine)side
Direction of the wind

(Pusher fan)
Fan Mounting Orientation
10-36 29402-00120
3. Cooling System - Install

Thoroughly clean and dry the coolant passage.
3.1 Water Pipe (Air Cooler) - Install

Apply silicone sealant on both sides of packings between
the air cooler inlet/outlet connectors and the water pipes.
3.2 Water Outlet Pipe - Install

Tighten the water outlet pipe mounting bolts to the specified
torque.
Water outlet pipe
54 ± 5 N·m
{5.5 ± 0.5 kgf·m}
[40 ± 3.7 lbf·ft]
Water Outlet Pipe - Install
29402-00120
10-37
1. Inlet and Exhaust Systems - Remove and Inspect ............................................. 11-3
1.1 Inlet System - Remove and Inspect........................................................................................ 11-3
1.2 Exhaust System - Remove and Inspect.................................................................................. 11-8
2. Inlet and Exhaust Systems - Disassemble, Inspect, and Assemble ............... 11-11
2.1 Air Cooler - Disassemble, Inspect, and Assemble................................................................ 11-11
2.2 Pre-Cleaner - Wash .............................................................................................................. 11-15
3. Inlet and Exhaust Systems - Install.................................................................... 11-16
3.1 Exhaust Manifold - Install...................................................................................................... 11-16
3.2 Exhaust Manifold - Tighten ................................................................................................... 11-17
29402-00120
11-1
1. Inlet and Exhaust Systems - Remove and Inspect

1.1 Inlet System - Remove and Inspect
PTA, MPTA spec
Replace
MPTA, Y1MPTA, Y2MPTK spec
Replace
3
1
2
Inlet System - Remove and Inspect

Removing sequence
1 Connector 3 Air Cooler
2 Duct (PTA, MPTA spec : approx 56 kg [123 lb])
(MPTA, Y1MPTA, Y2MPTK spec : approx 56 kg [123 lb])
29402-00120
11-3
PTAA spec
1 Air cooler
2 5 Air cooler
3
6
Replace
Replace
Turbocharger

Removing sequence
1 Rubber hose 4 Air duct 7 Rubber hose
2 Air duct 5 Rubber hose 8 Air duct
3 Rubber hose 6 Air duct 9 Inlet manifold
11-4 29402-00120
Y2TAA-1 spec
Turbocharger 1
A
Replace
2
5
B
Air cooler
3
B
4
Replace 7

Removing sequence
1 Rubber hose 5 Connector
2 Air duct 6 Rubber hose
3 Rubber hose 7 Air duct
4 Air duct 8 Inlet manifold
29402-00120
11-5
E2PTAA-1 spec
1 Air cooler
Replace Turbocharger
5
4
3
6 Air cooler
8 7
Replace
10

Removing sequence
1 Rubber hose 5 Connector 9 Air duct
2 Air duct 6 Rubber hose 10 Inlet manifold
3 Rubber hose 7 Air duct
4 Air duct 8 Rubber hose
11-6 29402-00120
MTK,MTK2,T2MTK3,T2MTKM,Y1MPTK,Y3MPTK spec
MTK2,
T2MTK3 Replace
Replace
MTK, T2MTKM,
Y1MPTK,Y3MPTK
6
MTK2,T2MTK3
5
6
Replace
5
Replace MTK2,
Replace T2MTK3
4
4
7 Replace Replace
8
1 2
Replace Turbocharger
Replace Replace
2
Replace
3
MTK2,T2MTK3

Removing sequence
1 Rubber hose 5 Air cooler assembly
2 Air duct 6 Air duct
3 Air duct 7 Inlet manifold
4 Air duct 8 Air heater
29402-00120
11-7
1.2 Exhaust System - Remove and Inspect
Air cooling exhaust manifold spec

Horizontal manifold spec
1
3
Replace
Replace
6 6
Replace
Replace 6
Replace
4
5
4
5 4
4 3
6 2
1
With insulator spec
Exhaust System - Remove and Inspect

Removal sequence
1 V-clamp 4 Coupling
2 Exhaust pipe 5 Flexible joint
3 Turbocharger 6 Exhaust manifold
11-8 29402-00120
Water cooling exhaust manifold spec
3 1
Replace
Replace Replace
4
Crack, flaw

Removing sequence
1 V-clamp 4 Exhaust manifold (Approx 50 kg [110 lb])
2 Exhaust pipe 5 Cover
3 Turbocharger
29402-00120
11-9
Y2TAA-1 spec
Replace
2 Replace
Replace
5
Replace
8
7 6 Replace
6
8 4
Replace

Removing sequence
1 Clamp 5 Pre-cleaner
2 Exhaust pipe 6 Coupling
3 Muffler 7 Flexible joint
4 Turbocharger 8 Exhaust manifold
11-10 29402-00120
2. Inlet and Exhaust Systems - Disassemble, Inspect, and Assemble

2.1 Air Cooler - Disassemble, Inspect, and Assemble
PTA, MPTA spec
Replace
Replace
The gap between the element

and plate must be sealed withnt
KE45-W (Shin-Etsu Chemical Co.)
or equivalent silicon sealant.
Air Cooler - Disassemble, Inspect, and Assemble

1 Air cooler cover 2 Air cooler element (approx 27 kg [59 lb]) 3 Inlet manifold
29402-00120
11-11
MPTA, Y1MPTA, Y2MPTK spec
Replace
Replace
1
The gap between the element

and plate must be sealed with
3 KE45-W (Shin-Etsu Chemical Co.)
or equivalent silicon sealant.
Air Cooler - Disassemble, Inspect and Assemble

1 Air cooler cover 2 Air cooler element (approximately 27 kg [59 lb]) 3 Inlet manifold
11-12 29402-00120
MTK,MTK2,T2MTK3,T2MTKM,MPTK,Y3MPTK spec
Replace: every 500hours

or within 12 months
MTK2,T2MTK3 MTK, MPTK, T2MTKM,Y3MPTK
Replace Replace
+5 2
29 0 N·m
{2.9 +0.5
0 kgf·m}
+3.7
[21 0 lbf·ft]
Replace
2
3 3
1 1
Relace or within 12 months
or within 12 months
22 ± 2 N·m
{2.2 ± 0.2 kgf·m}
[16 ± 1.5 lbf·ft]
Air Cooler - Disassemble, Inspect and Assemble

1 Tank 2 Tank 3 Air cooler element (approx 46 kg [101 lb])
29402-00120
11-13
2.1.1 Air Cooler - Inspect
The air cooler differs in material and structure depend-

ing on the application (freshwater or seawater). Pay
attention to the difference when handling the air cooler
2.1.2 Air Cooler - Clean PTA, MPTA, Y1MPTA, Y2MPTK spec
Apply compressed air (at a pressure of 0.29 to 0.49 MPa {3
to 5 kgf/cm2} [42 to 71 psi] or less) through the air cooler in
the opposite direction to the normal air flow to remove the
accumulation of dust and dirt. Then, inspect for corrosion
and cracks.
Compressed air
Intake side
Air Cooler - Clean
MTK, T2MTKM, Y1MPTK, Y3MPTK spec
Intake side
Compressed air
Air Cooler - Clean
MTK2, T2MTK3 spec
Intake side
Compressed air
Air Cooler - Clean
11-14 29402-00120
2.1.3 Air Cooler - Check for Leak

