Service Manual: Pub. No. 29502-00120 Issued: March 2011

SERVICE MANUAL
Issued: March 2011
Pub. No. 29502-00120

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

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

Nominal value
means the basic nominal size of a part to be measured.
Standard value
means the standard dimension and tolerances of the part.
Limit value
means the value, which the measured value reaches, the part needs repair or replacement with a new one.
Abbreviations and Standards

MUI (Mechanical Unit Injector) = Mechanically controlled unit injector
ECUI (Electronically Controlled Unit Injector) = Electric valve controlling unit injector
TDC (Top Dead Center) = Uppermost point of movement of pis-
ton in a cylinder
BTDC (Before Top Dead Center) = Positions before TDC
ATDC (After Top Dead Center) = Positions after TDC
BBDC (Before Bottom Dead Center) = Positions before BDC
ABDC (After Bottom Dead Center) = Positions after BDC
TIR (Total Indicator Reading) = Total amount of indicator travel
API (American Petroleum Institute) = US trade association which represents
all aspects of US oil and natural gas
industry.
ASTM (American Society for Testing and Materials) = An international standards organiza-
tion that develops and publishes volun-
tary consensus technical standards for a
wide range of materials, products, sys-
tems, and services.
JIS (Japanese Industrial Standards) = Japanese Industrial Standards
LLC (Long Life Coolant) = Long Life Coolant
RH (Right half) = Right half
LH (Left half) = Left half
MSDS (Material Safety Data Sheet) = Material Safety Data Sheet
SAE (Society of Automotive Engineers) =Society of Automotive Engineers
(U.S.A.)
P/N (Part Number) = Part No.
PCD (Pitch Circle Diameter) = Pitch Circle Diameter
Unit of Measurement
Measurements are based on the International System of Units (SI), and their converted metric values are indicated in { } and
US customary values are in [ ]. For metric conversion, the following rates are used.
Pressure : 1 MPa = 10.197 kgf/cm2

1 kPa = 10.197 cmH2O (cmAq)
Torque : 1 N·m = 0.10197 kgf·m
Force : 1 N = 0.10197 kgf
Output
1 kW = 1.341 HP = 1.3596 PS
power :
Rotation
1 min-1 = 1 rpm
speed
III
Safety Cautions
Safety Cautions
Fire and Explosion Precautions
Use Explosion-Proof Light
Keep Flames Away When inspecting fuel, engine oil, coolant, battery elec-
Do not use flames near the engine (in trolyte, etc., use an explosion-proof light. If the lighting
the engine room). The flame is dan- is not an explosion-proof type, it may ignite and cause
gerous to ignite combustibles and an explosion.
cause a fire. Wipe off spilled fuel, oil Prevent Electrical Wires From
and LLC immediately and thoroughly.
Short Circuit
Store the fuel and engine oil in a well ventilated area in
Avoid inspecting or servicing the electrical system with
accordance with rules and regulations. Make sure that
the battery cable connected to the battery. Otherwise,
the fuel and engine oil container caps are tightly fas-
a fire could result from short circuit. Be sure to discon-
tened.
nect the battery cable from the negative (-) terminal
Keep Engine Surrounding Area before starting work. A loose terminal and a damaged
Tidy and Clean cable or wire may result in a short circuit and a fire.
Do not place combustible or explosive material, such Inspect, and if any defect is found, repair or replace it
as fuel, engine oil, LLC or explosive powder near the before starting work.
engine. Such substances can cause a fire or explo- Keep Fire Extinguishers and First-
sion. Thoroughly remove dust, dirt and other foreign
Aid Kit Handy
material collected on the engine and the area around
Keep fire extinguishers handy, and
the engine. Such material can cause a fire or the
become familiar with their usage.
engine to overheat. In particular, clean the top surface
Keep a first-aid kit at the designated
of the battery thoroughly. Dust can cause a short-cir-
place to be ready for use in an emer-
cuit. Always place the engine at a position at least 1 m
gency. Make counteract procedures
[3.28 ft.] apart from buildings and other equipment to
against a fire or an accident. Provide the contact per-
prevent a possible fire caused by engine heat.
son and means of communication in case of emer-
Do Not Open Side Covers Until gency.
Engine Cools
Do not try to open the side cover of crankcase before
the engine cools down. Wait at least 10 minutes after
stopping the engine. Opening the cover when the
engine is hot allows fresh air to flow into the crank-
case, which can cause oil mist to ignite and explode.
Pay Attention to Fuel, Oil and

