September 2007

SERVICE MANUAL

SERVICE MANUAL
for KOBELCO CONSTRUCTION MACHINERY CO., LTD.
for KOBELCO CONSTRUCTION MACHINERY CO.,LTD.

Pub. No.

September 2007
99616-21100

Printed in Japan Pub. No. 99616-21100 Pub. No. 99616-21100

 INTRODUCTION

This service manual describes the specifications, maintenance and service procedures
for Mitsubishi diesel engines.
To maintain the performance of the engine for many years and to ensure safe operation,
it is important to use the engine correctly and conduct regular inspection and maintenance,
and also to take necessary measures which involves the disassembly, inspection, repair and
reassembly of the engine and engine parts.
Read this manual carefully and understand the work procedures fully before
disassembling, inspecting, repairing or reassembling the engine.
The contents of the manual are based on the engine models that are being produced at
the time of publication. Due to improvements made thereafter, the actual engine that you
work on may differ partially from the one described in this manual.

Pub.No.99616-21100
 INTRODUCTION

How to use this manual

This service manual consists of several Groups, which are arranged so as to allow you to make reference quickly to
specifications, maintenance standards, adjustment procedures and service procedures including methods for disassembly,
inspection, repair and reassembly of the Mitsubishi Diesel Engine (standard model for land use).
A short summary describing the content of each Group is given in the General Contents page, and there is also a detailed table
of contents at the beginning of each Group.
Regarding the procedures for operation and periodical maintenance of the engine, refer to the Operation and Maintenance
Manual. For information on the engine components and ordering of service parts, refer to the Parts Catalogue. Structure and
function of the engine are described in the relevant training manuals.

Methods of presentation
(1) Index numbers allotted to parts in exploded views are not only a call-out of part names listed in the text but also an indi-
cation of the sequence of disassembly.
(2) Inspections to be conducted during disassembly process are indicated in boxes in the relevant exploded views.
(3) Maintenance standards required for inspection and repair works are indicated in the appropriate positions in the text.
They are also collectively indicated in Group 2, the General Contents group.
(4) Fasteners to be tightened in “wet” condition, or with engine oil applied, are identified by [Wet] placed after tightening
torque values. If no such indication is suffixed, the fastener should be tightened in “dry” condition, or without lubricating
with engine oil.
(5) In this manual, important safety or other cautionary instructions are emphasized with the following marks headed.

'$1*(5

Indicates an immediately hazardous situation which, if not avoided, will result in death or serious injury.

:$51,1*

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

&$87,21

Indicates an immediately hazardous situation which, if not avoided, may result in minor or moderate injury.

&$87,21

Indicates a potentially hazardous situation which, if not avoided, can result in property damage.



Emphasizes important matter, or indicates information useful for operation or maintenance of the engine.

I
INTRODUCTION

Terms used in this manual

Nominal
means the rated (design) size or magnitude of a part to be measured.
Standard
means the quantitative requirement for dimension of a part, clearance between parts and performance. This is given in a form of
tolerance. Therefore, the values shown are not in agreement with the design values.
Limit
means that, if this value is reached, the part must be repaired or replaced with a new part.

Abbreviations
• BTDC: Before Top Dead Center
• ATDC: After Top Dead Center
• BBDC: Before Bottom Dead Center
• ABDC: After Bottom Dead Center
• TIR: Total Indicated Runout
• API: American Petroleum Institute
• ASTM: American Society for Testing and Materials
• JIS: Japanese Industrial Standards
• LLC: Long Life Coolant
• MIL: Military Specifications and Standards (U.S.A)
• MSDS: Material Safety Data Sheet
• SAE: Society of Automotive Engineers (U.S.A)

Units of measurement
Measurements are based on the International System of Units (SI), and their converted metric values are indicated in
parentheses {}. For metric conversion, the following rates are used.
• Pressure: 1 MPa ＝ 10.197 kgf/cm²
• Torque: 1 N·m ＝ 0.10197 kgf·m
• Force: 1 N = 0.10197 kgf
• Horsepower: 1 kW = 1.341 HP = 1.3596 PS
• Meter of mercury: 1 kPa = 0.7 cmHg
• Meter of water: 1 kPa ＝ 10.197 cmH2O (cmAq)
• Rotational speed: 1min-1 ＝ 1 rpm

II

Safety Cautions
:$51,1*
Fire and explosion
Keep flames away
Store fuel and engine oil in a well
ventilated designated area.
Make sure that the caps of fuel and
engine oil containers are tightly
closed.
Do not use flames, do not smoke,
and do not work near a heater or other fire hazard
where fuel or oil is handled or when cleaning solvent is
being used for washing parts.
Wipe off spilled fuel, oil and LLC immediately and thor-
oughly. Spilled fuel, oil and LLC may ignite and cause
a fire.
Keep surrounding area tidy and clean
Do not leave combustible or explosive materials, such
as fuel, engine oil and LLC, near the engine. Such sub-
stances can cause fire or explosion.
Remove dust, dirt and other foreign materials accumu-
lated on the engine and surrounding parts thoroughly.
Such materials can cause fire or the engine to over-
heat. In particular, clean the top surface of the battery
thoroughly. Dust can cause a short-circuit.
Always operate the engine at a position at least 1 m
[3.28 ft.] away from buildings and other equipment to
prevent possible fire caused by engine heat.
INTRODUCTION
Care about fuel, oil and exhaust gas leakage
If any fuel, oil or exhaust gas leakage is found, immedi-
ately take corrective measures to stop it.
Such leakages, if left uncorrected, can cause fuel or
engine oil to reach hot engine surfaces or hot exhaust
gas to contact flammable materials, possibly leading to
personal injury and/or damage to equipment.
Use explosion-proof lighting apparatus
When inspecting fuel, engine oil, coolant, battery elec-
trolyte, etc., use a flameproof light. An ordinary light, if
accidentally broken, may ignite and cause an explo-
sion.
Prevent electrical wires from short-circuit-
ing
Avoid inspecting or servicing the electrical system with
the ground cable connected to the battery. Otherwise,
a fire could result from short-circuiting. Be sure to dis-
connect the battery cable from the negative (-) terminal
before beginning with the work procedure.
Short-circuits, possibly resulting in fire, may be caused
by a loose terminal or damaged cable/wire. Inspect the
terminals, cables and wires, and repair or replace the
faulty parts before beginning with the service proce-
dure.
Keep fire extinguishers and first-aid kit
handy
Keep fire extinguishers handy, and
become familiar with their usage.
Keep a first-aid kit at the designated
place where it is easily accessible
by anyone at any time.
Establish response procedures to
follow in the event of fire or accident. Provide an emer-
gency evacuation route, contact points, and means of
communication in case of emergency.
III
INTRODUCTION
:$51,1*
Stay clear of all rotating and moving parts
Install protective covers on rotating parts
Make sure the protective covers for
engine rotating parts are properly
installed as intended. Repair loose
or damaged protective covers as
necessary.
Never remove the covers guarding
personnel from rotating parts, when the engine is oper-
ating.
When combining the engine with the engine-driven ma-
chine or radiator, always provide a cover on every ex-
posed moving part such as driving belt and coupling.
Never remove protective covers.
Ensure safety of neighboring people before
starting engine
Before starting the engine, ensure that there is nobody
in the neighborhood and that no tools are left on or near
the engine. Verbally notify people around the engine or
in the work area when starting the engine.
When the starter device is posted with a sign that pro-
hibits startup operation, do not operate the engine.
Stay clear of moving parts during engine
running
Do not approach rotating or sliding
parts of the engine when the engine
is in operation.
Keep objects likely to be caught by
rotating parts away from such parts.
If any part of the clothing or outfit-
ting is caught by a rotating part, se-
rious bodily injuries could result.
IV
Lockout and Tagout
Be sure to lockout and tagout before starting inspection
and maintenance.
Lockout and tagout are effective methods of cutting off
machines and equipment from energy sources.
To accomplish the lockout/tagout, remove the starter
switch key, set the battery switch to OFF and attach a
"Do Not Run" or similar caution tag to the starter switch.
The starter switch key must be kept by the person who
performs inspection and maintenance during the work.
In the case of pneumatic starting type, close the main
valve of the air tank and post a tag saying "Do Not
Open the Valve" or the like.
Keep engine stopped during servicing
Be sure to stop the engine before proceeding to inspec-
tion and service procedure. Never attempt to make ad-
justments on the engine parts while the engine is
running. Rotating parts such as belt can entangle your
body and cause serious injuries.
Always restore engine turning tools after
use
Do not forget to remove the tools which have been
used for turning the engine during inspection or servic-
ing, after the procedure is finished. Remember also
that the turning gear must be returned to the operating
condition before starting the engine.
Starting the engine with the turning tools inserted or
with the turning gear in engagement can lead to not
only engine damage but also personal injuries.
 INTRODUCTION

:$51,1* :$51,1*

Be careful of burns Protect ears from noises

Do not touch the engine during or immedi- Wear ear plugs
ately after operation Always wear ear plugs when enter-
Do not touch the engine during or ing the machine room (engine
immediately after operation to room). Combustion sound and me-
avoid risk of burns. chanical noise generated by the en-
To conduct maintenance and in- gine can cause hearing problems.
spection work, wait until the engine
has cooled sufficiently, checking
the temperature gauge.

Slowly and carefully open radiator cap

Never attempt to open the radiator cap while the engine
is running or immediately after the engine stops. Give a
sufficient cooling time to the engine coolant before
opening the cap.
When opening the radiator cap, slowly turn the cap to
release internal pressure. To prevent scalds with steam
gushing out, wear thick rubber gloves or cover the cap
with a cloth.
Close the radiator cap tightly without fail.
The coolant is very hot and under pressure during en-
gine running or just after the engine stops. If the radia-
tor cap is not closed tightly, steam and hot coolant may
gush out and can cause scalds.

Add coolant only after the coolant tempera-

ture dropped
Do not add coolant immediately after the engine stops.
Wait until the coolant temperature lowers sufficiently to
avoid a risk of burns.

V
INTRODUCTION
:$51,1*
Be careful of falling down
Lift engine correctly
To lift the engine, always use a cor-
rect wire rope capable of withstand-
ing the engine weight.
Attach the wire rope to the lifting
hangers provided on the engine us-
ing a correct sling.
During lifting process, keep the en-
gine in a well-balanced position by taking the center of
gravity of the engine into consideration.
During lifting process, keep the engine in a well-bal-
anced position by taking the center of gravity of the en-
gine into consideration.
If the wire rope contacts the engine directly, place a
cloth or other soft padding to avoid damage to the en-
gine and wire rope.
Do not climb onto the engine
Do not climb onto the engine, nor step on any engine
parts located on the lateral sides.
To work on parts located on the upper section of en-
gine, use a ladder, stool, etc., that is firmly secured.
Climbing on the engine may not only damage engine
parts but also cause parts to fall off and result in per-
sonal injuries.
VI
&$87,21
Be careful of handling fuel, engine
oil and LLC
Use only specified fuel, engine oil and long-
life coolant (LLC)
Use only the fuel, oil and LLC specified in this manual,
and handle them carefully.
Use of any other fuel, oil or LLC, or improper handling
may cause various engine problems and malfunctions.
Obtain the Material Safety Data Sheets (MSDS) issued
by the fuel, oil and LLC suppliers, and follow the direc-
tions in the MSDSs for proper handling.
Handle LLC (long life coolant) carefully
When handling LLC, always wear rubber gloves and
protective face mask. If LLC or cooling water containing
LLC comes into contact with your skin or eyes, or if it is
swallowed, you would suffer from inflammation, irrita-
tion or poisoning.
Should LLC be accidentally swallowed, induce vomit-
ing immediately and seek medical attention. Should
LLC enter your eyes, flush them immediately with plen-
ty of water and seek medical attention. If LLC splashes
onto your skin or clothing, wash it away immediately
with plenty of water.
Keep flames away from LLC. The LLC can catch
flames, causing a fire.
Coolant containing LLC is a hazardous material. Do not
dispose of it in unauthorized manner. Abide by the ap-
plicable law and regulations when discarding drained
coolant.
Proper disposal of waste oil and coolant
(LLC)
Do not discharge waste engine oil or coolant into sew-
erage, river, lake or other similar places. Such a way of
disposal is strictly prohibited by laws and regulations.
Dispose of waste oil, coolant and other environmentally
hazardous waste in accordance with the applicable law
and regulations, or consult a Mitsubishi dealer.

&$87,21
Service battery
Handle the battery correctly
• Never use flames or allow sparks
to generate near the battery. The
battery releases flammable
hydrogen gas and oxygen gas.
Any flames or sparks in the vicin-
ity could cause an explosion.
• Do not use the battery the fluid level of which is low-
ered below the lower limit line. Sustained use of the
battery could result in an explosion.
• Do not short the battery terminals with a tool or other
metal object.
• When disconnecting battery cables, always remove
the cable from the negative (-) terminal first. When
reconnecting the cables, attach the cable to the posi-
tive (+) terminal first.
• Charge the battery in a well-ventilated area, with all
filling hole plugs removed.
• Make sure the cable clamps are securely installed on
the battery terminals. A loose cable clamp can cause
sparks that may result in an explosion.
• Before servicing electrical components or conducting
electric welding, set the battery switch to the [Open/
OFF] position or disconnect the cable from the nega-
tive (-) battery terminal to cut off the electrical cur-
rent.
• Electrolyte (battery fluid) contains dilute sulfuric acid.
Careless handling of the battery can lead to the loss
of sight and/or skin burns. Also, keep the battery fluid
off the mouth.
• Wear protective goggles and rubber gloves when
working with the battery (when adding water, charg-
ing, etc.).
• If electrolyte is spilled onto the skin or clothing,
immediately wash it away with lots of water. Use
soap to thoroughly clean.
• The battery fluid can cause blindness if splashing
into eyes. If it gets into eyes, immediately flush it
away with plenty of clean fresh water, and seek
immediate medical attention.
• If the battery fluid is accidentally swallowed, gargle
with plenty of water, then drink lots of water, and
seek immediate medical attention.
INTRODUCTION
&$87,21
When abnormality occurs
Stop overheated engine after cooling run
Even if the engine comes to overheat, do not stop the
engine immediately. Abrupt stopping of an overheated
engine can cause the coolant temperature to rise, re-
sulting in seized engine parts. If the engine comes to
overheat, run the engine at low idling speed (cooling
operation), and stop the engine after the coolant tem-
perature lowers sufficiently.
Do not add coolant immediately after stopping the en-
gine. Adding coolant to a hot engine can cause the cyl-
inder heads to crack due to sudden change in
temperature. Add coolant little by little after the engine
cools down to room temperature.
Avoid immediate restart after abnormal stop
If the engine stops abnormally, do not restart the en-
gine immediately. If the engine stops with an alarm,
check and remedy the cause of the problem before re-
starting. Sustained use of the engine without any rem-
edy could result in serious engine problems.
Avoid continuous engine operation with too
low oil pressure
If an abnormal engine oil pressure drop is indicated,
stop the engine immediately, and inspect the lubrica-
tion system to locate the cause. Continuous engine op-
eration with low oil pressure may cause bearings and
other parts to seize.
Stop the engine immediately if the fan belt
breaks
If the fan belt breaks, stop the engine immediately. con-
tinuous engine operation with the broken fan belt could
cause the engine to overheat and thereby the coolant
to boil into steam, which may gush out from the reserve
tank or radiator, and cause personal injuries.
VII
INTRODUCTION

&$87,21

Other cautions
gine remarkably.
Modification of engine prohibited
Unauthorized modification of the engine will void the Cooling operation before stopping engine
manufacturer’s warranty. Always conduct the cooling operation (low speed
Modification of the engine may not only cause engine idling) for 5 to 6 minutes before stopping the engine.
damage but also produce personal injuries. Abruptly stopping the engine immediately after high-
load operation can cause partial overheating and short-
Pre-operational check and periodic inspec-
en the service life of the engine.
tion/maintenance
During cooling operation, check the engine for abnor-
Be sure to perform the pre-operational checks and pe-
malities.
riodic inspection/maintenance as described in this
manual. Protection of engine against water entry
Neglecting the pre-operational check or periodic in- Do not allow rainwater, etc. to enter the engine through
spection/maintenance can arouse various engine trou- the air inlet or exhaust openings.
bles such as damage to parts, eventually leading to Do not wash the engine while it is operating. Cleaning
serious accidents. fluid (water) can be sucked into the engine.
Starting the engine with water inside the combustion
Break-in operation
chambers can cause the water hammer action which
A new engine needs to be broken in for the first 50
may result in internal engine damage and serious acci-
hours of operation. During this period, do not subject
dents.
the engine to heavy loads.
Operating a new engine under high loads or severe Maintenance of air cleaner or pre-cleaner
conditions during the break-in period can shorten the The major cause of abnormal wear on engine parts is
service life of the engine. dust entering with intake air. Worn parts produce many
problems such as an increase of oil consumption, de-
Warming-up operation
crease of output, and starting difficulties. For effective
After starting the engine, run the engine at low idling
removal of dust from intake air, conduct maintenance
speeds for 5 to 10 minutes for warming-up. Start the
of the air cleaner according to the following instruc-
work after this operation is completed.
tions.
Warm-up operation circulates the lubricant through the
• Do not conduct maintenance of the air cleaner/pre-
engine. Therefore, individual engine parts are well lu-
cleaner while the engine is operating. Engine opera-
bricated before they are subjected to heavy loads. This
tion without the air cleaner/precleaner in place allows
is very important for longer service life, high-perfor-
foreign matters to enter the turbocharger, causing it
mance and economical operation.
to damage seriously.
Do not conduct warm-up operation for a longer time
• Remove the air cleaner/pre-cleaner slowly to prevent
than necessary. Prolonged warm-up operation causes
dust accumulated on the element from falling off.
carbon build-up in the cylinders that leads to incom-
After removing the air cleaner or pre-cleaner, imme-
plete combustion.
diately cover the opening (inlet port in case of air
Avoid engine operations in a overload con- cleaner; port in body in case of pre-cleaner) with
dition plastic sheet or similar means to prevent dust from
If the engine is considered to be in an overloaded con- entering the engine.
dition which is identified by too much black smoke, etc., • Air cleaners equipped with a dust indicator will issue
immediately reduce the load on the engine such that an alarm if the element gets clogged. Service the
the correct output and load conditions may be cleaner as soon as possible if an alarm is issued.
achieved.
Overloading the engine causes not only high fuel con-
sumption but also excessive carbon deposits inside the
engine. Excessive carbon deposits can cause various
engine problems and shorten the service life of the en-

VIII

Observe safety rules at work site
Observe the safety rules established at your workplace
when operating and maintaining the engine.
Do not operate the engine if you are feeling ill.
Operation of the engine with reduced awareness may
cause improper operation that could result in accidents.
In such a case, inform your supervisor of your condi-
tion.
When working in a team of two or more people, use
specified hand signals to communicate among work-
ers.
Work clothing and protective gear
Wear a hardhat, face shield, safety shoes, dust mask,
gloves and other protective gear as needed.
When handling compressed air, wear safety goggles,
hardhat, gloves and other necessary protective gear.
Works without wearing proper protective gear could re-
sult in serious injuries.
Use of tools optimum for each work
Always keep in mind to select most appropriate tools
for the work to be performed and use them correctly. If
tools are damaged, replace with new tools.
Avoidance of prolonged time of starter oper-
ation
Do not operate the starter for more than 10 seconds at
a time even if the engine does not start. Wait for at least
30 seconds before next engine cranking.
Continuous operation of the starter will drain the battery
power and cause the starter to seize.
Do not turn off battery switch during opera-
tion
If the battery switch is turned OFF when the engine is
running, not only various meters will stop working but
also the alternator may have its diode and transistor
deteriorated.
INTRODUCTION
Cautionary instructions for transporting en-
gine
When transporting the engine on a truck, consider the
engine weight, width and height to ensure safety. Abide
by road traffic law, road vehicles act, vehicle restriction
ordinance and other pertinent laws.
Avoid continuous engine operation in a low
load condition
Do not operate the engine continuously for more than
10 minutes at a load of less than 30%. Engine opera-
tion in a low load condition increases the emission of
unburned fuel. Therefore, a prolonged time of engine
operation in a low load condition increases the quantity
of unburned fuel adhering to engine parts, provoking
the possibility of engine malfunctioning and shortening
the service life of the engine.
Ventilation of engine room
Always keep the engine room well ventilated. Insuffi-
cient amount of intake air causes the operating temper-
ature to rise, resulting in poor output and lowered
performance.
It is highly recommended to calculate the required
amount of air supply to the engine and install an ade-
quate ventilation system before installing the engine.
Avoid contact with high-pressured fuel
Should fuel leak from a fuel injection pipe, do not touch
the spouting fuel directly.
Fuel in the fuel injection pipes is under high pressure. If
high-pressured fuel contacts you skin, it penetrates
through the skin and may result in gangrene.
IX
INTRODUCTION

&$87,21

About warning labels

Maintenance of warning labels
Make sure all warning/caution labels are legible.
Clean or replace the warning/caution labels when the description and/or illustration are not clear to read.
For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvents, gasoline or other
chemicals to prevent the letters from getting blurred or the adhesion from being weakened.
Replace damaged or fractured labels with new ones.
If any engine part on which a warning label is attached is replaced with a new one, attach a new identical warning
label to the new part.

Warning labels

X
 GENERAL CONTENTS

Group Name Contents Group No.

External view
System flow diagrams
General Engine serial number location 1
Main specifications
Tips on disassembling and reassembling
Maintenance service data
Service data 2
List of tightening torque
Service tools Special tools 3
Determining overhaul timing
Determination of overhaul 4
Testing compression pressure
Disassembling and inspecting cylinder head and valve mechanism
Disassembling and inspecting flywheel
Disassembly of basic engine 5
Disassembling and inspecting gear case, timing gear and camshaft
Disassembling and inspection crankcase, crankshaft and piston
Inspecting and repairing cylinder head and valve mechanism
Inspecting and repairing flywheel
Inspection and repair of basic engine 6
Inspecting and repairing timing gear and camshaft
Inspecting and repairing piston, connecting rod, crankshaft and crankcase
Reassembling piston, connecting rod, crankshaft and crankcase
Reassembling timing gear and camshaft
Reassembly of basic engine 7
Reassembling flywheel
Reassembling cylinder head and valve mechanism
Removing fuel system
Fuel system 8
Installing fuel system
Removing and inspecting lubrication system
Lubrication system Disassembling, inspecting and reassembling lubrication system 9
Installing lubrication system
Removing cooling system
Cooling system Inspecting cooling system 10
Installing cooling system
Removing inlet and exhaust sysytem
Inlet and exhaust system Disassembling, inspecting and reassembling inlet and exhaust system 11
Installing inlet and exhaust system
Removing electrical system
Electrical system Disassembling, inspecting and reassembling electrical system 12
Installing electrical system
Adjusting engine
Adjustment and operation Break-in operation 13
Performance test (JIS standard)
Troubleshooting by diagnosis codes
Scan tester
Diagnosis code cross reference
Troubleshooting 14
Troubleshooting reference chart
Inspecting sensors
Inspecting wiring
 GENERAL
1. External view...................................1-2

2. System flow diagrams .....................1-3

2.1 Fuel system - flow diagram ...................... 1-3
2.2 Lubrication system - flow diagram ........... 1-3
2.3 Cooling system - flow diagram................. 1-4
2.4 Inlet and exhaust system - flow diagram.. 1-4
2.5 Electrical system - wiring diagram ........... 1-5

3. Engine serial number location.........1-6

4. Main specifications..........................1-7

5. Tips on disassembling and

reassembling.................................1-10
5.1 Disassembling........................................ 1-10
5.2 Reassembling ........................................ 1-10

1-1
GENERAL

1. External view

Oil filler
Exhaust manifold
Front hanger Turbocharger
Thermostat

Fan Rear hanger

Front Rear

Alternator

Crankshaft pulley
Starter
Belt
Oil pan

Engine left view

Inlet manifold
Breather
Oil level gauge
Air heater

Oil filter Water pump

Rear Front

Common rail

Fuel pump

Flywheel housing Oil pump

Flywheel

Engine right view

1-2
 GENERAL

2. System flow diagrams

2.1 Fuel system - flow diagram

Injector

Common rail

Fuel pump

To fuel tank

From fuel tank

Fuel system - flow diagram

2.2 Lubrication system - flow diagram

Tappet Turbocharger Valve mechanism

Piston
Camshaft

Piston cooling nozzle

Oil filter

Main gallery
Oil cooler
Timing gear
Relief valve

Oil pump
Crankshaft
Oil strainer
Safety valve

Lubrication system - flow diagram

1-3
GENERAL

2.3 Cooling system - flow diagram

Outlet

Thermostat
Cylinder head
Bypass pipe

Inlet
Oil cooler Water pump
Water jacket

Cooling system - flow diagram

2.4 Inlet and exhaust system - flow diagram

Inlet
Exhaust Turbocharger

Muffler

Cylinder

Inlet and exhaust system - flow diagram

1-4
 GENERAL

2.5 Electrical system - wiring diagram

Injector power supply

Air heater relay
Inlet manifold pressure sensor

Water temperature sensor

Common rail

Common rail pressure sensor

Speed/timing sensor
(Camshaft side)
Speed/timing sensor
(Crankshaft side)
High pressure pump

High pressure pump

Engine oil pressure switch solenoid sensor (MPROP)

Connector

Electronic control unit

Electrical system - wiring diagram

1-5
GENERAL

3. Engine serial number location

The engine serial number is stamped on the side of the
crankcase.

Engine serial number

Stamp location of engine serial number

1-6
 GENERAL

4. Main specifications
Table 1-1 Main specifications (1 / 3)
Engine model D04FR-TAA
Type Water cooled, 4 cycle diesel engine, turbocharged
No. of cylinders - arrangement 4 cylinder in-line
Combustion system Direct injection
Valve mechanism Overhead
Cylinder bore × stroke 102 × 130 mm [4.02 × 5.12 in.]
Displacement 4.249 L [259 cu. in.]

Main Compression ratio 17.8

specification Fuel Diesel fuel
Firing order 1-3-4-2
Direction of rotation Counterclockwise when viewed from flywheel side
Length 911 mm [35.87 in.]
Dimensions
(varies depending on the Width 719 mm [28.3 in.]
specifications)
Height 940 mm [37.0 in.]
Dry weight Approx. 395 kg [870.8 lbs]
Cylinder sleeve type Dry
Compression ring 2
Number of piston ring
Oil ring 1 (with expander)
Open BTDC 15°
Inlet valve
Valve timing (when Close ABDC 45°
Engine engine is hot) Open BBDC 49°
main parts Exhaust valve
Close ATDC 15°

Internal EGR valve tim- Open ATDC 21°

Exhaust valve
ing Close BBDC 55°
Starting system Starter
Starting aid system Air heater
Type Common rail fuel injection system
Fuel
Model number CP1H
system
Manufacturer Bosch Corporation

1-7
GENERAL

Table 1-1 Main specifications (2 / 3)

Engine model D04FR-TAA
Lubricating method Forced circulation type (oil pump pressure feed type)
Classification API classification CF-4 or above class
Engine oil Total capacity
17.5 L [4.62 US gallons]
(including oil filter)
Type Gear type oil pump
Oil pump 40 L [10.57 US gallons]
Delivery capacity
Lubrication /1800 min-1
system Type Piston valve type
Relief valve 0.35 ± 0.05 MPa
Valve opening pressure
{3.5 ± 0.5 kgf/cm²} [50 ± 7 psi]
Oil cooler type Water-cooled, multi-plate type
Oil filter type Cartridge type paper element
1.1 MPa
Safety valve opening pressure
{11 kgf/cm²} [157 psi]
Cooling method Water-cooled, forced circulation
Coolant capacity (Engine water jacket) 6 L [1.6 US gallons] approx.
Type Centrifugal
Water pump 133 L [35 US gallons]
Discharge capacity
/1800 min-1
Cooling
Water pump pulley speed ratio Varies depending on the specifications
system
Fan belt type Ribbed belt
Fan Type ø600 mm [23.62 in.]
Type Wax type
Thermostat Valve opening tempera-
71 ± 2°C [160 ± 3.6°F]
ture
Inlet and Model number TD04HL
exhaust sys- Turbocharger
tem Qty 1

Control sys- ECU Model number EDC16UC40

tem (Electronic Control Unit) Manufacturer Bosch Corporation

1-8
 GENERAL

Table 1-1 Main specifications (3 / 3)

Engine model D04FR-TAA
Manufacturer Nikko Electric Industry
Type 0-24000-0188
Pinion meshing type Pinion shift
Output 24V - 5kW
Qty 1
Ring gear and pinion ratio 10/127
Voltage 23V
Starter No-load charac-
Current 85A or below
teristics
Speed 3300 min-1 or more
Voltage 9V
Load character-
Current 1400A or below
istics
Torque 88.26 N·m {9.0 kgf·m} [65 lbf·ft] or above
Minimam operating volt-
16V or below
Electrical age
system Minimam holding voltage 8V or below
Manufacturer Nikko Electric Industry
Model number 0-35000-4838
Output 24V - 50A
Rated speed 5000 min-1
Direction of rotation Clockwise when viewed from pulley side
Alternator
Drive system PK type, V ribbed, 12 ribs
Ground system One conductor (-) side
Regulated voltage 28.5V ± 1V
Temperature range
-30 to +100°C [-22 to +212°F]
tolarance
Type Electric heater
Air heater
Capacity 2.1kW
Heater relay Fuse capacity 127A

1-9
GENERAL

5. Tips on disassembling and reassem-

bling 5.2 Reassembling
This service manual specifies the recommended procedures (1) Wash all engine parts, except such parts as oil seals, O-
to be followed when servicing Mitsubishi engines. The rings and rubber sheets, in cleaning oil and dry them
manual also specifies the special tools that are required for with compressed air.
the work, and the basic safety precautions to follow when (2) Use correct tools and instruments.
working. (3) Use only high-quality lubricating oils and greases of
Note that this manual does not exhaustively cover potential appropriate types. Be sure to apply oil, grease or
hazards that could occur during maintenance, inspection and adhesive to the part wherever specified.
service work of engine. (4) Use a torque wrench to tighten parts correctly when
When working on an engine, follow the relevant directions their tightening torques are specified.
given in this manual and observe the following instructions: Refer to "List of Tightening Torque."
(5) Replace all gaskets and packings with new ones unless
5.1 Disassembling specified otherwise. Apply adhesive if necessary. Use
(1) Use correct tools and instruments. Serious injury or only the proper amount of adhesive.
damage to the engine will result from using the wrong
tools and instruments.
(2) Use an overhaul stand or work bench if necessary, and
follow the disassembling procedures described in this
manual.
(3) Keep the engine parts in order of removal to prevent
losing them.
(4) Pay attention to assembling marks. Put your marks on
the parts, if necessary, to ensure correct reassembling.
(5) Carefully check each part for defects during
disassembling or cleaning. Do not miss symptoms
which can not be detected after disassembling or
cleaning.
(6) When lifting or carrying heavy parts, exercise utmost
caution to ensure safety. Pay attention to balance of
heavy parts when handling. (Get help, and use jacks,
chain blocks and guide bolts as necessary.)