Immerse the air cooler in water. In this condition, blow
PTA, MPTA, Y1MPTA, Y2MPTK spec
compressed air (at a pressure of 0.39 MPa {4 kgf/cm2} [57
psi]) to the coolant passage to check for air leak.
Air leakage
Air Cooler - Check for Leak
MTK, T2MTKM, Y1MPTK,Y3MPTK spec

Air leakage
MTK2,T2MTK3 spec
Air leakage

2.1.4 Air Cooler - Assemble
To assemble, follow the disassemble sequence in reverse. Mild
Seal the clearance between the PTA, PTA2, PTK, and detergent
MPTA spec air cooler element and the plate with KE45-W
(Shin-Etsu Chemical Co., ltd.) or equivalent silicone seal- Water
ant. (Wash) (Rinse)
2.2 Pre-Cleaner - Wash

Install
(1) Remove the pre-cleaner from the silencer, and hand- (Dry)
wash the pre-cleaner using a neutral detergent.
(2) Rinse with freshwater.
(3) Dry it thoroughly, and install it to the silencer. Pre-Cleaner - Wash
Note: If the pre-cleaner is damaged or torn, replace it with a
new one.
29402-00120
11-15
3. Inlet and Exhaust Systems - Install

Thoroughly clean and dry the inlet and exhaust passages.
3.1 Exhaust Manifold - Install
3.1.1 Precautions for Installation of Exhaust Manifold
(1) Make sure that the centers of exhaust manifold and cou-
pling are aligned when installing. The misalignment of
exhaust manifold and coupling causes gas leaks.
(2) Orient the exhaust gasket so that the printed side faces
the exhaust manifold.
(3) Whenever installing the exhaust gaskets, replace all the
TOP
gaskets with new ones.
Place the letters to the exhaust manifold side.
Precautions for Installation of Exhaust Manifold

3.1.2 Exhaust Manifold Coupling - Tighten
Do not distort the exhaust manifold coupling.
(1) Apply MOLYKOTE (molybdenum disulfide anti-seize)

or equivalent on the bolt.
(2) Tighten the nuts to the specified torque.
(3) Lightly shake the outer circumference of exhaust mani- 8.3 ± 0.5 N·m
{0.85 ± 0.05 kgf·m}
fold coupling to make a snug contact between the [6 ± 0.4 lbf·ft]
exhaust manifold mating face and the exhaust manifold
coupling taper face. Exhaust Manifold Coupling - Tighten
(5) Lightly shake again to check for loose bolt.
3.1.3 V-clamp - Tighten

Bolt
Do not deform the V-clamp. It results in the decrease M6×1: 6 ± 1 N·m

{0.6 ± 0.1 kgf·m}
of tightening force. [4.4 ± 0.7 lbf·ft]
(1) Apply MOLYKOTE (molybdenum disulfide anti-seize)

or equivalent on the bolt.
(2) Tighten the nuts to the specified torque. V groove
portion
(3) Lightly shake the outer circumference of V-clamp to
make a snug contact between the exhaust manifold mat-
ing face and the V-clamp tapered face. V-clamp - Tighten
(5) Lightly shake again to check for loose bolt.
11-16 29402-00120
3.2 Exhaust Manifold - Tighten

Install the exhaust manifold and tighten the bolts to the
specified torque.
54 ± 5 N·m
{5.5 ± 0.5 kgf·m}
[40 ± 3.7 lbf·ft]
Exhaust Manifold - Tighten
29402-00120
11-17
1. Air Start System - Remove and Inspect............................................................... 12-3
1.1 Magnetic Valve - Remove and Inspect ................................................................................... 12-3
1.2 Air Pipe, Starter Valve and Distributor Valve - Remove and Inspect...................................... 12-4
1.3 Air Starter - Remove and Inspect ........................................................................................... 12-5
2. Air Start System - Disassemble, Inspect and Assemble.................................... 12-6
2.1 Magnetic Valve - Disassemble and Inspect............................................................................ 12-6
2.2 Magnetic Valve - Assemble .................................................................................................... 12-7
2.3 Starter Valve - Disassemble and Inspect................................................................................ 12-8
2.4 Starter Valve - Inspect ............................................................................................................ 12-9
2.5 Starter Valve - Assemble ...................................................................................................... 12-10
2.6 Distributor Valve - Disassemble and Inspect ........................................................................ 12-11
2.7 Distributor Valve - Inspect..................................................................................................... 12-12
2.8 Distributor Valve - Assemble ................................................................................................ 12-13
3. Air Start System - Install ..................................................................................... 12-13
29402-00120
12-1
1. Air Start System - Remove and Inspect

1.1 Magnetic Valve - Remove and Inspect
Air direct starting spec
Replace
5
6
1
8
3
2
Magnetic Valve - Remove and Inspect

Removing sequence
1 Air pipe 5 Flange
2 Flexible pipe 6 Magnetic valve
3 Air pipe 7 Valve stay
4 Strainer 8 Valve bracket
29402-00120
12-3
1.2 Air Pipe, Starter Valve and Distributor Valve - Remove and Inspect
Air direct starter spec

Replace
Replace
Replace
1
Replace
Replace 2
Air Pipe, Starter Valve and Distributor Valve - Remove and Inspect
Removing sequence
1 No.1 thru 6 pilot air pipes 3 Distributor valve
2 Main air pipe 4 Starter valve
12-4 29402-00120
1.3 Air Starter - Remove and Inspect
Air starter spec

3
2 1
Air Starter - Remove and Inspect

Removing sequence
1 Auto-muffler 2 Air motor (Weight: approx 60 kg [132 lb]) 3 Flexible hose
29402-00120
12-5
2. Air Start System - Disassemble, Inspect and Assemble

2.1 Magnetic Valve - Disassemble and Inspect
Air direct starting or air motor starting spec
2
Disconnection
3
Fatigue, crack
Replace
8
6
Replace
Replace
7
Fatigue, crack
Replace
Replace
Magnetic Valve - Disassemble and Inspect

Removing sequence
1 Magnetic valve 5 Piston assembly
2 Coil 6 Valve
3 Plunger spring 7 Return spring
4 Piston spring 8 Valve spring
12-6 29402-00120
2.2 Magnetic Valve - Assemble
Air direct starting or air motor starting spec
Magnetic Valve - Assemble
29402-00120
12-7
2.3 Starter Valve - Disassemble and Inspect
Replace
1 7
Replace
Replace
5
6
2
Settling, crack
3
4
Seat face defect, wear
Starter Valve - Disassemble and Inspect