Exhaust Gas Leak
If any fuel, oil or exhaust gas leakage is found, imme-
diately take corrective measures to stop it. Such leak-
ages, if left uncorrected, can cause fuel or engine oil to
reach hot engine surfaces or hot exhaust gas to con-
tact flammable material, may results in a fire, personal
injury and damage to the equipment.
1
Stay Away From Rotating and Be Sure to Stop the Engine Before
Moving Parts Inspection and Maintenance
Be sure to stop the engine before proceeding to
inspection and maintenance work. Never try to make
Install Protective Covers Over adjustments on the engine parts while the engine is
Rotating Parts running. Rotating parts such as belt can reel in your
Check the covers over engine rotating body and cause serious injuries.
parts for correct installation and free
Always Put Back Engine Turning
from looseness or damage. Never
remove the covers during engine run- Tool After Use
ning. When the engine is coupled with Be sure to remove all turning tools used during inspec-
a radiator or other equipment, install protective covers tion and maintenance work. Make sure to pull back the
over the exposed belt and coupling. turning gear to the engine running position before
starting the engine. If the engine is started with a turn-
Check Work Area for Safety ing tool inserted or turning condition, it can not only
Before Starting cause a damage to the engine, but also lead to a per-
Before starting the engine, make sure that no one is sonal injury.
near the engine and that tools are not left on or near
the engine. Verbally notify persons within the immedi-
Be Careful of Exhaust Gas
ate area when starting the engine. When the starter Poisoning
device is tagged with the warning sign saying DO NOT
RUN, never start the engine. Be careful of Ventilation to Oper-
Stay Away From Moving Parts ate Engine
While Engine Operates If the engine is installed in an
Keep away from the rotating parts enclosed area, and the exhaust gas is
while the engine is running. Do not ducted outside, make sure that duct
leave any objects that may get caught joints are free from gas leak. Exhaust
in rotating parts. If clothes or a tool gas from the engine contains harmful
gets caught in rotating parts, serious components such as carbon monoxide. Operating the
injury will result. engine in an ill-ventilated area can cause gas poison-
ing.
Lockout and Tagout
Before proceeding with the inspection and mainte- Be Careful of Hearing Loss
nance work, lockout and tagout the machine from the
energy source to prevent the machine or equipment
Wear Ear Plugs
from moving. Remove the starter switch key, set the
Always wear ear plugs when entering
battery switch to OFF position and attach a DO NOT
the machine room (engine room).
RUN or equivalent caution tag to the starter switch.
Combustion sound and mechanical
The starter switch key must be kept by the person who
noise of engine can cause hearing
performs inspection and maintenance work.
loss.
2
Be Careful of Falling Be Careful When Handling Fu-
el, Engine Oil or LLC
Lift Engine Carefully
Use slings or wire ropes strong Use Specified Fuel, Engine Oil and
enough to lift the load considering the Long-Life Coolant (LLC) Only
engine weight. To lift the engine, use
Use the fuel, oil and LLC specified in the operation
the hangers installed on the engine
manual only, and handle them carefully. Use of any
and keep the engine in a well-bal-
other fuel, oil or LLC may cause various engine
anced position, thinking carefully of
defects and malfunctions. Get the MSDS issued by the
the engine center of gravity.
oil and LLC suppliers, and follow the directions in the
The hangers prepared on the engine are designed for
MSDS for the proper handling.
lifting the weight of engine only. In the case where the
generator, marine gear, and others are installed to the
Handle Fuel, Engine Oil and LLC
engine, consideration that the additional weight will not Carefully
affect the hangers of the engine. When handling fuel, engine oil or LLC, wear rubber
Keep the angle formed by slings attached to hangers gloves and a protective face mask. If it contacts your
within 60°. If the angle exceeds this limit, excessive skin, or get into your eyes or mouth, it may cause
load may be applied to the hangers and cause a dam- injury of skin or eyes, or poisoning. If accidentally
age. If the wire rope contacts the engine directly, swallowed, induce vomiting immediately and seek
place a cloth or other soft pad to avoid damage to the medical attention. If it enter your eyes, flush them
engine and the rope. immediately with plenty of water and seek medical
attention. If it contacts your skin or clothing, wash it
Do Not Climb Onto the Engine
away immediately with plenty of water. Do not discard
Do not climb onto the engine, nor step on any engine
waste engine oil or water (with LLC) in an unauthor-
parts on the engine sides. To work on parts located
ized procedure, because the oil and water are toxic.
high on the engine, use a ladder, footing, and others to
prevent from slipping and falling. Climbing onto the Be Careful of Burns
engine may result in engine part damage and your
injury by falling down.
Do Not Touch the Engine During
Always Prepare a Stable Footing or Immediately After Operation
When working on the upper part of
Do not touch any parts of the engine
the engine and other hard-to-reach
during or immediately after operation.
places, use a stable footing. Stand-
You can get burned. Before starting
ing on an old footstool or parts box
the maintenance and inspection work,
may result in personal injury. Do not
check the water temperature meter to make sure that
put any unnecessary objects on a footing.
the engine is cooled down.
3
Be Careful to Open and Close the Battery
Radiator Cap
Never open the radiator cap while the engine is run- Be Careful with Battery
ning or immediately after the engine stops. Stop the Never use flames or generate
engine and give a sufficient time to allow the coolant to sparks near the battery. The bat-
cool down before opening the cap. When opening the tery gives off highly flammable
radiator cap, slowly open the cap so as to release hydrogen gas and oxygen gas and
internal pressure. To prevent hot steam scalds, wear may cause an explosion.
thick rubber gloves or cover the cap with a cloth. When Do not use the battery if its fluid level is below the
closing the radiator cap, tightly close the cap. Do not lower limit line. Wrong use of the battery may result
open the radiator cap during engine running or imme- in an explosion.
Do not short the battery terminals with a tool or other
diately after engine stop. Otherwise hot steam and
metal object.
coolant gush out and can cause burns.
When disconnecting battery cables, always remove
Refill Coolant Only After the Cool- first from negative (-) terminal first. When recon-
ant Temperature Dropped necting the cables, always connect first to the posi-
tive (+) terminal.
Do not refill coolant immediately after the engine
Charge the battery in a well-ventilated area, with all
stops. Wait until the coolant temperature lowers suffi-
battery plugs removed.
ciently to avoid risk of burns.
Make sure the cable clamps are securely fastened to
Replace Oil and Filter After Cool- the battery terminals. A loose terminal can cause
ing Down the Oil Temperature sparks that may result in an explosion.
Before servicing electrical components or conducting
Do not replace oil or filter immediately after the engine
electric welding, set the battery switch to the [Open/
stop. Wait until the temperature lowers sufficiently to a
OFF] position or disconnect the cable from the nega-
room temperature. Replacement job immediately after
tive (-) battery terminal to cut off the electrical cur-
the engine stop may cause burns.
rent.
Do not Remove Heat Shields Electrolyte (battery fluid) contains dilute sulfuric acid.
The exhaust system, which becomes extremely hot Careless handling of the battery may lead to the loss
while the engine is operating, is provided with various of sight and/or skin burns.
Wear protective goggles and rubber gloves when
heat shields. Never remove the heat shields. If any of
working with the battery (such as adding water or
these heat shields were inevitably removed for the
charging).
inspection and maintenance, be sure to install them
If battery electrolyte is spilled onto the skin or cloth-
after the work.
ing, immediately wash it away with lots of water. Use
soap to clean thoroughly.
Battery fluid can make you blind if splash into your
eyes. Immediately flush it away with plenty of clean
water, and seek immediate medical attention.
If battery fluid is accidentally swallowed, gargle with
plenty of water, then drink lots of water, and seek
immediate medical attention.
4
Precautions for Engine Opera- Warm-up the Engine Before Use
After starting the engine, run the engine at a low idling
tion
speed for 5 to 10 minutes for warming-up. Start the
work after this operation is completed. Warm-up oper-
Conduct Inspections ation circulates lubricant in the engine, and works for
Conduct the daily inspection before starting the engine the longer service life and economical operation. Do
as described in the operation manual. not continue the warm-up operation for a longer time
Failure to conduct the specified inspections may cause than necessary. Long warm-up operation causes car-
various engine problems, damage to parts, and a seri- bon deposits in the cylinders, and may lead to incom-
ous accident. plete combustion.
Be Careful of Engine Room Venti- Do Not Continue Low Load Opera-

lation tion
Always keep the engine room well-ventilated. Insuffi- Low load continuous operation (less than 30%) must
cient intake air amount of the engine can cause an be limited within one hour. Long warm-up operation
increase in the engine temperature, and could result in causes carbon deposits in the cylinders, and may lead
a decrease in the output power and poor performance. to incomplete combustion. Also, after low load opera-
It is highly recommended to calculate the required tion for approx one hour, run the engine at a 30% or
amount of air supply to the engine and install an ade- higher load for five minutes or more.
quate ventilation system before installing the engine.
Do Not Operate the Engine in an
Do Not Operate Starter for a Long Overloaded Condition
Time If the engine shows an overloaded condition such as
Do not use the starter for more than 10 seconds at a black exhaust smoke, reduce the load immediately to
time. If the engine does not start, wait for at least 1 an appropriate load condition. Overloading causes not
minute before starting again. Cranking the starter con- only high fuel consumption but also excessive carbon
tinuously could result in a flat battery and a starter deposits inside the engine. Carbon deposits cause
burning out. various problems and will shorten the service life of the
Do Not Turn Off the Battery Switch engine.
During Operation Use Care to Protect Engine From

Do not turn off the battery switch during operation. If Water
the battery switch is turned OFF when the engine is Use care to protect engine from water such as rain
running, not only various meters will stop working but entering through the air inlet or exhaust openings. Do
also the diodes and transistors in the starter can be not wash the engine while it is running. Cleaning fluid
damaged. or water can be sucked into the engine. Starting the
Break-in the Engine engine with water inside the combustion chambers
can cause the water hammering, and may result in
To break-in a new engine or overhauled engine, oper-
engine inner parts damage and serious accident.
ate the engine at speeds lower than the rated speed in
light load conditions during the first 50 hours of opera-
tion.
5
Do not perform maintenance of Be Careful to Restart After an
the air cleaner or pre-cleaner dur- Abnormal Stop
If the engine stops abnormally, do not restart the
ing operation.
engine immediately after the stopping. Investigate the
Never perform maintenance of the air cleaner or pre-
cause of abnormality, correct the defect, then re-start
cleaner during operation. Foreign material enters the
the engine. If the engine is kept operating in such a
turbocharger and may result in a serious failure.
condition, it can result in serious engine failure.
Check the dust indicator visually during engine opera-
tion. If the indicator shows the filter clogging. Be sure Immediately Stop the Engine
to stop the engine then conduct the maintenance When Engine Oil Pressure Drops
work.
If the engine oil pressure drops significantly, stop the
Do Not Touch High Pressure Fuel engine immediately, and inspect the lubrication sys-
tem to find the cause. Continuous engine operation
Jet.
with low oil pressure may cause bearings and other
Do not touch the fuel jet leaked or sprayed from the
parts to seize.
high pressure injection pipe. Fuel in the fuel injection
system has a high pressure and if the fuel impinges Stop the Engine Immediately
your skin, it may cause the skin damage. When the Belt Break
Cool Down the Engine Before If the belt breaks, stop the engine immediately. Contin-
uous engine operation with the broken belt can cause
Stop
the engine to overheat. Steam of boiled cooling water
Cool down the engine at a low idling for five to six min-
may gush out from the reserve tank or radiator, and
utes before stopping it. Stopping the engine immedi-
results in burns.
ately after high-load operation will cause local heat up
of engine parts and shorten the service life of the Other Cautions
engine. During the cooling operation, check the
engine for abnormalities.
Cautions for Engine Transporta-
Inspect the Engine After Opera-
tion
tion To road-transport the engine, consider the engine
After the engine operation, inspect each part of engine weight, width and height, and obey applicable laws
once again. If any defect is found, correct immediately. and regulations such as road traffic laws, vehicle road
Abnormality during Engine acts and vehicle restriction ordinances.
Operation
Do Not Add Cooling Water Imme-