1-10
 SERVICE DATA
1. Maintenance service data ...............2-2
1.1 Engine general......................................... 2-2
1.2 Basic engine ............................................ 2-3
1.3 Lubrication system ................................... 2-7
1.4 Cooling system ........................................ 2-7
1.5 Inlet and exhaust system ......................... 2-7
1.6 Electrical system ...................................... 2-8

2. List of tightening torque...................2-9

2.1 Major bolts and nuts tightening torque..... 2-9
2.1.1 Basic engine...............................................2-9
2.1.2 Fuel system ..............................................2-10
2.1.3 Lubrication system ...................................2-10
2.1.4 Cooling system.........................................2-10
2.1.5 Inlet and exhaust system .........................2-11
2.1.6 Electrical system ......................................2-11
2.1.7 Sensors and ECM ....................................2-11
2.2 Standard bolt and nut tightening torque. 2-12
2.3 Standard eyebolt tightening torque ........ 2-13
2.4 Standard union nut tightening torque..... 2-13

2-1
SERVICE DATA

1. Maintenance service data

1.1 Engine general
Table 2-1 Maintenance service data table - Engine general Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
-1 -1
Maximum revolution speed 2240 min ± 10 min

Minimum revolution speed 1015 min-1 ± 20 min-1

When oil and water tem-
2.9 MPa 2.6 MPa
-1 peratures
Compression pressure (at 300 min ) {30 kgf/cm²} {27 kgf/cm²}
at 20 to 30°C
[427 psi] {[384 psi]
[68 to 86 °F]
0.2 to 0.4 MPa 0.15 MPa
Rated speed {2 to 4 kgf/cm²} {1.5 kgf/cm²}
[28.4 to 56.9 psi] [21.3 psi] Oil temperature
Lubricating
at 70 to 90 °C
oil pressure 0.1 MPa 0.05 MPa [158 to 194 °F]
Low idling {1 kgf/cm²} {0.5 kgf/cm²}
[14.2 psi] [7.1 psi]
Open BTDC 15°
Inlet
Close ABDC 45° ±3°
Valve timing
Open BBDC 49° (crank angle)
Exhaust
Close ATDC 15°

Internal EGR Open ATDC 21°

Exhaust
valve timing Close BBDC 55°

Valve clearance Inlet 0.25 [0.0098]

(when cold) Exhaust 0.40 [0.0157]
Deflection when the belt
forcefully pressed with a
7 to 9 thumb
Fan belt deflection
[0.276 to 0.354] New fan belt standard
value 4 to 6 [0.158 to
0.236]

2-2
 SERVICE DATA

1.2 Basic engine

Table 2-2 Maintenance service data table - Basic engine (1 / 4) Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
Reface minimum as possible.
Total grinding thickness of
Crankcase Flatness of top surface 0.05 [0.0020] or less 0.20 [0.008] crankcase top and cylinder
head bottom is 0.2 [0.008]
max.
ø 102 102.010 to 102.045 102.700 If limit (102.200 [4.0236]) is
Inside diameter
[4.02] [4.0161 to 4.0175] [4.0433] exceeded, use oversize
Cylinder sleeve, and hone to +0.010 to
Circularity 0.01 [0.0004] or less
sleeve +0.045 [0.0004 to 0.0018].
Use oversize piston and pis-
Cylindricality 0.015 [0.0006] or less
ton ring.
If the measured value
exceeds the standard and is
less than the limit, replace
Clearance between main bearing and 0.050 to 0.118 0.200
bearing.
crank journal [0.0020 to 0.0046] [0.0079]
Main If the limit is exceeded, grind
bearing the crank journal, and use
undersize bearing.
Replace thrust plate. The
Width of thrust journals 0.100 to 0.264 (0.300
limit value means a play in
(Thrust clearance) [0.0039 to 0.0104] [0.0118])
the direction of thrust.
ø 22 22.000 to 22.021 22.100 Repair limit:
Inside diameter
[0.87] [0.8661 to 0.8670] [0.8701] 102.200 [4.0236]
Tappet
hole Replace tappet if diameter of
Clearance between tappet and tappet 0.035 to 0.086 0.120
tappet hole is +0.10 [0.0039]
hole [0.0014 to 0.0034] [0.0047]
or less.
Front 0.04 to 0.09 0.15
Clearance between Middle [0.0016 to 0.0035] [0.0059]
Camshaft Replace bushing.
bushing and cam-
bushing 0.04 to 0.119 0.15 (Ream if necessary.)
shaft journal Rear
[0.0016 to 0.0047] [0.0059]
Reface minimum as possible.
Total grinding thickness of
Cylinder Distortion of bottom surface 0.05 [0.0020] or less 0.20 [0.008] crankcase top and cylinder
head head bottom is 0.2 [0.008]
max.
Compressed thickness of gasket 1.7 [0.07] ±0.05 [0.0020]
7.940 to 7.955 7.900
Inlet
Valve stem diame- ø8 [0.3126 to 0.3132] [0.3110]
ter [0.315] 7.920 to 7.940 7.850
Exhaust
[0.3118 to 0.3126] [0.3091]
Valve and
0.055 to 0.085 0.150
valve Inlet
Clearance between [0.0022 to 0.0033] [0.0059]
guide
guide and stem 0.070 to 0.105 0.200
Exhaust
[0.0028 to 0.0041] [0.0079]
17 17.2 to 17.4
Height to top of valve guide
[0.669] [0.6772 to 0.6850]

2-3
SERVICE DATA

Table 2-2 Maintenance service data table - Basic engine (2 / 4) Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
Inlet
Valve seat angle 30°
Exhaust
0.4 0.3 to 0.5 1.1
Inlet Seat width
[0.016] [0.0118 to 0.0197] [0.0433]
Valve sinkage
0.5 0.4 to 0.6 1.1
Valve seat Exhaust
[0.020] [0.0157 to 0.0236] [0.0433]
and valve
Inlet Valve Valve
1.4 1.2 to 1.6 1.8 Valve sinkage margin
Seat width
Exhaust [0.055] [0.0472 to 0.0630] [0.071] seat angle

Refacing permissi-
Valve margin 2.13 [0.084] 2.13 [0.084] ble up to 1.2
[0.047]
Free length 56.40 [2.221] 55.00 [2.165]

θ = 2.0°or less ǰ
Δ = 2.0 [0.079] or Δ = 2.0 [0.079] ٌ
Perpendicularity
less over entire length Lf
Valve
springs Lf = 56.4 [2.221]

44.0 [1.732]/222.7 to
44.0 [1.732]/207 N
246.1 N
Set length/load {21.2 kgf}
{22.7 to 25.1 kgf}
[153.3 lbf]
[164.2 to 181.5 lbf]
ø 20 20.011 to 20.094
Rocker bushing inside diameter
[0.79] [0.7878 to 0.7911]
Rocker ø 20 19.966 to 19.984
Rocker shaft diameter
arm [0.79] [0.7861 to 0.7868]
Clearance between rocker bushing 0.027 to 0.128 0.150
and rocker shaft [0.0011 to 0.0050] [0.0059]
Pushrod Runout 0.4 [0.016] or less 0.4 [0.016] TIR

2-4
 SERVICE DATA

Table 2-2 Maintenance service data table - Basic engine (3 / 4) Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
0.04 0.10
Runout TIR
[0.0016] or less [0.0039]
If the diameter is the limit or
more, replace bearing.
ø 90 89.95 to 89.97 89.85 If the diameter is less than
Crank journal diameter
[3.54] [3.5413 to 3.5421] [3.5374] the limit, grind the journal
and use undersize bearing.
Service limit: 89.10 [3.5079]
ø 65 64.945 to 64.965 64.800
Crankpin diameter
[2.56] [2.5569 to 2.5577] [2.5512]
Distance between centers of journal
65 [2.56] ± 0.05 [± 0.002]
and crankpin
Pin maximum defec-
Crank- Parallelism between journal and
tion: 0.01 [0.0004] or
shaft crankpin
less
Roundness of journals and crankpins 0.01 0.03
(diameter difference) [0.0004] or less [0.0012]
Cylindericity of journals and crank-
0.01 0.03
pins
[0.0004] or less [0.0012]
(diameter difference)
Fillet radius of journals R3 [0.12] ± 0.2 [± 0.008]
Fillet radius of pins R4 [0.16] ± 0.2 [± 0.008]
If end play is less than the
limit, replace thrust plates.
0.100 to 0.264 0.300
End play If end play exceeds the limit,
[0.0039 to 0.0104] [0.0118]
replace with oversize thrust
plates.
101.915 to 101.945 101.730
STD
[4.0124 to 4.0136] [4.0051]
Outside diameter 0.25 [0.0098]/ ø 102 102.165 to 102.195 101.980
(at piston skirt) OS [4.02] [4.0222 to 4.0234] [4.0150]
0.50 [0.0197]/ 102.415 to 102.445 102.230
OS [4.0321 to 4.0333] [4.0248]
Bearing clearance check.
Gasket compressed
Protrusion from crankcase 0.8 [0.031]
(installed) thickness: 1.7 ±
0.05 [0.067 ± 0.0020]
Pistons Clearance between piston pin hole 0.005 to 0.021 0.050
and piston pin [0.0002 to 0.0008] [0.0020]
Weight difference in one engine 5.0 g [0.2 oz.] or less
No.1
0.08 to 0.12 0.200
compression
[0.0031 to 0.0047] [0.0079]
ring
Clearance between
No.2
piston ring and 0.08 to 0.12 0.150
compression
ring groove [0.0031 to 0.0047] [0.0059]
ring
0.025 to 0.065 0.150
Oil ring
[0.0010 to 0.0026] [0.0059]
Compression 0.30 to 0.45
Piston rings [0.0118 to 0.0177] 1.50
End gap
ring 0.30 to 0.50 [0.0591]
Oil ring
[0.0118 to 0.0197]

2-5
SERVICE DATA

Table 2-2 Maintenance service data table - Basic engine (4 / 4) Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
ø 34 33.991 to 33.997
Outside diameter
[1.34] [1.3382 to 1.3385]
Clearance between pin and connect- 0.023 to 0.054 0.080
Piston pin
ing rod bushing [0.0009 to 0.0021] [0.0031]
ø 34 34.020 to 34.045
Inside diameter of bushing
[1.34] [1.3394 to 1.3404]
0.05/100 0.150
Bend and twist
[0.0020/3.94] or less [0.0059]
Clearance between crankpin and con- 0.035 to 0.100 0.200
Connect- necting rod bearing [0.0014 to 0.0039] [0.0079]
ing rod
0.15 to 0.35 0.50 Replace connecting rod bear-
End play
[0.0059 to 0.0138] [0.0197] ings.
Weight difference in one engine 10 g [0.4 oz.] or less
Flatness 0.15 [0.0059] or less 0.5 [0.0197]
Flywheel
Runout 0.15 [0.0059] or less 0.5 [0.0197]
TIR
0.10
Runout 0.04 [0.0016] or less Repair using a press, or
[0.0039]
replace.
Major axis Major axis - minor
+0.1 Major axis - minor
Inlet 46.911 -0.3 axis = 6.189
axis = 6.689 [0.2633] Major axis
[1.8469
+0.004
-0.012 ] [0.2437]
Cam lift Minor
Major axis Major axis - minor axis
+0.1 Major axis - minor
Camshaft Exhaust 46.256 -0.3 axis = 5.729
+0.004
axis = 6.229 [0.2452]
[1.8211 -0.012 ] [0.2256]

ø 54 53.94 to 53.96 53.90

Front, middle
[2.13] [2.1236 to 2.1244] [2.1220]
Journal diameter
ø 53 52.94 to 52.96 52.90
Rear
[2.09] [2.0842 to 2.0850] [2.0827]
0.10 to 0.25 0.30
End play Replace thrust plate.
[0.0039 to 0.0098] [0.0118]
Clearance between idler bushing and 0.009 to 0.050
0.100 [0.0039] Replace bushing.
shaft [0.0004 to 0.0020]
0.05 to 0.20 0.35
Idler Idler gear end play Replace thrust plate.
[0.0020 to 0.0079] [0.0138]
Interference between shaft and crank- 35 -0.016 to -0.035
case hole [1.38] [-0.0006 to -0.0138]
Between crankshaft gear 0.053 to 0.154 0.25
and idler gear [0.0021 to 0.0061] [0.0098]
Between camshaft gear 0.049 to 0.160 0.25
Timing and idler gear [0.0019 to 0.0063] [0.0098]
gear back- Replace gear.
lash Between injection pump idler gear 0.050 to 0.228 0.25
and idler gear [0.0020 to 0.0090] [0.0098]
Between injection pump idler gear 0.044 to 0.163 0.25
and injection pump gear [0.0017 to 0.0064] [0.0098]

2-6
 SERVICE DATA

1.3 Lubrication system

Table 2-3 Maintenance service data table - Lubrication system Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
Backlash between the oil pump idler gear and 0.051 to 0.197 0.35
the idler gear [0.0020 to 0.0078] [0.0138]
Replace gear.
Backlash between the oil pump idler gear and 0.049 to 0.166 0.35
the oil pump drive gear [0.0019 to 0.0065] [0.0138]
-0.01 to 0.054 0.150
End clearance of gears in case
[-0.0004 to 0.0021] [0.0059]
0.05 to 0.098 0.100
Radial clearance of gear in case
[0.0020 to 0.0039] [0.0039]
Oil pump Clearance between gear shaft and pump body,
0.04 to 0.07 0.15
and clearance between gear shaft and pump
[0.0016 to 0.0028] [0.0059]
cover.
ø 25 24.939 to 24.960
Spindle outside diameter
[0.98] [0.9818 to 0.9827]
ø 25 25.000 to 25.021
Oil pump idler gear bushing inside diameter
[0.98] [0.9843 to 0.9851]
0.10 to 0.27
Oil pump idler gear end play
[0.0039 to 0.0106]
0.35 ± 0.05 MPa
Relief valve Valve opening pressure {3.5 ± 0.5 kgf/cm²}
[49.8 ± 7.1 psi]
1.1 MPa
Safety valve Valve opening pressure {11 kgf/cm²}
[157 psi]

1.4 Cooling system

Table 2-4 Maintenance service data table - Cooling system Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
71 ± 2°C
Valve opening temperature
[160 ± 3.6°F]
Thermostat
Temperature at which valve lift becomes 85°C
10mm [0.039 in.] or more [185°F]

1.5 Inlet and exhaust system

Table 2-5 Maintenance service data table - Inlet and exhaust system Unit: mm [in.]
Inspection point Nominal Standard Limit Remarks
Distortion of exhaust manifold 0.2 [0.008] or less

2-7
SERVICE DATA

1.6 Electrical system

Table 2-6 Maintenance service data table - Electrical system Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
0.06
Armature shaft runout TIR
[0.0024]
0.10
Commutator runout
[0.0039]
0.7 to 0.9 0.2
Undercut depth
[0.028 to 0.035] [0.008]
Starter
17 to 18 10
Height
[0.67 to 0.71] [0.39]

Brush Less than

21.56 to 27.44 N
21.56 N
Spring tension {2.2 to 2.8 kgf}
{2.2 kgf}
[15.9 to 20.3 lbf]
[15.9 lbf]
25°C [77°F]
Alternator Adjusting voltage 27.5 to 29.5V
l=2

2-8
 SERVICE DATA

2. List of tightening torque

2.1 Major bolts and nuts tightening torque
2.1.1 Basic engine
Table 2-7 Major bolts and nuts tightening torque - Basic engine
Threads Tightening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Cylinder head bolt 12 × 1.75 137 ± 5 14 ± 0.5 101 ± 3.6

Rocker cover bolt 8 × 1.25 20 ± 2 2.0 ± 0.2 14.5 ± 1.4
Rocker shaft bracket bolt 8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.4
Rocker arm adjusting nut 8 × 1.25 20 ± 2 2.0 ± 0.2 14.5 ± 1.4
Main bearing cap bolt 14 × 2 137 ± 5 14 ± 0.5 101 ± 3.6
Connecting rod cap nut 12 × 1.25 103 ± 5 10.5 ± 0.5 76 ± 3.6
Flywheel bolt 12 × 1.25 83 ± 5 8.5 ± 0.5 62 ± 3.6
Camshaft thrust plate bolt 8 × 1.25 12 ± 2 1.2 ± 0.2 9 ± 1.4
8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.4
Front plate bolt
10 × 1.5 35 ± 5 3.5 ± 0.5 25.3 ± 3.6
8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.5
Timing gear case bolt
10 × 1.5 35 ± 5 3.5 ± 0.5 25.3 ± 3.6
Crankshaft pulley nut 30 × 1.5 706 ± 59 72 ± 6 521 ± 43
Idler thrust plate bolt 10 × 1.25 34 ± 5 3.5 ± 0.5 25 ± 3.6
Piston cooling nozzle 12 × 1.25 34 ± 5 3.5 ± 0.5 25 ± 3.6
Oil pan bolt 8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.4
Oil pan drain cock 24 × 1.5 49 ± 5 5 ± 0.5 36 ± 3.6
Oil pan drain plug 24 × 1.5 59 ± 5 6.0 ± 0.5 43.4 ± 3.6
Lifting bolt 12 × 1.75 102 ± 10 10.4 ± 1.0 75.2 ± 7.2

2-9
SERVICE DATA

2.1.2 Fuel system

Table 2-8 Major bolts and nuts tightening torque - Fuel system
Threads Tightening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Nozzle gland 8 × 1.25 30 ± 3.0 3.1 ± 0.3 22.4 ± 2.2

+2.5 +0.25 +1.8
Fuel pump fuel relief joint mouting eye bolt 12 × 1.25 25 0 2.5 0 18 0

Fuel pump gear nut 14 × 1.5 70 ± 5 7.1 ± 0.5 51.4 ± 3.6

Fuel injection pipe nut
14 × 1.5 25 ± 3 2.5 ± 0.3 18.1 ± 2.2
(Injector side, Rail side)
Fuel pump fuel supply high pressure pipe
14 × 1.5 25 ± 3 2.5 ± 0.3 18.1 ± 2.2
(Rail side)
Fuel pump fuel supply high pressure pipe
12 × 1.5 20 ± 2.0 2.0 ± 0.2 14.5 ± 1.4
(Pump side)
Fuel filter air bleed plug 14 × 1.5 21 ± 4 2.1 ± 0.4 15.2 ± 2.9
Fuel filter fuel inlet eye bolt 14 × 1.5 21 ± 4 2.1 ± 0.4 15.2 ± 2.9
Fuel filter fuel outlet eye bolt 14 × 1.5 21 ± 4 2.1 ± 0.4 15.2 ± 2.9
Fuel pump mouting bolt 8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.4
Fuel pump idler shaft wahsher mouting bolt 10 × 1.25 34 ± 5 3.5 ± 0.5 25.3 ± 3.6
Fuel pump idler shaft mouting bolt 12 × 1.25 112.2 ± 22 11.4 ± 2.2 82.5 ± 15.9

2.1.3 Lubrication system

Table 2-9 Major bolts and nuts tightening torque - Lubrication system
Threads Tightening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Relief valve 22 × 1.5 49 ± 4.9 5 ± 0.5 36.2 ± 3.6

Relief valve plug 18 × 1.5 44 ± 4.9 4.5 ± 0.5 32.5 ± 3.6
Safety valve 18 × 2.0 69 ± 4.9 7 ± 0.5 50.6 ± 3.6
Oil pump cover bolt 10 × 1.5 35 ± 3.5 3.6 ± 0.3 25.3 ± 2.4
Turbocharger oil feed eye bolt 10 × 1.25 17 ± 2 1.7 ± 0.2 12.3 ± 1.4

2.1.4 Cooling system

Table 2-10 Major bolts and nuts tightening torque - Cooling system
Threads Tightening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Fan and water pump pulley mouting bolt 10 × 1.5 49 ± 5 5.0 ± 0.5 36.2 ± 3.6
Water pump, oil pump mouting bolt(together
10 × 1.5 35 ± 3.5 3.6 ± 0.3 25.3 ± 2.4
with gear case)
Water pump mouting bolt(together with gear
8 × 1.25 19 ± 1.9 1.9 ± 0.2 13.7 ± 1.4
case)

2-10
 SERVICE DATA

2.1.5 Inlet and exhaust system

Table 2-11 Major bolts and nuts tightening torque - Inlet and exhaust system
Threads Tightening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Air heater terminal nut 6×1 9±1 0.9 ± 0.1 6.5 ± 0.7
Air heater terminal flange nut 6×1 9±1 0.9 ± 0.1 6.5 ± 0.7
Inlet manifold bolt 8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.4
Exhaust manifold nut 8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.4

2.1.6 Electrical system

Table 2-12 Major bolts and nuts tightening torque - Electrical system
Threads TIghtening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Starter mouting bolt 10 × 1.25 35.3 ± 5.9 3.6 ± 0.6 255.4 ± 42.6
Starter B terminal 10 × 1.5 18 ± 2 1.8 ± 0.2 13.0 ± 1.4
Starter protection cover screw 5 × 0.8 2.25 ± 0.25 0.22 ± 0.02 1.6 ± 0.1
Starter through bolt 6×1 10.29 ± 2.45 1.0 ± 0.24 7.2 ± 1.7
Alternator E terminal 6×1 5.9 ± 1 0.6 ± 0.1 4.3 ± 0.7
Alternator B terminal 5 × 0.8 5.9 ± 1 0.6 ± 0.1 4.3 ± 0.7
Alternator pulley nut 20 × 1.5 97 ± 12.7 9.9 ± 1.3 71.6 ± 9.4
Alternator through bolt 6×1 5.9 ± 1 0.6 ± 0.1 4.3 ± 0.7
Alternator mounting bolt 14 × 1.5 97 ± 9.7 9.9 ± 1.0 71.6 ± 7.2

2.1.7 Sensors and ECM

Table 2-13 Major bolts and nuts tightening torque - Sensors and ECM
Threads Tightening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Water temperature sensor 10 × 1.25 21 ± 2.1 2.0 ± 0.2 15.2 ± 1.5

Inlet manifold pressure sensor R1/4 25 ± 2 2.5 ± 0.2 18.1 ± 1.4
Engine oil pressure switch R1/8 10 ± 2 1.0 ± 0.2 7.2 ± 1.4
Speed/timing sensor mouting bolt
6 × 1.0 9±1 0.9 ± 0.1 6.5 ± 0.7
(camshaft, crankshaft)
ECU mouting bolt 6 × 1.0 8.0 ± 2 0.8 ± 0.1 5.8 ± 1.4
Pickup mouting hexagon bolt 6 × 1.0 29.4 ± 4.9 3.0 ± 0.5 212.8 ± 35.5

2-11
SERVICE DATA

2.2 Standard bolt and nut tightening torque

Table 2-14 Standard bolt and nut tightening torque
Threads Width Strength classification
Description Dia × Pitch across flats
(mm) (mm) [in.] 7T 10.9

7 10
N·m kgf·m lbf·ft N·m kgf·m lbf·ft
M8 × 1.25 12 [0.47] 17 1.7 13 30 3.1 22
M10 × 1.25 14 [0.55] 33 3.4 24 60 6.1 44
M12 × 1.25 17 [0.67] 60 6.1 44 108 11.0 80
Metric automobile screw thread
M14 × 1.5 22 [0.87] 97 9.9 72 176 17.9 130
M16 × 1.5 24 [0.94] 145 14.8 107 262 26.7 193
M18 × 1.5 27 [1.06] 210 21.4 155 378 38.5 279
M20 × 1.5 30 [1.18] 291 29.7 215 524 53.4 386
M22 × 1.5 32 [1.26] 385 39.3 284 694 70.8 512
M24 × 1.5 36 [1.42] 487 49.7 359 878 89.5 648
M27 × 1.5 41 [1.61] 738 75.3 544 1328 135.5 979

N·m kgf·m lbf·ft N·m kgf·m lbf·ft

M10 × 1.5 14 [0.55] 32 3.3 24 58 5.9 43
M12 × 1.75 17 [0.67] 57 5.8 42 102 10.4 75
Metric course screw thread M14 × 2 22 [0.87] 93 9.5 69 167 17.0 123
M16 × 2 24 [0.94] 139 14.2 103 251 25.6 185
M18 × 2.5 27 [1.06] 194 19.8 143 350 35.7 258
M20 × 2.5 30 [1.18] 272 27.7 201 489 49.9 361
M22 × 2.5 32 [1.26] 363 37.0 268 653 66.6 482
M24 × 3 36 [1.42] 468 47.7 345 843 86.0 622
M27 × 3 41 [1.61] 686 70.0 506 1236 126.0 912

Note: (a) This table lists the tightening torque for standard bolts and nuts.
(b) The numerical values in the table are for fasteners with spring washers.
(c) The table shows the standard values with a maximum tolerance value of ±10%.
(d) Use the tightening torque in this table unless otherwise specified.
(e) Do not apply oil to threaded portions. (Dry)

2-12
 SERVICE DATA

2.3 Standard eyebolt tightening torque

Table 2-15 Standard eyebolt tightening torque
Strength classification
Threads Width
Dia × Pitch across flats 4T
(mm) (mm) [in.]
N·m kgf·m lbf·ft
M8 × 1.25 12 [0.47] 8±1 0.8 ± 0.1 6 ± 0.7
M10 × 1.25 14 [0.55] 15 ± 2 1.5 ± 0.2 11 ± 1.5
M12 × 1.25 17 [0.67] 25 ± 3 2.5 ± 0.3 18 ± 2.2
M14 × 1.5 19 [0.75] 34 ± 4 3.5 ± 0.4 25 ± 3.0
M16 × 1.5 22 [0.87] 44 ± 5 4.5 ± 0.5 32 ± 3.7
M18 × 1.5 24 [0.94] 74 ± 5 7.5 ± 0.5 55 ± 3.7
M20 × 1.5 27 [1.06] 98 ± 10 10.0 ± 1.0 72 ± 7.4
M24 × 1.5 32 [1.26] 147 ± 15 15.0 ± 1.5 108 ± 11.1
M27 × 1.5 41 [1.61] 226 ± 20 23.0 ± 2.0 167 ± 14.8
(Dry)

2.4 Standard union nut tightening torque

Table 2-16 Standard union nut tightening torque
Width
Nominal Cap nut size
across flats N·m kgf·m lbf·ft
diameter M (mm)
(mm) [in.]
63 M14 × 1.5 19 [0.75] 39 4 29
80 M16 × 1.5 22 [0.87] 49 5 36
100 M20 × 1.5 27 [1.06] 78 8 58
120 M22 × 1.5 30 [1.18] 98 10 72
150 M27 × 1.5 32 [1.26] 157 16 116
180 M30 × 1.5 36 [1.42] 196 20 145
200 M30 × 1.5 36 [1.42] 196 20 145
220 M33 × 1.5 41 [1.61] 245 25 181
254 M36 × 1.5 41 [1.61] 294 30 217
(Maximum tolerance value: ±10%, dry condition)

2-13
 SERVICE TOOLS
1. Special tools ....................................3-2

3-1
SERVICE TOOLS

1. Special tools
Table 3-1 Special tool list (1 / 3)
Tool name Part number Illustration Use

Valve guide installer 32F91-00400 Valve guide installation

Valve guide remover 31391-10500 Valve guide removal

36791-00200
(Inlet)
Insert caulking tool Valve seat installation
36791-00300
(Exhaust)

Sleeve installer 34291-00200 Cylinder sleeve installation

Piston ring removal/

Piston ring pliers 30091-07100
installation

Piston guide 34291-00100 Piston installation

Injector remover 32G91-00100 Injector removal

3-2
 SERVICE TOOLS

Table 3-1 Special tool list (2 / 3)

Tool name Part number Illustration Use

Idler shaft puller MH061077 Idler shaft removal

Idler bushing removal/

Idler bushing puller 30091-07300
installation

Connecting rod bushing

Connecting rod bushing installer 32F91-03050
removal/installation

Oil and fuel filters removal/

Oil filter wrench 34591-00100
installation

Fuel injection pump

Universal extension 30091-01101
removal/installation

Socket 58309-73100 Engine turning

Engine compression pres-

Gauge adapter 32G91-00500
sure measurement

3-3
SERVICE TOOLS

Table 3-1 Special tool list (3 / 3)

Tool name Part number Illustration Use

Removal for
crankshaft gear,
Puller assembly 64309-12900
camshaft gear and
crankshaft pulley

Compression pressure mea-

Compression gauge 33391-02100
surement

Oil seal sleeve installation

Rear oil seal installer 34291-00020
on the crankshaft rear side

Camshaft bushing Camshaft bushing removal/

30691-00010
installer set installation

Camshaft bushing removal/

Valve spring pusher 30691-04500
Valve removal/installation
m
a
s
te
rt
e
c
h
Y
E
S

Scan tester 32G91-00600 Diagnosis codes display

H
E
L
P

N
O
R
C

F
V

1
1
S

E
E

N
N

T
4
D

E
R
4

2
E
X

F
IT

F
7

F
5

3
7

3
F

F
8

6
㧖

6
F

F
0
O

9
F
F

Ve
0

tr
O
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on
#

ix

3-4
 DETERMINATION OF OVERHAUL
1. Determining overhaul timing ...........4-2

2. Testing compression pressure ........4-3

4-1
DETERMINATION OF OVERHAUL

1. Determining overhaul timing

In most cases, the engine should be overhauled when the compression pressure of the engine becomes low. An increase in
engine oil consumption and blow-by gas are also considered to evaluate the engine condition. Besides, such symptoms as a
decrease in output, increase in fuel consumption, decrease in oil pressure, difficulty of engine starting and increase in noise are
also considered for judging the overhaul timing, although those symptoms are often affected by other causes, and are not
always effective to judge the overhaul timing. Decreased compression pressure shows a variety of symptoms and engine
conditions, thus making it difficult to accurately determine when the engine needs an overhaul. The following shows typical
problems caused by reduced compression pressure.
(1) Decreased output power
(2) Increased fuel consumption
(3) Increased engine oil consumption
(4) Increased blow-by gas through the breather due to worn cylinder liners and piston rings (Visually check the blow-by
amount)
(5) Increased gas leakage due to poor seating of inlet and exhaust valves
(6) Difficulty in starting
(7) Increased noise from engine parts
(8) Abnormal exhaust color after warm-up operation
The engine can exhibit these conditions in various combinations. Some of these problems are directly caused by worn engine
parts, while others are not. Phenomena described in items (2) and (6) will result from improper fuel injection volume, fuel
injection timing, 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 liners and pistons, as
described in item (4). In addition to this item, it is reasonable to take other problems into consideration for making the total
judgement.

4-2
 DETERMINATION OF OVERHAUL

2. Testing compression pressure

&$87,21
Compression gage
(a) Measure all cylinders for compression pressure. P/N:33391-02100
Do not measure only one cylinder and make
assumption about the other cylinders as it will lead
Gage adapter
to a wrong conclusion. P/N:32G91-00500
(b) Compression pressure varies depending on the
engine speed. When measuring the compression
pressure, be sure to measure the engine speed as
well.
(c) It is important to regularly check the compression
pressure so that you can tell the change with time.
Testing compression pressure
(1) Disconnect the harness connector from the injector
solenoid connector.
(2) Disconnect the harness connector from the MPROP
connector on the fuel pump.
(3) Select a cylinder, and remove the injector in the
cylinder. (Each cylinder is tested one at a time.)
(4) Install a gauge adapter in the same location that the
injector was mounted, and install a compression gauge
to the gauge adapter.
(5) Start the engine using starter. With the engine running
at specified speed, read the compression gauge.
(6) If the measured value is at the limit or below, overhaul
the engine.