1 Retaining screw 5 Packing
2 Nut 6 Starter valve
3 Retainer 7 Packing
4 Spring 8 Starter valve guide
Nozzle remover
2.3.1 Starter Valve - Remove P/N:36291-00900
Remove the retaining screw, nut, retainer and spring. Install
the starter valve adapter to the thread of starter valve.
Remove with the nozzle remover.
Starting valve
adapter
P/N:32691-01300
Starter Valve - Remove
12-8 29402-00120
2.4 Starter Valve - Inspect

2.4.1 Clearance Between Starter Valve and Starter
Valve Guide - Measure
(1) Measure the starter valve outside diameter and the
starter valve guide inside diameter, and calculate the
clearance.
(2) If the value exceeds the limit, replace the starter valve
or starter valve guide with a new one.Change prefera-
bly the part which has a larger difference value to the
standard.
Clearance Between Starter Valve and Starter Valve

Nominal Guide - Measure
value
Starter valve ø13 mm 12.973 to 12.984 mm
-
Outside diameter [0.51 in.] [0.5107 to 0.5112 in.]
Starter valve
ø13 mm 13.000 to 13.018 mm
Guide inside diam- -
[0.51 in.] [0.5118 to 0.5125 in.]
eter
Valve and valve 0.016 to 0.045 mm 0.100 mm
-
guide clearance [0.0006 to 0.0018 in.] [0.0039 in.]
2.4.2 Free Length of Valve Spring - Measure

Measure the free length of the valve spring.
If the value exceeds the limit, replace the valve spring with
a new one.

Valve spring free length 30 mm [1.18 in.] 28 mm [1.10 in.]
Free Length of Valve Spring - Measure
29402-00120
12-9
2.5 Starter Valve - Assemble
147 ± 7.35 N·m

{15 ± 0.75 kgf·m}
[108 ± 5.4 lbf·ft]
19 ± 0.95 N·m
{1.94 ± 0.1 kgf·m}
[14 ± 0.7lbf·ft]
Apply engine oil to

valve sliding portion.
Lapping:
Using lapping compound,
make sure that valve seat face
shows a uniform contact all
around the circumference.
Be sure to attach gasket.
Starter Valve - Assemble
12-10 29402-00120
2.6 Distributor Valve - Disassemble and Inspect
1
Crack, wear
6
5
4
Wear 7
Replace
Distributor Valve - Disassemble and Inspect

Removing sequence
1 Case cover 5 Distributor shaft
2 Packing 6 Bushing
3 Distributor valve, lock pin, E-ring 7 O-ring
4 Snap ring 8 Distributor case
29402-00120
12-11
2.7 Distributor Valve - Inspect

2.7.1 Distributor Valve Height - Measure
Measure the distributor valve height.If the value exceeds the
limit, replace the valve with a new one.
Nominal
value
Distributer valve 22 mm 21.8 to 21.9 mm 21.5 mm
height [0.87 in.] [0.858 to 0.862 in.] [0.847 in.]
Distributor Valve Height - Measure

2.7.2 Clearance Between Distributor Shaft and Bush-
ing - Measure
(1) Measure the distributor shaft outside diameter and the
bushing inside diameter, and calculate the clearance.
(2) If the value exceeds the limit, replace the distributor
shaft or the bushing with a new one.Change preferably
the part which has a larger difference value to the stan-
dard.
Nominal
Item Standard value Limit value Clearance Between Distributor Shaft and Bushing -
value
Measure
Distributor shaft ø20 mm 19.959 to 19.980 mm
-
outside diameter [ø0.79 in.] [0.7858 to 0.7866 in.]
Bushing inside ø20 mm 20.030 to 20.050 mm
-
diameter [ø0.79 in.] [0.7886 to 0.7894 in.]
Clearance between 0.050 to 0.091 mm 0.150 mm
-
shaft and bushing [0.0019 to 0.0036 in.] [0.0059 in.]
12-12 29402-00120
2.8 Distributor Valve - Assemble
Rotation direction Apply oil
Matching mark Lapping
No.1 cylinder TDC

No.6
3°
15°
Air inflow132°
Overlap 120° 120°
12° 3°
15° 120°
3°
No.3 cylinder TDC No.1 exhaust valve open
No.4 20° No.5 cylinder TDC
65° 15° No.2
Starting air blowing timing diagram
Distributor Valve - Assemble

Note: Align the match marks to assemble the distributor.The wrong assembling results in the 360° timing error of air blow and
the engine will not start.
3. Air Start System - Install

Install the parts in the reverse order of the disassemble sequence.(Refer to the illustration for disassembling.)
29402-00120
12-13
1. Engine - Adjust ...................................................................................................... 13-3
1.1 Valve Bridge and Adjusting Screw - Check ............................................................................ 13-3
1.2 Valve Clearance - Check ........................................................................................................ 13-3
1.3 Fuel Injection Timing - Check ................................................................................................. 13-3
1.4 Fuel System - Bleed Air .......................................................................................................... 13-3
1.5 Belt and Belt Tension - Inspect and Adjust............................................................................. 13-6
2. Break-In Operation ................................................................................................ 13-9
2.1 Preparation Before Engine Starting ........................................................................................ 13-9
2.2 Engine Start-up....................................................................................................................... 13-9
2.3 Break-In Operation ................................................................................................................. 13-9
3. Engine - Test and Adjustment ............................................................................ 13-11
3.1 Engine - General Performance Test ..................................................................................... 13-11
3.2 Exhaust Gas - Test ............................................................................................................... 13-11
3.3 Governor - Performance Test ............................................................................................... 13-11
3.4 Warning Activation and Emergency Stop - Test ................................................................... 13-11
3.5 Maximum Fuel Injection Volume - Set .................................................................................. 13-11
3.6 Seal ...................................................................................................................................... 13-12
13-1
1. Engine - Adjust
1.1 Valve Bridge and Adjusting Screw - Check

Check the adjustment of valve bridge and adjusting screw. If
it is not adjusted, adjust it to the standard value.
For adjustment, see "Valve Bridge and Adjusting Screw -
Adjust" of "ENGINE BODY - ASSEMBLE".
1.2 Valve Clearance - Check

Check the valve clearance.
If it is not adjusted, adjust it to the standard value.
For adjustment, see "Valve Clearance - Inspect and Adjust"
of "ENGINE BODY - ASSEMBLE".
1.3 Fuel Injection Timing - Check

Check the fuel injection timing.
If it is not adjusted, adjust the timing to the specified value.
For adjustment, see "Fuel Injection Timing - Check and
Adjust" of "ASSEMBLY OF BASIC ENGINE".
1.4 Fuel System - Bleed Air
(a) Thoroughly wipe off fuel spilled out of the air vent
A type (conventional) B type (new)
plug to prevent a risk of fire.
(b) After the air bleeding, be sure to lock the A type
priming pump handle securely. If loosely locked, it
can cause damage to the priming pump and result
in fuel leaks and a fire.
Note: The priming pump has A and B two types. The opera-
tion differs according to the type. Check the handling
procedure before the operation. Comparison of priming pump A and B types
To bleed air from the fuel system, start the air bleeding at
the place nearest to the fuel tank, from the fuel filter to the
injection pump, while feeding fuel with the priming pump.
29402-00120
13-3
A Type priming pump - Operate

"Unlock" "Priming" "Lock"
(1) Turn the priming pump handle counterclockwise to
Turn Move Turn clockwise
release the lock. counterclockwise. up and down. while pressing down.
(2) Feed fuel by moving the priming pump up and down.