diately After a Sudden Stop Due to
Overheating
If the engine stops suddenly due to overheating, or
you suddenly stop the engine by any reason, do not
add cooling water immediately. If water is added
immediately, parts such as cylinder heads can be
damaged due to the sudden drop of temperature. Add
cooling water slowly after the engine becomes cool.
6
Warning Labels
Maintenance of Warning Labels

Make sure all warning/caution labels are legible.
Clean or replace the warning or caution label when the description or illustration is not clear to read.
For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvent, gasoline or other
chemicals to prevent the label from fading and peering.
Replace a damaged or missing label with a new one.
If any engine part stuck with a warning label is replaced with a new one, attach a new identical warning label to the
new part.
To get new warning labels, contact our approved dealer.
Warning labels
7
Points on Disassembling and Assembling
Points on Disassembling and Assembling
Always keep the safety in mind. Points on Disassembling

Refer to the "Safety Cautions" and obey the rules Carefully check each part for defects just before and
below for the safety maintenance job. during disassembling. Do not miss symptoms which
Obey the safety rules and keep a healthy physical can not be found after disassembling. And, keep in
condition. mind to record the log.
Point and refer the job for safety. Utilize visual or pho- Disassemble the parts checking the matching marks
nic signals for a collaborative work. and numbers. Apply new markings if necessary.
Wear proper clothes proper protective gears. Do not place the parts on the floor directly. Place
To lift a heavy part or component, use the verified them on a workbench or in a box arranging them in
rope or sling and pay attention to the center of grav- the order.
ity. Thoroughly clean the parts with wash oil, and dry the
And also pay attention to a stable footing and keep cleaned parts with compressed air. And visually
the workshop neat and organized. Prepare a dedi- inspect the parts. Apply a rust preventive treatment
cated footing for a raised position work. as required to prevent the washed parts from rust-
Pay attention to a heating or chilling job for burns. ing.
Use Proper Tools for Maintenance Points on Assembling

Replace the consumable pars such as gaskets, pack-
Work
ings and O-rings with new ones.
Always keep in mind to select most appropriate tools
Apply new engine oil to sliding surfaces unless other-
for the work and use them correctly. If a tool is dam-
wise specified.
aged, replace with new tool.
Be sure to apply the specified liquid gasket on the
Do Not Tamper mating surface where the application is specified.
If tampered, the warranty is totally void even in the For the other mating faces, apply an appropriate
gasket for the purpose.
warranty period. Tampering with the engine can not
Obey the specification of the torque method and the
only damage the engine but also may lead to personal
controlled angle method if so specified.
injury.
When reusing the engine parts, unless there is a spe-
Do not break the seal unless it is cial reason, install them to their original positions.
absolutely necessary. Pay attention to matching marks and numbers to

assemble correctly.
The fuel control mechanism is sealed in many posi-
tions to protect the correct performance of engine. If
the seal is broken and an incorrect adjustment is done,
a serious accident may occur with the defects below:
Abnormally high or low output to the rated power
Overrunning
Load sharing imbalance between right and left banks
Uneven combustion of each cylinder
The release and re-sealing must be conducted in an
approved service shop with facilities and by approved
personnel.
8
GENERAL CONTENTS
Chapter 1 GENERAL
1. External View
2. Outline of Systems
3. Contents of Plate and Label
4. Specifications
Chapter 2 SERVICE DATA

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

1. Special Tools
Chapter 4 OVERHAUL INSTRUCTIONS

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

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

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

1. Crankshaft and Main Bearing - Install
2. Cylinder Liner, Piston and Connecting Rod - Assemble
3. Front Mechanism - Assemble
4. Rear Mechanism - Assemble
5. Cylinder Head and Valve Mechanism - Assemble
Chapter 8 FUEL SYSTEM
1. Fuel System - Remove and Inspect
2. Fuel System - Disassemble, Inspect and Assemble
3. Fuel System - Install
Chapter 9 LUBRICATION SYSTEM

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

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

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

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

1. Engine - Adjust
2. Break-in Operation
3. Engine-Test and Adjustment
4. Seal (MUI)
Chapter 1 GENERAL
1. External View ........................................................................................................... 1-3
1.1 S12H-PTA ................................................................................................................................ 1-3
1.2 S12H-PTK ................................................................................................................................ 1-5
1.3 S12H-Y2PTAW......................................................................................................................... 1-7
2. Outline of Systems .................................................................................................. 1-9
2.1 Fuel System.............................................................................................................................. 1-9
2.2 Lubrication System ................................................................................................................... 1-9
2.3 Cooling System....................................................................................................................... 1-10
2.4 Inlet and Exhaust System ....................................................................................................... 1-11
3. Contents of Plate and Label ................................................................................. 1-12
3.1 Name Plate ............................................................................................................................. 1-12
3.2 Caution Plate .......................................................................................................................... 1-12
3.3 Emission Certification Label ................................................................................................... 1-12
4. Specifications ........................................................................................................ 1-13
1-1
Chapter 1 GENERAL
Chapter 1 GENERAL
1. External View
A standard model is shown because the equipment differs in accordance with the customization and specification.
1.1 S12H-PTA
S12H-PTA with fan MUI spec

Coolant outlet
Thermostat case Thermostat case
Fuel main pipe,

Boost balance pipe check valve
Breather
(Front upward)
Water pump
Rocker case
Cylinder head
Fan drive
Oil pan Damper
Engine Front View

Exhaust pipe
Rotation speed sensor
Fuel feed pump

Rotation
direction
Flywheel
Oil pan
Engine Rear View
1-3
Chapter 1 GENERAL

Boost balance pipe
Turbocharger
Air cooler Fuel filter
Water drain cock
Oil filler
Front Rear
Priming pump
Relief valve
Bypass oil filter

Oil filter Starter
Oil level gauge

Fuel outlet Fuel inlet
Left Side View
Turbocharger Coolant outlet
Air cooler
Water drain cock
Governor
Coolant inlet
Rear Front
Stop solenoid
Fan
Starter
Air heater
Alternator
Right Side View
1-4
Chapter 1 GENERAL
1.2 S12H-PTK
S12H-PTK without fan parallel cooling MUI spec

Engine coolant outlet
Thermostat case
Thermostat case
Rocker cover
Air cooler coolant outlet
Rocker case
Boost balance pipe
Fuel main pipe,

Water pump Check valve
Cylinder head
Damper
Oil pan
Engine Front View

Exhaust pipe
Breather
(Front downward)
Rotation speed sensor
Fuel feed Rotation

pump direction
Flywheel
Engine Rear View
1-5
Chapter 1 GENERAL
Turbocharger S12H-PTK without fan parallel cooling MUI spec

Boost balance pipe
Fuel filter
Air cooler
Breather Water drain cock
(Front downward)
Oil filler
Priming pump
Front Rear
Relief valve
Bypass oil filter