Item Standard Limit

Engine speed 300 min-1 -
2.6 MPa
2.9 MPa
{27 kgf/cm²}
Compression pressure {30kgf/cm²}
[384 psi]
[427 psi]
or more

4-3
 DISASSEMBLY OF BASIC ENGINE
1. Disassembling and inspecting cylinder
head and valve mechanism ............5-2
1.1 Removing injector .................................... 5-3
1.2 Removing rocker shaft assembly............. 5-4
1.3 Disassembling rocker shaft assembly...... 5-4
1.4 Removing cylinder head bolt.................... 5-4
1.5 Removing cylinder head assembly .......... 5-5
1.6 Removing valve and valve spring ............ 5-5
1.7 Removing valve stem seal ....................... 5-5

2. Disassembling and inspecting

flywheel ...........................................5-6
2.1 Removing flywheel................................... 5-7
2.2 Removing flywheel housing ..................... 5-7

3. Disassembling and inspecting gear

case, timing gear and camshaft ......5-8
3.1 Removing crankshaft pulley..................... 5-8
3.2 Removing timing gear case ..................... 5-9
3.3 Measuring timing gear backlash .............. 5-9
3.4 Measuring idler gear end play.................. 5-9
3.5 Removing idler gear............................... 5-10
3.6 Removing camshaft ............................... 5-10
3.7 Separating camshaft gear...................... 5-10
3.8 Installing camshaft gear and thrust plate 5-11
3.9 Removing front plate.............................. 5-11

4. Disassembling and inspection

crankcase, crankshaft and piston..5-12
4.1 Removing connecting rod cap ............... 5-13
4.2 Removing carbon deposits from the upper part
of cylinder liner....................................... 5-13
4.3 Pulling out piston.................................... 5-13
4.4 Removing piston ring ............................. 5-14
4.5 Removing piston pin .............................. 5-14
4.6 Removing main bearing cap .................. 5-14
4.7 Removing crankshaft ............................. 5-15

5-1
DISASSEMBLY OF BASIC ENGINE

1. Disassembling and inspecting cylinder head and valve mechanism

12
8 6
Wear, damage Wear, clogging

11 Fatigue, damage
Wear
7 Wear, damage,
13 bend
17
10 18
9 Wear, 19 23 14
clogging 20

Fatigue, damage

3
Local wear
4
22

2
1

5 15 Replace

Crack, damage,
Replace water leak, oil leak,
carbon deposit,
scale deposit

16
21
Local wear, damage,
Local wear fatigue, carbon deposit

21

Disassembling and inspecting cylinder head and valve mechanism

Disassembling sequence

1 Leak off hose 9 Eye bolt, oil pipe 17 Valve cap

2 Nozzle ground 10 Snap ring, spacer 18 Valve cotter
3 Injector 11 Rocker arm 19 Valve retainer
4 Rocker cover 12 Rocker shaft spring 20 Valve spring
5 Rocker cover gasket 13 Rocker shaft 21 Valve, valve seat
6 Adjusting screw 14 Cylinder head bolt 22 Valve guide, stem seal
7 Bolt (short) 15 Cylinder head 23 Push rod
8 Bolt (long) 16 Cylinder head gasket

5-2
 DISASSEMBLY OF BASIC ENGINE

1.1 Removing injector

(1) Hold the injection connector by using a spanner, loosen
Leak off hose connector
the injection pipe nut and remove the injection pipe.
(2) With pushing the pin on top of the injector, remove the Injector Leak off hose
leak off hose. Pin
(3) Disconnect the harness connector of main harness and
Nozzle
injector connector.
gland
(4) Using the injector puller, remove the injector and the Injection pipe
nozzle ground at the same time. Injection connector
(5) Remove the gasket from the cylinder head injector
Gasket
insertion opening.
Removing injector

Injector

Push
Pin

Pushing pin on top of injector

Injector puller
P/N:32G91-00100

Injector

Pulling out injector

5-3
DISASSEMBLY OF BASIC ENGINE

1.2 Removing rocker shaft assembly

Adjusting screw
&$87,21
Always loosen shorter bolts first. Failing to do so may
cause the damage to the rocker shaft bracket.
(1) Loosen the rocker arm adjusting screws by rotating
about one turn.
(2) Loosen the shorter rocker bracket bolts first.
Rocker arm
(3) Then, loosen the longer rocker bracket bolts.
(4) Remove the rokcer bracket bolts, and remove the
Rocker bracket bolt
rocker shaft assembly from the cylinder head.
(5) Remove push rods. Removing rocker shaft assembly

1.3 Disassembling rocker shaft assembly

(1) Remove eye bolt, oil pipe, and snap ring.
(2) Disassemble the rocker shaft assembly into the rocker
arms, brakets, rocker shaft springs and rocker shaft.
Rocker shaft spring
Note: (a) Be sure to arrange the parts of rocker shaft
assembly in the order of disassembly. Rocker shaft
Reassemble the rocker shaft assembly in the Oil pipe Bracket
reverse order of disassembly by making sure of Rocker arm
the original combination of rocker arm and shaft
Snap ring
assembly so that the same clearance between the
rocker shaft and arms is restored when Eye bolt

reassembling. Disassembling rocker shaft assembly

(b) Do not remove the rocker bush when it is not
faulty, and its inside diameter is not exceed the
limit.

1.4 Removing cylinder head bolt

Loosen cylinder head bolts in the numerical order as shown
in the illustration.
3 7 11 15 16 12 8 4

1 9 17 10 2

5 13 14 6

Removing cylinder head bolt

5-4
 DISASSEMBLY OF BASIC ENGINE

1.5 Removing cylinder head assembly

&$87,21
When removing the cylinder head gasket, be careful
not to damage the cylinder head or crankcase surface
by tools such as a screwdriver.
(1) Remove the cylinder head bolt.
(2) Remove the cylinder head assembly by lifting it up.
Note: If the cylinder head assembly cannot be removed due
to crimping of the cylinder head gasket, tap the thick
area on the side of the cylinder head using a plastic
hammer to give a shock.
Removing cylinder head assembly
(3) Remove the gasket from the cylinder head.
Note: If there is a cylinder head problem, check the bolts for
tightness with a torque wrench before removing the
cylinder head bolts.

1.6 Removing valve and valve spring

Using a valve spring pusher, compress the valve spring Valve spring pusher
evenly and remove the valve cotters. P/N:30691-04500
Note: If valves are reusable, mark each valve seat and the
mating valve guide for identifying their original
positions. Do not mix valve seats with other valve
guides.

Removing valve and valve spring

1.7 Removing valve stem seal

Grab the stem seal with pliers and remove.
Note: Be sure to replace the stem seal with the new one
when reassembling the valve and valve spring.
Stem seal

Removing valve stem seal

5-5
DISASSEMBLY OF BASIC ENGINE

2. Disassembling and inspecting flywheel

Replace

3
Replace 1

2
Wear, damage, aging

Wear, crack, damage

Disassembling and inspecting flywheel

Disassembling sequence

1 Flywheel 3 Oil seal 5 Speed/timing sensor (crankshaft

side), sensor bracket
2 Flywheel housing 4 Pick up

5-6
 DISASSEMBLY OF BASIC ENGINE

2.1 Removing flywheel

&$87,21
Guide bolt
(a) Be careful not to cut yourself with the ring gear
Crankshaft pulley
when pulling out the flywheel.
Be careful not to drop or hit the flywheel when
removing.
(b) The personnel who holds the pulley must pay due
attention to safety.
Also, personnel must stay in close contact with
each other during work. (Front) (Rear)
(1) One personnel must firmly hold the pulley with a
Removing flywheel
wrench to prevent the flywheel from turning.
(2) Remove one bolt from the flywheel.
(3) Screw a guide bolt into the threaded hole of the bolt that
has been removed.
(4) Remove remaining bolts from the flywheel.
(5) Hold the flywheel firmly with both hands, and by
moving it back and forth, pull it out straight.
Note: The ring gear is shrink fitted to the flywheel. Do not
remove the ring gear unless it is defective.

2.2 Removing flywheel housing

&$87,21
Be careful not to damage the oil seal.
(1) Remove bolts from the flywheel housing.
(2) Remove the flywheel housing.

Removing flywheel housing

5-7
DISASSEMBLY OF BASIC ENGINE

3. Disassembling and inspecting gear case, timing gear and camshaft

Damage, wear
Flaking, contact, damage, Oil hole clogging, wear
abnormality
Replace

10

7
6 Wear
9
Wear
4
Wear, damage,
5 8 11 aging

Crack, dowel hole defect,

oil hole clogging

Replace
Wear

2
1

Disassembling and inspecting gear case, timing gear and camshaft

Disassembling sequence

1 Crankshaft pulley 5 Idler gear 9 Tappet

2 Timing gear case 6 Thrust plate 10 Fuel pump gear,
Fuel pump idler gear
3 Oil seal 7 Camshaft
4 Thrust plate 8 Camshaft gear 11 Front plate

3.1 Removing crankshaft pulley

Prevent crankshaft
&$87,21 from rotating
The bar that stops the the crankshaft from turning may
Crankshaft pulley
come off. Pay due attention to safety.
(1) Screw two guide bolts into the threaded holes at the rear
end of the crankshaft. Stick a bar across the guide bolts
to prevent the crankshaft from turning.
(2) Remove the crankshaft pulley.
(3) Take out the woodruff key of the crankshaft. Guide bolt (M12×1.25mm)
(Front) (Rear)

Removing crankshaft pulley

5-8
 DISASSEMBLY OF BASIC ENGINE

3.2 Removing timing gear case

&$87,21 Timing gear case

The front plate is bolted to the crankcase from inside
the gear case. Do not attempt to remove the front plate
together with the gear case by tapping.
(1) Remove bolts from the timing gear case.
(2) Remove the timing gear case.
Note: Bolts have different lengths. Pay attention to the
positions of bolts to ensure correct reassembling. Gasket

Removing timing gear case

3.3 Measuring timing gear backlash

Measure the backlash of the timing gears by using one of
the following two methods; measure the gear play with the
dial gauge plunger applied to a tooth flank on the pitch
circle at a right angle to the tooth axis, or measure the
clearance between gears by inserting a feeler gauge between
the gears at the tooth-to-tooth contacting area. Replace the
faulty gear pair if the limit is exceeded.

Item Standard Limit

Backlash crankshaft gear and
idler gear
Backlash camshaft gear and
idler gear
Backlash Fuel injection pump
idler gear and idler gear
0.053 to 0.154 mm 0.25 mm
[0.0021 to 0.0061 in.] [0.0098 in.]
Measuring timing gear backlash
0.049 to 0.160 mm 0.25 mm
[0.0019 to 0.0063 in.] [0.0098 in.]
0.050 to 0.228 mm 0.25 mm
[0.0020 to 0.0090 in.] [0.0098 in.]

Backlash fuel injection pump

0.044 to 0.163 mm 0.25 mm
idler gear and fuel injection
[0.0017 to 0.0064 in.] [0.0098 in.]
pump gear

Note: With the fuel injection pump gear and the fuel
injection pump idler gear attached to the pump, install
the both gears to the front plate.

3.4 Measuring idler gear end play

Using a feeler gauge or dial gauge, measure the end play of
idler gear.
If the measured value exceeds the limit, replace the idler
gear with the new gear.

Item Standard Limit

0.05 to 0.20 mm 0.35 mm
End play
[0.0020 to 0.0079 in.] [0.0138 in.]
Idler gear

Measuring idler gear end play

5-9
DISASSEMBLY OF BASIC ENGINE

3.5 Removing idler gear

(1) Remove the thrust plate bolt.
(2) Remove the idler gear while turning the gear.
Idler gear

Thrust plate

Removing idler gear

3.6 Removing camshaft

&$87,21
Be careful not to damage the cams of camshaft and
the bushings. Camshaft gear

(1) Reverse the crankcase.

(2) Remove the thrust plate bolt.
(3) Remove the camshaft from the crankcase.
(4) Remove the tappet.

Removing camshaft

3.7 Separating camshaft gear

Using a puller, remove the camshaft gear and thrust plate Puller
from the camshaft. P/N: 64309-12900
Note: Do not remove the camshaft gear from the camshaft Camshaft gear
unless the camshaft gear or the thrust plate is
defective.

Separating camshaft gear

5-10
 DISASSEMBLY OF BASIC ENGINE

3.8 Installing camshaft gear and thrust plate

(1) Install the woodruff key and the thrust plate on the
crankshaft.
Note: Be sure to install the thrust plate before installing the
camshaft gear.
(2) Heat the camshaft gear with a gear heater to a
temperature of about 250°C [482°F].
Thrust plate
(3) Install the camshaft gear into the crankcase by tapping
with a plastic hammer. Camshaft gear

Installing camshaft gear and thrust plate

3.9 Removing front plate

(1) Remove the front plate bolts.
(2) Remove the front plate from the crankcase. Front plate
Note: If it is difficult to remove the front plate, lightly tap it
with a plastic hammer.

Removing front plate

5-11
DISASSEMBLY OF BASIC ENGINE

4. Disassembling and inspection crankcase, crankshaft and piston

Wear, scratch, rust

4
Wear, damage
5 Top surface distortion
6 Fatigue
9
Wear Scratch, crack, damage, Scale deposit,
wear, carbon deposit corrosion, flaking
8
7

Wear, crack,
oil hole clogging
19
Wear, oil hole
clogging

10
Damage

3 17
18
Wear, seizure,
flaking, damage
Scratch, crack, dent,
2 Clogging oil hole clogging, wear

1
16

Flaking,
14
local contact 15

Replace

12 13

Scratch, seizure,
flaking Damage
11

Crack

Disassembling and inspection crankcase, crankshaft and piston

Disassembling sequence

1 Nut 8 Piston pin 15 Main bearing (lower)

2 Connecting rod cap 9 Piston 16 Crankshaft
3 Connecting rod bearing 10 Connecting rod 17 Main bearing (upper)
4 No.1 compression ring 11 Main bearing cap bolt 18 Piston cooling nozzle
5 No.2 compression ring 12 Main bearing cap 19 Crankcase
6 Oil ring 13 Side seal
7 Snap ring 14 Thrust plate

5-12
 DISASSEMBLY OF BASIC ENGINE

4.1 Removing connecting rod cap

(1) Lay the engine by its side.
(2) Mark the cylinder number on the connecting rod and Connecting rod cap
connecting rod cap so that their combination is not
changed when reassembling.
(3) Remove the connecting rod caps.
Note: Mark the cylinder No. and upper/lower on connecting
rod bearings to ensure correct reassembling.

Removing connecting rod cap

4.2 Removing carbon deposits from the upper

part of cylinder liner

&$87,21
Be sure to remove carbon deposits from the upper part
of the cylinder liner before removing the piston, as they
could cause damage to the piston and piston ring.
Remove carbon deposits from the upper part of cylinder
liner using a cloth or oil paper.
Note: Be careful not to damage the inner surface of the
cylinder liner.

Removing carbon deposit from cylinder sleeve upper

area

4.3 Pulling out piston

(1) Turn the crankshaft to bring the piston to the top dead
center.
(2) Using a piece of wood such a hammer handle, push the
mating surface of the connecting rod cap, and pull the
piston and connecting rod upward from the cylinder.

Pulling out piston

5-13
DISASSEMBLY OF BASIC ENGINE

4.4 Removing piston ring

Remove the piston rings using piston ring pliers. Piston ring pliers
P/N:30091-07100

Removing piston ring

4.5 Removing piston pin

(1) Using snap ring pliers, remove the snap ring.
(2) Remove the piston pin, and separate the piston from the
connecting rod. Snap ring pliers
Note: Heat the piston with a piston heater or in hot water if
the piston pin is stubborn.

Removing piston pin

4.6 Removing main bearing cap

(1) Reverse the engine.
Sliding hammer
(2) Remove the main bearing cap bolt.
(3) Remove the main bearing cap together with the lower
main bearing.
Use a sliding hammer to remove main bearing caps on
the front and rear ends.
Main bearing
Note: (a) Be careful not to damage main bearings. cap bolt
(b) Mark each main bearing for its cylinder number.

Removing main bearing cap

5-14
 DISASSEMBLY OF BASIC ENGINE

4.7 Removing crankshaft

&$87,21
Be careful not to damage bearings when removing the
crankshaft.
(1) Slowly lift the crankshaft straight up.
(2) Arrange the bearings in the order of disassembly so that
their original positions are restored when reassembling.
Note: (a) When raising the crankshaft, do not allow wire
chain to come into contact with the crankshaft.
To avoid damage to the crankshaft when raising,
use a cloth belt or pad.
Removing crankshaft
(b) Mark the bearings for their cylinder numbers.

5-15
 INSPECTION AND REPAIR OF BASIC ENGINE
1. Inspecting and repairing cylinder head
and valve mechanism .....................6-2
1.1 Measuring clearance between rocker
bushing and rocker shaft.......................... 6-2
1.2 Replacing rocker bushing ........................ 6-2
1.3 Measuring valve stem outside diameter and
valve guide inside diameter ..................... 6-3
1.4 Replacing valve guide.............................. 6-3
1.5 Inspecting valve face ............................... 6-4
1.6 Refacing valve face.................................. 6-4
1.7 Refacing valve seat.................................. 6-5
1.8 Replacing valve seat................................ 6-6
1.9 Lapping valve and valve seat................... 6-7
1.10 Measuring perpendicularity and free length of
valve spring.............................................. 6-7
1.11 Measuring distortion of the bottom surface of
the cylinder head...................................... 6-8
1.12 Measuring push rod runout ...................... 6-8
2. Inspecting and repairing flywheel ....6-9
2.1 Measuring flatness of flywheel................. 6-9
2.2 Measuring flywheel face and
radial runouts ........................................... 6-9
2.3 Inspecting ring gear ................................. 6-9
2.4 Replacing ring gear.................................. 6-9
2.4.1 Removing ring gear ....................................6-9
2.4.2 Installing ring gear ......................................6-9
3. Inspecting and repairing timing gear and
camshaft........................................6-10
3.1 Measuring timing gear backlash ............ 6-10
3.2 Measuring cam lift.................................. 6-10
3.3 Measuring camshaft runout ................... 6-10
3.4 Measuring camshaft journal outside
diameter ................................................. 6-11
3.5 Measuring camshaft bushing inside
diameter ................................................. 6-11
3.6 Replacing camshaft bushing.................. 6-11
3.6.1 Removing camshaft bushing ....................6-11
3.6.2 Installing camshaft bushing ......................6-12
3.7 Measuring front idler bushing inside dia. and
front idler shaft outside diameter............ 6-12
3.8 Replacing idler bushing.......................... 6-13
3.9 Replacing idler shaft .............................. 6-13
3.10 Inspecting tappet.................................... 6-13
3.11 Measuring clearance between tappet and
tappet guide hole ................................... 6-14
4. Inspecting and repairing piston,
connecting rod, crankshaft and
crankcase ..................................... 6-15
4.1 Measuring crankcase top surface
distortion................................................. 6-15
4.2 Measuring cylinder inside diameter........ 6-16
4.3 Replacing cylinder sleeve ...................... 6-17
4.3.1 Removing cylinder sleeve........................ 6-17
4.3.2 Installing cylinder sleeve.......................... 6-17
4.4 Measuring piston outside diameter ........ 6-18
4.5 Measuring piston ring end gap............... 6-18
4.6 Measuring clearance between piston ring
groove and piston ring............................ 6-19
4.7 Measuring piston pin bore diameter and piston
pin outside diameter............................... 6-19
4.8 Measuring piston protrusion................... 6-20
4.9 Measuring clearance between connecting rod
bearing and crankpin.............................. 6-21
4.10 Measuring clearance between connecting rod
bushing and piston pin ........................... 6-21
4.11 Replacing connecting rod bushing ......... 6-22
4.12 Removing connecting rod bushing......... 6-22
4.13 Installing connecting rod bushing........... 6-22
4.14 Inspecting connecting rod bend and twist6-23
4.15 Inspecting connecting rod bearing ......... 6-23
4.16 Measuring connecting rod end play ....... 6-24
4.17 Weight difference of connecting rod assembly
in one engine.......................................... 6-24
4.18 Measuring crankshaft journal outside
diameter ................................................. 6-24
4.19 Measuring crankshaft crankpin outside
diameter ................................................. 6-25
4.20 Grinding crankshaft ................................ 6-25
4.21 Measuring crankshaft end play .............. 6-26
4.22 Measuring crankshaft runout.................. 6-26
4.23 Replacing crankshaft gear ..................... 6-27
4.23.1 Removing crankshaft gear....................... 6-27
4.23.2 Installing crankshaft gear......................... 6-27
4.24 Replacing front oil seal........................... 6-28
4.25 Replacing rear oil seal............................ 6-28
4.26 Inspecting main bearing surface ............ 6-29
4.27 Measuring clearance between main bearing
and crankshaft journal............................ 6-29
6-1
INSPECTION AND REPAIR OF BASIC ENGINE

1. Inspecting and repairing cylinder head and valve mechanism

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

Rocker bushing ø 20 mm 20.011 to 20.094 mm

-
inside diameter [0.7874 in.] [0.7878 to 0.7911 in.]
Measuring
Rocker shaft ø 20 mm 19.966 to 19.984 mm points
-
diameter [0.7874 in.] [0.7861 to 0.7868 in.]

Clearance
between rocker 0.027 to 0.128 mm 0.150 mm Measuring rocker bushing and rocker shaft
-
bushing and [0.0011 to 0.0050 in.] [0.0059 in.]
shaft

1.2 Replacing rocker bushing

To replace rocker bushings, use a hydraulic jack.
Rocker bush installer
With the rocker bushing and the rocker arm oil holes mated,
and the bushing joint faced upward, press fit the rocker
bushing. Oil hole

Replacing rocker bushing

6-2
 INSPECTION AND REPAIR OF BASIC ENGINE

1.3 Measuring valve stem outside diameter and

valve guide inside diameter
Measure the diameter at the top and bottom ends at right Measuring
angles to the outer and inner surfaces, since valve stems and directions
valve guides are more likely to wear at both ends. If the
outside diameter is less than the limit, or the clearance
exceeds the limit, replace either the valve or the valve guide
with a new one. Measuring
points
Item Nominal Standard Limit

Valve ø 8 mm 7.940 to 7.955 mm 7.900mm

Inlet
stem [0.315 in.] [0.3126 to 0.3132 in.] [0.3110 in.]
Measuring valve stem outside diameter
outside ø 8 mm 7.920 to 7.940 mm 7.850 mm
diameter Exhaust
[0.315 in.] [0.3118 to 0.3126 in.] [0.3091 in.]
Measuring
Clearance 0.055 to 0.085 mm 0.150 mm directions
Inlet -
between [0.0022 to 0.0033 in.] [0.0059 in.] Internal micrometer
valve stem
and valve 0.070 to 0.105 mm 0.200 mm
Exhaust -
guide [0.0028 to 0.0041 in.] [0.0079 in.]

Valve guide mount- 17 mm 17.2 to 17.4 mm

-
ing dimension [0.67 in.] [0.6772 to 0.6850 in.]

Measuring
points

Measuring valve guide inside diameter

1.4 Replacing valve guide
Valve guide remover
&$87,21 P/N:31391-10500
Because valve guides must be inserted to the speci-
fied amount, be sure to use a valve guide installer.
(1) To remove valve guides, use a valve guide remover.

Removing valve guide

(2) To press-fit valve guides, use a valve guide installer.
(3) Check contacts between valves and valve seats after
17 mm [0.67 in.]

Press Valve guide installer

replacing valve guides. P/N:34491-00400

Press-fitting valve guide

6-3
 INSPECTION AND REPAIR OF BASIC ENGINE

1.5 Inspecting valve face

Apply a thin coat of Shinmyoutan or equivalent lead-free
coloring paste on the valve face, and strike the valve face
against the valve seat using a valve lapper to check for
contact condition. If the contact is not even, or any defects
Valve lapper
are found, or if the limit is exceeded, reface or replace the
valve.
Note: (a) Inspect the valve face after the valve guide is
repaired or replaced.
(b) Do not rotate the valve when pressing the valve Shinmyoutan
face coated with Shinmyoutan or equivalent lead-
free dye against the valve seat. Inspecting valve face
(c) Always lap the valve and valve seat after the
valve has been refaced or replaced.

Item Standard Limit

Valve seat angle 30° -

0.4 ± 0.1 mm
Inlet
Valve [0.0157 ± 0.0039 in.] 1.1 mm
Valve
sinkage 0.5 ± 0.1 mm [0.043 in.]
seat Exhaust
[0.0197 ± 0.0039 in.]
Good Bad
1.4 ± 0.2 mm 1.8 mm
Seat width
[0.0551 ± 0.0079 in.] [0.071 in.]

Refacing permissi-
2.13 mm Contact between valve seat and valve
Valve margin ble up to 1.2 mm
[0.0839 in.]
[0.047 in.]

Seat width

Valve margin
Valve seat
Valve sinkage
angle

Measuring positions of valve seat and valve

1.6 Refacing valve face
If the valve face is significantly worn out, reface the valve Valve refacer
face using a valve refacer.
Note: (a) Grind the valve face using the valve refacer at the
specified angle.
(b) Secure the valve margin width equal to or greater
than the limit. If the dimensions after refacing
does not meet the specified values, replace the Set the valve face
valve with a new one. angle at the specified
angle.

Refacing valve face

6-4
 INSPECTION AND REPAIR OF BASIC ENGINE

1.7 Refacing valve seat

(1) Use the valve seat cutter or valve seat grinder to reface
the valve seat. After refacing, sand the valve seat lightly
using 400 grit sandpaper, inserting it between the cutter
and valve seat.
(2) Lap the valve in the valve seat.
Note: (a) Valve seat refacing should be kept to an absolute
minimum.
(b) If the valve seat width exceeds the limit due to
wear or refacing, replace the valve seat with a
new one.
(c) If the valve sinkage exceeds the limit after Refacing valve seat
refacing, replace the valve seat with a new one.

6-5
INSPECTION AND REPAIR OF BASIC ENGINE

1.8 Replacing valve seat

(1) To remove the valve seat, weld a stud to the valve seat
as illustrated. Then, insert a rod into the valve guide
Weld
hole from the top of the cylinder head, and press out the
Shaft
valve seat with the rod.
Note: Be careful not to allow spatters to adhere to the Valve seat
machined surface of the cylinder head during
welding.
(2) Before inserting a new valve seat, measure the cylinder
head bore diameter and valve seat outside diameter to Stud

make sure the interference meets the specified value.

(3) Cool the valve seat for four minutes or more in liquid Removing valve seat
nitrogen (at approximately -170°C [-274°F]) before
fitting it into the cylinder head, while keeping the Inlet Exhaust Unit: mm [in.]
cylinder head at room temperature. Or heat the cylinder

4
head to 80 to 100°C [176 to 212°F] and cool the valve
seat sufficiently in ether or alcohol mixed with dry ice
before fitting it into the hot cylinder head.
(4) Fit the cold valve seat into the cylinder head using a
insert caulking tool.
9 ± 0.1 9.5 ± 0.1
[0.3543 ± 0.0039] [0.3740 ± 0.0039]

40° 45°
ø 48 +0.025
0 [ø 1.89 +0.0010
0 ] ø 39 +0.025
0 [ø 1.54 +0.0010
0 ]

Valve seat fitting bore

Insert caulking tool

(In)P/N:36791-00200
(Ex)P/N:36791-00300

Installing valve seat

6-6
 INSPECTION AND REPAIR OF BASIC ENGINE

1.9 Lapping valve and valve seat

Always lap the valve against the valve seat after refacing the
valve seat or after replacing the valve.
(1) Apply a thin coat of lapping compound evenly to the
valve face.
Note: (a) Do not allow the compound to adhere on the
valve stem.
(b) Compound spreads more evenly if it is mixed Compound
with a small amount of engine oil.
(c) Use medium-grain compound (120 to 150 mesh)
for initial lapping, then use fine-grain compound
(200 mesh or finer) for finishing. Coating valve with lapping
(2) Use a valve lapper for lapping. Strike the valve against
the valve seat while rotating the valve little by little.
(3) Wash off the compound using diesel fuel.
(4) Coat the contact surface of the valve with engine oil,
then lap the valve again.
(5) Check valve-to-seat contact.

Lapping valve and valve seat

1.10 Measuring perpendicularity and free length
of valve spring
Measure the perpendicularity and free length of the valve
spring. If the limit is exceeded, replace the valve spring with
Spring perpendicularity (gap)
a new one.

Item Standard Limit

56.40 mm 55.00 mm Free length
Free length
[2.2205 in.] [2.1653 in.]

θ = 2.0°or
less
ǰ Less than Entire length
Perpendicu- ٌ
larity
Δ2.0 mm Δ = 2.0mm Measuring spring perpendicularity and free length
Lf [0.079 in.]
[0.079 in.]
Lf = 56.40 mm
[2.2205 in.]
44 mm
44 mm [1.73 in.]
[1.73 in.]
Set length/ /222.7 to 246.1 N
/207 N
set force {22.7 to 25.1 kgf}
{21.2 kgf}
[164.2 to 181.5 lbf]
[153 lbf]

6-7
INSPECTION AND REPAIR OF BASIC ENGINE

1.11 Measuring distortion of the bottom surface

of the cylinder head

&$87,21
Refacing of cylinder head should be kept to an abso-
lute minimum.
Excessive grinding of the cylinder head may result in
defects such as defective combustion and stamping
(contact between piston and valve).
With a straight edge placed on the bottom face of the
cylinder head, measure the bottom face distortion using a
feeler gauge. If the measurement exceeds the limit, grind the
Measuring distortion of cylinder head bottom surface
bottom face using a surface grinder.

Item Standard Limit

Bottom surface 0.05 mm 0.20 mm
distortion [0.0020 in.] or less [0.008 in.]

Note: Do not grind the surfaces more than 0.2 mm [0.008

in.] in total (cylinder head bottom surface plus
crankcase top surface).

1.12 Measuring push rod runout

Measure the runout of each push rod. Replace if the limit is
exceeded.

Item Standard Limit Remark

Pushrod
Push 0.4 mm
0.4 mm
rod [ 0.016 in.] TIR
[0.016 in.]
runout or less
1/2L 1/2L

Measuring push rod runout

6-8
 INSPECTION AND REPAIR OF BASIC ENGINE

2. Inspecting and repairing flywheel

2.1 Measuring flatness of flywheel
Place the flywheel on a surface plate and move a dial gauge
on the friction surface of the flywheel to measure the
flatness.
Grind the friction surface of the flywheel if the limit is
exceeded.

Item Standard Limit

0.15 mm 0.50 mm
Flywheel flatness
[0.0059 in.] or less [0.0197 in.]

Measuring flatness of flywheel

2.2 Measuring flywheel face and radial runouts
Measure the runouts of the flywheel in the installed
condition. If the measured value exceeds the standard,
check the bolt for looseness as well as the accumulation of
foreign matter on the mounting face.
Face runout
measuring point
Item Standard Limit
Radial runout
Flywheel face runout Within 0.15 mm 0.50 mm measuring point
and radial runout [0.0059 in.] [0.0197 in.]

Measuring flywheel face and radial runout

2.3 Inspecting ring gear

Inspect the ring gear for a missing tooth or worn teeth, and
if defects are found, replace the ring gear.

2.4 Replacing ring gear

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

2.4.2 Installing ring gear

(1) Heat the ring gear evenly up to approx. 150°C [176°F] Ring gear
with an appropriate heater.
(2) Install the ring gear onto the flywheel with the no-gear- Removing ring gear
chamfering side faced to the flywheel.
Note: Do not heat the ring gear excessively.

6-9
INSPECTION AND REPAIR OF BASIC ENGINE

3. Inspecting and repairing timing gear and camshaft

3.1 Measuring timing gear backlash
Measure the backlash of the timing gears by using one of
the following two methods; measure the gear play with the
dial gauge plunger applied to a tooth flank on the pitch
circle at a right angle to the tooth axis, or measure the
clearance between gears by inserting a feeler gauge between
the gears at the tooth-to-tooth contacting area. Replace the
faulty gear pair if the limit is exceeded.

Item Standard Limit

Backlash crankshaft gear and 0.053 to 0.154 mm 0.25 mm
idler gear [0.0021 to 0.0061 in.] [0.0098 in.]
Measuring timing gear backlash
Backlash camshaft gear and 0.049 to 0.160 mm 0.25 mm
idler gear [0.0019 to 0.0063 in.] [0.0098 in.]

Backlash Fuel injection pump 0.050 to 0.228 mm 0.25 mm

idler gear and idler gear [0.0020 to 0.0090 in.] [0.0098 in.]

Backlash fuel injection pump

0.044 to 0.163 mm 0.25 mm
idler gear and fuel injection
[0.0017 to 0.0064 in.] [0.0098 in.]
pump gear

Note: With the fuel injection pump gear and the fuel
injection pump idler gear attached to the pump, install
the both gears to the front plate.

3.2 Measuring cam lift

Measure the minor and major axes of cam to determine cam Major axis
lobe lift. If the lift is less than the limit, replace the camshaft
Minor
with a new one.
Measuring Measuring
Item Nominal Standard Limit directions points
Major axis Major axis – Major axis –
+0.1 Minor axis Minor axis
Inlet 46.911 -0.3 mm
+0.004
= 6.689 mm = 6.189 mm
[1.8469 -0.012 in.] [0.2633 in.] [0.2437 in.]
Cam
lift Major axis – Major axis –
Major axis
+0.1 Minor axis Minor axis
Exhaust 46.256 -0.3 mm
= 6.229 mm = 5.729 mm
[1.8211
+0.004
-0.012 in.] [0.2452 in.] [0.2256 in.] Measuring cam lift

3.3 Measuring camshaft runout

Measure the camshaft runout using a dial gauge. If the limit
is exceeded, correct the camshaft using a press, or replace
the camshaft with a new one.
Note: With a dial gauge set on the camshaft, rotate the
camshaft one turn and read the gauge indication.

Item Standard Limit Remark

0.04 mm 0.10 mm
Camshaft runout TIR
[0.016 in.] or less [0.0039 in.]

Measuring camshaft runout

6-10
 INSPECTION AND REPAIR OF BASIC ENGINE

3.4 Measuring camshaft journal outside diame-

ter Measuring
Measure the diameter of each camshaft journal in two points
direction at right angles to each other. If the limit is
exceeded, replace the camshaft with a new one.