(3) When the fuel flowing from the bleed holes no longer
contains air bubbles, lock the priming pump by turning
the handle clockwise while pushing it down. Then
tighten the air bleed plug.
A Type priming pump - Operate

B Type priming pump - Operate
(1) Move the priming pump up and down several times to
discharge fuel.
Note: The release and lock of the pump are not required as
the pump has a lock - less structure.
Push several times
to discharge fuel.
B Type priming pump - Operate

1.4.1 Fuel Filter (Standard Spec) - Bleed Air
Priming pump Air vent plug
cap 9 ±1 N·m
{0.9 ± 0.1 kgf·m}
If the air vent plugs, threads of bracket or sealing [6.6 ± 0.7 lbf·ft]
washers are damaged, replace them with new ones.
(1) Loosen the air vent plug of fuel filter by approx 1.5
turns.
(2) Feed fuel by moving the priming pump up and down.
(3) When fuel flowing from the vent holes no longer con-
tains air bubbles, tighten the air vent plugs to the speci-
fied torque. Fuel Filter (Standard Spec) - Bleed Air
1.4.2 Fuel Filter (Change Over Spec) - Bleed Air

Air vent plug Changeover cock
9 ±1 N·m {0.9 ± 0.1 kgf·m}
[ 6.6 ± 0.7 lbf·ft] Position during
operation
If the air bleed plugs, threads of bracket or sealing
washers are damaged, replace them with new ones.
Pin B A Pin
(1) Switch the cock to the air bleeding filter, and loosen the
air bleed plug of the fuel filter by approx 1.5 turns. Right side
(2) Feed fuel by moving the priming pump up and down. Left side filter Changeover cock
filter
(3) When fuel flowing from the bleed hole no longer con-
A: Air bleed position of left side filter
tains air bubbles, tighten the air bleed plug to the speci- B: Air bleed position of right side filter
fied torque. Fuel Filter (Change Over Spec) - Bleed Air
(4) Turn the changeover cock to the operation position.
13-4 29402-00120
1.4.3 Fuel Injection Pump - Bleed Air

(1) Loosen the air bleed plug of fuel injection pump by Air vent plug
about 1.5 turns.
(2) Feed fuel by moving the priming pump handle up and
down.
(3) When the fuel flowing from the bleed holes no longer
contains air bubbles, lock the A type priming pump by
turning the handle clockwise while pushing it down. Priming pump handle
Then tighten the air bleed plug.
Note:(a) To check the function of check valve, tighten the all
Fuel Injection Pump - Bleed Air (PE(S) - P Type)
air bleed plugs, then lock the priming pump handle.
The priming pump handle resists the push-in, but Air vent plug
the check valve opening pressure is stabilized and
the valve function is verified with this procedure.
(b) Thoroughly wipe off fuel spilled out of the air bleed
plug.
Priming pump cap
Fuel Injection Pump - Bleed Air (PS6 Type)
1.4.4 A Type Priming Pump Cap - Lock (PS6 Type)

Gently tighten 90 ± 10°
the priming cap
by hand until
If the priming pump handle is locked loosely, the screw the tightening Priming pump
force suddenly handle
in the handle wears due to the engine vibration, which increases.
can result in the priming pump handle to pop out and
the fuel to leak.
Or if it is over-tightened, the threaded portion of prim-
ing pump head can be damaged. Make sure to tighten
the handle to the correct angle.
A Type Priming Pump Handle - Lock
Check the head packing of priming pump for deforma-

tion and damage. If any deformation or damage is
Head packing
found, replace the priming pump with a new one.
(1) Gently tighten the priming handle by hand until the
tightening force suddenly increases. Then, mark the
priming pump handle in this position.
(2) Using a tool such as a wrench, further tighten the prim-
ing pump handle by 90 ± 10° from the marked position.
(3) Check the mounting condition of head packing. If any
defects such as deformation or dent are found, replace A Type Priming Pump Head Packing
the priming pump with a new one.
29402-00120
13-5
1.5 Belt and Belt Tension - Inspect and Adjust
If any defect such as separation or damage is found during inspection, replace the belt with a new one.
Keep the belt free from oil and grease. Oil or grease causes the belt to slip and shorten the service life.
Excessive belt tension can cause rapid wear of the alternator bearing and shorten the service life of the belt. Adjust
the belt tension properly by following the instructions below.
1.5.1 Belt - Inspect

(1) Inspect the belt visually for separation or damage. If any defect is found, replace the belt with a new one.
(2) Inspect the tension (deflection) and pressing force of the belt.
V-Belt
Inspect the belt deflection by pressing it with approx 98 to 147 N {10 to 15 kgf} [22 to 33 lbf] force at the center of its span.
The belt deflection of 10 to 15 mm [0.39 to 0.59 in.] is normal.
If the deflection is out of the standard, adjust the belt tension.
Ribbed Belt
Push the belt at the middle point between pulleys with the gauge. If the pressing force does not meet the standard when the belt
deflection is 15 mm [0.59 in.], adjust the belt tension.
1.5.2 Belt Tension (Fan) - Adjust
V-belt drive
Fixing bolt (4 places)
(1) Remove the belt cover.
Fan pulley
(2) Loosen all the fixing bolts of the fan bracket.
Tension bolt Lock nut
(3) Loosen the lock nut, and adjust the belt tension by turn-
ing the tension bolt.
(4) Secure the tension bolt with lock nut. 10 to 15 mm
[0.39 to 0.59 in.]
(5) Tighten all the fixing bolts of fan bracket.
(6) Install the belt cover.
Fan Belt (V-belt Drive) Tension - Adjust

Ribbed belt drive
(1) Remove the belt cover. Tension pulley Fan pulley
(2) Loosen all the fixing bolts of tension bracket. Lock nut
(3) Loosen the lock nut, and adjust the belt tension by turn- Tension bolt
ing the tension bolt. Fixing bolt
Gauge width
(4) Secure the tension bolt with lock nut. Approx 10 mm
[0.39 in.]
(5) Tighten all the fixing bolts of tension bracket.
Fixing bolt
15 mm
Pressing
force
Gauge
Crankshaft pulley
Ribbed velt
Fan Belt (Ribbed Belt Drive) Tension - Adjust
13-6 29402-00120
1.5.3 Belt Tension (Alternator) - Adjust

V-belt drive
(1) Remove the belt cover. Fixing bolt
(2) Loosen all the fixing bolts of alternator.
10 to 15 mm
(3) Loosen the lock nut, and adjust the belt tension by turn- Adjusting bolt [0.39 to 0.59 in.]
ing the adjusting bolt.