Starter
Oil filter
Oil level gauge Fuel inlet

Fuel outlet
Left Side View

Air cooler
Engine coolant
outlet
Water drain cock
Air cooler Air cooler

coolant inlet coolant outlet
Rear Front
Stop solenoid
Engine coolant
inlet
Governor
Air heater
Starter
Alternator
Right Side View
1-6
Chapter 1 GENERAL
1.3 S12H-Y2PTAW
Air cooler coolant outlet S12H-Y2PTAW with fan dual cooling ECUI spec

Air cooler thermostat case
Thermostat case
Thermostat case
Rocker cover
Rocker case
Fuel main pipe,

Check valve
Cylinder head
TDC sensor
Air cooler
water pump
Fan drive
Damper
Water pump
Oil pan
Engine Front View
Exhaust pipe S12H-Y2PTAW with fan dual cooling ECUI spec
Breather (Rear upward)
TDC sensor
Rotation sensor
(For ECUI)
Fuel feed pump Rotation

direction
Flywheel
Rotation sensor
Oil pan
Engine Rear View
1-7
Chapter 1 GENERAL
S12H-Y2PTAW with fan dual cooling ECUI spec

Turbocharger
Fuel filter
Intercooler
Cam sensor
Water drain cock
(For cylinder No.
identification)
Oil filler
Front Rear
Priming pump
Relief valve
Starter
Bypass oil filter
Oil filter
Fuel outlet
Oil level gauge Fuel inlet
Left Side View
S12H-Y2PTAW with fan dual cooling ECUI spec

Engine coolant outlet Air cooler coolant outlet
Air cooler
Boost sensor
Engine coolant
inlet
Rear Front
Water
drain cock
Air cooler
Starter coolant inlet
Alternator
Controller
Right Side View
1-8
Chapter 1 GENERAL
2. Outline of Systems
2.1 Fuel System
Feed pump with relief valve

Opening valve pressure:
Fuel filter ASSY
0.6 MPa {6.12 kgf/cm2} [87 psi]
Fuel tank
R bank
Air bleeding Fuel filter ASSY

valve (Primary filter)
Overflow valve UI UI UI UI UI UI
Opening valve pressure:
Fuel inlet
0.5 MPa {5.1 kgf/cm2} No.1 No.2 No.3 No.4 No.5 No.6
CYL CYL CYL CYL CYL CYL
Fuel [72.52 psi}
outlet
L bank
Air bleeding Hand priming pump

valve Fuel filter
Overflow valve UI UI UI UI UI UI
ASSY
Opening valve pressure: Priming pump
No.7 No.8 No.9 No.10 No.11 No.12
0.5 MPa {5.1 kgf/cm2} CYL CYL CYL CYL CYL CYL bracket
[72.52 psi}
Outline of Fuel System
2.2 Lubrication System
Filter alarm
DPS DPAH ON: 0.15 MPa {1.5 kgf/cm2} [21 psi] Turbocharger
Oil PI PSL
Oil filter pressure Shutdown
gauge T C T C
PT PS Pressure
Pressure
switch
limiter
Cylinder head
Cam
Piston
Hose
Bypass oil filter Timing gear
Crank shaft
Oil pressure governor Oil level
gauge
Safety valve LI Breather
Relief valve
Oil pump Oil
filler
Oil cooler
Oil
strainer
Oil pan
Diesel engine
Oil drain
Outline of Lubrication System
1-9
Chapter 1 GENERAL
2.3 Cooling System
S12H-PTA
0.07 MPa {0.7 kgf/cm2} [10 psi] ON: 98°C [208.4°F]

TSH
Overflow TS Thermo
switch
Coolant outlet Thermostat
Water temperature gauge
TI
Temperature Air
sensor TT Oil cooler cooler
Air
Radiator cooler
Coolant inlet
Water pump
Diesel engine
Outline of Cooling System
S12H-Y2PTAW
(Dual cooling)
ON: 98°C[208.4°F]
TSH
TS Thermo switch
TI Water temperature
gauge Air
TT Temperature sensor
Oil cooler cooler
Air
cooler
Coolant inlet
Water pump
Coolant inlet
Air cooler
water pump
Diesel engine
Outline of Cooling System
1-10
Chapter 1 GENERAL
2.4 Inlet and Exhaust System
Air cleaner
Turbocharger T C
Air cooler
Flexible TI
pipe
Muffler coupling Balance pipe
(MUI)
Air cooler
Turbocharger T C
Diesel engine Air cleaner
Outline of Inlet and Exhaust System
1-11
Chapter 1 GENERAL
3. Contents of Plate and Label

3.1 Name Plate
The name plate is attached on the lateral side of the engine,
and shows the following information:
Engine serial number
Manufacturing month, year
Engine model name
Total displacement
Rated output/revolution speed
Left side
Name plate
3.2 Caution Plate
The caution plate is attached to the top face of the rocker
cover of No. 1 cylinder and shows the following informa-
tion:
3.2.1 Caution plate (1)
Valve clearance
Firing order
Injection timing
Note: In case of the ECUI specification, the plate shows the
VALVE CLEARANCE(COLD)
setting number of the injection mode, it is different
INLET 0.6 mm EXHAUST 0.8 mm
from the real injection timing. FIRING ORDER
1-12-5-8-3-10-6-7-2-11-4-9
Connecting rod weight rank
FUEL INJECTION TIMING BTDC
CON-ROD RANK
Caution plate (1)

3.2.2 Caution plate (2)
Front/rear and right/left positions
Cylinder No.
Direction of rotation
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416#6+1 0
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Caution plate (2)