Measuring
Item Standard Limit directions
Front, 53.94 to 53.96 mm 53.90 mm
Camshaft journal Middle [2.1236 to 2.1244 in.] [2.1220 in.]
outside diameter 52.94 to 52.96 mm 52.90 mm
Rear
[2.0842 to 2.0850 in.] [2.0827 in.]

Measuring camshaft journal outside diameter

3.5 Measuring camshaft bushing inside diame-

ter Measuring
With the camshaft bushings installed in the crankcase, directions
measure the inside diameters using a cylinder gauge. If the
limit is exceeded, replace the bushing with a new one.

Item Standard Limit

Clearance between Front, 0.04 to 0.09 mm

camshaft journal Middle [0.0016 to 0.0035 in.] 0.15 mm
and camshaft 0.04 to 0.119 mm [0.0059 in.]
bushing Rear
[0.0016 to 0.0047 in.]

Measuring camshaft bushing inside diameter

3.6 Replacing camshaft bushing

3.6.1 Removing camshaft bushing Adapter
(1) Install a camshaft bushing installer set to the camshaft Bushing

bushing.
(2) Remove the camshaft bushing by tapping the end of the
rod of camshaft bushing installer set.

Camshaft bushing
installer set Rod
P/N:30691-00010

Removing camshaft bushing

6-11
INSPECTION AND REPAIR OF BASIC ENGINE

3.6.2 Installing camshaft bushing

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

Camshaft bushing Rod

installer set Oil hole
P/N:30691-00010

Installing camshaft bushing

3.7 Measuring front idler bushing inside dia.

and front idler shaft outside diameter
Measure the front idler bushing inside diameter and the
front idler shaft outside diameter. If the inside diameter of
front idler bushing exceeds the limit, replace the front idler
bushing with a new one. If the outside diameter of front
idler shaft is less than the limit, replace the front front idler
shaft with a new one.

Item Standard Limit

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

6-12
 INSPECTION AND REPAIR OF BASIC ENGINE

3.8 Replacing idler bushing

(1) Use the idler bushing puller to replace idler bushing.
(2) To install the bushing, drive it from the boss side so that Idler bushing puller
it is flush with the gear boss face. P/N:30091-07300
(3) After installing the bushing, measure the bushing inside
diameter, and if the inside diameter exceeds the
standard, ream the bushing.

Removing Installing

Replacing idler bushing

Idler gear Idler gear bushing

1 mm
[0.039 in.]

Idler bushing press fitting dimension

3.9 Replacing idler shaft
To remove the idler shaft, use the idler shaft puller. Idler shaft puller
Note: When installing the idler shaft into the crankcase, P/N:MH061077
orient the idler shaft so that its oil hole faces the upper
crankcase.

Removing idler shaft

3.10 Inspecting tappet
Inspect the cam contact surface of the tappets. Fit new
tappets if the surface is excessively worn or damaged.

Good Bad Bad

Tappet surface in contact with camshaft

6-13
INSPECTION AND REPAIR OF BASIC ENGINE

3.11 Measuring clearance between tappet and

tappet guide hole Measuring Measuring
Measure clearance between the tappet and tappet hole. points directions
Replace the tappet with a new one if the limit is exceeded.

Item Standard Limit

Tappet hole 22.000 to 22.021 mm 22.10 mm
inside diameter [0.8661 to 0.8670 in.] [0.8701 in.]

Clearance between tappet 0.035 to 0.086 mm 0.12 mm

and tappet hole [0.0014 to 0.0034 in.] [0.0047 in.]

Measuring clearance between tappet and tappet guide

hole

6-14
 INSPECTION AND REPAIR OF BASIC ENGINE

4. Inspecting and repairing piston, connecting rod, crankshaft and crankcase

4.1 Measuring crankcase top surface distor-
tion

&$87,21
Refacing of cylinder head should be kept to an abso-
lute minimum.
Excessive grinding of the cylinder head may result in
defects such as defective combustion and stamping
(contact between piston and valve).
Apply a straight edge to the top surface of the crankcase and
measure its distortion using a feeler gauge. If the distortion
exceeds the limit, grind the cylinder head using a surface
Measuring distortion of crankcase top surface
grinder.
Note: Do not overgrind the cylinder head, as the piston
protrusion deviates from the standard value.

Item Standard Limit

Distortion of crankcase 0.05 mm 0.20 mm
top surface [0.0020 in.] or less [0.008 in.]

Note: Do not grind the surfaces more than 0.2 mm

[0.008 in.] in total (cylinder head bottom surface plus
crankcase top surface).

6-15
INSPECTION AND REPAIR OF BASIC ENGINE

4.2 Measuring cylinder inside diameter

(1) Measure the inside diameter of the cylinder at three Measuring
directions
levels, i.e., upper (with much stepped wear), middle,

11 [0.43]
and lower levels, in both directions parallel to and

65 [2.56]
perpendicular to the crankshaft direction.

150 [5.91]
(2) If the measurement is between the repair limit and
replacement limit, re-bore the cylinder to +0.25 mm
[0.0098 in.] or +0.5 mm [0.0197 in.] oversize. Hone the
re-bored cylinder to the accuracy of the standard. Measuring
points
(3) Use an oversize piston and piston rings to fit the re-
Unit: mm [in.]
bored cylinder.
(4) If the cylinder is worn unevenly, select an oversize that Measuring cylinder sleeve inside diameter
ensures complete cylindericity when the cylinder is re-
bored to the maximum. All cylinders must be re-bored
to the same oversize if one cylinder is re-bored.
(5) If the cylinder has a slight wear and is reused after
replacing only the piston rings, remove the steps in
worn portion in the upper part of the cylinder using a
ridge reamer. Hone it as necessary.

Item Standard Limit

Repair limit:
Cylinder sleeve 102.010 to 102.045 mm 102.200 mm [4.0236 in.]
inside diameter [4.0161 to 4.0175 in.] Replacement limit:
102.700 mm [4.0433 in.] Refacing using a ridge reamer
0.01mm
Roundness -
[0.0004 in.] or less

0.015 mm
Cylindericity -
[0.0006 in.] or less

Note: The roughness of cylinder sleeve inner surface is

Ra 6.3 µm [0.248 µ in.]

6-16
 INSPECTION AND REPAIR OF BASIC ENGINE

4.3 Replacing cylinder sleeve

If the inside diameter of a cylinder sleeve exceeds the limit 0.5 mm [0.020 in.]
or a clinder is found defective, replace the cylinder sleeve
only, provided that the defective cylinder has no effects on
the other cylinders.
4.3.1 Removing cylinder sleeve
(1) Set up a boring machine on the crankcase by aligning it
with the center of the less-worn area of the sleeve at the
bottom.
(2) Bore the sleeve until its stock thickness becomes
approximately 0.5 mm [0.020 in.].
(3) Carefully break and remove the sleeve, taking care not Boring cylinder sleeve
to cause damage to the inside surface of crankcase.

Removing cylinder sleeve

4.3.2 Installing cylinder sleeve
(1) Use a cylinder sleeve installer to install a sleeve. Sleeve installer
(2) Put the sleeve into the crankcase, leaving a protrusion P/N:34291-00200
of 0.3 to 0.5 mm [0.012 to 0.020 in.] at the top. Then
make it flush with the crankcase top.
(3) Bore and hone the sleeve to the specified diameter.

Installing cylinder sleeve

6-17
INSPECTION AND REPAIR OF BASIC ENGINE

4.4 Measuring piston outside diameter

(1) Measure the piston outside diameter of the piston skirt
at right angles to the piston pin. If it is less than the
limit, replace the piston with a new piston. When
replacing piston, be sure to select a piston so that the Measuring point
piston weight difference in one engine is kept within
the permissible range.

Measuring piston outside diameter

(2) The piston weight is stamped on the top of piston head.

Weight stamp Number stamp

Item Standard Limit
(The prefix letter "F"
101.915 to 101.945 mm 101.730 mm and the last five
STD
[4.0124 to 4.0136 in.] [4.0051 in.] digits of part number)
Piston
outside 102.165 to 102.195 mm 101.980 mm F
0.25 OS
diameter [4.0222 to 4.0234 in.] [4.0150 in.]
(iskirt) Front mark
102.415 to 102.445 mm 102.230 mm
0.50 OS
[4.0321 to 4.0333 in.] [4.0248 in.]

Weight difference per

5g [0.2 oz.] or less -
piston

Piston weight stamp location

4.5 Measuring piston ring end gap

Place the piston ring in a gauge or a new sleeve to measure
the ring end gap. If the limit is exceeded, replace all the
rings as a set.
Note: Use a piston to push the piston ring squarely into the
gauge or the sleeve. Piston ring
Feeler gauge

Item Standard Limit

Compres- 0.30 to 0.45 mm
Piston sion ring [0.0118 to 0.0177 in.] 1.50 mm
ring
0.30 to 0.50 mm [0.0591 in.]
end gap Oil ring
[0.0118 to 0.0197 in.]
Measuring piston ring end gap

6-18
 INSPECTION AND REPAIR OF BASIC ENGINE

4.6 Measuring clearance between piston ring

groove and piston ring
Piston
&$87,21 Feeler gauge
Remove carbon deposits from pistons and check the
entire circumference of the piston.
(1) Remove deposits such as carbon from each ring groove. Straight edge
(2) Check each ring groove for wear or damage. If it is Piston ring

worn or damaged, replace the piston with a new one.

(3) Insert the piston ring into the piston ring groove. Apply
a straight edge and insert thickness gauges to measure
the clearance between ring and ring groove.
Measuring clearance between piston ring groove and
If the limit is exceeded, replace the piston ring with a piston ring
new one.
(4) When the piston ring has been replaced, measure the
clearance again, and if the limit is exceeded, then
replace the piston with a new one.

Item Standard Limit

No.1 com- 0.08 to 0.12 mm 0.200 mm
pression [0.0031 to 0.0047 in.] [0.0079 in.]
Clearance
between pis- No.2 com- 0.08 to 0.12 mm 0.150 mm
ton ring and pression [0.0031 to 0.0047 in.] [0.0059 in.]
ring groove
0.025 to 0.065 mm 0.150 mm
Oil
[0.0010 to 0.0026 in.] [0.0059 in.]

4.7 Measuring piston pin bore diameter and

piston pin outside diameter
Measure the piston pin bore diameter and piston pin outside
diameter. Replace if the limit is exceeded.

Item Nominal Standard Limit

Piston pin
outside
ø 34 mm 33.991 to 33.997 mm
- Measuring points Measuring directions
[1.34 in.] [1.3382 to 1.3385 in.]
diameter

Clearance
between piston 0.005 to 0.021 mm 0.050 mm
-
pin bore and [0.0002 to 0.0008 in.] [0.0020 in.]
piston pin
Measuring piston pin bore and piston pin

6-19
INSPECTION AND REPAIR OF BASIC ENGINE

4.8 Measuring piston protrusion

&$87,21
Piston protrusion must always meet the standard, as
the amount of protrusion not only influences on the
engine performance, but also it is important to prevent
valve interference.
Measure the protrusion of each piston following the
instructions below. If the measured value does not meet the
standard, inspect the clearances between various parts
involved.
(1) Bring the piston to the top dead center.
Measuring piston protrusion
(2) Apply the dial gauge plunger to the top surface of the
crankcase, and zero the dial gauge.
(3) Measure the protrusion at four points on the piston
head, and calculate the mean value.
Note: Subtract the mean value from the thickness of the
gasket compressed by tightening the cylinder head,
and the clearance between the piston top and cylinder
head will be determined.

Item Standard
0.8 mm
Piston protrusion
[0.031 in.]
Compressed thickness of 1.7 ± 0.05 mm
cylinder head gasket [0.067 ± 0.0020 in.]

6-20
 INSPECTION AND REPAIR OF BASIC ENGINE

4.9 Measuring clearance between connecting

rod bearing and crankpin Connecting rod cap
tightening torque
&$87,21 Measuring Measuring
103 ± 5 N·m
{10.5 ± 0.5 kgf·m}
When grinding crank pins, be sure to grind all the pins directions points
[76 ± 3.6 lbf·ft]
to the same size.
Finish the fillet radius to the specified dimension.
(1) Reassemble the bearing into the big end of the
connecting rod.
(2) Tighten the connecting rod cap bolts to the specified
torque.
(3) Measure the inside diameter of the connecting rod
Measuring connecting rod bearing inside diameter
bearing.
(4) Measure the outside diameter of the crank pin.
(5) Calculate the clearance from the difference between the
inside diameter of the connecting rod bearing and
outside diameter of the crank pin.
(6) Replace the connecting rod bearing if the clearance Measuring Measuring
exceeds the limit. directions points
(7) Measure the clearance between the connecting rod
bearing and the crank pin again. Use the undersize
bearing if the limit is exceeded.
(8) If an undersize bearing is used, grind the crank pin to
the specified undersize. Measuring crank pin diameter

Item Nominal Standard Limit

Crankpin outside ø 65 mm 64.945 to 64.965 mm 64.800 mm
diameter [0.026 in.] [2.5569 to 2.5577 in.] [2.5512 in.]

Clearance between
crankpin and 0.035 to 0.100 mm 0.200 mm
-
connecting rod [0.014 to 0.0039 in.] [0.0079 in.]
bearing

4.10 Measuring clearance between connecting

rod bushing and piston pin
Measure the inside diameter of the connecting rod bushing
and the outside diameter of the piston pin. Replace if the
limit is exceeded.
Measuring
Item Nominal Standard Limit directions
Bushing inside ø 34 mm 34.020 to 34.045 mm
- Measuring
diameter [1.34 in.] [1.3394 to 1.3404 in.]
points
Clearance between
0.023 to 0.054 mm 0.080 mm
bushing and piston -
[0.0009 to 0.0021 in.] [0.0031 in.]
pin
Measuring connecting rod bushing inside diameter

6-21
INSPECTION AND REPAIR OF BASIC ENGINE

4.11 Replacing connecting rod bushing

Use a connecting rod bushing installer to replace the
Oil hole
connecting rod bushing.
(1) With the bushing joints oriented as shown in the
40°
illustration, align the oil hole of bushing with the oil
hole of connecting rod, and press-fit the connecting rod
bushing into the connecting rod.
30°
(2) After press-fitting, insert the piston pin, and make sure
Oil hole
the smooth movement of the connecting rod and piston
without looseness. 30°
Bushing joint

Replacing connecting rod bushing

4.12 Removing connecting rod bushing
(1) Apply engine oil to the inner surface of the connecting Connecting rod Mandrel
rod bushing. bushing installer
Collar A
P/N:32F91-03050
(2) Install the collar A to the connecting rod bushing. Connecting rod
(3) Install the collar A and B to the mandrel, and tighten bushing
the nut.
(4) Align the match mark (red line) on the collar A with the Connecting
rod
match mark on the base.
Collar B
(5) Using a press, apply pressure slowly on the head of the
Align match Nut
mandrel to force out the connecting rod bushing. mark.
Base

Removing connecting rod bushing

4.13 Installing connecting rod bushing

(1) With the oil hole of busing aligned with the match mark Connecting rod Connecting rod
on the collar A, install the new connecting rod bushing bushing installer bushing
P/N:32F91-03050
onto the collar A. Align match
(2) Install the collars A and B to the mandrel, and tighten mark.
the nut.
(3) Apply engine oil to the outer periphery of the
connecting rod bushing. Align the oil hole in the
connecting rod bushing with the match mark (red line)
on the collar, then press the bushing into the connecting Collar A
rod.
Installing connecting rod bushing (1)

Connecting rod Mandrel

bushing installer Collar B
P/N:32F91-03050
Connecting rod
bushing

Connecting
rod
Collar A
Align match Nut
mark.
Base

Installing connecting rod bushing (2)

6-22
 INSPECTION AND REPAIR OF BASIC ENGINE

4.14 Inspecting connecting rod bend and twist

(1) Measure the dimensions of C and L in the illustration to Connecting rod cap tightening torque:
103 ± 5 N·m {10.5 ± 0.5 kgf·m}
check bend and twist of the connecting rod. Straighten [76 ± 3.6 lbf·ft]
the connecting rod with a press to meet the standard. C 0.05 0.002
C [ ]
L 100 3.9
If the standard is exceeded after correction, replace the
L
connecting rod with a new one. L
C 0.05 0.002
Piston [ ] C
(2) In general, a connecting rod aligner is used to check pin L 100 3.9
bend and twist. Twist of
Note: Before checking bend, tighten the connecting rod cap connecting rod
to the specified torque. Bend of
connecting rod Unit: mm [in.]
(3) To inspect the connecting rod with the piston installed,
turn the piston upside down and place it on a surface Inspecting connecting rod bend and twist
plate. Insert a round bar having the same diameter as
the crankpin into the big-end bore, and measure the D
height of the bar using a dial gauge.
C
Item Standard Limit
Connecting rod 0.05/100 mm 0.15 mm C 0.05
bend and twist [0.0020/3.94 in.] or less [0.0059 in.] ҇ A B
D 100

Unit: mm [in.]

Measuring with a dial gauge

4.15 Inspecting connecting rod bearing
Inspect the connecting rod bearings. If any defect is found,
replace it with a new one.

Scratches
Flaking
Fusion

Inspecting connecting rod bearing

6-23
 INSPECTION AND REPAIR OF BASIC ENGINE

4.16 Measuring connecting rod end play

(1) Install the connecting rods onto the respective
crankpins and tighten the connecting rod cap bolts to Connecting rod cap
the specified torque. tightening torque:
(2) Measure the clearance to the crank arm (end play) at 103 ± 5 N·m
{10.5 ± 0.5 kgf·m}
two positions (above and below the crankpin). [76 ± 3.6 lbf·ft]
(3) If the limit is exceeded, replace the connecting rod with
a new one.

Item Standard Limit

0.15 to 0.35 mm 0.50 mm
Connecting rod end play
[0.0059 to 0.0138 in.] [0.0197 in.]
Measuring connecting rod end play

4.17 Weight difference of connecting rod

assembly in one engine
When replacing a connecting rod, be sure to check the
weight rank of the connecting rod. In one engine, all the
connecting rods must be of the same weight rank.

Tolerance on
Item
weight Mating mark

#
for assembly
Weight difference of connecting rod 10 g [0.35 oz.]
assembly or less per engine Weight rank mark

Weight difference in connecting rod assembly

4.18 Measuring crankshaft journal outside diam-

eter
Measure the crankshaft journal diameter using a
micrometer. Check the crankshaft journal for roundness,
cylindricality and the clearance with the bearing. If the
measurement value is below the repair limit, grind the
Measuring Measuring
journal to fit the undersize bearing. If the measurement directions points
value is below the service limit, replace the crankshaft with
a new one.

Item Nominal Standard Limit

Repair limit = Measuring crankshaft journal outside diameter
ø 90 mm 89.95 to 89.97 mm 89.85 mm [3.5374 in.]
Diameter
[3.54 in.] [3.5413 to 3.5421 in.] Service limit =
89.10 mm [3.5079 in.]

0.01 mm 0.03 mm
Roundness -
[0.0004 in.] or less [0.0012 in.]

Cylinderic- 0.01 mm 0.03 mm

-
ity [0.0004 in.] or less [0.0012 in.]
Deviation of
0.01 mm [0.0004 in.]
Parallelism - -
or less over entire
pin length

6-24
 INSPECTION AND REPAIR OF BASIC ENGINE

4.19 Measuring crankshaft crankpin outside

diameter
Measure the crankpin outside diameter using a micrometer.
Check the crankpin for roundness, cylindricality, and the
clearance with the bearing. If the measurement value is
below the limit, grind the journal to fit the undersize Measuring Measuring
bearing. If the measurement value is below the service limit, directions points
replace the crankshaft with a new one.

Item Nominal Standard Limit

Service limit =
ø 65 mm 64.945 to 64.965 mm
Diameter 64.800 mm
[2.56 in.] [2.5569 to 2.5577 in.]
[2.5512 in.] Measuring crankshaft diameter
0.01 mm 0.03 mm
Roundness -
[0.0004 in.] or less [0.0012 in.]

Cylinderic- 0.01 mm 0.03 mm

-
ity [0.0004 in.] or less [0.0012 in.]

Deviation of
0.01 mm [0.0004 in.] or
Parallelism - -
less over entire pin
length

4.20 Grinding crankshaft

Grind the crankshaft journal (or pin) in the diameter that fit
the inside diameter of the next undersize main (or
connecting) bearing. By doing so, the fitness check with an
actual bearing can be omitted.
When grinding, be careful not to change the fillet radius and
width. If the surface hardness is considered to have been
reduced considerably, re-harden the crankshaft and check
for flaws by means of magnetic particle inspection.
Ensure that the surface finish accuracy of the crankpins and
journals is kept within the standard even after the correction
by grinding.

Item Undersize Finished size

0.25 mm 89.70 to 89.72 mm
[0.0098 in.] [3.5315 to 3.5323 in.]
Crank 0.50 mm 89.45 to 89.47 mm
journal [0.0197 in.] [3.5216 to 3.5224 in.]
0.75 mm 89.20 to 89.22 mm
[0.0295 in.] [3.5118 to 3.5126 in.]
0.25 mm 65.695 to 65.715 mm
[0.0098 in.] [2.5864 to 2.5872 in.]
0.50 mm 65.445 to 65.465 mm
Crankpin
[0.0197 in.] [2.5766 to 2.5774 in.]
0.75 mm 65.195 to 65.215 mm
[0.0295 in.] [2.5667 to 2.5675 in.]

6-25
INSPECTION AND REPAIR OF BASIC ENGINE

4.21 Measuring crankshaft end play

(1) Measure the crankshaft end play (clearance between the
33 +0.039
0 mm
crank arm at the thrust force receiving journal and the [1.3 +0.0015
0 in.]
bearing cap with thrust plate attached). If the limit is
exceeded, replace the thrust plate with a new one.
(2) If the limit is still exceeded after a new thrust plate has
been installed, use an oversize thrust plate.
Note: In general, the rear thrust bearing wears faster than
the front thrust bearing. Therefore, in most cases, the
correction is achieved by replacing the rear thrust
plate with a next oversize one.
Width of crankshaft thrust journal
Item Standard Limit
0.100 to 0.246 mm 0.300 mm
Crankshaft end play
[0.0039 to 0.0104 in.] [0.0118 in.]

Crankshaft thrust size after grinding

OS, used OS, used
Item on one on both Tolerance
side sides
+0.15 mm 33.15 mm 33.30 mm
[+0.0059 in.] OS [1.3051 in.] [1.3110 in.]

+0.30 mm 33.30 mm 33.45 mm 0 to 0.039 mm

[+0.0118 in.] OS [1.3110 in.] [1.3169 in.] [0 to 0.0015 in.]
Measuring crankshaft end play
+0.45 mm 33.45 mm 33.60 mm
[+0.0177 in.] OS [1.3169 in.] [1.3228 in.]

4.22 Measuring crankshaft runout

Support the crankshaft at the front and rear journals with V-
blocks, and measure the crankshaft runout at the center
journal using a dial gauge. If the runout deviates from the
standard only slightly, grind the crankshaft to repair. If the
runout exceeds the standard considerably, straighten the
crankshaft using a press.
If the limit is exceeded, replace the crankshaft.
If the crankshaft has been repaired by grinding or pressing,
inspect the crankshaft for cracks and other harmful damage
using a magnetic particle method.
Measuring crankshaft runout
Item Standard Limit Remark
Crankshaft 0.04 mm 0.10 mm
TIR
runout [0.0016 in.] or less [0.0039 in.] or less

6-26
 INSPECTION AND REPAIR OF BASIC ENGINE

4.23 Replacing crankshaft gear

4.23.1 Removing crankshaft gear
Using a gear puller, remove the gear from the crankshaft.
Note: Do not strike the gear with a hammer. Crankshaft gear

Puller
P/N:64309-12900

Removing crankshaft gear

4.23.2 Installing crankshaft gear

(1) Install the key on the crankshaft.
(2) Press-fit the gear fully in alignment with the key.
Key
Aligning position

Crankshaft gear

Installing crankshaft gear

6-27
INSPECTION AND REPAIR OF BASIC ENGINE

4.24 Replacing front oil seal

&$87,21
Be careful not to damage the crankshaft pulley with a
chisel when breaking the sleeve. Be careful not to dent Crankshaft
or scratch the outer surface of sleeve. pulley
When a oill leaks from the oil seal, replace both sleeve and
oil seal with new ones.
(1) Removing sleeve
Apply a chisel at right angles to the end surface of the
Sleeve
sleeve and strike it with a hammer at three locations to
loosen the sleeve and then remove the sleeve.
Removing front oil seal sleeve
Note: If the sleeve cannot be removed, apply the chisel to
the sleeve in the axial direction of the sleeve and tap it
lightly to make a cut and remove crankshaft-to-sleeve
interference.
(2) Installing sleeve Sleeve
Install the sleeve using a press so that the end of pulley
Crankshaft pulley
becomes flush.

Installing front oil seal sleeve

4.25 Replacing rear oil seal

&$87,21
Be careful not to damage the crankshaft when remov- Rear slinger
ing the rear oil seal. Be careful not to dent or scratch
the outer surface of sleeve.
When a oill leaks from the oil seal, replace the oil seal with
a new one.
(1) Removing rear oil seal
Remove the oil seal with a puller.
(2) Installing rear side oil seal
Apply an oil on the slinger inner surface of oil seal.
Removing rear oil seal sleeve
Install the oil seal with an oil seal installer.
Note: The oil seal is united with the slinger.
Rear oil seal installer
P/N:34291-00020
Oil seal

Installing rear oil seal sleeve

6-28
 INSPECTION AND REPAIR OF BASIC ENGINE

4.26 Inspecting main bearing surface

Check the inside surface of each main bearing shell for
abnormal contact, scratches, corrosion and peeling from Scratch on the inner
foreign material. Also check the outside surface of each and outer circumference,
corrosion, and detachment
bearing shell which comes into contact with the crankcase
or main bearing cap for abnormal seating.

Inspecting main bearing surface

4.27 Measuring clearance between main bear-

ing and crankshaft journal Measuring Measuring
directions points

&$87,21
(a) When grinding crank journals, be sure to grind all
the journals to the same size.
(b) Finish the fillet radius to the specified dimension.
(1) Reassemble main bearings.
(2) Tighten the main bearing caps to the specified torque.
Main bearing cap bolt
(3) Measure the inside diameter of the main bearings. tightening torque:
(4) Measure the outside diameter of the crank journal. 137 ± 5 N·m {14 ± 0.5 kgf·m} [101 ± 3.6 lbf·ft]
(5) Calculate the clearance between the inside diameter of Measuring inside diameter of lower hole of main
the main bearing and outside diameter of the crank bearing
journal.
(6) Replace the main bearing if the clearance exceeds the
limit.
(7) Measure the clearance between the main bearing cap
and the crank journal again. Use the undersize bearing
if the limit is exceeded. Measuring Measuring
(8) If an undersize bearing is used, grind the crank journal directions points
to the specified undersize.

Item Standard Limit

Clearance between main 0.050 to 0.118 mm 0.200 mm
bearing and crankshaft journal [0.0020 to 0.0046 in.] [0.0079 in.]
Measuring crank journal outside diameter

6-29
 REASSEMBLY OF BASIC ENGINE
1. Reassembling piston, connecting rod,
crankshaft and crankcase ...............7-2
1.1 Installing main bearing ............................. 7-2
1.2 Installing thrust plate ................................ 7-2
1.3 Installing crankshaft ................................. 7-2
1.4 Installing main bearing caps .................... 7-3
1.5 Inserting side seal .................................... 7-3
1.6 Installing main bearing cap bolt ............... 7-3
1.7 Measuring crankshaft end play ................ 7-4
1.8 Reassembling piston and connecting rod 7-4
1.9 Installing piston ring ................................. 7-5
1.10 Preparation for installing pistons.............. 7-5
1.11 Installing connecting rod bolt and connecting
rod bearing............................................... 7-6
1.12 Installing Pistons ...................................... 7-6
1.13 Installing connecting rod cap ................... 7-7

2. Reassembling timing gear and

camshaft..........................................7-8
2.1 Installing front plate.................................. 7-8
2.2 Installing tappet........................................ 7-8
2.3 Installing camshaft ................................... 7-8
2.4 Installing front idler gear........................... 7-9
2.5 Inspecting and adjusting timing gear after
installation ................................................ 7-9
2.5.1 Inspecting backlash and end play ..............7-9
2.6 Installing front oil seal ............................ 7-10
2.7 Installing timing gear case ..................... 7-10
2.8 Installing crankshaft pulley..................... 7-10

3. Reassembling flywheel .................7-11

3.1 Installing flywheel housing ..................... 7-11
3.2 Installing flywheel................................... 7-11

4. Reassembling cylinder head and valve

mechanism ....................................7-12
4.1 Cleaning cylinder head bottom surface.. 7-12
4.2 Installing valve stem seal ....................... 7-12
4.3 Installing valve and valve spring ............ 7-12
4.4 Installing cylinder head gasket............... 7-13
4.5 Installing cylinder head assembly .......... 7-13
4.6 Tightening cylinder head bolts ............... 7-13
4.7 Inserting push rod .................................. 7-14
4.8 Reassembling rocker shaft assembly .... 7-14
4.9 Installing rocker shaft assembly............. 7-14
4.10 Installing injector .................................... 7-15
4.11 Adjusting valve clearance ...................... 7-15
4.12 Installing rocker cover ............................ 7-15

7-1
REASSEMBLY OF BASIC ENGINE

1. Reassembling piston, connecting rod, crankshaft and crankcase

1.1 Installing main bearing
Main bearing upper
&$87,21
Do not apply oil to the bearing outer surface, as the oil
may cause the bearing seizure.
(1) Press the upper main bearing into position by aligning
its lug to the lug groove on the crankcase.
Note: The oil hole of the main bearing is aligned with the Align with lug groove.
oil hole of the crankcase by installing the upper main
bearing in alignment with the lug groove. Thrust plate
(2) Apply a small amount of engine oil to each bearing.
Installing main bearing upper

1.2 Installing thrust plate

Install the thrust plates to the crankcase outside face of
Thrust plate, upper
rearmost bearing and to the main bearing cap with their
grooves facing outward.

Thrust plate, lower

Thrust plate, lower

Installing thrust plate

1.3 Installing crankshaft

(1) Make sure that the main bearing upper shells that are
installed in the crankcase bores have their inner
periphery (the surface comes into contact with the
journal) lubricated with an even coat of fresh engine
oil.
(2) Wash the crankshaft thoroughly with cleaning oil and
dry it completely by blowing compressed air. Then,
apply an even coat of fresh engine oil to the crankshaft
journals.
Note: When cleaning the crankshaft, pay special attention to
the oil holes in the crank journals and crankpins, and Installing crankshaft
make sure that they are free from any foreign matter.
(3) Sling up the crankshaft horizontally, then move it above
the crankcase and lower it slowly into position.
Note: When lifting the crankshaft with a chain block, do not
attach a metal hook or similar fitting directly onto the
crankshaft. Such metal fittings can damage the
crankshaft easily. Always lift the crankshaft using
cloth belts or pads on the supporting points.

7-2
 REASSEMBLY OF BASIC ENGINE

1.4 Installing main bearing caps

&$87,21
The foremost and rearmost caps should be installed
so that they are flush with the crankcase surface.
Install the main bearing caps from the front side in the order
of the numbers marked on them.
(1) Apply engine oil to lower main bearings and install
them to the main bearing caps.
(2) Apply ThreeBond 1212 to the mating surface of the Apply ThreeBond 1212.
foremost and rearmost caps and the crankcase mating
faces before installing the main bearing caps.
Installing main bearing cap
Note: Do not apply ThreeBond 1212 to any other surface
other than the mating surfaces of the foremost and
rearmost caps and the crankcase mating faces.
(3) Install the main bearing caps and temporarily tighten
bolts.

1.5 Inserting side seal

(1) Apply a sealant to the outer periphery of new side seals.

Crankcase Bearing cap Side seal

Sealant THREEBOND 1212 or 1211

(2) With the round section of the side seals facing outward,
press them partway into the front and rear caps using
hands.
(3) When the side seals are installed partway into caps, use
a tool with flat surface such as flat-head screwdriver to
R section
install completely, taking care not to bend them.

Inserting side seal

1.6 Installing main bearing cap bolt

(1) Tighten the main bearing cap bolts alternately and Main bearing cap bolt tightening torque
progressively to the specified torque. 137 ± 5 N·m {14 ± 0.5 kgf·m}
[101 ± 3.6 lbf·ft]
(2) Make sure that the crankshaft rotates smoothly.