(4) Secure the adjusting bolt bolt with the lock nut.
(5) Tighten all the fixing bolts of alternator.
Water pump
Alternator pulley
Fixing bolt V-belt
Alternator Belt (V-belt Drive) Tension - Adjust

Ribbed belt drive
(1) Remove the belt cover. Lock nut Fixing bolt
(2) Loosen all the fixing bolts of alternator.
10 to 15 mm
(3) Loosen the lock nut, and adjust the belt tension by turn- [0.39 to 0.59 in.]
Adjusting bolt
ing the adjusting bolt.
(4) Secure the adjusting bolt bolt with the lock nut.
(5) Tighten all the fixing bolts of alternator.
Fixing bolt
Water
Alternator pump pulley
Alternator Belt (Ribbed Belt Drive) Tension - Adjust
29402-00120
13-7
Ribbed belt tension (N) table

Num- Belt straight distance (mm) [in.]
Item ber of 300 [11.81] or more than 300 to 400 more than 400 to 500 more than 500 to 600 more than 600
ribs below [11.81 to 15.75] [15.75 to 19.69] [19.69 to 23.62] [23.62]
74 N {7.55 kgf} 49 N {5.00 kgf} 37 N {3.77 kgf} 29 N {2.96 kgf} 25 N {2.55 kgf}
3
[16.64 lbf] [11.02 lbf] [8.32 lbf] [6.52 lbf] [5.62 lbf]
4
5
6
132 N {13.46 kgf} 88 N {8.97kgf} 66 N {6.73 kgf} 53 N {5.40 kgf} 44 N {4.49 kgf}
7
When a new [29.67 lbf] [19.78 lbf] [14.84 lbf] [11.91 lbf] [9.89 lbf]
belt is installed 147 N {14.99 kgf} 98 N {9.99 kgf} 74 N {7.55 kgf} 59 N {6.02 kgf} 49 N {5.00 kgf}
8
9
10
11
12
3
4
5
6
7
When re- [20.91 lbf] [13.94 lbf] [10.34 lbf] [8.32 lbf] [6.97 lbf]
adjusted 103 N {10.50 kgf} 69 N {7.04 kgf} 51 N {5.20 kgf} 41 N {4.18 kgf} 34 N {3.47 kgf}
8
9
10
11
12
The force when the middle point of belt straight line is pushed and deflected by 15 mm [0.59 in.].
13-8 29402-00120
2. Break-In Operation
2.1 Preparation Before Engine Starting
Check the levels of fuel, engine oil, and coolant, and also bleed air from fuel system and cooling system.
Remove the breather pipe at arbitrary position.
Inspect the link between governor output lever and the fuel injection pump rack. Check that the fuel control rack is at the no-
injection position when the engine is stopped. Make sure that the control rack is at the "0" position when the stop lever is
pulled.
Check the wiring of electrical system (sensor, meter alarm panel, starter, alternator, stop solenoid, and battery). Turn ON the
controller main switch to check for abnormality.
Set the governor speed lever so that the engine runs at a low idle speed after start-up.
Operate the stop solenoid, and make sure that the fuel injection pump rack moves to the no injection position.
Install the pressure gauge, thermometer, and flow meter as required.
2.2 Engine Start-up

(1) Pull the stop lever to the no injection position, and crank the engine for approx. 10 seconds with starter to circulate engine
oil in the engine. Repeat the cranking 2 or 3 times with one minute or more intervals between them.
Check that there is no abnormality such as abnormal noise or rotation speed fluctuation.
(2) Start the engine in the normal procedure.
Make sure that the engine can run at a low idle speed after start-up.
(3) Make sure that the oil pressure increases immediately, and the coolant circulates.
(4) Make sure the engine is free from fluid leaks such as oil, coolant, and fuel, and gas (air) leaks, and abnormal noise and
abnormal vibration.
(5) After making sure the engine is running at the low idle speed without any problem, stop the engine.
2.3 Break-In Operation
Be prepared to activate the emergency stop for an unforeseeable trouble of engine operation.
2.3.1 Break-in Operation Load and Time

The load during break-in operation is to be increased progressively as shown in the table.
Note that the time shown in the table is the minimum time required to check the engine in a stable condition.
Break-In Operation
Classi-
Generator Marine main engine
fication
Load Time Load Time
Item Rotating speed (min-1) Rotating speed (min-1)
(PS) (min) (PS) (min)
1 Low rotating speed 600 to 900 No-load 20 Low rotating speed 600 to 900 No-load 20
2 Medium rotating speed 1000 to 1200 No-load 10 Medium rotating speed 1000 to 1200 No-load 10
3 High rotating speed 1400 to rated speed No-load 10 High rotating speed 1400 to rated speed No-load 10
Equivalent to 25 %
4 25 % 20 25 % 20
output
Marine
Equivalent to 50 %
5 50 % 20 Partial load 50 % 20
Rated speed output
Rotational speed
Equivalent to 75 %
6 75 % 30 75 % 30
output
7 100 % 20 Rated speed 100 % 20
29402-00120
13-9
2.3.2 Engine - Inspect during Operation

During the break-in operation, pay attention to the followings and make sure that there is no abnormality.
Oil pressure and oil temperature Exhaust temperature
Coolant temperature and level Difference of exhaust temperatures between right and left
Fluid leaks such as oil, coolant, and fuel, especially oil banks
leaks from turbocharger lubricating oil pipe mounting sec- Blow-by gas (amount and color)
tion Rotational fluctuation
Noise and vibration Face and radial runouts of rotating parts
Intake air pressure and intake air temperature Indication and operation of meters and warnings
Exhaust color and odor
2.3.3 After Break-in Operation - Inspect and Adjust

Valve clearance (when cold)
Fuel injection timing
Re-tightening of external bolts and nuts
Belt tension
Inspection and repair of defects such as oil leak
13-10 29402-00120
3. Engine - Test and Adjustment
(a) Engine test, adjustment, and seal shall be performed at the certified maintenance shop only.
When the seal of engine is to be done at a service shop other than the certified shops, ask a certified shop for
the presence of qualified person for the test, adjustment, and seal.
(b) Performance check and adjustment of the engine shall be conducted when the water and oil temperatures
become stable after sufficient warm-up operation.
When the engine runs normally after the break-in operation, check and adjust the performance and functions of the engine.
Record the test results by referring to the engine data at factory.
3.1 Engine - General Performance Test
Fuel consumption rate, various temperatures and pressures,
and exhaust color
3.2 Exhaust Gas - Test
Exhaust gas analyses
3.3 Governor - Performance Test
Minimum speed at no-load (low idle) - set
Maximum speed at no-load (high idle) - set
Load sudden application and rejection tests
Governor droop, hunting, and rotational fluctuation - check
Setting conditions of governor controller and others - check
3.4 Warning Activation and Emergency Stop - Test
Oil pressure decrease, water temperature increase, and over-
speed
3.5 Maximum Fuel Injection Volume - Set