3.3 Emission Certification Label
The certification sticker of the exhaust emission regulation
is attached on the top face of No. 7 cylinder.
1-12
Chapter 1 GENERAL
4. Specifications
Engine model S12H
Type Water cooled, 4 stroke cycle diesel, turbocharged with air cooler
No. of cylinders - arrangement 12-V
Combustion system Direct injection system
Valve mechanism Overhead
Cylinder bore × stroke 150×175 mm [5.91 X 6.89 in.]
Total displacement 37.11 L [2265 cu in]
Firing order 1-12-5-8-3-10-6-7-2-11-4-9
Direction of rotation Counterclockwise as viewed from flywheel side
Engine oil Class CF or CH-4 (API service classification)
Specification table
The mark "○" in the table represents the installed equipment of each engine type.
Note:(a) This table shows the general information. The installation of equipment differs in accordance with the customization
and specifications.
(b) The specification and part number may be changed with the design progress without prior notice.
S12H
Y2PTAW-1
V2PTK-1
Y1PTA-2
Y1PTA-3
Y1PTA-4
PTA-S
Equipment name Specification name
PTK
PTA
Compression ratio: 14.0 (35C17-20101) ○ ○ ○
Piston
Compression ratio: 14.5 (35C17-00700) ○ ○ ○ ○ ○
Single damper ○
Damper
Double damper ○ ○ ○ ○ ○ ○ ○
Alternator pulley (37725-14102) ○ ○ ○ ○ ○ ○ ○ ○
Front pulley Crankshaft pulley (35B25-02501) ○ ○ ○ ○ ○ ○
Pulley for dual system water pump and alternator ○
(35B30-30010) ○ ○ ○ ○ ○ ○ ○
Air cooler
Large size (35B30-10050) ○
TD13L-41QV22-27.5 ○ ○
TD13L-45QV22-30 ○ ○
TD13L-43QV23.5-27.5 ○
Turbocharger TD13L-45QRC-34 ○
TD13L-43QV23.5-34 ○
TD13L-43QV23.5-40 ○ ○
TD13L-48Q23.5VRC(40)RCC Cover ○
Fan D1524(35B48-00100) ○ ○ ○ ○ ○ ○
Air cooler water pump ○
RUN ON ○ ○ ○ ○
Rack control solenoid
RUN OFF ○
MUI ○ ○ ○ ○ ○ ○ ○
Unit injector
ECUI ○
Diesel fuel ○ ○ ○ ○ ○ ○ ○ ○
Fuel filter
Fuel oil (A : JIS K2205) ○ ○
1-13
Chapter 1 GENERAL
S12H
Y2PTAW-1
V2PTK-1
Y1PTA-2
Y1PTA-3
Y1PTA-4
PTA-S
Equipment name Specification name
PTK
PTA
Woodward make PSG type governor ○ ○ ○
Woodward make PROACT type actuator ○ ○ ○ ○ ○ ○
Woodward make DYNA8200 type actuator ○ ○ ○
Governor
Toho co. make SG4030BR-01 type actuator ○ ○ ○ ○
Toho co. make SG4030BR-AD type actuator ○ ○ ○
Woodward make WCM3 controller ○
Right: 37566-40301
(0-23000-6902) 24V-7.5kW single wire type
Starter ○ ○ ○ ○ ○ ○ ○ ○
Left : 35B66-20102
(0-23000-7512) 24V-7.5kW single wire type
04343-38000 24V-30A Self-excitation, V-belt pulley ○ ○ ○ ○ ○ ○ ○ ○
Alternator 04343-38200 24V-35A Separate excitation, ribbed belt
○
pulley
RUN ON ○ ○ ○ ○ ○ ○ ○
Stop solenoid
RUN OFF ○ ○ ○
1-14
1. Maintenance Service Data ...................................................................................... 2-3
1.1 Maintenance Service Data of Engine General.......................................................................... 2-3
1.2 Maintenance Service Data of Basic Engine.............................................................................. 2-4
1.3 Maintenance Service Data of Fuel System............................................................................... 2-9
1.4 Maintenance Service Data of Lubrication System .................................................................. 2-10
1.5 Maintenance Service Data of Cooling System ....................................................................... 2-11
2. Tightening Torque Table....................................................................................... 2-12
2.1 Tightening Torque Spec for Basic Engine .............................................................................. 2-12
2.2 Tightening Torque Spec for Fuel System ............................................................................... 2-13
2.3 Tightening Torque Spec for Lubrication System..................................................................... 2-13
2.4 Tightening Torque Spec for Cooling System .......................................................................... 2-14
2.5 Tightening Torque Spec for Inlet and Exhaust System .......................................................... 2-14
2.6 Tightening Torque Spec for Electrical System........................................................................ 2-14
2.7 General Bolts and Nuts........................................................................................................... 2-15
2.8 General Union Bolt ................................................................................................................. 2-16
2.9 General Union Nut .................................................................................................................. 2-16
2-1
1. Maintenance Service Data

1.1 Maintenance Service Data of Engine General
Item Nominal value Standard value Limit value Remarks

Rated speed 1500 min-1, 1800 min-1 Depending on the specification
Minimum speed 600 min-1
1.9 MPa
2.4 MPa
Compression pressure {19.3 kgf/cm2} Engine speed (min-1) room temperature
{24.4 kgf/cm2} [348 psi]
[276 psi]
0.92 to 1.57 mm
Top clearance
[0.0362 to 0.0618 in.]
0.58 MPa 0.53 to 0.63 MPa 0.39 MPa
Equivalent to relief valve opening pres-
Rated {5.9 kgf/cm2} {5.4 to 6.4 kgf/cm2} {4.0 kgf/cm2}
sure
[84.1 psi] [76.9 to 91.4 psi] [56.6 psi]
Engine oil pressure
0.25 MPa 0.20 to 0.30 MPa 0.10 MPa
When oil temperatures at 60 to 70°C
Idling {2.5 kgf/cm2} {2.0 to 3.0 kgf/cm2} {1 kgf/cm2}
[140 to 158°F]
[36.3 psi] [29.0 to 43.5 psi] [14.5 psi]
Open BTDC 55°
Inlet
Close ABDC 65°
Valve clearance 0 mm
Open BBDC 65°
Exhaust
Close ATDC 55°
Valve timing
Open BTDC 14°
Inlet
Close ABDC 21° ±2°
Valve clearance 2 mm [0.08 in.]
Open BBDC 27° (crank angle)
Exhaust
Close ATDC 14°
0.6 mm 0.55 to 0.65 mm
Inlet
Valve clearance [0.024 in.] [0.0217 to 0.0256 in.]
(when cold) 0.8 mm 0.75 to 0.85 mm
Exhaust
[0.031 in.] [0.0295 to 0.0335 in.]
Check the caution plate on No. 1 rocker
Fuel injection timing ±1°
cover.
2-3
1.2 Maintenance Service Data of Basic Engine

Unit: mm [in.]
Nominal Limit
Item Standard value Remarks
value value
0.03 [0.0012] 0.07
Bottom surface flatness
or less [0.0028]
154.9 to 155.1
Cylinder head Height (reference) 155 [6.10]
[6.098 to 6.106]
55.00 to 55.03 55.10
Inside diameter of valve seat counterbore ø55 [ø2.17]
[2.165 to 2.167] [2.1693]
1.77 to 1.83
Cylinder head gasket Thickness 1.8 [0.071]
[0.0697 to 0.0720]
Valve seat angle 30º ±15'
2.2 to 2.4 2.8
Seat width 2.3 [0.091]
[0.087 to 0.095] [0.1102]
55.10 to 55.13
Standard
[2.1693 to 2.1705]
Valve seat Outside diame- 55.13 to 55.16
0.03 [0.0012] ø55 [ø2.17]
ter [2.1750 to 2.1716]
55.16 to 55.19
0.06 [0.0024]
[2.1716 to 2.1728]
0.07 to 0.13
Interference
[0.0028 to 0.0051]
Guide height after installation 27.5 [1.083]
Valve guide 10.000 to 10.015 10.060
Inside diameter ø10 [ø0.39]
[0.3937 to 0.3943] [0.3961]
9.94 to 9.96 9.91
Stem outside diameter ø10 [ø0.39]
[0.3913 to 0.3921] [0.3902]
3.0 2.9 to 3.1 2.5
Thickness at margin
[0.118] [0.114 to 0.122] [0.0984]
-0.1 to 0.1 0.5
Sinkage 0
[-0.0039 to 0.0039] [0.0197]
Bridge guide height after installation 49.5 [1.9488] Thread type in ECUI spec
11.985 to 12.000
MUI
Bridge guide [0.4718 to 0.4724] 11.300
Valve
outside diameter 11.982 to 12.000 [0.4449]
ECUI ø12 [0.47]
[0.4717 to 0.4724]
12.050 to 12.077 12.130
Valve bridge hole inside diameter
[0.4744 to 0.4755] [0.4776]
Clearance Adjusting screw side 6.1 [0.2402]
between bottom
face of valve
bridge and top Plane screw side 5.1 [0.2008]
face of valve
rotator
2-4
Unit: mm [in.]
Nominal Limit
value value
70.2 to 70.8 69.0
MUI 70.5 [2.776]
[2.764 to 2.787] [2.717]
Free length
75.2 to 75.8 74.0
ECUI 75.5 [2.972]
[2.961 to 2.984] [2.913]
B = 2.5
[0.098] at
A = 1.5º or less
whole
length
MUI
B=1.8 [0.071]
or less
A
Lf = 70.5 [2.776] B
Squareness
B = 2.6 Lf
Valve spring [0.102] at