Installing main bearing cap bolt

7-3
REASSEMBLY OF BASIC ENGINE

1.7 Measuring crankshaft end play

Attach a dial gauge to the end of the crankshaft to measure
the end play.
If the end play deviates from the standard value, loosen the
main bearing cap bolts and retighten.
Make sure that the camshaft turns freely.

Item Standard Limit

0.100 to 0.246 mm 0.300 mm
Crankshaft end play
[0.0039 to 0.0104 in.] [0.0118 in.]

Measuring crankshaft end play

1.8 Reassembling piston and connecting rod

(1) Apply engine oil to the piston pin, and reassemble the
piston and the connecting rod by inserting the piston F

Front
pin, observing the orientation of piston and connecting Piston pin
rod shown in the illustration. Snap ring
Note: The pistons and piston pins are assembled to each
other in clearance fit. However, the piston pins are
more easily inserted into the pistons if the pistons are Apply engine oil
warmed up with a heater or in hot water.

Matching mark

Reassembling piston and connecting rod

(2) Using ring pliers, install the snap ring. Check the snap
ring for its tension, and make sure the ring fits snugly in
the groove.
Note: Install all the snap rings so that their end gap faces
toward the bottom of the piston.

7-4
 REASSEMBLY OF BASIC ENGINE

1.9 Installing piston ring

&$87,21 No.1 compression ring

Every piston ring has a top mark such as “R” near the Top mark
end gap. Install all piston rings with this mark facing
upward. No.2 compression ring
If the rings are installed upside down, it could cause
malfunctions such as excessive oil consumption or an
engine seizing.
(1) Install the piston rings to the piston with a ring Oil ring
expander.
(2) Install the oil ring with its end gap 180° away from the
Reassembling piston and piston ring
butt joint of the coil spring, as shown in the illustration.

Coil spring butted ends

180°

Oil ring abutment

Reassembling oil ring

1.10 Preparation for installing pistons

(1) Lay the engine along its side.
(2) Clean the cylinder sleeve inner surface and the crank
pin with a cloth, and apply engine oil.

Cleaning and lubricating cylinder sleeve inner surface

7-5
REASSEMBLY OF BASIC ENGINE

1.11 Installing connecting rod bolt and connect-

ing rod bearing
(1) Press fit the connecting rod bolts into the connecting Lug groove
rod.
Note: When press fitting the bolt, make sure that the bolt
fully contacts its seating position without any
interference with the shoulder of mounting surface.
(2) Install the upper connecting rod bearing with its lug
fitted in the lug groove of connecting rod.
(3) Install the lower connecting rod bearing with its lug
fitted in the lug groove of connecting rod cap.
(4) Apply engine oil to the inner surface of bearing. Installing connecting rod bolt and upper bearing

Lug groove

Installing lower connecting rod bearing

1.12 Installing Pistons

&$87,21 Camshaft side

Do not forcefully insert the piston, as it may cause
No.1
damage to the piston rings and crank pin. 180° compression
(1) Apply engine oil to the circumference of the piston and ring end gap
piston rings.
No.2
(2) Orient the ring end gaps diagonally opposite each other compression Oil ring end gap
avoiding the piston pin direction and its right angle ring end gap 60° 60°
direction.
Combustion chamber side
(3) Turn the crankshaft to bring the crank pin of the
cylinder to the top dead center.
Orientation of piston ring end gap
(4) Orient the front mark on the top of piston toward engine
front.
(5) Using a piston guide, insert the piston from the top face
of crankcase into the cylinder sleeve.

Piston guide
P/N:34291-00100

Installing piston

7-6
 REASSEMBLY OF BASIC ENGINE

1.13 Installing connecting rod cap

(1) When the big end of the connecting rod comes into
Camshaft
contact with the crank pin, turn the crankshaft 180°
Matching mark
while pressing the piston head.
(2) Install the connecting rod cap with its match mark
facing on the same side as the match mark on the Connecting rod cap
connecting rod. nut tightening torque:
(3) Tighten the connecting rod cap nuts evenly and 103 ± 5 N·m
{10.5 ± 0.5 kgf·m}
progressively to the specified torque.
[76 ± 3.6 lbf·ft]
(4) Inspect end play of the connecting rod. If end play is Wood block
small, loosen and retighten the cap nuts.
Installing connecting rod cap

7-7
REASSEMBLY OF BASIC ENGINE

2. Reassembling timing gear and camshaft

2.1 Installing front plate
(1) Clean the mounting surface of the gasket. Front plate bolt tightening torgue:
M10 × 1.5 35 ± 5 N·m {3.5 ± 0.5 kgf·m} [25.3 ± 3.6 lbf·ft]
(2) Apply sealant to the gasket to prevent it from falling. M8 × 1.25 19 ± 2 N·m {1.9 ± 0.2 kgf·m} [13.7 ± 1.4 lbf·ft]
(3) With aligning to the dowel pin, install the gasket and
the front plate. Front plate
(4) Secure the front plate with mounting bolts.

Installing front plate

2.2 Installing tappet
Coat the periphery of tappets with engine oil, insert them
into the tappet holes and place them gently on the
camshafts.

2.3 Installing camshaft

&$87,21
Be careful not to damage camshaft journals, cams and
camshaft holes during insertion. Camshaft gear

(1) Apply engine oil to the camshaft journals and cams.

(2) Slowly insert the camshaft assembly.
(3) Tighten the thrust plate bolt to the specified torque.
Camshaft thrust plate
(4) Make sure that the camshaft rotates lightly. Move the
bolt tightening torque
camshaft gear back and forth, and make sure there is 12 ± 2 N·m{1.2 ± 0.2 kgf·m}
end play. [9 ± 1.4 lbf·ft]

Installing camshaft

7-8
 REASSEMBLY OF BASIC ENGINE

2.4 Installing front idler gear

(1) Apply engine oil to the idler gear shaft.
Thrust plate bolt
(2) Install the idler gear with all match marks on it aligned tightening torque
with the marks on the other gears. 34 ± 5 N·m
Idler gear
(3) Install the thrust plate with its hole matching the pin of {3.5 ± 0.5 kgf·m}
[25 ± 3.6 lbf·ft]
the idler gear shaft.
(4) Tighten the thrust plate bolt to the specified torque.
(5) Move the idler gear back and forth, and make sure there
is end play.

Thrust plate

Installing idler gear

Injection pump
idler gear
Camshaft gear

 


 

㩩

Injection pump Idler gear

gear Crank gear

Timing gear train

2.5 Inspecting and adjusting timing gear after
installation
Be sure to inspect and adjust the timing gear when the
timing gear has been reassembled.

2.5.1 Inspecting backlash and end play

After installing the timing gears, be sure to inspect and
adjust the backlash and end play between gears.

Idler gear

Measuring idler gear end play

Measuring backlash of timing gear

7-9
REASSEMBLY OF BASIC ENGINE

2.6 Installing front oil seal

Using an installer, install new oil seal in the timing gear
case. Make sure the oil seal is flush with the gear case.

Installing front oil seal

2.7 Installing timing gear case
(1) Install the baffle plate to the front end of crankshaft. Timing gear case tightening torque:
M10 × 1.5 35 ± 5 N·m {3.5 ± 0.5 kgf·m} [25.3 ± 3.6 lbf·ft]
(2) Apply sealant to the gasket to prevent it from M8 × 1.25 19 ± 2 N·m {1.9 ± 0.2 kgf·m} [13.7 ± 1.4 lbf·ft]
displacing, and install the gasket on the front plate.
(3) Apply engine oil to the oil seal lip.
(4) Orient the cutaway of the baffle plate so that the baffle
plate does not overlap the oil pump idler gear.
(5) Install the timing gear case, and secure it with the bolts.

Gasket
Timing gear case

Installing timing gear case

Oil pump idler gear

Baffle plate cutaway

Baffle plate cutaway position

2.8 Installing crankshaft pulley
Crankshaft pulley nut The bar that prevnets
&$87,21 tightening torque: crankshaft rotation
706 ± 59 N·m {72 ± 6 kgf·m}
The bar could come off. Be very careful.
[521 ± 43 lbf·ft]
(1) Screw two guide bolts into the threaded holes at the rear Crankshaft pulley
end of the crankshaft. Place a bar across the two guide
bolts so that the crankshaft does not turn.
(2) Install the woodruff key on the crankshaft.
(3) Install the crankshaft pulley and tighten the nuts to the
specified torque. Guide bolt (M12×1.25mm)
(Front) (Rear)

Installing crankshaft pulley

7-10
 REASSEMBLY OF BASIC ENGINE

3. Reassembling flywheel
3.1 Installing flywheel housing
(1) Clean the mounting surface of the gasket.
(2) Apply sealant to the gasket to prevent it from falling
off.
(3) Install the gasket.
(4) Install the flywheel housing, aligning its dwel pin holes
and dowel pins, and tighten the bolts.
Note: When the dowel pins are worn or when the flywheel
housing is replaced, replace the dowel pins with new
ones.

Installing flywheel housing

3.2 Installing flywheel

Flywheel bolt tightening
&$87,21 torque:
83 ± 5 N·m {8.5 ± 0.5 kgf·m}
The person who holds the pulley must be very careful
Crankshaft pulley [62 ± 3.6 lbf·ft]
to assure safety by communicating with the person Guide bolt
who is installing the flywheel.
(1) One person must firmly hold the pulley with a wrench
to prevent the crankshaft from turning.
(2) Screw the guide bolt into the rear end of the crankshaft.
(3) Align the bolt hole of flywheel with the guide bolt and
install the flywheel to the crankshaft.
Front
Rear
(4) Temporarily tighten bolts. Installing flywheel
(5) Remove the guide bolt and temporarily tighten the last
bolt.
(6) Tighten the flywheel bolts to the specified torque.

7-11
REASSEMBLY OF BASIC ENGINE

4. Reassembling cylinder head and valve mechanism

4.1 Cleaning cylinder head bottom surface
Taking care not to damage the cylinder head bottom surface,
remove residue of old gasket.
Note: First, roughly scrape off residue of old gasket using a
scraper. Then, grind off the remaining residue using
an engine-oil immersed oil stone.

Cleaning cylinder head bottom surface

4.2 Installing valve stem seal

&$87,21 Push the shoulder of valve stem seal.

Do not apply oil or liquid gasket to the inner side of ω ω
stem seal that comes in contact with the valve guide.
Valve stem seal
(1) Apply engine oil to the lip of new valve stem seal.
(2) Push the shoulder of the valve stem seal and fit the
valve stem steal into the valve guide. Valve guide
(3) Insert the valve stem seal into the valve guide using the
valve stem seal installer.

Installing valve stem seal

4.3 Installing valve and valve spring
(1) Install the valve spring and retainer on the valve guide. Valve spring pusher
Install the valve cotter using a valve spring pusher. P/N:30691-04500
(2) Tap the top of valve stem lightly several times with a
soft hammer to make sure that the valve spring and
valve cotter are properly installed and seated firmly.

Installing valve and valve spring

Valve cotter

Installing valve cotter

7-12
 REASSEMBLY OF BASIC ENGINE

4.4 Installing cylinder head gasket

(1) Make sure that there is no dirt or dents on the top
surfaces of the crankcase and pistons.
(2) Place new gasket on the crankcase by aligning it with
dowel pins on the crankcase.

4.5 Installing cylinder head assembly

Install the cylinder head on the crankcase by aligning it with
the dowel pins.
Note: Be careful not to displace the cylinder gasket when
installing.

Installing cylinder head assembly

4.6 Tightening cylinder head bolts

In the numerical order as shown in the illustration, tighten
cylinder head bolts progressively to the specified torque. Cylinder head bolt tightening torque:
137 ± 5 N·m {14 ± 0.5 kgf·m} [101 ± 3.6 lbf·ft]

15 11 7 3 2 6 10 14

17 9 1 8 16

13 5 4 12

Tightening order of cylinder head bolt

7-13
REASSEMBLY OF BASIC ENGINE

4.7 Inserting push rod

(1) Insert each push rod into its hole in the cylinder head.
(2) Make sure that the ball end of each push rod is placed
Pushrod
correctly on the tappet cup.

Tappet

Inserting push rod

4.8 Reassembling rocker shaft assembly

(1) Apply engine oil to the rocker shaft.
(2) When reassembling, install the rocker shaft assembly in
the same position as it was.
Rocker shaft spring
Note: If the rocker shaft assembly is not installed as it was,
the clearance becomes different, and it may result in a Rocker shaft
defect such as wear increase. Oil pipe Bracket
(3) After reassembling, make sure the rocker arm and oil Rocker arm
pipe move freely.
Snap ring
Eye bolt

Reassembling rocker shaft assembly

4.9 Installing rocker shaft assembly

(1) Install the valve caps to the valve heads.
(2) Tighten the long bolts of the rocker bracket to the
specified torque.
(3) Tighten the short bolts of the rocker bracket.

Rocker shaft bracket bolt tightening torque:

19 ± 2 N·m {1.9 ± 0.2 kgf·m} [13.7 ± 1.4 lbf·ft]

Installing rocker shaft assembly

7-14
 REASSEMBLY OF BASIC ENGINE

4.10 Installing injector

(1) Install the gasket to the injector.
Leak off hose connector
(2) Install the injector with the nozzle gland to the cylinder
head. Injector Leak off hose
(3) With the washer spherical side faced toward nozzle Pin
gland, install the washer, and secure it by tightening the
Nozzle
hexagon socket head bolt to the specified torque.
gland
(4) Apply engine oil to the O-ring of leak off hose Injection pipe
connector. Injection connector
(5) With pushing the pin on top of the injector, install the
Gasket
leak off hose connector.
(6) Install the injection pipe to the injector. Installing injector
Note: Make sure that the injector is reassembled into the
same cylinder as it was before.

Injector

Push
Pin

Pushing pin on top of injector

4.11 Adjusting valve clearance
Adjust the valve clearance.
For adjusting procedures, refer to "Adjustment and
Operation."

Adjusting valve clearance

4.12 Installing rocker cover
(1) Make sure that the gasket is firmly installed into the Rocker cover bolt tightening torque:
rocker cover. 20 ± 2 N·m {2.0 ± 0.2 kgf·m}
[14.5 ± 1.4 lbf·ft]
(2) Tighten the rocker cover mounting nuts to the specified
torque.

Installing rocker cover

7-15
 FUEL SYSTEM
1. Removing fuel system.....................8-2
1.1 Removing fuel system (Part 1)................. 8-2
1.2 Removing fuel system (Part 2)................. 8-3

2. Installing fuel system.......................8-4

2.1 Installing fuel system (Part 1)................... 8-4
2.2 Installing fuel system (Part 2)................... 8-5
2.3 Replacing fuel pump ................................ 8-6
2.3.1 Removing fuel pump ..................................8-6
2.3.2 Replacing fuel pump gear ..........................8-6
2.3.3 Replacing fuel pump idler gear ..................8-6
2.3.4 Installing fuel pump ....................................8-7

8-1
FUEL SYSTEM

1. Removing fuel system

&$87,21
(a) Keep open flame or heat away from fuel system before conducting the removal work. It could cause a fire.
(b) Wipe off any spilled fuel. Spilled fuel could cause a fire.
(c) Cover or plug any inlet and outlet openings to prevent dust from entering the fuel system.
(d) For fuel pump, common rail, and injector, have a specialized maintenance shop do the maintenance work.
1.1 Removing fuel system (Part 1)

Replace: Sealing washer

O-ring 8
B
Gasket
Leak off hose
6

10
2
3
4 1
5 11
16
A
18 14
17 D
15 7 9
B
C 13

12
19
D

A 20

Removing fuel system (Part 1)

Removing sequence

1 Pipe clamp 8 Pipe cramp 15 Common rail

2 No.1 injection pipe 9 Fuel pipe 16 Hexagon bolt
3 No.2 injection pipe 10 Bracket 17 Nozzle ground
4 No.3 injection pipe 11 Bolt 18 Injector
5 No.4 injection pipe 12 Hose cramp 19 Fuel pump nut
6 Leak off hose 13 Fuel hose 20 Fuel pump flange, fuel pump
7 Fuel hose 14 Fuel return pipe

8-2
 FUEL SYSTEM

1.2 Removing fuel system (Part 2)

1
2

6
5

Removing fuel system (Part 2)

Removing sequence

1 Fuel pump nut 4 Fuel pump 7 Fuel pump idler gear, bearing
2 Fuel pump gear 5 Bolt
3 Bolt 6 Washer

8-3
FUEL SYSTEM

2. Installing fuel system

2.1 Installing fuel system (Part 1)

19 ± 2 N·m
{1.9 ± 0.2 kgf·m}
[13.7 ± 1.4 lbf·ft]

70 ± 5 N·m
{7.1 ± 0.5 kgf·m}
[51.4 ± 3.6 lbf·ft]
112 ± 22 N·m
{11.4 ± 2.2 kgf·m}
[82.5 ± 15.9 lbf·ft]

34 ± 5 N·m
{3.5 ± 0.5 kgf·m}
[25.3 ± 3.6 lbf·ft]

Installing fuel system (Part 1)

8-4
 FUEL SYSTEM

2.2 Installing fuel system (Part 2)

Replace: Sealing washer 8

O-ring B
Gasket
Leak off hose

30 ± 3.0 N·m
{3.1 ± 0.3 kgf·m}
25 ± 3 N·m
[22.4 ± 3 lbf·ft]
{2.5 ± 0.3 kgf·m}
[18.1 ± 2.2 lbf·ft]
A
D

25 ± 3.0 N·m B 20 ± 2.0 N·m

{2.5 ± 0.3 kgf·m} C {2.0 ± 0.2 kgf·m}
[18.1 ± 3 lbf·ft] [14.5 ± 1.4 lbf·ft]
C

25+2.5
0 N·m

{2.5 +0.25
0 kgf·m}
[18.1 +1.8
0 lbf·ft]

Installing fuel system (Part 2)

8-5
FUEL SYSTEM

2.3 Replacing fuel pump

2.3.1 Removing fuel pump
(1) Remove the inspection cover for fuel pump idler gear Put a mating mark
and idler gear from the timing gear case. Fuel pump gear
mouting nut
(2) Put a mating mark on the fuel pump idler gear and idler
gear with white paint.
(3) Remove the inspection cover for fuel pump nut. Loosen
the fuel pump nut and tighten it by hand temporary.
Fuel pump
(4) Disconnect fuel pipe and oil pipe from the fuel pump. idler gear
Idler gear
Fuel pump gear
(5) Remove the harness connector.
(6) Remove the fuel pump together with the fuel pump
flange from timing gear case. Removing fuel pump
(7) Remove the fuel pump nut, and remove the fuel pump
gear from the fuel pump.
(8) Remove the fuel pump from the fuel pump flange.

2.3.2 Replacing fuel pump gear

(1) Remove the fuel pump nut, and remove the fuel pump
gear.
(2) Install the new fuel pump gear, aligning with the fuel
pump shaft key.
Fuel pump gear
(3) Install the fuel pump nut and tighten it by hand
temporary.

Fuel pump

Replacing fuel pump gear

2.3.3 Replacing fuel pump idler gear

(1) Remove the bolt and the washer from the fuel pump
idler gear.
(2) Remove the fuel pump idler gear from the shaft
together with the bearing and the snap ring.
(3) Remove the bearing and the snap ring from the fuel
pump idler gear.
(4) Install the bearing and the snap ring to the new fuel
pump idler gear.
(5) Install the fuel pump idler gear to the shaft together Fuel pump
Fuel pump idler gear
with the snap ring and the bearing, and install the
washer and the bolt. Replacing fuel pump idler gear

8-6
 FUEL SYSTEM

2.3.4 Installing fuel pump

(1) Install the fuel pump to the fuel pump flange.
(2) Install the fuel pump nut and tighten it by hand
temporary.
(3) Install the O-ring to the fuel pump flange.
(4) With the match marks on the fuel pump idler gear and
the idler gear aligned, install the fuel pump flange to the
timing gear case.
(5) Tighten the fuel pump nut to the specified torque.
(6) Connect the harness connector.
(7) Install the fuel pipe and the oil pipe, and tighten to the
specified torque. Installing fuel pump
(8) Install the fuel pump idler gear and idler gear inspection
cover and the fuel pump nut inspection cover to the
timing gear case.

8-7
 LUBRICATION SYSTEM
1. Removing and inspecting lubrication
system .............................................9-2
1.1 Removing and inspecting oil filter and
oil cooler................................................... 9-2
1.2 Removing and inspecting oil pan and
breather.................................................... 9-3

2. Disassembling, inspecting and

reassembling lubrication system .....9-4
2.1 Disassembling and inspecting oil pump... 9-4
2.1.1 Removing oil pump gear ............................9-4
2.1.2 Removing spindle and idler gear................9-5
2.2 Inspecting and adjusting oil pump............ 9-5
2.2.1 Measuring end clearance between gears and
case............................................................9-5
2.2.2 Measuring side clearance between gears and
case............................................................9-5
2.2.3 Measuring clearance between outside diameter
of gear shaft and inside diameters of pump body
and pump cover .........................................9-6
2.2.4 Measuring spindle outside diameter and idler
bushing inside diameter .............................9-6
2.3 Reassembling oil pump............................ 9-7
2.3.1 Reassembling oil pump gear and drive gear
assembly ....................................................9-7
2.4 Inspecting oil filter .................................... 9-8
2.5 Inspecting relief valve .............................. 9-8
2.6 Inspecting safety valve............................. 9-8

3. Installing lubrication system ............9-9

3.1 Installing oil filter and oil cooler ................ 9-9
3.2 Installing oil pan and breather................ 9-10

9-1
LUBRICATION SYSTEM

1. Removing and inspecting lubrication system

1.1 Removing and inspecting oil filter and oil cooler

Clogging, crack
Replace: Every 500 hrs

Replace

Clogging, crack
8 Replace: Every 500 hrs

Replace
1
10

6 3
Replace 5

Replace
4
2
9

Replace

Removing and inspecting oil filter and oil cooler

Removing sequence

1 Oil filter 5 Filter base 9 Oil cover

2 Drain hose 6 Rail bracket 10 Relief valve
3 Filter bracket 7 Oil cooler cover
4 Drain plug 8 Oil cooler element

9-2
 LUBRICATION SYSTEM

1.2 Removing and inspecting oil pan and breather

3
Replace
5 2

Replace Replace

Replace 8

Replace
6

Removing and inspecting oil pan and breather

Removing sequence

1 Breather hose 4 Breather 7 Oil pan

2 Breather pipe 5 Oil level gauge 8 Oil strainer
3 Vinyl tube 6 Drain cock 9 Safety valve

9-3
LUBRICATION SYSTEM

2. Disassembling, inspecting and reassembling lubrication system

2.1 Disassembling and inspecting oil pump

Gear defect, wear

Once removed, replace the gear
with a new one.

Gear defect, wear

3

Wear

2
Replace

4
Crack, damage
1 Gear defect, wear

Disassembling and inspecting oil pump

Removing sequence

1 Gear cover 3 Oil pump gear 5 Spindle

2 Driven gear 4 Drive gear 6 Idler gear assembly
Note: Inspect the oil pump prior to the removal of gears.

2.1.1 Removing oil pump gear

Oil pump gear
&$87,21
Puller
Once the oil pump gear is removed, the oil pump gear P/N:64309-12900
and the drive gear are no longer reusable. Replace
them with new ones.
Remove the oil pump gear with a puller.

Removing oil pump gear

9-4
 LUBRICATION SYSTEM

2.1.2 Removing spindle and idler gear

Remove the spindle and the idler gear as a unit. Remove the
spindle and the idler gear by tapping the edge of idler gear
with a wood rod inserted through the oil seal mounting hole
of timing gear case.
Note: When tapping the idler gear with a wood rod, turn the
gear.

Spindle Idler gear

Removing spindle and idler gear

2.2 Inspecting and adjusting oil pump
2.2.1 Measuring end clearance between gears
and case
Measure the end clearance between gear width and case
depth with a dial gauge placed as shown in the illustration.
If the limit is exceeded, replace the drive and driven gear
assemblies.

Item Standard Limit

End clearance between -0.01 to 0.054 mm 0.150 mm
gear width and case depth [-0.0004 to 0.0021 in.] [0.0059 in.]

Measuring clearance between gear and case

2.2.2 Measuring side clearance between gears
and case
Measure the side clearance between gear teeth and case bore
with feeler gauges. If the limit is exceeded, replace the drive
and driven gear assemblies.

Item Standard Limit

Side clearance between 0.05 to 0.098 mm 0.100 mm
gear teeth and case bore [0.0020 to 0.0039 in] [0.0039 in.]

Measuring clearance between gear teeth and case

9-5
LUBRICATION SYSTEM

2.2.3 Measuring clearance between outside

diameter of gear shaft and inside diameters Pump body Pump cover
of pump body and pump cover
Measuring
locations
&$87,21
When replacing drive and driven gears, replace the
gear assemblies.
(1) Check gear teeth for condition. If the teeth are
defective, replace the gear assemblies.
(2) Measure the inside diameters of pump body (cover) and
Measuring points
the diameter of gear shafts. If the clearance is more than
the limit, replace the gear assemblies, pump body, and
Measuring clearance between gear shaft outside
pump cover whichever is badly worn. diameter and pump body, pump cover inside diameter

Item Standard Limit

Clearance between gear shafts 0.04 to 0.07 mm 0.15 mm
and pump body (cover) [0.0016 to 0.0028 in.] [0.0059 in.]

2.2.4 Measuring spindle outside diameter and

idler bushing inside diameter
Measure the spindle outside diameter and the idler bushing
inside diameter. If excessive wear is found, replace the part
with a new one.

Item Nominal Standard

ø 25 mm 24.939 to 24.960 mm
Spindle outside diameter
[0.98 in.] [0.9818 to 0.9827 in.]
ø 25 mm 25.000 to 25.021 mm
Bushing inside diameter
[0.98 in.] [0.9843 to 0.9851 in.]

Measuring spindle outside diameter and idler gear

bushing inside diameter

9-6
 LUBRICATION SYSTEM

2.3 Reassembling oil pump

Heat to 180 to 220°C [356 to 428°F].

Oil pump gear should be flush with
the shaft. Backlash
Standard: 0.049 to 0.166 mm
[0.0019 to 0.0065 in.]
Limit: 0.35 mm [0.0138 in.]

35 ± 3.5 N·m
{3.6 ± 0.3 kgf·m}
[25.3 ± 2.4 lbf·ft]

Make sure the oil pump

Apply ThreeBond 1215 gear rotates smoothly
(ash color) to the mating
surface with the case and
cover.

Apply engine oil to every sliding section.

Reassembling oil pump

2.3.1 Reassembling oil pump gear and drive gear

assembly Flush

&$87,21
The oil pump gear and drive gear assembly is nonre-
usable parts. Replace the assembly with a new one.
(1) Heat the oil pump gear between 180 to 220°C [356 to
428°F]
(2) Support the shaft at end and force the gear onto the
shaft until its end face is flush with the end of shaft.
Shaft end surface

Reassembling oil pump gear and drive gear assembly

9-7
LUBRICATION SYSTEM

2.4 Inspecting oil filter

When replacing the oil filter, sample the oil (500 ml
[30.5 cu.in.]) 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 the element to identify the cause.

Inspecting oil filter

2.5 Inspecting relief valve

(1) Check the relief valve and its seat for contact. Check
the spring for fatigue and damage. If faulty, replace the Tightening torque
relief valve with new one. 49 ± 4.9 N·m
{5 ± 0.5 kgf·m}
(2) Measure the relief valve opening pressure. If the [36.2 ± 3.6 lbf·ft]
pressure does not fall within the standard range, replace
the relief valve with new one. Tightening torque
44 ± 4.9 N·m
Item Standard {4.5 ± 0.5 kgf·m}
[32.5 ± 3.6 lbf·ft]
0.35 ± 0.05 MPa
Relief valve opening pressure
{3.5 ± 0.5 kgf/cm² } [49.8 ± 7.1 psi] Relief valve

Inspecting relief valve

2.6 Inspecting safety valve

(1) Make sure that the steel ball inside safety valve slides
smoothly. If faulty, replace the safety valve with new
one.
(2) Measure the safety valve opening pressure. If the
pressure does not fall within the standard range, replace
the safety valve with new one.
Tightening torque
Item Standard 69 ± 4.9 N·m
Safety valve opening pressure 1.1 MPa {11 kgf/cm² } [157 psi] {7 ± 0.5 kgf·m}
[50.6 ± 3.6 lbf·ft]

Inspecting safety valve

9-8
 LUBRICATION SYSTEM

3. Installing lubrication system

3.1 Installing oil filter and oil cooler

When installing, apply engine

oil to the gasket, and tighten
Replace the filter 3/4 to one turn after
the gasket contacts with the
mounting surface.

Replace Replace

Replace
49 ± 4.9 N·m
{5 ± 0.5 kgf·m}
[36.2 ± 3.6 lbf·ft}

Replace

Replace

Installing oil filter and oil cooler

To install the lubrication system, follow the removal procedure in reverse order, observing the followings:
(1) Use new gaskets and O-rings when reinstalling.
(2) Clean oil passage of each part thoroughly in wash oil,
and dry it completely using compressed air.
(3) Install the bracket first, then install the oil filter.

9-9
LUBRICATION SYSTEM

3.2 Installing oil pan and breather

Replace

Replace Replace

Replace

69 ± 4.9 N·m
{7 ± 0.5 kgf·m}
[50.6 ±3.6 lbf·ft}
Replace

Installing oil pan and breather

9-10
 COOLING SYSTEM
1. Removing cooling system .............10-2

2. Inspecting cooling system .............10-3

2.1 Checking water pump for smooth rotation10-3
2.2 Inspecting thermostat............................. 10-3

3. Installing cooling system ...............10-4

10-1
COOLING SYSTEM

1. Removing cooling system

Replace
5

Crack, water leakage, damage

Replace
4

2 3

Crack, wear

Removing cooling system

Removing sequence

1 Fan 3 Belt 5 Thermostat assembly

2 Spacer 4 Water pump assembly

10-2
 COOLING SYSTEM

2. Inspecting cooling system

2.1 Checking water pump for smooth rotation
Check to make sure that the impeller and shaft of water
pump rotate smoothly without noise and irregularities. If
faulty, replace the water pump assembly.

2.2 Inspecting thermostat

&$87,21
Be careful of burns or a fire when measuring tempera-
ture, as it involves a high-temperature and open flame.
To test the thermostat operation, immerse the thermostat in a
container filled with water. Heat the water, while measuring
the water temperature. Record the temperature at the
conditions shown in the table below. If the temperatures are
not within the standard range, replace the thermostat.
Note: (a) Stir the water in the container with a stick to
ensure uniform temperature distribution.
Inspecting thermostat
(b) Before installing the thermostat, be sure to check
the valve opening temperature stamped on the
thermostat valve side face.

Item Standard
Temperature at which valve starts 71 ± 2°C
opening [160 ± 3.6°F]
Temperature at which valve lift
85°C [185°F]
becomes 10 mm [0.39 in.] or more.

Note: When assembling, orient the thermostat with its air

breed hole faced upward.

10-3
COOLING SYSTEM

3. Installing cooling system

Replace

Crack, water leakage, damage

Replace

M10 × 1.5
35 ± 3.5 N·m {3.6 ± 0.3 kgf·m} [25.3 ± 2.2 lbf·ft]
M8 × 1.25
19 ± 1.9 N·m {1.9 ± 0.2 kgf·m} [13.7 ± 1.4 lbf·ft]

Crack, wear

Installing cooling system

10-4
 INLET AND EXHAUST SYSTEM
1. Removing inlet and exhaust
sysytem .........................................11-2
1.1 Removing inlet system........................... 11-2
1.2 Removing exhaust system..................... 11-3

2. Disassembling, inspecting and

reassembling inlet and exhaust
system ...........................................11-4
2.1 Measuring exhaust manifold distortion .. 11-4

3. Installing inlet and exhaust system11-5

3.1 Installing inlet system............................. 11-5
3.2 Installing exhaust system....................... 11-6

11-1
INLET AND EXHAUST SYSTEM

1. Removing inlet and exhaust sysytem

1.1 Removing inlet system

Air inlet
Cylinder head

Replace Replace
2

Replace

Removing inlet system

Removing sequence

1 Air inlet elbow 2 Air heater 3 Inlet manifold

11-2
 INLET AND EXHAUST SYSTEM

1.2 Removing exhaust system

Replace 1

Cylinder head

Replace

Removing exhaust system

Removing sequence

1 Turbocharger 2 Exhaust manifold

11-3
INLET AND EXHAUST SYSTEM

2. Disassembling, inspecting and reassembling inlet and exhaust system

2.1 Measuring exhaust manifold distortion
(1) Check the flange for crack.
(2) Check the flange suface for distortion. If the distortion
exceeds the standard, retouch the surface.