PE(S)-P type pump
Stopper Maximum load
(1) Run the engine under the maximum rated load. rack position
(2) Loosen lock nut located at the end of rack stopper. Pump rack
Lock nut
(3) Fix lock nut in position where stopper comes in contact zero position
with face of rack plate.
Rack plate
Decrease
Increase
Maximum Fuel Injection Volume - Set (PE(S)-P type)
PS6 type pump
(1) Run the engine under the maximum rated load. STOP
Rack
(2) Connect link to rack at 66 mm position from pump
Rack position at maximum load
face.
(3) Connect stop lever to link.
(4) Install rack set bar.
Link Pump rack
zero position
Rack set bar
Increase Decrease
Connect the link at
66mm [2.60in.] from the edge
Maximum Fuel Injection Volume - Set (PS6 type)
29402-00120
13-11
3.6 Seal
After all performance tests and adjustments are completed, stop the engine, and seal the specified parts between governor actu-
ator and fuel injection pump rack.
3.6.1 Tamper Proof - Remove

Tamper proof nut is composed of double structure, and can-
not be removed by rotating.
To remove, cut the outer cylinder nut and remove the inner
nut.
Inner nut
Self-locking nut
Outer cylinder nut
(Tamper proof nut)
Tamper Proof - Remove
3.6.2 Tamper Proof - Install
Tamper proof nut
(1) Tighten the tamper proof nut to the specified torque, (Outer cylinder nut)
35 ± 5 N·m
and make sure that the inner nut is separated. {3.6 ± 0.51 kgf·m}
(2) Tighten the self locking nut to the specified torque, and [25.8 ± 3.69 lbf·ft]
caulk the end of the nut. Caulking
Self-locking nut
33 ± 3.3 N·m {3.4 ± 0.34 kgf·m}
[24.3 ± 2.43 lbf·ft]
Tamper Proof - Install
13-12 29402-00120
Engine inspection record sheet (SA series)
No. 1 Cylinder liner bore inside diameter - measure

No. 2 Cylinder liner flange protrusion - measure
No. 3 Valve guide inside diameter and Vale stem diameter - measure
No. 4 Cylinder head valve sinkage, seat width, and valve margin - measure
No. 5 Cylinder head bottom face distortion - measure
No. 6 Connecting rod bushing inside diameter and connecting rod big-end bore diameter
- measure
No. 7 Rocker bushing inside diameter and rocker shaft outside diameter - measure
No. 8 Piston pin bore inside diameter and piston pin outside diameter - measure
No. 9 Valve clearance - measure
No. 10 Fuel injection nozzle injection pressure - measure
Camshaft bushing inside diameter and camshaft journal outside diameter (right
No. 11
side) - measure
Camshaft bushing inside diameter and camshaft journal outside diameter (left side)
No. 12
- measure
No. 13 Crankshaft end play - measure
INSPECTION RECORD SHEET No.1
SA
Engine Model
Customer Serial No.
Date
Item Cylinder liner bore inside diameter - measure Unit mm[in.]
Measuring location Standard

Item to be
Nominal Standard Limit
measured
Cylinder liner φ150 150.000 to 150.040 150.140
inside diameter [5.91] [5.9055 to 5.9071] [5.9110]
Location
a 30 [1.18]
b 100 [3.94]
c 250 [9.84]
Measured value
Item Cylinder liner bore inside diameter Item Cylinder liner bore inside diameter
No. Direction A B C No. Direction A B C
X X
1 7
Y Y
X X
2 8
Y Y
X X
3 9
Y Y
X X
4 10
Y Y
X X
5 11
Y Y
X X
6 12
Y Y
Remark Approved by Checked by Measured by

No.2 INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Item Cylinder liner bore flange protrusion - measure Unit mm[in.]

Item to be measured Standard
Cylinder liner 0.10～0.19
flange protrusion [0.0039 to 0.0075]
Measured value
Item Cylinder liner bore flange protrusion

No. A B C D Average value
1
2
3
4
5
6
7
8
9
10
11
12

INSPECTION RECORD SHEET No.3(1/2)
SA
Engine Model
Customer Serial No.
Date
Valve guide inside diameter and Valve stem diameter -
Item measure (1/2)
Unit mm[in.]
Measuring Standard
location
Item to be measured Nominal Standard Limit
Valve guide inside diameter φ10 10.000 to 10.015 10.060
(same for inlet and exhaust) [0.39] [0.3937 to 0.3943] [0.3961]
Valve stem φ10 9.940 to 9.960 9.910
Inlet [0.39] [0.3913 to 0.3921] [0.3902]
outside
φ10 9.910 to 9.930 9.880
diameter Exhaust [0.39]
[0.3902 to 0.3909] [0.3890]
Measured value
Item Valve guide inside diameter Valve stem outside diameter Clearance
A B A B A B
No. Direction
X Y X Y X Y X Y Max. Min. Max. Min.
a
Inlet
b
1
Exhaust
a
b
a
Inlet
b
2
Exhaust
a
b
a
Inlet
b
3
Exhaust
a
b
a
Inlet
b
4
Exhaust
a
b
a
Inlet
b
5
Exhaust
a
b
a
Inlet
b
6
Exhaust
a
b

No.3(2/2) INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Valve guide inside diameter and Valve stem diameter -
Item measure (2/2)
Unit mm[in.]
Measuring Standard
location
Valve guide inside diameter φ10 10.000 to 10.015 10.060
(same for inlet and exhaust) [0.39] [0.3937 to 0.3943] [0.3961]
Valve stem φ10 9.940 to 9.960 9.910
Inlet [0.39] [0.3913 to 0.3921] [0.3902]
outside
φ10 9.910 to 9.930 9.880
diameter Exhaust [0.39]
[0.3902 to 0.3909] [0.3890]
Measured value
Item Valve guide inside diameter Valve stem outside diameter Clearance
A B A B A B
No. Direction
X Y X Y X Y X Y Max. Min. Max. Min.
a
Inlet
b
7
Exhaust
a
b
a
Inlet
b
8
Exhaust
a
b
a
Inlet
b
9
Exhaust
a
b
a
Inlet
b
10
Exhaust
a
b
a
Inlet
b
11
Exhaust
a
b
a
Inlet
b
12
Exhaust
a
b

INSPECTION RECORD SHEET No.4(1/2)
SA
Engine Model
Customer Serial No.
Date
Cylinder head valve sinkage, seat width, and valve margin -
Item measure(1/2)
Unit mm[in.]