A = 1.5º or less
whole
length
ECUI
B = 2.0 [0.079]
or less
Lf = 75.5 [2.97]
61.8 [2.433]/254.5
to 281.3
MUI
{25.95 to 28.69}
Set length/load [57.21 to 63.24]
(mm [in.]/N
{kgf} [lbf]) 61.8 [2.433]/383.1
to 423.5
ECUI
{39.06 to 43.18}
[8.78 to 9.71]
43.975 to 43.991 43.930
Rocker shaft outside diameter
[1.7313 to 1.7319] [1.7295]
Rocker ø44 [ø1.73]
44.000 to 44.075 44.125
Rocker bushing inside diameter
[1.7323 to 1.7352] [1.7372]
Push rod Runout 0.5 [0.0197] or less TIR
Inlet cam lift (major diameter - minor 14.35 14.30 to 14.40 13.65
diameter) [0.5650] [0.563 to 0.567] [0.5362]
Exhaust cam lift (major diameter - minor 9.25 9.20 to 9.30 8.55
diameter) [0.3642] [0.3622 to 0.3661] [0.3366]
86.16 to 86.24 85.5
Injector cam height (major diameter) 86.2 [3.394]
[3.3921 to 3.3953] [3.3661]
99.92 to 99.94 99.86
Camshaft Journal diameter Oil clearance
ø100 [3.9339 to 3.9346] [3.9315]
0.08 to 0.175
Camshaft bushing inside diameter [ø3.94] 100.020 to 100.095 100.15 [0.0031 to 0.0069]
(as installed in crankcase) [3.9378 to 3.9407] [3.9429]
0.16
Runout 0.1 [0.004] or less TIR
[0.0063]
0.2 to 0.4 0.5
End play
[0.008 to 0.016] [0.0197]
29.959 to 29.980 29.93
Shaft outside diameter
[1.1795 to 1.1803] [1.1783]
ø30 [ø1.18]
30.000 to 30.075 30.12
Cam follower Bushing inside diameter
[1.1881 to 1.1841] [1.1858]
40.95 to 41.05 40.9
Roller tappet outside diameter ø41 [ø1.61]
[1.6122 to 1.6161] [1.5783]
2-5
Unit: mm [in.]
Nominal Limit
value value
Inside diameter of main bearing housing ø147 147.000 to 147.025 147.045
bore [ø5.79] [5.7874 to 5.7884] [5.7892]
15.00 to 15.05
Depth of counterbore in crankcase 15 [0.59]
[0.5906 to 0.5925]
Crankcase 0.15 [0.0059] 0.25
Distortion of top surface
or less [0.0098]
Height from the center of crank journal to 468.95 to 469.05
the top of crankcase 469 [18.46] [18.4626 to
(reference value) 18.4665]
ø150 150.00 to 150.04 150.1
Inside diameter
[ø5.91] [5.9055 to 5.9071] [5.9094]
0.02 [0.0008]
Roundness, cylindricity
or less
0.2 0.16 to 0.24 0.1
Cylinder liner Top ridge height
[0.0079] [0.0063 to 0.0094] [0.0039]
15 15.15 to 15.19
Flange thickness
[0.59] [0.5965 to 0.5980]
0.10 to 0.19 0.05
Flange protrusion
[0.0039 to 0.0075] [0.0020]
At a height of 30 mm [1.18 in.]
ø149.8 149.78 to 149.82 149.68 from the piston lower end in
Outside diameter
[ø5.898] [5.8968 to 5.8984] [5.8929] the right angle to the piston
pin.
58.002 to 58.012 58.04
Piston pin bore inside diameter ø58 [ø2.28]
[2.2835 to 2.2839] [2.2850]
Piston
0.45 to 0.95
Protrusion To crankcase top face
[0.0177 to 0.0374]
Unit weight ±15 g [0.53 oz]
within 10 g
Weight difference in one engine
[0.35 oz]
57.987 to 58.000 57.97
Piston pin Outside diameter ø58 [ø2.28]
[2.2829 to 2.2835] [2.2823]
0.29 MPa 0.29±0.03 MPa
Piston cooling nozzle Valve opening pressure {3 kgf/cm2} {3±0.3 kgf/cm2}
[42 psi] [435.1±43.5 psi]
0.6 to 0.8 1.7
No.1 compression
[0.0236 to 0.0315] [0.0669]
0.5 to 0.7 1.6
Piston ring End gap No.2 compression
[0.0197 to 0.0276] [0.0630]
0.5 to 0.7 1.3
Oil
[0.0197 to 0.0276] [0.0512]
2-6
Unit: mm [in.]
Nominal Limit
value value
58.02 to 58.04 58.07
Inside diameter of connecting rod bushing ø58 [ø2.28]
[2.2842 to 2.2850] [2.2862]
Mini-
mum:
109.95
ø110 110.000 to 110.022 [4.3287]
Inside diameter
[ø4.33] [4.3307 to 4.3316] Maxi-
Big end bearing housing
mum:
110.05
[4.3327]
Connecting rod
0.022 [0.0009] 0.1
Roundness
or less [0.0039]
54 53.7 to 53.8
Width
[2.13] [2.1142 to 2.1181]
Big end side face
0.6 to 0.9 1.1
End play
[0.0236 to 0.0354] [0.0433]
0.05/100
Bend and twist [0.0020/3.94]
or less
3.000 2.987 to 3.000 2.950
Standard
[0.1181] [0.0236 to 0.0354] [0.1161]
0.25 3.125 3.112 to 3.125 3.075
[0.0098] [0.1230] [0.1225 to 0.1230] [0.1211]
Oil clearance
Thickness at 0.50 3.25 3.237 to 3.250 3.200
0.08 to 0.148 [0.0031 to
Connecting rod bear- center Under [0.0197] [0.1280] [0.1274 to 0.1280] [0.1260]
0.0069]
ing size 0.75 3.375 3.362 to 3.375 3.325
[0.0295] [0.1329] [0.1324 to 0.1329] [0.1309]
1.00 3.50 3.487 to 3.500 3.450
[0.0394] [0.1378] [0.1373 to 0.1378] [0.1358]
111 to 112.5 110
Spread
[4.3701 to 4.4291] [4.33]
0.28 [0.011]
Face runout (reference) SAE#18
or less
Flywheel
0.13 [0.0051]
Radial runout (reference)
or less
Face runout (reference) 0.5 [0.0197]
Damper
Radial runout (reference) or less
49.950 to 49.975 49.900