Item Standard
Less than 0.2 mm
Exhaust manifold distortion
[0.008 in.]

Measuring exhaust manifold distortion

11-4
 INLET AND EXHAUST SYSTEM

3. Installing inlet and exhaust system

3.1 Installing inlet system

19 ± 2 N·m
{1.9 ± 0.2 kgf·m}
[13.7 ± 1.4 lbf·ft]

Air inlet
Cylinder head

Replace Replace

Replace

Installing inlet system

11-5
INLET AND EXHAUST SYSTEM

3.2 Installing exhaust system

Replace

Cylinder head

Replace

19 ± 2 N·m
{1.9 ± 0.2 kgf·m}
[13.7 ± 1.4 lbf·ft]

Installing exhaust system

11-6
 ELECTRICAL SYSTEM
1. Removing electrical system ..........12-2
1.1 Removing starter.................................... 12-2
1.2 Inspecting before removing alternator ... 12-3
1.2.1 Inspecting alternator operation.................12-3
1.2.2 Handling precaution .................................12-3
1.3 Removing alternator............................... 12-4
2. Disassembling, inspecting and
reassembling electrical system .....12-5
2.1 Disassembling and inspecting starter .... 12-5
2.1.1 Removing pinion set.................................12-6
2.1.2 Removing magnet switch .........................12-7
2.1.3 Removing rear bracket .............................12-7
2.1.4 Removing brush holder and
brush assembly ........................................12-8
2.1.5 Removing yoke and armature ..................12-8
2.1.6 Removing planetary gear .........................12-9
2.1.7 Removing overrunning clutch.................12-10
2.1.8 Removing internal gear ..........................12-11
2.2 Inspecting and repairing starter ........... 12-12
2.2.1 Inspecting magnetic switch ....................12-12
2.2.2 Inspecting magnetic switch contactor ....12-12
2.2.3 Measuring armature shaft runout ...........12-12
2.2.4 Measuring commutator radial runout .....12-13
2.2.5 Measuring undercut depth .....................12-13
2.2.6 Inspecting insulation between commutator and
shaft (core) .............................................12-13
2.2.7 Inspecting field coil .................................12-14
2.2.8 Inspecting overrunning clutch ................12-14
2.2.9 Inspecting reduction gear .......................12-14
2.2.10 Inspecting bearings ................................12-14
2.2.11 Inspecting brushes for wear ...................12-15
2.2.12 Measuring brush spring load ..................12-15
2.2.13 Inspecting safety switch .........................12-15
2.3 Reassembling starter ........................... 12-16
2.3.1 Installing E-ring ......................................12-16
2.3.2 Installing shaft lever ...............................12-16
2.3.3 Installing ball ..........................................12-16
2.3.4 Installing cover .......................................12-17
2.3.5 Installing yoke ........................................12-17
2.3.6 Installing pinion ......................................12-18
2.4 Disassembling and inspecting alternator12-19
2.4.1 Removing cover .....................................12-20
2.4.2 Removing through bolts .........................12-20
2.4.3 Disassembling the alternator to front side and
rear side .................................................12-20
2.4.4 Removing fan and pulley........................12-21
2.4.5 Removing rotor.......................................12-21
2.4.6 Removing front bearing ..........................12-21
2.4.7 Removing field coil ................................ 12-22
2.4.8 Removing stator .................................... 12-22
2.4.9 Removing rear bracket locked-in parts.. 12-23
2.5 Inspecting alternator............................. 12-24
2.5.1 Inspecting rectifier ................................. 12-24
2.5.2 Inspecting condensor ............................ 12-24
2.5.3 Inspecting regulator ............................... 12-24
2.5.4 Inspecting field coil ................................ 12-25
2.5.5 Inspecting stator coil.............................. 12-25
2.5.6 Inspecting bearings ............................... 12-26
2.6 Reassembling alternator ...................... 12-27
2.6.1 Installing rectifier.................................... 12-27
2.6.2 Slodering field coil and regulator ........... 12-27
2.6.3 Slodering stator coil and rectifier ........... 12-27
2.6.4 Reassembling front bearing................... 12-27
2.6.5 Reassembling front bracket and rotor ... 12-28
2.6.6 Installing rear bracket ............................ 12-28
2.6.7 Installing through bolt ............................ 12-28
2.7 Inspecting after reassembling .............. 12-28
2.8 Performance test of alternator.............. 12-29
2.8.1 Measuring regulator adjusting voltage... 12-29
2.8.2 Measuring output current....................... 12-29
3. Installing electrical system .......... 12-30
3.1 Installing starter.................................... 12-30
3.2 Installing alternator............................... 12-31
3.3 Replacing ECU..................................... 12-32
3.3.1 Removing ECU...................................... 12-32
3.3.2 Installing ECU........................................ 12-32
3.3.3 Test operation after replacing ECU ....... 12-32
3.4 Installing sensors ................................. 12-33
12-1
ELECTRICAL SYSTEM

1. Removing electrical system

1.1 Removing starter

Removing starter
Removing sequence

1 Starter

12-2
 ELECTRICAL SYSTEM

1.2 Inspecting before removing alternator

1.2.1 Inspecting alternator operation
Locate the cause of faulty charging from malfunctions
described below. Do not remove the alternator for
inspection and repair unless inspection cannot be performed
with the alternator installed on the engine.

Adjusted value of voltage regulator is high.

Overcharge
Faulty battery.
Low adjusted value of voltage relay.
Faulty alternator output.
Over dis-
Electric power consumption is extremely high.
charge
Special load is used.
Faulty wiring.

1.2.2 Handling precaution

Improper handling could cause damage or failure to the
alternator.
(1) Connect battery cables correctly. B terminal is positive
(+), and E terminal is negative (-).
(2) Do not use any high voltage tester such as megger.
(3) Do not disconnect lead wire from B terminal of the
alternator while the engine is running.
(4) Battery voltage is constantly applied to B terminal of
the alternator. Do not ground at this terminal.
(5) Do not short circuit or ground at L terminal. (For a
built-in IC regulator type)
(6) When a steam cleaner is used, do not allow the steam
directly contact the alternator.

12-3
ELECTRICAL SYSTEM

1.3 Removing alternator

Removing alternator
Removing sequence

1 Alternator 2 Adjusting plate 3 Set bolt

12-4
 ELECTRICAL SYSTEM

2. Disassembling, inspecting and reassembling electrical system

2.1 Disassembling and inspecting starter

11
12
4
14
Open or short circuit

25
18
15
16
17 Damage, wear

13

23 Damage, wear
24
22
Damage, wear
3 21
19 Replace

20 Function of
overrunning clutch
2
6
1 Replace
5
Wear
Damage, wear
7

Replace Brush dust accumulation,

8
local wear, rust,
Replace
deterioration, insulation

Open or short circuit

9

Open or short circuit,

10 ground, damage, wear

Disassembling and inspecting starter

Disassembling sequence

1 Clip ring 10 Armature 19 E ring

2 Pinion stopper, pinion, spring 11 Cover 20 Over runnning clutch
3 Bolt 12 Packing 21 Internal gear
4 Magnet switch 13 Planetary gear 22 Plate
5 Screw 14 Ball 23 Gear shaft
6 Through bolt 15 Packing 24 Front bracket
7 Rear bracket 16 Plate 25 Safety relay
8 Brush holder 17 Spring
9 Yoke assembly 18 Shift lever

12-5
ELECTRICAL SYSTEM

2.1.1 Removing pinion set

(1) Install the jig to hold the pinion.

Removing pinion set (1)

(2) Place an appropriate tube on the pinion stopper.
Hit the tube with a hammer to push the pinion stopper
down.

Removing pinion set (2)

(3) Remove the clip ring using snap ring plier.
Note: Do not reuse the clip ring for reassembly.

Removing pinion set (3)

(4) Remove the pinion stopper, pinion, spring.

Note: Check the pinion for wear and damage.

Removing pinion set (4)

12-6
 ELECTRICAL SYSTEM

2.1.2 Removing magnet switch

(1) Disconnect the terminal M leads on the magnetic
switch.

Removing magnet switch (1)

(2) Remove the through bolts, and remove the magnetic
switch.

Removing magnet switch (2)

2.1.3 Removing rear bracket
(1) Remove the screws from the rear bracket.

Removing rear bracket (1)

(2) Remove the through bolts, and remove the rear bracket.

Removing rear bracket (2)

12-7
ELECTRICAL SYSTEM

2.1.4 Removing brush holder and brush assem-

bly
(1) Remove the brush holder.
(2) Lift the brush spring up, and remove the brush from the
brush holder.

Removing brush

2.1.5 Removing yoke and armature

(1) Remove the yoke, and the armature.

Removing yoke and armature (1)

(2) Remove the front side O-ring and the rear side O-ring.
Do not reuse the removed O-ring. Replace it with new
one.

O-ring O-ring

Removing yoke and armature (2)

12-8
 ELECTRICAL SYSTEM

2.1.6 Removing planetary gear

(1) Remove the cover.

Removing planetaly gear (1)

(2) Remove the packing.

Removing planetaly gear (2)

(3) Remove the planetary gears.

Removing planetaly gear (3)

(4) Remove the balls from the shaft.

Note: Be careful not to lose the ball.

Removing planetaly gear (4)

12-9
ELECTRICAL SYSTEM

2.1.7 Removing overrunning clutch

(1) Remove the packing, the plate and the spring.

Removing overrunning clutch (1)

(2) Remove the shift lever and overrunning clutch from the
front bracket cover.

Removing overrunning clutch (2)

(3) Insert the flat-blade screwdriver to the groove of the E-
ring, then remove the E-ring.

Removing overrunning clutch (3)

(4) Remove the overrunning clutch.

Removing overrunning clutch (4)

12-10
 ELECTRICAL SYSTEM

2.1.8 Removing internal gear

Remove the internal gear.

Removing internal gear

12-11
ELECTRICAL SYSTEM

2.2 Inspecting and repairing starter

2.2.1 Inspecting magnetic switch
Inspect the pressure coil and the holding coil for open
circuit using the tester.
Inspect the electrical continuity between the terminal M and
the case, if there is no electrical continuity between them,
the magnetic switch circuit is an open circuit.

Inspecting magnetic switch

2.2.2 Inspecting magnetic switch contactor

The service limit of the contactor is decided by the S.S
condition of the contact surface. Inspect the contactor by C
following method. B
A
Measure the load current of the starter. If the voltage drop Ammeter
between the terminal B and the terminal M is 0.3 V per 100 C2 C1
M V

Battery
A or more, replace the magnetic switch. F1
Note: (a) When measuring the voltage drop, use a digital Digital voltmeter
volt meter. Measuring by an analog volt meter Ar

results breakage. E
Starter
(b) Be extremely careful when connecting an
ammeter to the starter because of the high current Inspecting magnetic switch contactor
flowing into the starter.

2.2.3 Measuring armature shaft runout

Using a dial gauge, measure the shaft runout. If the runout
exceeds the standard, repair or replace the armature.
Armature shaft
Item Standard
0.06 mm
Armature shaft runout
[0.0024 in.]

Measuring armature shaft runout

12-12
 ELECTRICAL SYSTEM

2.2.4 Measuring commutator radial runout

(1) Inspect the commutator surface. If the surface is rough,
polish it using a 400 to 600 grit sandpaper.
(2) Measure the commutator radial runout with a dial
gauge. If the measured value exceeds the limit, replace
the armature with a new one.

Item Limit
Commutator radial
0.10 mm [0.0039 in.] Commutator
runout

Measuring commutator radial runout

2.2.5 Measuring undercut depth
Measure the depth of undercutting between the commutator
segments.
If the measured value is less than the limit, repair or replace Insufficient recutting
with a new part. Defective Good
(need recutting)

Item Standard Limit

0.7 to 0.9 mm
0.7 to 0.9 mm 0.2 mm [0.028 to 0.035 in.]
Undercutting depth
[0.028 to 0.035 in.] [0.008 in.]

Measuring undercut depth

2.2.6 Inspecting insulation between commutator
and shaft (core)
(1) Inspect the armature coil using a growler. Apply a iron Iron plate
Growler tester
plate to the armature core. Replace the armature if the
iron plate vibrates.

Inspecting armature coil for short circuit

(2) Check the insulation between the commutator and the
shaft with a tester. If faulty, replace the armature with a
new one.

Inspecting insulation between commutator and shaft

12-13
ELECTRICAL SYSTEM

2.2.7 Inspecting field coil

(1) Inspect the field coil for open circuit with a tester. It is
an open circuit if there is no conticuity between the
terminal M of field coil and the bush lead.
(2) Inspect the electrical conticuity between the field coil
and the yoke with a tester.

Inspecting field coil for open circuit

2.2.8 Inspecting overrunning clutch
(1) Rotate the pinion by hand and check that the pinion
rotates lightly to one direction.
(2) Inspect the tooth flank. If wear or damage is found,
replace it with new one.

Inspecting over running clutch

2.2.9 Inspecting reduction gear
Inspect the reduction gear for wear.

Inspecting reduction gear

2.2.10 Inspecting bearings
Rotate the outer race of bearing by hand. Check that the
outer race rotates smoothly. Bearing

Inspecting bearing

12-14
 ELECTRICAL SYSTEM

2.2.11 Inspecting brushes for wear

Measure the length of the brushes. If the measured value is Unit: mm [in.]
less than the limit, replace both the brush holder assembly
and the brush assembly with new ones.

[0.67 to 0.71]
[0.40]
17 to 18
10
Item Standard Limit
17 to 18 mm 10 mm
Brush length
[0.67 to 0.71 in.] [0.40 in.]

Wear limit

Inspecting brush for wear

2.2.12 Measuring brush spring load

Using a new brush, measure the spring load at which the
spring lifts from the brush. If the measured value is less than
the limit, replace the spring with a new one.

Item Standard Limit

Less than
21.56 to 27.44 N
Brush spring load 21.56 N
{2.2 to 2.8 kgf}
(when brush is installed) {2.2 kgf}
[15.9 to 20.3 lbf]
[15.9 lbf]

2.2.13 Inspecting safety switch

&$87,21 Safety relay

ground (E) terminal
When connecting the battery, be sure to connect the
battery in correct polarity. Terminal S

Connect the components as shown and check the operation

of starter and safety switch.
(1) Connect the terminal R to the battery negative terminal.
(2) Turn on the switch and check if the starter operates
Terminal R
(rotates).
(3) While operating the starter, disconnect the terminal R
from the battery negative terminal and connect the Inspecting operation of safety switch
terminal R to the battery positive terminal. Check if the
starter stops.
Note: On some specifications, starter stops operation when
the connection to the battery negative terminal is
disconnected.

12-15
ELECTRICAL SYSTEM

2.3 Reassembling starter

To reassemble the starter, follow the disassembly in reverse order and observe bellow.
2.3.1 Installing E-ring
Install the washer, the center bracket and overrunning clutch
assembly to the shaft, and install the E-ring.
Note: Install the E-ring using a plier.

Installing E-ring

2.3.2 Installing shaft lever

Being careful with the direction, install the shift lever.
Note: Apply grease (Nikko grease R) to the shift lever when
reassembling.

Installing shift lever

2.3.3 Installing ball

Be careful not to forget to install the ball to the shaft before
installing the planetary gears.

Installing ball

12-16
 ELECTRICAL SYSTEM

2.3.4 Installing cover

(1) Be careful with the installation position when installing
the cover.
Notch

Cover

Installing cover

2.3.5 Installing yoke

(1) Install the yoke to the front bracket with aligning the
mark.

Installing yoke (1)

(2) Install the yoke to the rear bracket with aligning the
mark.

Installing yoke (2)

12-17
ELECTRICAL SYSTEM

2.3.6 Installing pinion

(1) Install the spring and the pinion, and install the jig.
(plate)

Plate

Installing pinion (1)

(2) Install the pinion stopper. Insert the clip ring to the jig
(holder) and install the clip ring using the jig. (guide)

Holder

Guide

(3) Using the jig (presser), install the clip ring to the pinion Installing pinion (2)
stopper.

Installing pinion (3)

12-18
 ELECTRICAL SYSTEM

2.4 Disassembling and inspecting alternator

4 5
6
3
3
11 Crack, damage

Rotation
10

9
12
7
17
Coil open circuit, ground
3

14

8 13

Rotation
22 Short or open circuit

16 20

18 19

23
15
Crack, damage
21

2 1

Disassembling and inspecting alternator

Disassembling sequence

1 Screw 9 Retainer 17 Stator coil

2 Cover 10 Front bearing 18 Holder
3 Through bolt 11 Front bracket 19 Regulator
4 Nut, spring washer, plain washer 12 Collar 20 Terminal B
5 Pulley 13 Rear bearing 21 Condensor
6 Fan 14 Rotor 22 Rectifier
7 Collar 15 Screw 23 Rear bracket
8 Screw 16 Field coil

12-19
ELECTRICAL SYSTEM

2.4.1 Removing cover

Remove the screws, and remove the cover.

Removing alternator cover

2.4.2 Removing through bolts
Remove the through bolts which secures front side and rear
side.

Removing through bolt

2.4.3 Disassembling the alternator to front side
and rear side
(1) Disassemble the alternator to front side and rear side. Heat the
Disassemble the alternator with heating the rear bracket bearing case
bearing case. Disassembling the alternator without
heating the rear bracket bearing case cause the damage
of the alternator.
Note: Be sure to heat the rear bracket bearing case only. Do
not heat the other parts.

Disassembling alternator to front side and rear side (1)

(2) Remove the rotor from the front bracket using press.
Then, use the through bolt hole.
Note: Do not hit the alternator with plastic hammer.
Protect the parts
from damage

Disassembling alternator to front side and rear side (2)

12-20
 ELECTRICAL SYSTEM

2.4.4 Removing fan and pulley

Remove the nuts using an inpact wrench, then remove the
spring washer, the plain washer, the pulley, the fan and the
collar.
Note: Fixing the rotor with vice could result the
deformation. Do not use the vice.

Removing fan and pulley

2.4.5 Removing rotor
Remove the rotor from the front bracket.
Note: (a) Remove the rotor using the press.
(b) When working with the rotor, place the buffer
under the rotor to prevent the damage.

Removing rotor
2.4.6 Removing front bearing
(1) Remove the screws, and remove the retainer.

Removing retainer
(2) Remove the front bearing from the front bracket.
Note: Do not reuse the removed front bearing. Replace it
with new one.

Removing bearing

12-21
ELECTRICAL SYSTEM

2.4.7 Removing field coil

(1) Unsolder the field coil and regulator.
Note: Unsoldering must be finished by 5 seconds or less.

(2) Remove the screws, and remove the field coil. Removing field coil (1)

Removing field coil (2)

2.4.8 Removing stator
(1) Unsolder the stator coil and the rectifier.

Removing stator (1)

(2) Remove the stator from the rear bracket.

Removing stator (2)

12-22
 ELECTRICAL SYSTEM

2.4.9 Removing rear bracket locked-in parts

(1) Remove the screws from the rear bracket.
Rectifier
(2) Remove the screws from the regulator, and remove the Terminal B
regulator. Condensor
(3) Remove the screw from the terminal B, and remove the
terminal B.
(4) Remove the screw from the condensor, and remove the
Regulator
condensor.
(5) Remove the rectifier assembly.

Removing rear bracket locked-in parts

12-23
ELECTRICAL SYSTEM

2.5 Inspecting alternator

2.5.1 Inspecting rectifier
Check the rectifier for resistance of forward direction and
reverse direction.
If the resistance of forward direction is low, and the
resistance of reverse direction is high, it is normal.
If test result is not as above, it is faulty. Replace the rectifier
with new one.

Inspecting rectifier

2.5.2 Inspecting condensor

Charge the condensor with a tester. (RangeΩ × 1000)
Connect the tester lead in reverse direction. It is normal that
the pointer moves slightly and return.
If test result is not as above, it is faulty. Replace the
condensor with new one.

Inspecting condensor

2.5.3 Inspecting regulator

Measure the resistance between the regulator connector R
and L with a tester. (Range Ω × 1000)
If the diode of the regulator and the resistor of the regulator
are normal, the resistance of the forward direction is low
and the resistance of the reverse direction is high.
If test result is not as above, it is faulty. Replace the
regulator with new one.

Inspecting regulator

12-24
 ELECTRICAL SYSTEM

2.5.4 Inspecting field coil

(1) Inspect the insulation of the field coil.
Measure the electrical continuity between the terminal
and the core with a tester. (RangeΩ × 1000)
Replace the field coil with new one if electrical
continuity is indicated.

Inspecting field coil (1)

(2) Measure the resistance between the terminals of field
coil.
If measured resistance is Approx 6.62Ω (When 20°C
[68°F]), it is normal.
If test result is not as above, it is faulty. Replace the
field coil with new one.

Inspecting field coil (2)

2.5.5 Inspecting stator coil
(1) Inspect the insulation of the stator coil.
Measure the electrical continuity between the stator coil
and the core with a tester. (RangeΩ × 1000)
Replace the stator coil with new one if electrical
continuity is indicated.

Inspecting stator coil (1)

(2) It is normal that the electrical continuity is indicated
between the stator coil lead N and other three leads.
If test result is not as above, it is faulty. Replace the
stator coil with new one.

Inspecting stator coil (2)

12-25
ELECTRICAL SYSTEM

2.5.6 Inspecting bearings

Inspect the bearing for smooth rotation and abnormal noise.
If abnormality is found, replace the bearing with new one.

Inspecting bearing

12-26
 ELECTRICAL SYSTEM

2.6 Reassembling alternator

To reassemble the alternator, follow the disassembly in reverse order and observe bellow.
2.6.1 Installing rectifier
When reassembling the rectifier, apply rocktite to the
screws.

Installing rectifier
2.6.2 Slodering field coil and regulator
Soldering field coil and regulator must be finished as
quickly as possible.

Soldering field coil and regulator

2.6.3 Slodering stator coil and rectifier
Solder the stator coil and rectifier after caulking.
Soldering must be finished as quickly as possible.

Soldering stator coil and rectifier

2.6.4 Reassembling front bearing
Reassemble the front bearing with heating the front bearing
case.
Reassembling the front bearing without heating the front
bearing case cause the damage of front bearing.

Reassembling front bearing

12-27
ELECTRICAL SYSTEM

2.6.5 Reassembling front bracket and rotor

Use a press to reassemble the front bracket and the rotor.
Note: Be careful not to forget to install the collar when
Collar
reassembling.

Reassembling front bracket and rotar

2.6.6 Installing rear bracket
Reassemble the rear bracket with heating the bearing case.
Note: (a) Reassembling the rear bracket without heating
the bearing case cause the damage of the bearing.
(b) Be sure to heat the bearing case only. Do not heat
the other parts.

Installing rear bracket

2.6.7 Installing through bolt
Install the through bolt with fixing the front side and the rear
side using the alternator installation hole.

Installing through bolt

2.7 Inspecting after reassembling
After reassembling, rotate the pulley by hand to check the
smooth rotation.

Inspecting alternator after reassembling

12-28
 ELECTRICAL SYSTEM

2.8 Performance test of alternator

Measure the adjusting voltage and output current with wiring as schematic bellow.

Terminal R Terminal L SW1 SW2

CL (24V 3W)

+
V
-

Electric schematic of IC regulator built-in alternator performace test

2.8.1 Measuring regulator adjusting voltage 2.8.2 Measuring output current

(1) Close the SW1, and operate the alternator at 1500min-1
for 5 to 10 minutes until the ammeter indicates 6 A or
less.
(2) Make sure that ammeter indicates 2 to 6 A or less, then
operate the alternator at 3000 to 4000min-1.
If the indication of voltmeter is within the standard
value, the adjusting voltage of the alternator is normal.
(3) If the indication of ammeter is 6 A or more, charge the
battery for a while or replace the battery with fully
charged one.
If the indication of voltmeter is out of the standard
value, replace the regulator with new one.
Close the SW1 and SW2. Measure the maximaum output
current with a variable resistor operating the alternator at
5000min-1 and keeping the indication of voltmeter at 27 V.
It is normal that the measured output current is 50A or
more.
&$87,21
(a) Do not disconnect the battery when operating the
alternator.
(b) Do not connect the terminal L when the charge
lamp （24V, 3W）is not used. The terminal L and
circuit B must not be connected. It causes damege
of diode.

Item Standard
Adjusting voltage 27.5 to 29.5 V (at 25°C [77°F])

12-29
ELECTRICAL SYSTEM

3. Installing electrical system

3.1 Installing starter

35.3 ± 5.9 N·m

{3.6 ± 0.6 kgf·m}
[255.4 ± 42.6 lbf·ft]

Installing starter

12-30
 ELECTRICAL SYSTEM

3.2 Installing alternator

97 ± 9.7 N·m
{9.9 ± 1.0 kgf·m}
[71.6 ± 7.2 lbf·ft]

Installing alternator

12-31
ELECTRICAL SYSTEM

3.3 Replacing ECU

3.3.1 Removing ECU
(1) Make sure that the ignition switch is in the OFF
position.
(2) Uplift the lever of the connector, and pull out the
connector. Then, do not pull the harness. Pull out the
connector with holding the connector.
Note: (a) Do not forget to uplift the lever before pulling out
the connector. Do not pull the connector forcedly.
(b) Be careful for the removed connector not to
contact with other parts.
(3) Remove the ECU mouting bolts. Replacing ECU（1）
(4) Remove the ECU.

3.3.2 Installing ECU

(1) Make sure that the Q-Rank number attached on the new
ECU is same as the number attached on the previous
ECU.
Note: If the ECU which has different Q-Rank number is
installed, it causes the excess and deficiency of the
engine power.
(2) Install the ECU and tighten the ECU mouting bolts to
specified torque.
(3) Push the connector into the ECU securely, and push Replacing ECU（2）
down the lever to lock. After connecting, check the
connector for excessive play.

3.3.3 Test operation after replacing ECU

(1) Turn the ignition switch to ON position. If the diagnosis
code is not displayed on the monitor for 2 to 3 minutes,
start the engine and operate the engine in low idle.
(2) Inspect that the diagnosis code is displayed on the
monitor. Inspect the engine for noise, odor and
vibration.

12-32

3.4 Installing sensors
Speed/timing sensor
(crankshaft side)
9 ± 1 N·m
{0.9 ± 0.1 kgf·m}
[6.5 ± 0.7 lbf·ft]
Pick up
29.4 ± 4.9 N·m
{3.0 ± 0.5 kgf·m}
[212.8 ± 35.5 lbf·ft]
ELECTRICAL SYSTEM
Inlet manifold pressure sensor
25 ± 2 N·m
{2.5 ± 0.2 kgf·m}
[18.1 ± 1.4 lbf·ft]
Water temperature sensor
21 ± 2 N·m
{2.0 ± 0.2 kgf·m}
[15.2 ± 1.5 lbf·ft]
Oil pressure switch
1.0 ± 2 N·m
{1.0 ± 0.2 kgf·m}
[7.2 ± 1.4 lbf·ft]
Speed/timing sensor
(camshaft side)
9 ± 1 N·m
{0.9 ± 0.1 kgf·m}
[6.5 ± 0.7 lbf·ft]
Installing sensors
12-33
 ADJUSTMENT AND OPERATION
1. Adjusting engine............................13-2
1.1 Inspecting and adjusting valve clearance13-2
1.1.1 Inspecting valve clearance .......................13-2
1.1.2 Adjusting valve clearances.......................13-2
1.2 Inspecting belt and adjusting belt tension13-3
1.2.1 Checking the belt .....................................13-3
1.2.2 Adjusting the belt tension .........................13-3

2. Break-in operation.........................13-4
2.1 Starting up.............................................. 13-4
2.2 Inspecting engine condition after
starting up .............................................. 13-4
2.3 Break-in operation time.......................... 13-4
2.4 Inspection and adjustment after break-in
operation ................................................ 13-4

3. Performance test (JIS standard) ...13-5

3.1 Engine equipment condition................... 13-5
3.2 Test items and purposes........................ 13-5
3.2.1 Operation load test ...................................13-5
3.2.2 Continuous load test ................................13-5
3.2.3 Low idle test .............................................13-5
3.3 Other inspections ................................... 13-5
3.4 Engine output adjustment ...................... 13-5
3.4.1 Standard atmospheric conditions: ............13-5
3.4.2 Calculation of corrected power.................13-6

13-1
ADJUSTMENT AND OPERATION

1. Adjusting engine
1.1 Inspecting and adjusting valve clearance
Inspect and adjust the valve clearance.
The valve clearance should be inspected and adjusted when
the engine is cold.
Note: (a) The inlet values are on the left side and the
exhaust values are on the right side when the
cylinder head is viewed from the camshaft gear
side.
(b) The valve clearance standard values are indicated
on the caution plate on the No.1 cylinder rocker
cover.

Item Standard
0.25 mm
Inlet
[0.0099 in.]
Valve clearance
0.40 mm
Exhaust
[0.0157 in.]

1.1.1 Inspecting valve clearance

(1) Inspect the valve clearance for all cylinders in the firing
Model Firing order Turning angle
order by turning the crankshaft to the specified degrees
D04FR 1-3-4-2 180°
in the normal direction (clockwise when viewed from
engine front side) to bring each piston to the top dead
center on the compression stroke.
"0" graduation mark on
Note: To turn the crankshaft, fit a socket and ratchet handle
crankshaft pulley
on the crankshaft pulley nut.
(2) When the No. 1 piston is at the top dead center on the
0 40
compression stroke, the "0" graduation mark on the
periphery of the crankshaft pulley is aligned with the
pointer on the timing gear case, and neither the inlet Inspecting valve clearance
valve nor the exhaust valve is not lifted off its seat by
the push rod.
(3) Insert a thickness gauge between the rocker arm and
valve cap to inspect the clearance.

1.1.2 Adjusting valve clearances

(1) Insert the feeler gauge of the specified thickness
between the rocker arm and bridge cap, then adjust the
clearance by turning the screw in either direction so that
the gauge is gripped softly between the rocker arm and
bridge cap.
(2) After adjusting the clearance, tighten the lock nut
firmly, and inspect the clearance again.

Adjusting valve clearance

13-2
 ADJUSTMENT AND OPERATION

1.2 Inspecting belt and adjusting belt tension

&$87,21
(a) If defects such as cuts or surface separations are Adjusting bolt
found during inspection, replace the belt. Alternator
(b) Keep oil and grease away from the belt, since they
may cause the belt to slip and shorten the service
life.
(c) Excessive belt tension can cause rapid wear of the Belt
alternator bearing and shorten the service life of
the belt. Adjust the belt tension accurately by fol-
lowing the procedures below.
Adjusting belt tension
1.2.1 Checking the belt
(1) Inspect the belt visually for separation or damage. If
any abnormality is found, replace the belt with a new
one.
(2) Inspect belt tension (deflection).
When pressing the belt strongly at the center of its span,
the deflection for a new belt should be 5±1 mm
[0.20±0.04 in.] and the deflection for the belt that is
reused should be 8±1 mm [0.32±0.04 in.]
Force on the belt: Approximately 98±10 N {10±1 kgf}
[22±2.2 lbf]
If the deflection of belt is not within the standard, adjust
the belt tension.
1.2.2 Adjusting the belt tension
(1) Remove the belt cover.
(2) Loosen all retaining bolts of the alternator and adjusting
plate.
(3) Adjust V-belt tension properly with the adjusting bolt.
(4) Tighten all retaining bolts of the alternator and
adjusting plate.
(5) Install the belt cover.

13-3
ADJUSTMENT AND OPERATION

2. Break-in operation
After the engine is overhauled, couple the engine to the 2.3 Break-in operation time
dynamometer, and run the engine for break-in operation and The relationship between the load in break-in operation and
inspection. the operation time is as shown below.