Item to be measured Standard Limit
Valve seat angle 30° -
-0.1 to 0.1 0.5
Valve sinkage
[-0.039 to 0.039] [0.020]
1.98 to 2.18 2.5
Inlet [0.0780 to 0.0858]
Seat [0.098]
Valve
width 1.75 to 1.95 2.3
seat Exhaust
[0.0689 to 0.0768] [0.091]
2.7 to 3.1
Inlet [0.106 to 0.122]
Valve Reface up to
margin 2.0 [0.079]
2.8 to 3.2
Exhaust
[0.110 to 0.126]
Measured value
Item Item
Valve seat Valve Valve seat Valve
Seat width Seat width
No. Direction angle sinkage No. Direction angle sinkage
a a
Inlet
Inlet
b b
1 4
Exhaust
Exhaust
a a
b b
a a
Inlet
Inlet
b b
2 5
Exhaust
Exhaust
a a
b b
a a
Inlet
Inlet
b b
3 6
Exhaust
Exhaust
a a
b b

No.4(2/2) INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Cylinder head valve sinkage, seat width, and valve margin -
Item measure(2/2)
Unit mm[in.]

Valve seat angle 30° -
-0.1 to 0.1 0.5
Valve sinkage
[-0.039 to 0.039] [0.020]
1.98 to 2.18 2.5
Inlet [0.0780 to 0.0858]
Seat [0.098]
Valve
width 1.75 to 1.95 2.3
seat Exhaust
[0.0689 to 0.0768] [0.091]
2.7 to 3.1
Inlet [0.106 to 0.122]
Valve Reface up to
margin 2.0 [0.079]
2.8 to 3.2
Exhaust
[0.110 to 0.126]
Measured value
Item Item
Valve seat Valve Valve seat Valve
Seat width Seat width
No. Direction angle sinkage No. Direction angle sinkage
a a
Inlet
Inlet
b b
7 10
Exhaust
Exhaust
a a
b b
a a
Inlet
Inlet
b b
8 11
Exhaust
Exhaust
a a
b b
a a
Inlet
Inlet
b b
9 12
Exhaust
Exhaust
a a
b b

INSPECTION RECORD SHEET No.5
SA
Engine Model
Customer Serial No.
Date
Item Cylinder head bottom face distortion - measure Unit mm[in.]
Item to be
Standard Limit
measured
Distortion of
0.03 [0.0012] 0.70
cylinder head
or less [0.0276]
bottom surface
Measured value
Item Cylinder head bottom face distortion

No. A B C D E F G
1
2
3
4
5
6
7
8
9
10
11
12

No. 6(1/2) INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Connecting rod bushing inside diameter and connecting rod
Item big-end bore diameter - measure (1/2)
Unit mm[in.]
Measuring
location
Standard Item to be measured Nominal Standard Limit

Connecting rod bushing φ58 58.020 to 58.040 58.070
Connecting rod big end φ110 110.000 to 110.022 Minimum: 109.950 [4.3287]
bore diameter [4.33] [4.3307 to 4.3316] Maximum: 110.050 [4.3327]
Measured value
Item Connecting rod bushing inside diameter Connecting rod big-end bore diameter
No. Direction X Y A B C
a
1
b
a
2
b
a
3
b
a
4
b
a
5
b
a
6
b

INSPECTION RECORD SHEET No. 6(2/2)
SA
Engine Model
Customer Serial No.
Date
Connecting rod bushing inside diameter and connecting rod
Item big-end bore diameter - measure (2/2)
Unit mm[in.]
Measuring
location
Standard Item to be measured Nominal Standard Limit

Connecting rod bushing φ58 58.020 to 58.040 58.070
Connecting rod big end φ110 110.000 to 110.022 Minimum: 109.950 [4.3287]
bore diameter [4.33] [4.3307 to 4.3316] Maximum: 110.050 [4.3327]
Measured value
Item Connecting rod bushing inside diameter Connecting rod big-end bore diameter
No. Direction X Y A B C
a
7
b
a
8
b
a
9
b
a
10
b
a
11
b
a
12
b

No. 7(1/2）
INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Rocker bushing inside diameter and rocker shaft outside
Item diameter - measure(1/2)
Unit mm[in.]

Rocker bushing φ32 32.055 to 32.080 32.100
Rocker shaft φ32 31.975 to 31.991 31.950
outside diameter [1.26] [1.2589 to 1.2595] [1.2614]
Measured value
Item Rocker bushing inside diameter Rocker shaft outside diameter Clearance
No. Direction X Y X Y Maximum Minimum
a
1
b
a
2
b
a
3
b
a
4
b
a
5
b
a
6
b

No. 7(2/2）
INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Rocker bushing inside diameter and rocker shaft outside
Unit mm[in.]

Rocker bushing φ32 32.055 to 32.080 32.100
Rocker shaft φ32 31.975 to 31.991 31.950
Measured value
Item Rocker bushing inside diameter Rocker shaft outside diameter Clearance
a
7
b
a
8
b
a
9
b
a
10
b
a
11
b
a
12
b

No. 8(1/2) INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Piston pin bore inside diameter and piston pin outside
Unit mm[in.]

Piston pin bore φ58 58.002 to 58.012 58.040
Piston pin φ58 57.987 to 58.000 57.970
Measured value
Item Piston pin bore diameter Piston pin outside diameter Clearance
A
1 B
C - - - -
A
2 B
C - - - -
A
3 B
C - - - -
A
4 B
C - - - -
A
5 B
C - - - -
A
6 B
C - - - -

INSPECTION RECORD SHEET No. 8(2/2)
SA
Engine Model
Customer Serial No.
Date
Piston pin bore inside diameter and piston pin outside
Unit mm[in.]

Piston pin bore φ58 58.002 to 58.012 58.040
Piston pin φ58 57.987 to 58.000 57.970
Measured value
Item Piston pin bore diameter Piston pin outside diameter Clearance
A
7 B
C - - - -
A
8 B
C - - - -
A
9 B
C - - - -
A
10 B
C - - - -
A
11 B
C - - - -
A
12 B
C - - - -

No. 9 INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Item Valve clearance - measure Unit mm[in.]

Item to be measured Standard
Valve Inlet 0.4 [0.016]
clearance (A) Exhaust 0.5 [0.020]
Measured value
Valve clearance Valve clearance
No. Inlet Exhaust No. Inlet Exhaust
Before Before
adjustment adjustment
1 After
7 After
Before Before
2 After
8 After
Before Before
3 After
9 After
Before Before
4 After
10 After
Before Before
5 After
11 After
Before Before
6 After
12 After

INSPECTION RECORD SHEET No. 10
SA
Engine Model
Customer Serial No.
Date
Item Fuel injection nozzle injection pressure - measure Unit MPa{kgf/cm2}[psi]
Measuring location
Standard
Item to be measured Part Number Nominal Standard
35A61-00010
21.6 22.1 to 22.6
35A61-01060
Screw adjust type {220} {225 to 230}
35A61-10030
[3133] [3205 to 3278]
S6A3 35A61-11050
35A61-11030 29.4 29.9 to 30.7
Shim adjust type {300} {304 to 313}
35A61-70030 [4267] [4324 to 4451]
Valve 32561-54010
opening 32561-57090 21.6 22.1 to 22.6
pressure Screw adjust
32561-64010 {220} {225 to 230}
type
32561-76050 [3133] [3205 to 3278]
32561-79010
S12A2
32661-01050
32661-01090 29.4 29.9 to 30.7
Shim adjust
32661-11060 {300} {304 to 313}
type
32661-11070 [4267] [4324 to 4451]
35A61-11030
Measured value
Injection pressure Service hours Injection pressure Injection pressure Service hours Injection pressure
No. (h)
No. (h)
Before adjustment After adjustment Before adjustment After adjustment
1 7
2 8
3 9
4 10
5 11
6 12