Front idler shaft outside diameter
[1.9665 to 1.9675] [1.9646]
ø50 [ø1.97]
50.000 to 50.025 50.06
Front idler bushing inside diameter Machine finish after press-in
[1.9685 to 1.9695] [1.9709]
Coaxiality <ø0.05 [<ø0.0020]
Squareness <ø0.1 [<ø0.004]
Front mechanism Front idler bushing
Surface rough-
Ra 0.8 μm [31 μin.]
ness
0.3 to 0.5 0.7
End play of front idler gear
[0.0118 to 0.0197] [0.0276]
Backlash between front idler gear and crank 0.11 to 0.28 0.5
gear [0.0043 to 0.00110] [0.0197]
2-7
Unit: mm [in.]
Nominal Limit
value value
49.950 to 49.975 49.900
Rear idler shaft outside diameter
[1.9665 to 1.9675] [1.9646]
ø50 [ø1.97]
50.000 to 50.025 +0.06
Rear idler bushing inside diameter Machine finish after press-in
[1.9685 to 1.9695] [+0.0024]
Squareness <ø0.1 [<ø0.004]
Rear mechanism Rear idler bushing
Surface rough-
Ra 0.8 μm [31 μin.]
ness
0.3 to 0.5 0.7
End play of rear idler gear
[0.0118 to 0.0197] [0.0276]
0.11 to 0.26 0.5
Timing gear backlash
[0.0043 to 0.0102] [0.0197]
ø104.00 103.90 to 103.92 103.86
Standard
[ø4.0945] [4.0905 to 4.0913] [4.0890]
ø103.75 103.65 to 103.67 103.61
0.25 [0.0098]
[ø4.0846] [4.0807 to 4.0815] [4.0791]
Crankpin ø103.50 103.40 to 103.42 103.36
0.50 [0.0197]
outside diameter Under [ø4.0748] [4.0709 to 4.0716] [4.0693]
size ø103.25 103.15 to 103.17 103.11
0.75 [0.0295]
[ø4.0650] [4.0610 to 4.0618] [4.0594]
ø103.00 102.90 to 102.92 102.86
1.00 [0.0394]
[ø4.0551] [4.0512 to 4.0520] [4.0496]
ø140.00 139.93 to 139.95 139.84
Standard
[ø5.5118] [5.5090 to 5.5098] [5.5055]
ø139.75 139.68 to 139.70 139.59
0.25 [0.0098]
[ø5.5020] [5.4992 to 5.5000] [5.4975]
Crank
ø139.50 139.43 to 139.45 139.34
journal outside 0.50 [0.0197]
Under [ø5.4921] [5.4894 to 5.4901] [5.4858]
diameter
size ø139.25 139.18 to 139.20 139.09
0.75 [0.0295]
[ø5.4823] [5.4795 to 5.4803] [5.4760]
ø139.00 138.93 to 138.95 138.84
1.00 [0.0394]
[ø5.4724] [5.4697 to 5.4665] [5.4661]
108.0 108.2 to 108.3 108.4
Crankpin width
[4.2520] [4.2598 to 4.2638] [4.2677]
Crankshaft
58.00 58.00 to 58.03
Standard
[2.2835] [2.2835 to 2.2846]
58.25 58.25 to 58.28
0.25 [0.0098]
[2.2933] [2.2933 to 2.2945]
58.50 58.50 to 58.53
0.50 [0.0197]
[2.3031] [2.3031 to 2.3043]
Rearmost crank
58.75 58.75 to 58.78
journal 0.75 [0.0295]
Over [2.3130] [2.3130 to 2.3142]
width
size 59.00 59.00 to 59.03
1.00 [0.0394]
[2.3327] [2.3228 to 2.3240]
59.25 59.25 to 59.28
1.25 [0.0492]
[2.3327] [2.3327 to 2.3339]
59.50 59.50 to 59.53
1.50 [0.0591]
[2.3425] [2.3425 to 2.3437]
0.03
Parallelism <0.01 [0.0004]
[0.0012]
0.03
Pin and journal Roundness <0.01 [0.0004]
[0.0012]
0.03
Cylindricity <0.01 [0.0004]
[0.0012]
7.0 to 7.2
Fillet radius of pin R7 [R0.28]
[0.2756 to 0.2835]
2-8
Unit: mm [in.]
Nominal Limit
value value
7.0 to 7.2
Fillet radius of journal R7 [R0.28]
[0.2756 to 0.2835]
Hardness of journal and crankpin HV>620 [24.4]
Finishing surface roughness Ra 0.2 μm [8 μin.]
Crankshaft Angular deviation between pins ±0.3°
0.08 [0.0031] 0.2
Runout TIR
or less [0.0079]
End play 0.3 to 0.495 0.7
(at shaft thrust bearings) [0.0118 to 0.0195] [0.0276]
3.500 3.467 to 3.480 3.450
Standard
[0.1378] [0.1365 to0.1370] [0.1358]
3.625 3.592 to 3.605 3.575
0.25 [0.0098]
[0.1427] [0.1414 to0.1419] [0.1407]
Thickness at 3.750 3.717 to 3.730 3.700
0.50 [0.0197]
center Under [0.1476] [0.1463 to 0.1469] [0.1457]
Main bearing
size 3.875 3.842 to 3.855 3.825
0.75 [0.0295]
[0.1526] [0.1513 to 0.1518] [0.1506]
4.000 3.967 to 3.980 3.950
1.00 [0.0394]
[0.1575] [0.1562 to 0.1567] [0.1555]
148.25 to 150.25 147
Spread
[5.8366 to 5.9153] [5.7874]
5.0 4.78 to 4.85 4.76
Standard
[0.1969] [0.1882 to 0.1909] [0.1874]
5.25 5.03 to 5.10 5.01
0.25 [0.0098]
[0.2067] [0.1980 to 0.2008] [0.1972]
Thrust plate Thickness
Over 5.50 5.28 to 5.35 5.26
0.50 [0.0197]
size [0.2165] [0.2079 to 0.2106] [0.2071]
5.75 5.33 to 5.40 5.31
0.75 [0.0295]
[0.2264] [0.2098 to 0.2126] [0.2091]
1.3 Maintenance Service Data of Fuel System

Unit: mm [in.]
Nominal Limit
value value
Free length 27.6 [1.0866]
A = 0.65º or less A
B = 0.31 [ 0.0122] or B
Squareness
less Lf
Nozzle spring
Lf = 27.6 [1.0866]
Unit injector
Set length/load
25.8/489.6 to 612.4
(mm [in.]/N {kgf}
{49.93 to 62.45}
[lbf])
29.4 MPa 28.9 to 30.9 MPa
Fuel injection starting pressure {300 kgf/cm2} {295 to 315 kgf/cm2} Shim adjust type
[4264 psi] [4191 to 4482 psi]
27.991 to 28.000 At needle bearing slid-
Governor drive Drive shaft outside diameter ø28 [ø1.10]
[1.1020 to 1.1024] ing face
0.49 MPa 0.49±0.025 MPa
Check valve Valve opening pressure {5.0 kgf/cm2} {5.0±0.25 kgf/cm2}
[71.07 psi] [71.07 to 3.6 psi]
2-9
1.4 Maintenance Service Data of Lubrication System

Unit: mm [in.]
Nominal Limit
value value
0.11 to 0.26 0.4
Backlash between oil pump gear and crankshaft gear
[0.0043 to 0.0102] [0.0157]
0.095 to 0.14 0.2
Top clearance between gear teeth and case
[0.0037 to 0.0055] [0.0079]
0.095 to 0.155 0.25
Side clearance between gear width and case face
[0.0037 to 0.0061] [0.0098]
40.000 to 40.016 39.930
Shaft outside diameter ø40 [ø1.57]
[1.5748 to 1.5754] [1.5720]
40.040 to 40.059 40.140
Bushing inside diameter ø40 [ø1.57]
[1.5764 to 1.5771] [1.5803]
Center distance 68.137 [2.4857]
Squareness <ø0.02 [ø0.0008]
Oil pump
Surface roughness Ra 0.2μm [8μin.]
1.4 MPa ±0.1 MPa
Shim 0 to 2
Valve opening pressure {14 kgf/cm2} {±1.0 kgf/cm2}
pieces
[203 psi] [14.5 psi]
93.7 to 94.3
Free length 94 [3.7]
[3.6890 to 3.7196]
A = 2.0º or less A
Safety valve B = 3.3 [0.123] or B
Squareness
less Lf
Spring
Lf = 94 [3.70]
Set length/load 73.4[2.890]/
(mm [in.]/N {kgf} 902 to 1040
[lbf]) {92 to 106}
[3.6 to 4.2]
Free length 66.5 [2.6181]
Spring set length / load 54.1 [0.120]/145
Oil cooler (mm [in.]/N{kgf} [lbf]) {14.8} [32.6]
Bypass valve
0.44 MPa ±0.05 MPa
Differential pressure to open {4.5 kgf/cm2} {±0.5 kgf/cm2}
[63.82 psi] [±7.25 psi]
0.58 MPa ±0.05 MPa
Valve opening pressure {5.9 kgf/cm2} {±0.5 kgf/cm2}
[84.1 psi] [±7.25 psi]
Relief valve
Free length 115 [4.52]
Spring Set length / load 92/354
(mm [in.]/N{kgf} [lbf]) {36.1} [79.6]
+0.03
0.15 MPa 0.15 0 MPa
Oil filter +0.3
Turn on start pressure (differential pressure) {1.5 kgf/cm2} {1.5 0 kgf/cm2}
alarm
[22 psi] +4.35
[22 0 psi]
2-10
1.5 Maintenance Service Data of Cooling System