2.1 Starting up Break-in operation time

(1) Before starting the engine, check the levels of coolant, Duration
Engine speed (min-1) Load
engine oil and fuel. (min)
Bleed air from the fuel and cooling systems. Low
(2) Stop the fuel supply, and crank the engine with the 1 rotation 800 to 1100 No-load 5
speed
starter for about 10 seconds to lubricate the engine.
(3) Move the control lever slightly in the fuel increase Medium
2 rotation 1200 to 1500 No-load 5
direction (but not to the "full injection" position), and
speed
then turn the starter switch key to the [START] position
High
to start the engine.
3 rotation 1600 to rated speed No-load 10
(4) After the engine is started, adjust the control lever to let speed
the engine operate at a minimum no-load speed (low
4 25 % 10
idle speed).
5 50 % 10
(5) Turn the starter switch key to the [OFF] position and Rated speed
make sure that the engine is stopped. 6 75 % 30
7 100 % 20
2.2 Inspecting engine condition after starting
Note: The table above is provided solely for reference
up
During the break-in operation, check the followings. purpose. Run the engine at appropriate speed and
If any abnormality is found, stop the engine, investigate the load for the break-in operation of your engine. Be
cause, and take appropriate measures. sure to perform break-in operation after overhaul or
installation.
(1) The oil pressure must be within the specified value.
(2) The coolant temperature must be within the specified
2.4 Inspection and adjustment after break-in
value.
operation
(3) The engine must be free from any leakages such as oil,
(1) Valve clearance adjustment
coolant and fuel. Pay special attention to oil leakage
(2) Ignition timing inspection
from the fitting face of turbocharger lube oil pipe.
(3) Exterior bolt and nut tightness check
(4) Check for an abnormal noise.
Note: Knocking noise will disappear as the coolant
temperature rises.
(5) Check for the color of smoke and odors.

13-4
 ADJUSTMENT AND OPERATION

3. Performance test (JIS standard)

The following describes the procedures specified in "Earth
moving machinery - Engines - Part 1: Test code of net
power (JIS D0006-1)" and "Earth moving machinery -
Engines - Part 2: Standard format of specifications and
testing methods of diesel engines (JIS D0006-2)."
Other test items may be required in some applications. All
test results should be evaluated comprehensively in order to
determine the engine performance.

3.1 Engine equipment condition

The engine must be equipped with standard auxiliary
devices such as cooling fan, air cleaner and alternator.

3.2 Test items and purposes

3.2.1 Operation load test
Conduct this test to evaluate the engine output, torque, fuel
consumption rate and governor performance under various
load conditions.
3.2.2 Continuous load test
Operate the engine continuously for 10 hours at 90% load
(continuous load application) of nominal net brake power
while the engine speed is maintained at revolutions
corresponding to the nominal brake power. In this test,
evaluate the fuel consumption rate and operating condition,
and confirm that the engine is capable of continuous
operation.
3.2.3 Low idle test
Conduct this test to confirm that the engine can operate
stably at the specified low idle speed.

3.3 Other inspections

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

3.4 Engine output adjustment

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

13-5
ADJUSTMENT AND OPERATION

3.4.2 Calculation of corrected power

Multiply the measured brake power or torque by the
calculated diesel engine correction factor to obtain a
corrected value.
If the applicable range of the correction formula is
exceeded, indicate the corrected values and record the test
conditions on the test record.

Colculation output = Correction factor

ǩc˜Measured brake power
࡮Atmospheric conditions during test
Temperature(T ):-
q
=q
% (?҇T ҇-
q
=q
% (?
Dry atmospheric pressure(Pd ):M2C
OO*I҇Pd ҇M2C
OO*I

ǩc=( f a ) f m ‫ޓ‬f a:Atmospheric factor‫ޓ‬fmEngine factor

࡮Range of correction equation use
‫ޓ‬6JGTCPIGQHEQTTGEVKQPHCEVQT
ǩcKUCUHQNNQYU
0.9҇ǩc҇1.1.
Calculation of engine factor
fm
Calculation of correction factor( f a ) f m0.036qc㧙1.14
࡮Natural aspiration engine and engine with qc%QTTGEVGFHWGNUWRRN[XQNWOG
mechanically driven air charger q
qc r
99 T 
f a 
㨯

z˜
(WGNHNQYTCVGg/s
Pd 298 q=

5VTQMGXQNWOGl˜
'PIKPGURGGFmin-1
࡮Turbocharged engine without air cooler z=120000
4E[ENGGPIKPG
or with air-to-air cooler r4CVKQDGVYGGPRTGUUWTGCVVWTDQEJCTIGTQT
99 
f a 
 T  CKTEQQNGTQWVNGVCPFCVOQURJGTKERTGUUWTG
㨯

Pd 298 ‫
ޓ‬r=1HQTPCVWTCNCURKTCVKQPGPIKPG
࡮Applicable range of engine factor
fm 
࡮Turbocharged engine with air-to-liquid
‫ޓ‬37.2҇qc҇65mg
lE[ENG
cooler
99  T  㨯qc҇37.2mg
lE[ENG㧦f m
EQPUVCPV
f a 
 㨯
 㨯65mg
lE[ENG҇qc㧦f m
EQPUVCPV
Pd 298

13-6
 TROUBLESHOOTING
1. Troubleshooting by diagnosis
codes.............................................14-2
1.1 Outline of control system ....................... 14-2
1.2 Diagnosis codes..................................... 14-2
1.3 Connecting scan tester and ECU........... 14-2
1.4 When ECU does not respond ................ 14-2

2. Scan tester ....................................14-3

2.1 Operation of scan tester......................... 14-3
2.1.1 Basic operation of scan tester ..................14-3
2.2 Check engine status .............................. 14-4
2.3 Check diagnosis codes .......................... 14-4
2.4 Check freeze data.................................. 14-4
2.5 Clear diagnosis codes............................ 14-4

3. Diagnosis code cross reference ....14-5

4. Troubleshooting reference chart ...14-7

4.1 Troubleshooting with diagnosis code..... 14-7
4.2 Related diagnosis code........................ 14-21

5. Inspecting sensors ......................14-25

5.1 Speed/timing sensor (crank, cam) ....... 14-25
5.2 Inlet manifold pressure sensor............. 14-25
5.3 Water temperature sensor ................... 14-25
5.4 Engine oil pressure switch ................... 14-26
5.5 Common rail pressure sensor.............. 14-26
5.6 Injector solenoid................................... 14-26
5.7 High pressure pump solenoid sensor
(MPROP) ............................................. 14-26

6. Inspecting wiring .........................14-27

6.1 Inspecting connector and harness ....... 14-27
6.1.1 Inspecting the intermittent fault ..............14-27
6.1.2 Inspecting connectors ............................14-27
6.1.3 Inspecting harness .................................14-27
6.1.4 Inspect open circuit and short circuit ......14-27
6.2 Pin location of the ECU connector and
extension harness connector ............... 14-28

14-1
 TROUBLESHOOTING
1. Troubleshooting by diagnosis codes
1.1 Outline of control system
This engine is controlled by electronic control unit (ECU).
The engine has the control parts and the sensors that
monitors the engine operation.
The ECU monitors the engine operation using the inputs
from various sensors, and controls the injectors and the fuel
injection pump.
This control system can provide appropriate engine control
for operating condition.
1.2 Diagnosis codes
When the ECU detects the abnormal engine operation
receiving signal input from the sensors, the ECU generates
an error code which is called a diagnosis code.
The diagnosis code includes the one which warns the
critical failure, and also the one which warns the light fault.
The diagnosis code can be seen on the monitor located on
the vehicle. It also can be seen by connecting the scan tester
（32G91-00600）to the ECU directly.
14-2
1.3 Connecting scan tester and ECU
To see the diagnosis code, connect the scan tester to the
ECU.
(1) Turn the ignition switch to OFF position.
(2) Connect the scan tester connector to the service
connector which is located on the vehicle.
(3) Turn the ignition switch to ON position.
1.4 When ECU does not respond
If the scan tester does not display with connecting to the
service connector, following conditions can be concerned.
• The harness and/or the connector between the service
connector and the ECU are faulty.
• The ECU is faulty.
At first, inspect the harness and connectors between the
service connector and the ECU. For the inspection, refer to
"Inspecting wiring"(14-28).
If the harness and the connectors are not faulty, replace the
ECU. For the replacement of ECU, refer to "Replacing
ECU"(12-32).
&$87,21
The engine may operates even if the ECU does not
respond with the scan tester. In this case, it is possible
that there are faults on the CAN circuit (communica-
tion circuit connecting the ECU and vehicle control
unit) inside the ECU. Do not operate the engine except
emergency situation, replace the ECU.
 TROUBLESHOOTING

2. Scan tester

mastertech

Startup screen OBD ΤFUNCTION MENU

YES NO ENTER

F1 F2 F3
HELP
1 2 3

F4 F5 F6
RCV
4 5 6
FUNCTION MENU OBD ΤTEST MENU
F7 F8 F9
SEND
7 8 9

F0 ON
EXIT 㧖 0 #
OFF

Vetronix

Scan tester

SELECT PROGRAM

Scan tester

2.1 Operation of scan tester (9) The menu screen of OBD Ⅱ FUNCTIONS is
Use scan tester to check the engine status and the diagnosis displayed.
codes. (10)Press EXIT key to return the previous screen.
2.1.1 Basic operation of scan tester (11)With pressing ON key, press EXIT key to turn off the
(1) Make sure that ignition key is OFF position. scan tester.
(2) Connect the scan tester to the service connector on the (12)Turn the ignition key to OFF position to turn off the
vehicle. ECU.
(3) Turn the ignition key to ON position to energize the
ECU.
(4) Press ON key located on the lower right section of scan
tester to energize the scan tester. When the scan tester is
energized, startup screen is displayed.
(5) Press ENTER key.
(6) FUNCTION MENU is dispalyed. Select SCAN TEST
and press ENTER key.
(7) SELECT PROGRAM is displayed. Select GLOBAL
OBD Ⅱ and press ENTER key.
(8) OBD Ⅱ TEST MENU is dispalyed. Select OBD Ⅱ
FUNCTIONS and press ENTER key.

14-3
TROUBLESHOOTING

2.2 Check engine status

(1) Select DATA LIST from the OBD Ⅱ FUNCTIONS
mastertech
menu and press ENTER key.
(2) The engine status is displayed. Check the engine status.

Vetronix

Engine status screen

2.3 Check diagnosis codes
(1) Select DTCs from the OBD Ⅱ FUNCTIONS menu and
mastertech
press ENTER key.
(2) DTC MENU is dispalyed. Select READ DTCs and
press ENTER key.
(3) The diagnosis codes are displayed. The diagnosis codes
are displayed in the order of generating. To display the
previous generated codes, press down key.
Vetronix

Diagnosis code screen

2.4 Check freeze data
(1) Select DTCs from the OBD Ⅱ FUNCTIONS menu and
mastertech
press ENTER key.
(2) DTC MENU is dispalyed. Select FREEZE DATA and
press ENTER key.
(3) The FREEZE DATA is displayed. The FREEZE DATA
is a backup data saving the engine status screen of when
the diagnosis code is generated.
Vetronix

Freeze data screen

2.5 Clear diagnosis codes
(1) Select DTCs from the OBD Ⅱ FUNCTIONS menu and
mastertech
press ENTER key.
(2) DTC MENU is dispalyed. Select CLEAR DIAG INFO
and press ENTER key.
(3) The confirmation screen is displayed. Press YES key,
and press ENTER key to delete the diagnosis codes.
However, the diagnosis codes cannot be deleted until
Vetronix

the recovery is completed.

Clear DIAG screen

14-4
 TROUBLESHOOTING

3. Diagnosis code cross reference

The P code shown in the chart below is displayed by connecting the scan tester to the service connector.
The vehicle side code is displayed on the vehicle monitor. Check the correspoding codes by following chart.
For the detail and treatment of diagnosis codes, refer to "Troubleshooting reference chart".

Table 14-1 Diagnosis code cross reference (2 / 4)

Table 14-1 Diagnosis code cross reference (1 / 4)
J1939 Vehicle
J1939 Vehicle P
P Item code side
Item code side code
code (DTC) code
(DTC) code
Shut off
Discrepancy between P0215 1110-12 1110-8
P0016 228-3 228-1 pass test
crank and cam signal
MPROP power stage
Backup control using P0230 2001-3 2001-1
P0021 635-3 635-1 short-circuit to battery
cam side signal
MPROP power stage
P0089 DBV valve opening 2041-3 2041-1 P0231 2002-4 2002-2
short-circuit to ground
P0089 DBV kick off 2042-4 2042-2 MPROP power stage open
P0252 2000-2 2000-4
P0090 DBV closed fixation 2043-2 2043-4 circuit

P0091 DBV pressure is too low 2045-4 2045-2 MPROP power stage over-
P0252 2000-12 2000-8
load
P0092 DBV pressure is too high 2044-3 2044-1
Inlet manifold pressure
P0235 102-12 102-8
P0117 Water temperature sensor 110-4 110-2 sensor
P0118 Water temperature sensor 110-3 110-1 Inlet manifold pressure
P0237 102-4 102-2
sensor
Accelerator signal
P0121 383-12 383-8
comparison Inlet manifold pressure
P0238 102-3 102-1
sensor
P0122 Accelerator sensor 1 29-4 29-2
P0261 Injector No.1 657-2 657-4
P0123 Accelerator sensor 1 29-3 29-1
P0262 Injector No.1 657-3 657-1
Rail pressure governor
P0191 2013-3 2013-1
deviation P0263 Injector No.1 657-12 657-8
Rail pressure governor P0264 Injector No.2 659-2 659-4
P0191 2014-3 2014-1
deviation
P0265 Injector No.2 659-3 659-1
Rail pressure governor
P0191 2015-3 2015-1 P0266 Injector No.2 659-12 659-8
deviation
P0192 Rail pressure SRC 2011-4 2011-2 P0267 Injector No.3 661-2 661-4

P0193 Rail pressure SRC 2011-3 2011-1 P0268 Injector No.3 661-3 661-1

Rail pressure sensor P0269 Injector No.3 661-12 661-8

P0192 2012-4 2012-2
offset monitoring P0270 Injector No.4 663-2 663-4
Rail pressure sensor P0271 Injector No.4 663-3 663-1
P0193 2012-3 2012-1
offset monitoring
P0272 Injector No.4 663-12 663-8
P0194 Rail pressure governor 2016-3 2016-1
Speed/timing sensor
P0194 Rail pressure governor 2017-3 2017-1 P0336 637-4 637-2
(crankshaft side)
P0201 Injector No.1 658-2 658-4 Speed/timing sensor
P0339 637-3 637-1
P0202 Injector No.2 660-2 660-4 (crankshaft side)

P0203 Injector No.3 662-2 662-4 Speed/timing sensor

P0341 636-4 636-2
(camshaft side)
P0204 Injector No.4 664-2 664-4
Speed/timing sensor
Shut off P0344 636-3 636-1
P0215 1110-4 1110-2 (camshaft side)
pass test
Air heater relay
Shut off P0540 677-12 677-8
P0215 power stage
1110-2 1110-4
pass test

14-5
TROUBLESHOOTING

Table 14-1 Diagnosis code cross reference (3 / 4) Table 14-1 Diagnosis code cross reference (4 / 4)
J1939 Vehicle J1939 Vehicle
P P
Item code side Item code side
code code
(DTC) code (DTC) code
Air heater relay P060B ADC monitoring 2008-12 2008-8
P0541 677-4 677-2
power stage
P060D CAN accelerator 91-2 91-4
Air heater relay
P0542 677-3 677-1 P060E APPREQ message time out 1674-2 1674-4
power stage
P061C Engine speed 2005-3 2005-1
Air heater relay
P0543 677-2 677-4
power stage Injector
P062D 651-12 651-8
drive bank 1
Power supply unit voltage
P0562 1543-4 1543-2
too low Injector
P062E 653-12 653-8
drive bank 2
Power supply unit voltage
P0563 1542-3 1542-1
too high P062F EEPROM 1235-4 1235-2
P0600 CAN transmitting time out 2028-2 2028-4 P062F EEPROM 1235-2 1235-4
P0600 CAN (A) pass off 1671-3 1671-1 P062F EEPROM 1235-12 1235-8
P0600 CAN (C) pass off 1673-3 1673-1 P0933 Oil pressure switch 19-12 19-8
P0606 SPI communication error 1231-3 1231-1 P0933 Oil pressure switch 100-12 100-8
P0606 Super vision 1484-12 1484-8 Injector
P2047 652-2 652-4
drive bank 1
P0607 Recovery occurred 1668-12 1668-8
Injector
P0607 Recovery occurred 1670-12 1670-8 P2048 651-4 651-2
drive bank 1
P0607 SPI watch dog error 2010-12 2010-8
Injector
P2049 651-3 651-1
P0611 Injector IC 655-3 655-1 drive bank 1
P0611 Injector IC 655-4 655-2 Injector
P2050 654-2 654-4
drive bank 2
P0611 Injector IC 655-2 655-4
Injector
P0611 Injector IC 655-12 655-8 P2051 653-4 653-2
drive bank 2
P0611 Injector IC 656-3 656-1
Injector
P2052 653-3 653-1
P0611 Injector IC 656-4 656-2 drive bank 2

P0611 Injector IC 656-2 656-4 Atomospheric pressure

P2228 108-4 108-2
sensor
P0611 Injector IC 656-12 656-8
Atomospheric pressure
Sensor supply voltage P2229 108-3 108-1
P0642 1079-4 1079-2 sensor
monitoring 1
Sensor supply voltage
P0643 1079-3 1079-1
monitoring 1
Sensor supply voltage
P0652 1080-4 1080-2
monitoring 2
Sensor supply voltage
P0653 1080-3 1080-1
monitoring 2
Sensor supply voltage
P0698 620-4 620-2
monitoring 3
Sensor supply voltage
P0699 620-3 620-1
monitoring 3
P060A TPU monitoring 2009-12 2009-8
P060B ADC monitoring 2008-3 2008-1
P060B ADC monitoring 2008-4 2008-2
P060B ADC monitoring 2008-2 2008-4

14-6
 TROUBLESHOOTING

4. Troubleshooting reference chart

4.1 Troubleshooting with diagnosis code
Note: The diagnosis codes which has * mark in the "Recovery" column recovers when the cause of fault has deleted and the
engine has restarted.

P0016 : Discrepancy between speed/timing sensor P0117 : Water temperature sensor

(crankshaft side/camshaft side) signal Vehicle side code : 110-2
Vehicle side code : 228-1 Faulty part Water temperature sensor
Speed/timing sensor The ECU detectes a faulty operation of
Faulty part
(crankshaft side/camshaft side) the water temperature sensor (open cir-
Detail
The ECU detects a discrepancy between cuit, short circuit). The input voltage
Detail speed/timing sensor (crankshaft side/ falls below the limiting value.
camshaft side) signal. Recovery *
Recovery * When engine is operated, the ECU con-
The ECU controls the engine using trols the engine as overheated
speed/timing sensor (crankshaft side) with fixing the temperature 120°C
Control signal. Control (warm mode). When starting the engine,
The ECU limits the maximum speed of the ECU controls the engine with fixing
the engine. the water temperature -20°C (cold
mode).
Speed limit The maximum speed is limited to 50%.
When the water temperature is 100°C or
Inspection Contact a Mitsubishi dealer. Speed limit above, the ECU controls the engine as
overheated.
P0021 : Backup control using camshaft side signal
Water temperature sensor, and wiring of
Vehicle side code : 635-1 Inspection
water temperature sensor.
Speed/timing sensor
Faulty part
(crankshaft side) P0118 : Water temperature sensor
The engine is operating without speed/ Vehicle side code : 110-1
timing sensor (crankshaft side) signal. Faulty part Water temperature sensor
Detail
The ECU controls the engine using cam-
shaft side signal. The input voltage exceeds the limiting
Detail
value.
Recovery *
Recovery *
The ECU limits the maximum speed of
Control When engine is operated, the ECU con-
the engine.
trols the engine as overheated
Speed limit The maximum speed is limited to 50%. with fixing the temperature 120°C
Speed/timing sensor (crankshaft side) Control (warm mode). When starting the engine,
Inspection and wiring of speed/timing sensor the ECU controls the engine with fixing
(crankshaft side). the water temperature -20°C (cold
mode).
When the water temperature is 100°C or
Speed limit above, the ECU controls the engine as
overheated.
Water temperature sensor, and wiring of
Inspection
water temperature sensor.

14-7
TROUBLESHOOTING

P0121 : Accelerator signal comparison P0191 : Rail pressure governor deviation

Vehicle side code : 383-8 Vehicle side code : 2013-1
Accelerator signal (CAN signal, analog Faulty part Common rail
Faulty part
signal)
The rail pressure control is abnormal.
Detail
The ECU compares the CAN signal and The target pressure is not achieved.
Detail analog signal, and detects a discrepacy
Recovery *
between them.
The ECU limits the maximum speed of
When a discrepancy is deleted, it recov- Control
Recovery the engine.
ers automatically.
Speed limit The maximum speed is limited to 75%.
Control The ECU warns to the operator.
Inspection Damage on the common rail.
Speed limit -
Inspection CAN signal and analog signal wiring.
Vehicle side code : 2014-1
P0122 : Accelerator sensor 1
Faulty part Common rail
Vehicle side code : 29-2
The rail pressure control is abnormal.
Faulty part Accelerator signal (analog signal)
Detail The target pressure is not achieved even
The ECU detects a faulty analog signal fully pressured by fuel pump.
Detail input from vehicle controller. The input
Recovery *
voltage falls below the limiting value.
Control Engine stop
When the input voltage recovers to the
Recovery specified value, it recovers automati- Speed limit -
cally.
Inspection Damage on the common rail.
When operating by CAN signal, the
ECU warns to the operator. When oper- P0192 : Rail pressure sensor offset monitoring
Control ating by analog signal, the ECU warns
Vehicle side code : 2012-2
to the operator and the engine operation
switches to the redundancy operation. Faulty part Rail pressure sensor
Speed limit - The input voltage falls below the limit-
Detail
ing value.
Inspection Accelerator signal (analog signal)
Recovery *
P0123 : Accelerator sensor 1 The ECU limits the maximum speed of
Vehicle side code : 29-1 Control
the engine.
Faulty part Accelerator signal (analog signal) Speed limit The engine speed is fixed to 8%.
The ECU detects a faulty analog signal Rail pressure sensor, and wiring of rail
Detail input from vehicle controller. The input Inspection
pressure sensor.
voltage exceeds the limiting value.
When the input voltage recovers to the
Recovery specified value, it recovers automati-
cally.
When operating by CAN signal, the
ECU warns to the operator. When oper-
Control ating by analog signal, the ECU warns
to the operator and the engine operation
switches to the redundancy operation.
Speed limit -
Inspection Accelerator signal (analog signal)

14-8
 TROUBLESHOOTING

P0193 : Rail pressure sensor offset monitoring P0202 : Injector No.2

Vehicle side code : 2012-1 Vehicle side code : 660-4
Faulty part Rail pressure sensor Faulty part Injector No.2
The input voltage exceeds the limiting The ECU detects an open circuit of the
Detail Detail
value. injector and/or injector harness.
Recovery * Recovery *
The ECU limits the maximum speed of The engine keeps operating if only one
Control
the engine. Control injector is faulty. The engine stops if
two or more injectors are faulty.
Speed limit The engine speed is fixed to 8%.
There is no specific control by the ECU,
Rail pressure sensor, and wiring of rail Speed limit
Inspection but the engine speed decreases.
pressure sensor.
Inspection Injector, and wiring of injector.
P0194 : Rail pressure governor
Vehicle side code : 2016-1 P0203 : Injector No.3
Vehicle side code : 662-4
Faulty part Common rail
Faulty part Injector No.3
The rail pressure falls below the limiting
Detail
value. The ECU detects an open circuit of the
Detail
injector and/or injector harness.
Recovery *
Recovery *
Control Engine stop
The engine keeps operating if only one
Speed limit -
Control injector is faulty. The engine stops if two
Inspection Damage on the common rail. or more injectors are faulty.
There is no specific control by the ECU,
P0201 : Injector No.1 Speed limit
but the engine speed decreases.
Vehicle side code : 658-4
Inspection Injector, and wiring of injector.
Faulty part Injector No.1
The ECU detects an open circuit of the P0204 : Injector No.4
Detail
injector and/or injector harness. Vehicle side code : 664-4
Recovery * Faulty part Injector No.4
The engine keeps operating if only one The ECU detects an open circuit of the
Detail
Control injector is faulty. The engine stops if two injector and/or injector harness.
or more injectors are faulty.
Recovery *
There is no specific control by the ECU,
Speed limit The engine keeps operating if only one
but the engine speed decreases.
Control injector is faulty. The engine stops if two
Inspection Injector, and wiring of injector. or more injectors are faulty.
There is no specific control by the ECU,
Speed limit
but the engine speed decreases.
Inspection Injector, and wiring of injector.

14-9
TROUBLESHOOTING

P0215 : Shut off pass test P0235 : Inlet manifold pressure sensor
Vehicle side code : 1110-2 Vehicle side code : 102-8
Faulty part ECU Inlet manifold pressure sensor power
Faulty part
supply line
The emergency injection stop circuit
Detail does not operate. The shut-off by watch The ECU detects an open circuit or short
Detail
dog is disabled. circuit of the sensor power supply (5V).
Recovery * Recovery *
Control The ECU warns to the operator. The ECU controls the engine using the
Control
backup data.(Approx. 1013 hpa)
Speed limit -
Speed limit The maximum speed is limited to 75%.
Inspection Contact a Mitsubishi dealer.
Inlet manifold pressure sensor power
Inspection
supply line wiring
Vehicle side code : 1110-4
P0237 : Inlet manifold pressure sensor
Faulty part ECU
Vehicle side code : 102-2
The emergency injection stop circuit
Faulty part Inlet manifold pressure sensor
Detail does not operate. The shut off by high
voltage monitoring is disabled. The ECU detects the faulty operation of
the inlet manifold pressure sensor (open
Recovery *
Detail circuit, short circuit, characteristic
Control The ECU warns to the operator. fault). The input voltage falls below the
limiting value.
Speed limit -
Recovery *
Inspection Contact a Mitsubishi dealer.
The ECU controls the engine using the
Control
backup data.
Vehicle side code : 1110-8 Speed limit The maximum speed is limited to 75%.
Faulty part ECU Inlet manifold pressure sensor, and wir-
Inspection
ing of inlet manifold pressure sensor.
The emergency injection stop circuit
Detail does not operate. The shut off by low
voltage monitoring is disabled. P0238 : Inlet manifold pressure sensor
Vehicle side code : 102-1
Recovery *
Faulty part Inlet manifold pressure sensor
Control The ECU warns to the operator.
The input voltage exceeds the limiting
Speed limit - Detail
value.
Inspection Contact a Mitsubishi dealer. Recovery *

P0231 : MPROP power stage short-circuit to ground The ECU controls the engine using the
Control
backup data.
Vehicle side code : 2002-2
Speed limit The maximum speed is limited to 75%.
Faulty part MPROP
Inlet manifold pressure sensor, and wir-
The ECU detects a short circuit on the Inspection
Detail ing of inlet manifold pressure sensor.
ground line of the MPROP harness.
Recovery *
The ECU limits the maximum speed of
Control
the engine.
Speed limit The engine speed is fixed to 8%.
Inspection MPROP, and wiring of MPROP.

14-10
 TROUBLESHOOTING

P0261 : Injector No.1 P0265 : Injector No.2

Vehicle side code : 657-4 Vehicle side code : 659-1
Faulty part Injector No.1 Faulty part Injector No.2
The ECU detects a short circuit of the The injector is faulty. The low side is a
Detail
injector and/or injector harness. There short circuit to the battery.
Detail
are short circuits on the high side and
Recovery *
low side.
Control Engine stop
Recovery *
Speed limit -
Control Engine stop
Inspection Injector, and wiring of injector.
Speed limit -
Inspection Injector, and wiring of injector. P0266 : Injector No.2
Vehicle side code : 659-8
P0262 : Injector No.1
Faulty part Injector No.2
Vehicle side code : 657-1
Unclassifiable error in the injector and/
Faulty part Injector No.1
Detail or the injector harness. The injector is
The injector is faulty. The low side is a disabled.
Detail
short circuit to the battery.
Recovery *
Recovery *
Control Engine stop
Control Engine stop
Speed limit -
Speed limit -
Inspection Injector, and wiring of injector.
Inspection Injector, and wiring of injector.
P0267 : Injector No.3
P0263 : Injector No.1 Vehicle side code : 661-4
Vehicle side code : 657-8
Faulty part Injector No.3
Faulty part Injector No.1
The ECU detects a short circuit of the
Unclassifiable error in the injector and/ injector and/or injector harness. There
Detail
Detail or the injector harness. The injector is are short circuits on the high side and
disabled. low side.
Recovery * Recovery *
Control Engine stop Control Engine stop
Speed limit - Speed limit -
Inspection Injector, and wiring of injector. Inspection Injector, and wiring of injector.

P0264 : Injector No.2 P0268 : Injector No.3

Vehicle side code : 659-4 Vehicle side code : 661-1
Faulty part Injector No.2 Faulty part Injector No.3
The ECU detects a short circuit of the The injector is faulty. The low side is a
Detail
injector and/or injector harness. There short circuit to the battery.
Detail
are short circuits on the high side and
Recovery *
low side.
Control Engine stop
Recovery *
Speed limit -
Control Engine stop
Inspection Injector, and wiring of injector.
Speed limit -
Inspection Injector, and wiring of injector.

14-11
TROUBLESHOOTING

P0269 : Injector No.3 P0336 : Speed/timing sensor (crankshaft side)

Vehicle side code : 661-8 Vehicle side code : 637-2
Faulty part Injector No.3 Speed/timing sensor
Faulty part
(crankshaft side)
Unclassifiable error in the injector and/
Detail or the injector harness. The injector is The ECU detects the fault of speed/tim-
disabled. ing sensor (crankshaft side)(open cir-
Detail cuit, short circuit, tooth brakage). The
Recovery *
number of crank pulse and/or crank
Control Engine stop pulse position are faulty.

Speed limit - Recovery *

Inspection Injector, and wiring of injector. The ECU controls the engine using the
Control speed/timing sensor (camshaft side) sig-
P0270 : Injector No.4 nal.
Vehicle side code : 663-4 The maximum speed is limited to 50%
Speed limit
only when starting the engine.
Faulty part Injector No.4
Speed/timing sensor (crankshaft side),
The ECU detects a short circuit of the
Inspection and wiring of speed/timing sensor
injector and/or injector harness. There
Detail (crankshaft side).
are short circuits on the high side and
low side.
P0339 : Speed/timing sensor (crankshaft side)
Recovery * Vehicle side code : 637-1
Control Engine stop Speed/timing sensor
Faulty part
Speed limit - (crankshaft side)

Inspection Injector, and wiring of injector. The speed/timing sensor (crankshaft

Detail side) is faulty. The ECU is not receiving
P0271 : Injector No.4 the crank pulse.
Vehicle side code : 663-1 Recovery *
Faulty part Injector No.4 The ECU controls the engine using the
Control speed/timing sensor (camshaft side) sig-
The injector is faulty. The low side is a
Detail nal.
short circuit to the battery.
The maximum speed is limited to 50%
Recovery * Speed limit
only when starting the engine.
Control Engine stop
Speed/timing sensor (crankshaft side),
Speed limit - Inspection and wiring of speed/timing sensor
(crankshaft side).
Inspection Injector, and wiring of injector.

P0272 : Injector No.4

Vehicle side code : 663-8
Faulty part Injector No.4
Unclassifiable error in the injector and/
Detail or the injector harness. The injector is
disabled.
Recovery *
Control Engine stop
Speed limit -
Inspection Injector, and wiring of injector.

14-12
 TROUBLESHOOTING

P0341 : Speed/timing sensor (camshaft side) P0541 : Air heater relay power stage
Vehicle side code : 636-2 Vehicle side code : 677-2
Speed/timing sensor Faulty part Air heater relay
Faulty part
(camshaft side)
The air heater relay and/or connecting
Detail
The ECU detects the fault of speed/tim- harness are short circuits to the ground.
ing sensor (camshaft side) (open circuit,
Recovery *
Detail short circuit, tooth breakage). The num-
ber of cam pulse and/or cam pulse posi- The air heater is disabled. The ECU
Control
tion are faulty. warns to the operator.
Recovery * Speed limit -
The ECU controls the engine using Inspection Air heater relay, and wiring of air heater.
Control speed/timing sensor (crankshaft side)
signal. The ECU warns to the operator. P0542 : Air heater relay power stage
Speed limit - Vehicle side code : 677-1
Speed/timing sensor (camshaft side), Faulty part Air heater relay
Inspection and wiring of speed/timing sensor (cam-
The air heater relay is faulty. The air
shaft side).
Detail heater relay is a short circuit to the bat-
tery.
P0344 : Speed/timing sensor (camshaft side)
Vehicle side code : 636-1 Recovery *

Speed/timing sensor The air heater is disabled. The ECU

Faulty part Control
(camshaft side) warns to the operator.