No. 11 INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Camshaft bushing inside diameter and camshaft journal
Item outside diameter (right side) - measure
Unit mm[in.]
Measuring location
Standard
φ68 68.000 to 68.030 68.090
S6A3 [2.68] [2.6772 to 2.6783] [2.6807]
Camshaft bushing φ64 64.000 to 64.030 64.090
No.1 [2.5232]
inside diameter S12A2 [2.52] [2.5197 to 2.5209]
φ68 68.000 to 68.030 68.090
No.2～7 [2.68] [2.6772 to 2.6783] [2.6807]
φ68 67.920 to 67.940 67.870
S6A3 [2.68] [2.6740 to 2.6748] [2.6720]
Camshaft journal
φ64 63.920 to 63.940 63.870
bore outside No.1 [2.5146]
[2.52] [2.5165 to 2.5173]
diameter S12A2 φ68 67.920 to 67.940 67.870
No.2～7 [2.68] [2.6740 to 2.6748] [2.6720]
Measured value
Item Camshaft bushing inside diameter Camshaft journal outside diameter Clearance
No. Direction X Y X Y Minimum Maximum
a
1
b
a
2
b
a
3
b
a
4
b
a
5
b
a
6
b
a
7
b

INSPECTION RECORD SHEET No. 12
SA
Engine Model
Customer Serial No.
Date
Camshaft bushing inside diameter and camshaft journal
Item outside diameter (left side) - measure
Unit mm[in.]
Measuring location
Standard
φ64 64.000 to 64.030 64.090
Camshaft bushing No.1 [2.52] [2.5197 to 2.5209] [2.5232]
S12A2 φ68
inside diameter No.2～7 68.000 to 68.030 68.090
[2.68] [2.6772 to 2.6783] [2.6807]
Camshaft journal φ64 63.920 to 63.940 63.870
No.1 [2.52] [2.5165 to 2.5173] [2.5146]
bore outside S12A2 φ68 67.870
67.920 to 67.940
diameter No.2～7 [2.68] [2.6740 to 2.6748] [2.6720]
Measured value
Item Camshaft bushing inside diameter Camshaft journal outside diameter Clearance
No. Direction X Y X Y Minimum Maximum
a
1
b
a
2
b
a
3
b
a
4
b
a
5
b
a
6
b
a
7
b

No.13 INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Item Crankshaft end play - measure Unit mm[in.]
Measuring location
Standard
0.200～0.395 0.500
Crankshaft end play
[0.0079 to 0.0156] [0.0197]
Measured value
Before disassembly After reassembly

Revision History
Revision History
Mitsubishi Diesel Engine S6A3
Title
SERVICE MANUAL
Pub. No. 29402-00120
Revision Issued Description
- December 2017 First edition issued.
Changed the document number, cover Pub. No. 99259-12141 (issued in

- June 2018
December 2017) and issued it as a new publication.
Mitsubishi Diesel Engine S6A3
SERVICE MANUAL
Issued in December 2017

Pub. No. 29402-00120
Issued by Mitsubishi Heavy Industries Engine & Turbocharger, Ltd.

3000, Tana, Chuo-ku, Sagamihara, Kanagawa, 252-5293, Japan
Edited by MHI Sagami High-tech LTD.

Printed and bound by Fuji Xerox Service Link Co., Ltd.
• The manual with incorrect collating or missing pages is to be replaced.

• Without written approval from the publisher, for all or some part of this manual, unauthorized reproduction,
copy, reprinting in any way or method are prohibited.
Printed in Japan
Copyright © 2018 MITSUBISHI HEAVY INDUSTRIES ENGINE & TURBOCHARGER, LTD. All Rights Reserved.
December 2017 SERVICE MANUAL Pub. No. 29402-00120

29402-00120 - Service Manual S6A3 December 2017

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SERVICE MANUAL

Issued: December 2017

Pub. No. 29402-00120

HOW TO USE THIS MANUAL

Terms used in this manual

Keep Flames Away Be Alert for Leaking Fuel, Oil, or Exhaust

Stay Away From Rotating and Moving Parts

Install Protective Covers Over Rotating Lockout and Tagout

Work tion and maintenance. Lockout and tagout are effec-

result. to a personal injury.

Prevention of Exhaust Gas Poi- Fall Prevention

ing Engine enough to lift the load considering the

If the engine is installed in an engine weight. To lift the engine,

tains harmful components. Operating the engine in an center of gravity.

Do Not Climb Onto the Engine

Always Prepare a Stable Footing

Be Careful When Handling Fuel, Burn Protection

Burn Prevention When Changing Oil

Battery Safety Precautions When Abnormality Occurs

Be Careful When Handling Battery Do Not Add Coolant Immediately After a

Do Not Tamper Never Break the Seals

Gears or a serious accident due to overrunning of the

Warming Up Engine First Do Not Splash Water on Engine

Accumulated carbon in the cylinder may cause defec-

Obey Safety Rules at Work Site Engine Transportation Precautions

Do Not Operate Starter Continuously Do Not Touch High-Pressure Fuel Spray

Do Not Turn Off the Battery Switch During

Maintenance of Warning Labels

Common Warning Labels

Points on Disassembling and Assembling

Chapter 2 SERVICE DATA

Chapter 3 SERVICE TOOLS

Chapter 4 OVERHAUL INSTRUCTIONS

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

Chapter 7 ASSEMBLY OF BASIC ENGINE

Chapter 8 FUEL SYSTEM

Chapter 9 LUBRICATION SYSTEM

Chapter 10 COOLING SYSTEM

Chapter 11 INLET AND EXHAUST SYSTEMS

Chapter 12 AIR START SYSTEM

Chapter 13 ADJUSTMENT AND OPERATION

Note: Configuration varies depending on the destination and specifications.

Timing gear case

Exhaust pipe, exhaust outlet S6A3-PTA

Water drain cock

Water drain cock

Breather and oil filler Front hanger

Fuel feed pump

Oil level gauge

Fuel return port

Note: Configuration varies depending on the destination and specifications.

Coolant inlet port

Note: Configuration varies depending on the destination and specifications.

Timing gear case

Note: Configuration may differ depending on the customization and specifications.

Water drain cock

Water drain cock

Fuel feed pump

Oil level gauge

Fuel return port

Engine coolaant inlet S6A3-PTAA

Engine coolant outlet