The speed/timing sensor (camshaft side) Speed limit -

Detail is faulty. The ECU is not receiving the Inspection Air heater relay, and wiring of air heater.
cam pulse.
Recovery * P0543 : Air heater relay power stage
Vehicle side code : 677-4
The ECU controls the engine using
Control speed/timing sensor (crankshaft side) Faulty part Air heater relay
signal. The ECU warns to the operator.
The ECU detects an open circuit of air
Detail
Speed limit - heater relay and/or connecting harness.
Speed/timing sensor (camshaft side), Recovery *
Inspection and wiring of speed/timing sensor (cam-
The air heater is disabled. The ECU
shaft side). Control
warns to the operator.
P0540 : Air heater relay power stage Speed limit -
Vehicle side code : 677-8 Inspection Air heater relay, and wiring of air heater.
Faulty part Air heater relay
P0562 : Power supply unit voltage too low
The ECU detects an overload of air
Detail Vehicle side code : 1543-2
heater relay and/or connecting harness.
Faulty part ECU
Recovery *
The voltage of the power supply unit
The air heater is disabled. The ECU
Control Detail inside the ECU falls below the limiting
warns to the operator.
value.
Speed limit -
Recovery *
Inspection Air heater relay, and wiring of air heater.
Control Engine stop
Speed limit -
Inspection Replace the ECU.

14-13
TROUBLESHOOTING

P0563 : Power supply unit voltage too high P0600 : CAN (C) pass off
Vehicle side code : 1542-1 Vehicle side code : 1673-1
Faulty part ECU Faulty part CAN communication line
The voltage of the power supply unit The CAN communication is faulty. The
Detail
Detail inside the ECU exceeds the limiting ECU detects the CAN (C) pass off.
value.
Recovery *
Recovery *
The ECU uses the analog signal for
Control Engine stop Control backup control. The ECU warns to the
operator.
Speed limit -
Speed limit -
Inspection Replace the ECU.
Inspection CAN comunnication line, and ECU.
P0600 : CAN transmitting time out
Vehicle side code : 2028-4 P0606 : SPI communication error
Vehicle side code : 1231-1
Faulty part CAN communication line
Faulty part ECU
Detail The CAN message cannot be tranmitted.
There are serial communication errors
Recovery * Detail
between CPU and other IC.
The ECU uses the analog signal for
Control Recovery *
backup control.
Control Engine stop
Speed limit -
Speed limit -
Inspection CAN comunnication line, and ECU.
Inspection Replace the ECU.
P0600 : CAN (A) pass off
Vehicle side code : 1671-1 P0606 : Super vision
Vehicle side code : 1484-8
Faulty part CAN communication line
Faulty part ECU
The CAN communication is faulty. The
Detail ECU detects an open circuit or short cir- The ECU detects an abnormality by
Detail
cuit of CAN line. using self-diagnosis function.
Recovery * Recovery *
The ECU uses the analog signal for Control Engine stop
Control backup control. The ECU warns to the
Speed limit -
operator.
Inspection Replace the ECU.
Speed limit -
Inspection CAN comunnication line, and ECU. P0607 : Recovery occurred
Vehicle side code : 1668-8
Faulty part ECU
The recovery occurred by the fault of the
Detail
ECU.
Recovery *
Control The ECU warns to the operator.
Speed limit -
Inspection -

14-14
 TROUBLESHOOTING

Vehicle side code : 1670-8 Vehicle side code : 655-4

Faulty part ECU Faulty part ECU
The recovery occurred by the fault of the The injector control IC inside the ECU
Detail Detail
ECU. is faulty.
Recovery * Recovery *
Control The ECU warns to the operator. Control Engine stop
Speed limit - Speed limit -
Inspection - Inspection Replace the ECU.

P0607 : SPI watch dog error

Vehicle side code : 2010-8 Vehicle side code : 655-8
Faulty part ECU Faulty part ECU
The ECU detects an abnormality by The injector control IC inside the ECU
Detail
Detail using self-diagnosis function. Watch dog is faulty.
error.
Recovery *
Recovery occurs. It recovers automati-
Control Engine stop
cally if an error occurs three times in
Recovery two seconds. The engine stops if an Speed limit -
error occurs four times or more in two
seconds. Inspection Replace the ECU.

Control Engine stop

Speed limit - Vehicle side code : 656-1

Inspection Replace the ECU. Faulty part ECU

The injector control IC inside the ECU
P0611 : Injector IC Detail
is faulty.
Vehicle side code : 655-1
Recovery *
Faulty part ECU
Control Engine stop
The injector control IC inside the ECU
Detail Speed limit -
is faulty.
Recovery * Inspection Replace the ECU.

Control Engine stop

Speed limit - Vehicle side code : 656-2

Inspection Replace the ECU. Faulty part ECU

The injector control IC inside the ECU
Detail
is faulty.
Vehicle side code : 655-2
Recovery *
Faulty part ECU
Control Engine stop
The injector control IC inside the ECU
Detail Speed limit -
is faulty.
Recovery * Inspection Replace the ECU.

Control Engine stop

Speed limit -
Inspection Replace the ECU.

14-15
TROUBLESHOOTING

P0652 : Sensor supply voltage monitoring 2

Vehicle side code : 656-4 Vehicle side code : 1080-2
Faulty part ECU Faulty part ECU
The injector control IC inside the ECU The 5V power supply to the inlet mani-
Detail
is faulty. fold pressure sensor is faulty. The sup-
Detail
ply voltage falls below the limiting
Recovery *
value.
Control Engine stop
Recovery *
Speed limit -
The ECU controls the engine using the
Control
Inspection Replace the ECU. backup data.
Speed limit The maximum speed is limited to 75%.

Vehicle side code : 656-8 Inspection Replace the ECU.

Faulty part ECU P0653 : Sensor supply voltage monitoring 2

The injector control IC inside the ECU Vehicle side code : 1080-1
Detail
is faulty.
Faulty part ECU
Recovery *
The 5V power supply to the inlet mani-
Control Engine stop Detail fold pressure sensor is faulty. The sup-
ply voltage exceeds the limiting value.
Speed limit -
Recovery *
Inspection Replace the ECU.
The ECU controls the engine using the
Control
P0642 : Sensor supply voltage monitoring 1 backup data.
Vehicle side code : 1079-2 Speed limit The maximum speed is limited to 75%.
Faulty part ECU Inspection Replace the ECU.
The 5V power supply to the PTO accel-
Detail erator signal is faulty. The supply volt- P0698 : Sensor supply voltage monitoring 3
age falls below the limiting value. Vehicle side code : 620-2

Recovery * Faulty part ECU

Control The ECU warns to the operator. The 5V power supply to the rail pressure
Detail sensor is faulty. The supply voltage falls
Speed limit - below the limiting value.
Inspection Replace the ECU. Recovery *

P0643 : Sensor supply voltage monitoring 1 Control The ECU warns to the operator.
Vehicle side code : 1079-1 Speed limit -
Faulty part ECU Inspection Replace the ECU.
The 5V power supply to the PTO accel-
Detail erator signal is faulty. The supply volt-
age exceeds the limiting value.
Recovery *
Control The ECU warns to the operator.
Speed limit -
Inspection Replace the ECU.

14-16
 TROUBLESHOOTING

P0699 : Sensor supply voltage monitoring 3

Vehicle side code : 620-1 Vehicle side code : 2008-2
Faulty part ECU Faulty part ECU
The 5V power supply to the rail pressure The AD converter inside the ECU is
Detail sensor is faulty. The supply voltage Detail faulty. The standard voltage falls below
exceeds the limiting value. the limiting value.
Recovery * Recovery occurs. It recovers automati-
cally if an error occurs three times in two
Control The ECU warns to the operator.
Recovery seconds. The engine stops if an error
Speed limit - occurs four times or more in two sec-
onds.
Inspection Replace the ECU.
Control Engine stop
P060A : TPU monitoring Speed limit -
Vehicle side code : 2009-8
Inspection Replace the ECU.
Faulty part ECU
The ECU detects a fault of rotating pulse
Detail Vehicle side code : 2008-4
arithmetic circuit inside the ECU.
Recovery occurs. It recovers automati- Faulty part ECU
cally if an error occurs three times in
The AD converter inside the ECU is
Recovery two seconds. The engine stops if an
Detail faulty. The ECU detects the conversion
error occurs four times or more in two
error by using a test pulse.
seconds.
Recovery occurs. It recovers automati-
Control Engine stop
cally if an error occurs three times in
Speed limit - Recovery two seconds. The engine stops if an
error occurs four times or more in two
Inspection Replace the ECU. seconds.

P060B : ADC monitoring Control Engine stop

Vehicle side code : 2008-1 Speed limit -
Faulty part ECU Inspection Replace the ECU.
The AD converter inside the ECU is
Detail faulty. The standard voltage exceeds the
limiting value. Vehicle side code : 2008-8
Recovery occurs. It recovers automati- Faulty part ECU
cally if an error occurs three times in
The AD converter inside the ECU is
Recovery two seconds. The engine stops if an Detail
faulty. The conversion time is abnormal.
error occurs four times or more in two
seconds. Recovery occurs. It recovers automati-
cally if an error occurs three times in
Control Engine stop
Recovery two seconds. The engine stops if an
Speed limit - error occurs four times or more in two
seconds.
Inspection Replace the ECU.
Control Engine stop
Speed limit -
Inspection Replace the ECU.

14-17
TROUBLESHOOTING

P060D : CAN accelerator P062D : Injector drive bank 1

Vehicle side code : 91-4 Vehicle side code : 651-8
Faulty part ECU communication circuit Faulty part ECU
The ECU detects a fault of accelerator The ECU detects the short circuit of the
Detail
Detail opening (APPREQ) receiving from injector drive circuit inside the ECU.
CAN.
Recovery *
Recovery *
Control Engine stop
The ECU uses the analog signal for
Speed limit -
Control backup control. The ECU warns to the
operator. Inspection Replace the ECU.
Speed limit -
P062E : Injector drive bank 2
Inspection CAN communication circuit Vehicle side code : 653-8

P060E : APPREQ message time out Faulty part ECU

Vehicle side code : 1674-4 The ECU detects the short circuit of the
Detail
injector drive circuit inside the ECU.
Faulty part ECU communication circuit
Recovery *
The ECU cannot receive the accelerator
Detail
opening (APPREQ) signal. Control Engine stop
Recovery * Speed limit -
The ECU uses the analog signal for Inspection Replace the ECU.
Control backup control. The ECU warns to the
operator. P062F : EEPROM
Speed limit - Vehicle side code : 1235-2

Inspection CAN communication circuit Faulty part ECU

The ECU detects a read-write error of
P061C : Engine speed Detail the data memory bank inside the ECU.
Vehicle side code : 2005-1 The ECU cannot read the data.
Faulty part ECU Recovery *
The ECU is faulty. The engine speed Control The ECU warns to the operator.
Detail
data is faulty.
Speed limit -
Recovery occurs. It recovers automati-
cally if an error occurs three times in Inspection Replace the ECU.
Recovery two seconds. The engine stops if an
error occurs four times or more in two
seconds. Vehicle side code : 1235-4
Control The ECU warns to the operator. Faulty part ECU
Speed limit - The ECU detects a read-write error of
the data memory bank inside the ECU.
Inspection Replace the ECU. Detail
The ECU cannot write to the data mem-
ory.
Recovery *
Control The ECU warns to the operator.
Speed limit -
Inspection Replace the ECU.

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P2047 : Injector drive bank 1

Vehicle side code : 1235-8 Vehicle side code : 652-4
Faulty part ECU Faulty part ECU
The ECU detects a read-write error of The ECU detects an open circuit of the
Detail
Detail the data memory bank inside the ECU. injector drive circuit inside the ECU.
The ECU is using the substitute data.
Recovery *
Recovery *
Control Engine stop
Control The ECU warns to the operator.
Speed limit -
Speed limit -
Inspection Replace the ECU.
Inspection Replace the ECU.
P2048 : Injector drive bank 1
P0933 : Oil pressure switch Vehicle side code : 651-2
Vehicle side code : 19-8
Faulty part ECU
Faulty part Oil pressure switch
The ECU detects a short circuit of the
Detail
The oil pressure switch remains OFF injector drive circuit inside the ECU.
Detail position even the engine speed reaches
Recovery *
500min-1.
Control Engine stop
Recovery *
Speed limit -
Control The ECU keeps the engine low idling.
Inspection Replace the ECU.
Speed limit -
Oil pressure switch, and wiring of oil P2049 : Injector drive bank 1
Inspection
pressure switch. Vehicle side code : 651-1
Faulty part ECU
Vehicle side code : 100-8 The ECU detects a short circuit of the
Detail
injector drive circuit inside the ECU.
Faulty part Oil pressure switch
Recovery *
The oil pressure switch remains OFF
position for 30 second after engine start- Control Engine stop
Detail
ing. The oil pressure switch remains
Speed limit -
OFF position during engine operation.
Inspection Replace the ECU.
Recovery *
Control Engine stop P2050 : Injector drive bank 2
Speed limit - Vehicle side code : 654-4

Oil pressure switch, and wiring of oil Faulty part ECU

Inspection
pressure switch. The ECU detects an open circuit of the
Detail
injector drive circuit inside the ECU.
Recovery *
Control Engine stop
Speed limit -
Inspection Replace the ECU.

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P2051 : Injector drive bank 2 P2229 : Atomospheric pressure sensor

Vehicle side code : 653-2 Vehicle side code : 108-1
Faulty part ECU Faulty part ECU
The ECU detects a short circuit of the The ECU detects a faulty operation of
Detail
injector drive circuit inside the ECU. the atomospheric pressure sensor (open
Detail circuit, short circuit, characteristic
Recovery *
fault). The input voltage exceeds the
Control Engine stop limiting value.

Speed limit - Recovery *

Inspection Replace the ECU. The ECU controls the engine by using
Control
backup data.
P2052 : Injector drive bank 2 Speed limit The maximum speed is limited to 75%.
Vehicle side code : 653-1
Inspection Replace the ECU.
Faulty part ECU
The ECU detects a short circuit of the
Detail
injector drive circuit inside the ECU.
Recovery *
Control Engine stop
Speed limit -
Inspection Replace the ECU.

P2228 : Atomospheric pressure sensor

Vehicle side code : 108-2
Faulty part ECU
The ECU detects a faulty operation of
the atomospheric pressure sensor (open
Detail circuit, short circuit, characteristic
fault). The input voltage falls below the
limiting value.
Recovery *
The ECU controls the engine by using
Control
backup data.
Speed limit The maximum speed is limited to 75%.
Inspection Replace the ECU.

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4.2 Related diagnosis code

There are diagnosis codes which are caused by other diagnosis codes, for example, the diagnosis code generated by the fault of
the common rail causes the diagnosis code related to the DBV (pressure limiting valve). These codes can be recovered by
eliminating the fault of the causal diagnosis code.
Causal diagnosis code in the following chart must be checked when Related diagnosis code is generated.
Related diagnosis code can be recovered by eliminating the fault of Causal diagnosis code.
Also Related diagnosis code B can be generated by Related diagnosis code A. In this case, Causal diagnosis code and Related
diagnosis code A must be checked.

Table 14-2 Related diagnosis code (1 / 2)

Causal diagnosis Related diagnosis Related diagnosis
Cause A Cause B Remark
code code A code B
There is an open cir-
cuit on the MPROP.
P0089 The MPROP is fully
Vehicle side code : opened and the com-
- - -
P0252 2041-1 mon rail receives
Vehicle side code : DBV opening excessive pressure.
2000-4 The DBV will be
MPROP open circuit opened.
P0089 P0090
Pressure shock is The ECU clears P0089
Vehicle side code : Vehicle side code : The DBV does not
requested to open the when P0090 is gener-
2042-2 2043-4 open.
DBV ated.
DBV kick off DBV closed fixation
There is an overload
on the MPROP. The
P0089 MPROP is fully
Vehicle side code : opened and the com-
- - -
P0252 2041-1 mon rail receives
Vehicle side code : DBV opening excessive pressure.
2000-8 The DBV will be
MPROP overload opened.
P0089 P0090
Pressure shock is The ECU clears P0089
Vehicle side code : Vehicle side code : The DBV does not
requested to open the when P0090 is gener-
2042-2 2043-4 open.
DBV ated.
DBV kick off DBV closed fixation
There is a short circuit
on the MPROP. The
P0089 MPROP is fully
Vehicle side code : opened and the com-
P0230 - - -
2041-1 mon rail receives
Vehicle side code : DBV opening excessive pressure.
2001-1 The DBV will be
MPROP power stage opened.
short circuit to battery
P0089 P0090
Pressure shock is The ECU clears P0089
Vehicle side code : Vehicle side code : The DBV does not
requested to open the when P0090 is gener-
2042-2 2043-4 open.
DBV ated.
DBV kick off DBV closed fixation
The pressure in the
P0089 common rail keeps The ECU clears
Vehicle side code : exceeding the limiting P0089(2042-2) when
- -
P0089 2041-1 value, the engine P0089(2041-1) is gen-
Vehicle side code : DBV opening operation switches to erated.
2042-2 the limp home mode.
DBV kick off P0090
Pressure shock is The ECU clears P0089
Vehicle side code :
requested to open the - - when P0090 is gener-
2043-4
DBV ated.
DBV closed fixation

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Table 14-2 Related diagnosis code (2 / 2)

Causal diagnosis Related diagnosis Related diagnosis
Cause A Cause B Remark
code code A code B
The pressure in the
P0089 common rail keeps
Vehicle side code : exceeding the limiting
P0191 - - -
2041-1 value, the engine
Vehicle side code : DBV opening operation switches to
2015-1 the limp home mode.
Rail pressure gover-
nor deviation P0089 P0090
Pressure shock is The ECU clears P0089
Vehicle side code : Vehicle side code : The DBV does not
requested to open the when P0090 is gener-
2042-2 2043-4 open.
DBV ated.
DBV kick off DBV closed fixation
The pressure in the
P0089 common rail keeps
If DBV does not open,
Vehicle side code : exceeding the limiting
- - the ECU generates
P0194 2041-1 value, the engine
P0090, not 0089.
Vehicle side code : DBV opening operation switches to
2017-1 the limp home mode.
Rail pressure governor P0089 P0090
Pressure shock is The ECU clears P0089
Vehicle side code : Vehicle side code : The DBV does not
requested to open the when P0090 is gener-
2042-2 2043-4 open.
DBV ated.
DBV kick off DBV closed fixation
An error is detected
by SRC. The ECU
cannot control the
P0192 P0089 engine by feedback
In this case, P0192 and
Vehicle side code : Vehicle side code : from the common rail
- - P0089 are generated at
2011-2 2041-1 pressure sensor. The
the same time.
Rail pressure SRC DBV opening DBV will be opened.
The ECU controls the
engine using backup
data.
An error is detected
by SRC. The ECU
cannot control the
P0193 P0089 engine by feedback
In this case, P0192 and
Vehicle side code : Vehicle side code : from the common rail
- - P0089 are generated at
2011-1 2041-1 pressure sensor. The
the same time.
Rail pressure SRC DBV opening DBV will be opened.
The ECU controls the
engine using backup
data.
After the ECU deter-
P0091 mined that DBV has
Vehicle side code : been opened, the
P0091 is not gener-
2045-2 common rail pressure - -
ated separately.
DBV pressure is too exceeds the limiting
P0089 high value during backup
Vehicle side code : operation.
2041-1 After the ECU deter-
DBV opening P0092 mined that DBV has
Vehicle side code : been opened, the
P0092 is not gener-
2044-1 common rail pressure - -
ated separately.
DBV pressure is too exceeds the limiting
high value during backup
operation.

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P0089 : DBV valve opening P0092 : DBV pressure is too high.

Vehicle side code : 2041-1 Vehicle side code : 2044-1
Faulty part DBV Faulty part DBV
Detail The DBV is opening. The DBV pressure is abnormal. (too
Detail
high)
Recovery *
Recovery *
The ECU limits the maximum speed of
Control
the engine. Control Engine stop
Speed limit The engine speed is fixed to 8%. Speed limit -
Inspection Contact a Mitsubishi dealer. Inspection Contact a Mitsubishi dealer.

P0089 : DBV kick off P0191 : Rail pressure governor deviation

Vehicle side code : 2042-2 Vehicle side code : 2015-1
Faulty part DBV Faulty part Common rail
Pressure shock requested The rail pressure control is abnormal.
Detail Detail
to apply limp home mode. The pressure exceeds the target value.
Recovery * Recovery *
The ECU limits the maximum speed of The ECU limits the maximum speed of
Control Control
the engine. the engine.
Speed limit The engine speed is fixed to 8%. Speed limit The engine speed is fixed to 8%.
Inspection Contact a Mitsubishi dealer. Inspection Damage on the common rail.

P0090 : DBV closed fixation P0192 : Rail pressure sensor SRC (Signal Range
Vehicle side code : 2043-4 Check)
Faulty part DBV Vehicle side code : 2011-2

The DBV does not open. Closed fixa- Faulty part Rail pressure sensor
Detail
tion. The ECU detects an open or short circuit
Recovery * of rail pressure sensor and/or sensor har-
Detail
ness. The input voltage falls below the
Control Engine stop limiting value.
Speed limit - Recovery *
Inspection Contact a Mitsubishi dealer. The ECU limits the maximum speed of
Control
the engine.
P0091 : DBV pressure is too low
Speed limit The engine speed is fixed to 8%.
Vehicle side code : 2045-2
Rail pressure sensor, and wiring of rail
Faulty part DBV Inspection
pressure sensor.
The DBV pressure is abnormal. (too
Detail
low)
Recovery *
Control Engine stop
Speed limit -
Inspection Contact a Mitsubishi dealer.

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P0193 : Rail pressure sensor SRC (Signal Range P0252 : MPROP power stage overload
Check) Vehicle side code : 2000-8
Vehicle side code : 2011-1 Faulty part MPROP
Faulty part Rail pressure sensor The ECU detects an overload of
Detail
The input voltage exceeds the limiting MPROP and/or MPROP harness.
Detail
value. Recovery *
Recovery * The ECU limits the maximum speed of
Control
The ECU limits the maximum speed of the engine.
Control
the engine. Speed limit The engine speed is fixed to 8%.
Speed limit The engine speed is fixed to 8%. Inspection MPROP, and wiring of MPROP.
Rail pressure sensor, and wiring of rail
Inspection
pressure sensor.

P0194 : Rail pressure governor

Vehicle side code : 2017-1
Faulty part Common rail
The rail pressure exceeds the limiting
Detail
value.
Recovery *
The ECU limits the maximum speed of
Control
the engine.
Speed limit The engine speed is fixed to 8%.
Inspection Damage on the common rail.

P0230 : MPROP power stage short-circuit to battery

Vehicle side code : 2001-1
Faulty part MPROP
The ECU detects a short circuit on the
Detail
battery line of the MPROP harness.
Recovery *
The ECU limits the maximum speed of
Control
the engine.
Speed limit The engine speed is fixed to 8%.
Inspection MPROP, and wiring of MPROP.

P0252 : MPROP power stage open circuit

Vehicle side code : 2000-4
Faulty part MPROP
The ECU detects an open circuit of the
Detail
MPROP and/or MPROP harness.
Recovery *
The ECU limits the maximum speed of
Control
the engine.
Speed limit The engine speed is fixed to 8%.
Inspection MPROP, and wiring of MPROP.

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5. Inspecting sensors
5.1 Speed/timing sensor (crank, cam)
Measure the resistance between terminal A - B.
Standard value : 860±86Ω
If measured value is out of standard, replace the sensor with
a new one.
C B A

Speed/timing sensor
(crank, cam)
5.2 Inlet manifold pressure sensor
With applying pressure using an air compressor, measure
the voltage between terminal B - C.
Standard value
C A
• at 0 MPa {0 kgf/cm²} : 0.5V
• at 0.34 MPa {3.5 kgf/cm²} : 4.5V
If measured value is out of standard, replace the sensor with
a new one. B

Air compressor

Inspecting inlet manifold pressure sensor (1)

0.5
Air pressure MPa

0.4
0.3
0.2
0.1
0

0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5

Output voltage Vdc

Inspecting inlet manifold pressure sensor (2)

5.3 Water temperature sensor
Put the water temperature sensor to the container filled with
water, measure the output resistance between terminal 1 - 2.
Standard value
• 20°C : 2.38 ～ 2.63kΩ
• 80°C : 0.30 ～ 0.34kΩ
If the sensor is an open circuit, its resistance is infinity. If
measured value is out of standard, replace the sensor with a
new one. 1 2

Inspecting water temperature sensor

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5.4 Engine oil pressure switch

Apply 50±10 kPa {0.5±0.1 kgf/cm²} [7.11±1.42 psi]
pressure to the sensor using an air compressor.
Check that the micro switch is in OFF position. Air compressor
If the switch is not operate, replace the engine oil pressure 50 ± 10 kPa
switch with a new one. {0.5 ± 0.1 kgf/cm²}
[7.11 ± 1.42 psi]
On-Off differences
30 kPa
{0.3 kgf/cm²}
[4.27 psi]

Inspecting oil pressure switch

5.5 Common rail pressure sensor
Apply 5V between terminal A - C, and measure the voltage
at terminal B.
Standard value : Approx. 0.5V
If measured value is out of standard, replace the common
A B C
rail with a new one.

Inspecting common rail pressure sensor

5.6 Injector solenoid
Measure the resistance between terminal 1 - 2.
Standard（at 20 to 70°C [68 to 158 °F]）: 0.215 to 0.295 Ω
If measured value is out of standard, replace the injector
with a new one.

2 1

Inspecting injector solenoid

5.7 High pressure pump solenoid sensor
(MPROP)
Measure the resistance between terminal 1 - 2.
Standard （at 20°C [68 °F]）: 2.6 to 3.15 Ω
If measured value is out of standard, replace the fuel pump
with a new one.

2 1

Inspecting high pressure pump solenoid sensor

(MPROP)

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6. Inspecting wiring
6.1 Inspecting connector and harness
When the ECU generates the diagnosis code for the sensors,
the ECU and the relays, check the wiring that connects these
parts.
The looseness of the harness connection and/or poor
connection of connector may cause the electrical faults. In
these cases, reconnecting the connector and/or the repairing
the harness deletes the fault. Inspect the wiring connecting
to the sensor which causes diagnosis code.

6.1.1 Inspecting the intermittent fault

Wiggle the harness and connector in order to reproduce the Inspecting intermittent fault
intermittent fault.
If the diagnosis code is generated, reset the ECU and repeat
the above procedure. If the intermittent fault exists, replace
the connector and harness.
Inspecting locking device

6.1.2 Inspecting connectors

(1) Disconnect the connector and inspect the connector for
moisture and wear.
(2) Inspect that the terminals are correctly located in the
connector. Inspect that the terminals are not lost.
Inspect that the terminals does not rattle.
(3) Inspect that the locking wedge works correctly. Inspecting connector

6.1.3 Inspecting harness

(1) Inspect harness visually for wear, nicks and cuts.
Especially the part which is exposed to the engine must
be inspected. Nick
(2) Inspect the harness for pinch point caused by cramp.

6.1.4 Inspect open circuit and short circuit

(1) Remove the connector from either end of the harness. Pinch point
Measure the resistance between both ends of the
harness using tester. If measured value is between 0.1～
0.3 Ω, it is normal. If measured value is not in this Inspecting harness
range, it is an open circuit.
(2) Remove the connector from either end of the harness.
Measure the resistance between all terminals in the
connector. If measured value is 100kΩ or more, it is
normal. If measured value is 100kΩ or less, it is a short
circuit.

Inspecting open circuit and short circuit

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6.2 Pin location of the ECU connector and extension harness connector
The wirings of the sensors, the injectors and the fuel pump are connected to the ECU through the extension harness connector.
Inspect the pin of the ECU connector and extension harness connector when inspecting the wiring of the sensors, the injectors
and the fuel pump.

ECU terminal A ECU terminal B

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
3 4
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
5 6
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94

1‫ޓ‬Injector 3, + 1‫ޓ‬ECU power supply, +㧔1㧕

2‫ޓ‬Injector 2, + 2‫ޓ‬ECU ground, -㧔1㧕
7‫ޓ‬Speed/timing sensor (crankshaft side), shield 3‫ޓ‬ECU power supply, +㧔2㧕
8‫ޓ‬Rail pressure sensor, ground 4‫ޓ‬ECU ground, -㧔2㧕
10‫ޓ‬Speed/timing sensor (camshaft side) 5‫ޓ‬ECU power supply, +㧔3㧕
12‫ޓ‬Speed/timing sensor (crankshaft side) 6‫ޓ‬ECU ground, -㧔3㧕
14‫ޓ‬Inlet manifold pressure sensor, power supply 9‫ޓ‬Accelerator㧔1㧕
15‫ޓ‬Heater relay 12‫ޓ‬PTO accelerator, ground
16‫ޓ‬Injector 1, 23‫ޓ‬PTO accelerator, power supply
17‫ޓ‬Injector 4, 25‫ޓ‬K-LINE
19‫ޓ‬MPROP, + 28‫ޓ‬Ignition switch
20‫ޓ‬Speed/timing sensor (camshaft side), shield 36‫ޓ‬PTO accelerator
23‫ޓ‬Inlet manifold pressure sensor, ground 41‫ޓ‬Signal, ground
24‫ޓ‬Heater relay, power supply 54‫ޓ‬Oil pressure switch
26‫ޓ‬Rail pressure sensor, power supply 61‫ޓ‬CAN-L1
27‫ޓ‬Speed/timing sensor (crankshaft side) 62‫ޓ‬CAN-H1
31‫ޓ‬Injector 2, - 72‫ޓ‬Main relay
33‫ޓ‬Injector 4, - 73‫ޓ‬24V power supply
40‫ޓ‬Inlet manifold pressure sensor
41‫ޓ‬Water temperature sensor, ground
43‫ޓ‬Rail pressure sensor
46‫ޓ‬Injector 3, -
47‫ޓ‬Injector 1, -
49‫ޓ‬MPROP, - Point of view
50‫ޓ‬Speed/timing sensor (camshaft side)
58‫ޓ‬Water temperature sensor

Pin location of ECU connector

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Extension harness connector, 16 terminals Extension harness connector, 12 teminals

4 3 2 1
4 3 2 1
8 7 6 5
8 7 6 5
12 11 10 9
12 11 10 9
16 15 14 13

1‫ޓ‬Speed/timing sensor (camshaft side), power supply 1‫ޓ‬Injector 1, +

2‫ޓ‬Speed/timing sensor (camshaft side) 2‫ޓ‬Injector 1, -
3‫ޓ‬Speed/timing sensor (camshaft side), shield‫ޓ‬ 3‫ޓ‬Injector 4, +
5‫ޓ‬Speed/timing sensor (crankshaft side), power supply 4‫ޓ‬Injector 4, -
6‫ޓ‬Speed/timing sensor (crankshaft side) 5‫ޓ‬Injector 3, +
7‫ޓ‬Speed/timing sensor (crankshaft side), shield 6‫ޓ‬Injector 3, -
8‫ޓ‬MPROP, - 7‫ޓ‬Injector 2, +
9‫ޓ‬Rail pressure sensor, power supply 8‫ޓ‬Injector 2, -
10‫ޓ‬Rail pressure sensor 9‫ޓ‬Water temperature sensor
11‫ޓ‬Rail pressure sensor, ground 10‫ޓ‬Water temperature sensor, ground
12‫ޓ‬MPROP, + 11‫ޓ‬Oil pressure switch
13‫ޓ‬Inlet manifold pressure sensor, power supply 12‫ޓ‬Oil pressure switch
14‫ޓ‬Inlet manifoldpressure sensor‫ޓ‬
16‫ޓ‬Inlet manifoldpressure sensor, ground

Point of view for 16 teminals Connector location Point of view for 12 terminals

Pin location of extension harness connector

14-29