Unit: mm [in.]
Nominal Limit
value value
ø120 119.987 to 120.022
Inside diameter of pump case to fit to bearing
[4.72] [4.7239 to 4.7253]
ø110 110.005 to 110.040
Inside diameter of bearing case to fit Installed to front plate
[ø4.33] [4.3309 to 4.3323]
ø29.5 29.025 to 29.035
To press fit impeller
[ø1.161] [1.1427 to 1.1431]
ø30 30.045 to 30.06
To press fit unit seal ring
[1.18] [1.1829 to 1.1835]
ø50 49.938 to 50.000
Water pump Oil seal sliding face
[ø1.97] [1.9661 to 1.9685]
ø50 50.011 to 50.024
To press fit bearing and gear
[ø1.97] [1.9689 to 1.9694]
ø55 55.011 to 55.024
To press fit bearing
[ø2.17] [2.1658 to 2.1663]
ø40 39.966 to 39.991
To press fit pulley
[ø1.57] [1.5735 to 1.5744]
1.04 0.58 to 1.50
Impeller front clearance
[0.0409] [0.0228 to 0.059]
ø68 67.961 to 67.991
Inside diameter of case bearing housing
[ø2.68] [2.6756 to 2.6768]
ø68 67.987 to 68.000
Outside diameter To press fit impeller
[ø2.68] [2.6766 to 2.6772]
Bearing
For air cooler water ø28 27.990 to 28.000
Inside diameter To press fit unit seal
pump [ø1.10] [1.1020 to 1.1024]
ø28 28.002 to 28.015
Outside diameter of shaft to fit bearing To press fit bearing and pulley
[ø1.10] [1.1024 to 1.1030]
0.8 0.5 to 1.1
[0.0315] [0.0197 to 0.0433]
Valve opening tempera- 71ºC 69 to 73 ºC
ture [160 ºF] [156 to 163 ºF]
Temperature at which
Basic engine
valve lift becomes 9 85 ºC [185 ºF]
[0.35] or more
Lift 10 [0.39]
Thermostat
Valve opening tempera- 35ºC 33 to 37ºC
ture [95 ºF] [91.4 to 98.6 ºF]
For Air cooler Temperature at which
(Y2PTAW only) valve lift becomes 9 50ºC [122 ºF]
[0.35] or more
Lift 10 [0.39]
ø110 109.987 to 110.022
Inside diameter of rear bracket bearing hous- [ø4.33] [4.3302 to 4.3316]
ing ø120 119.987 to 120.022
[ø4.72] [4.7193 to 4.7253]
ø50 50.002 to 50.013
Fan drive
[ø1.97] [1.9686 to 1.9690]
To press fit bearing
ø45 45.002 to 45.013
[ø1.77] [1.7717 to 1.7722]
ø40 40.009 to 40.025
To press fit pulley
[ø1.57] [4.5748 to 1.5758]
2-11
2. Tightening Torque Table
(a) When [Wet] is indicated, apply engine oil to the threads and bolt seat surface.
(b) When [2-time tightening method] is indicated, tighten the bolts to the specified angle then loosen all bolts, and
retighten them.
2.1 Tightening Torque Spec for Basic Engine
Thread size Tightening torque

Description Remarks
Dia x Pitch N·m kgf·m lbf·ft
[Wet] [2-time tightening method], Note
Cylinder head bolt M22×2.5 539 ± 27 55 ± 2.75 398 ± 19.91
(a)
ECUI bridge guide M10×1.25 39.2 4.0 28.9
M12×1.25 108 ± 5.4 11 ± 0.55 80 ± 3.98
Rocker case
M10×1.25 60 ± 3.0 6 ± 0.3 44 ± 2.2
Rocker shaft M16×2.0 167 ± 8.4 17 ± 0.85 123 ± 6.2
Rocker arm (lock nut) M12×1.25 64 ± 3.2 6.5 ± 0.33 47 ± 2.36
Bridge (lock nut) M10×1.25 55 ± 2.8 5.6 ± 0.28 41 ± 2.07
Camshaft gear M14×1.5 176 ± 8.8 18 ± 0.9 130 ± 6.5
Camshaft thrust plate M12×1.25 108 ± 5.4 11 ± 0.55 80 ± 3.98
Cam follower shaft M12×1.25 88 ± 4.4 9 ± 0.45 65 ± 3.25
Adapter M12×1.25 78 ± 3.9 8 ± 0.4 58 ± 2.9
Main bearing cap M22×2.5 490 ± 24.5 50 ± 2.5 361 ± 18.1 [Wet], Note (b)
Main bearing cap (side bolt) M16×1.5 147 ± 7.4 15 ± 0.75 108 ± 5.46 [Wet], Note (b)
Rear hanger M16×1.5 255 ± 24.5 26 ± 2.5 188 ± 18.1
Piston cooling nozzle check valve M12×1.75 34 ± 1.7 3.5 ± 0.18 25 ± 1.25 Note (c)
M12×1.25 98 ± 4.9 10 ± 0.5 72 ± 3.6 Fixed to crankcase
Timing gear case M12×1.25 69 ± 3.5 7 ± 0.35 51 ± 2.58 Fixed to rear plate with nut
M16×1.5 255 ± 12.3 26 ± 1.3 188 ± 9.1
Rear plate M12×1.25 108 ± 5.4 11 ± 0.55 80 ± 3.98
Front mounting bracket M20×1.5 392 ± 19.6 40 ± 2.0 289 ± 14.5
Rear mounting bracket M18×2.5 294 ± 14.7 30 ± 1.5 217 ± 10.8
[Wet] [2-time tightening method], Note
Connecting rod bearing cap M18×1.5 343 ± 17 35 ± 1.7 253 ± 12.5
(a)
Balance weight M16×1.5 196 ± 9.8 20 ± 1.0 145 ± 7.2 [Wet]
Flywheel M22×1.5 588 ± 29.4 60 ± 3.0 434 ± 21.7 [Wet]
Damper M22×1.5 490 ± 24.5 50 ± 2.5 361 ± 18.1
Rear idler shaft M12×1.25 108 ± 5.4 11 ± 0.55 80 ± 3.98
Rear idler shaft thrust plate M10×1.25 60 ± 3.0 6.1 ± 0.31 44 ± 2.25
M12×1.25 98 ± 9.8 10 ± 1.0 72 ± 7.2 Fixed to crankcase
Front gear case M12×1.25 69 ± 6.9 7 ± 0.7 51 ± 5.1 Fixed to front plate with nut
M16×1.5 255 ± 25.5 26 ± 2.6 188 ± 18.8
Front plate M12×1.25 108 ± 10.8 11 ± 1.1 80 ± 8.0
Front idler shaft M12×1.25 108 ± 5.4 11 ± 0.55 80 ± 3.98
Front idler shaft thrust plate M16×1.5 216 ± 10.8 22 ± 1.1 159 ± 8.0
Note:(a) Follow the procedure below to tighten the cylinder head bolts using angle method.
For tightening procedure, refer to "Cylinder Head Bolt - Tighten" of "ASSEMBLY OF BASIC ENGINE."
1) Tighten the bolt with a snug torque of 294 ± 15 N·m {30 ± 1.5 kgf·m} [217 ± 11 lbf·ft].
2) Then tighten the bolt to the angle of 65±3°.
2-12
(b) For tightening of main bearing cap bolts and main bearing cap side bolts, follow the specified sequence. Snug tighten
all the bolts to the half of the specified torque, and after the snug tightening of all the bolts, tighten them to the specified
torque.
For the tightening procedure, refer to "Main bearing cap - Install" of "ASSEMBLY OF BASIC ENGINE."
(c) Be sure to tighten the piston cooling nozzle check valve to the specified torque. Do not over-tighten. If the tightening
torque exceeds the specified torque, it can cause malfunction of the check valve, which may result in piston seizure.
(d) Follow the procedure below to tighten the cylinder head bolts using angle method.
For the tightening procedure, refer to "Connecting rod cap - Install" of "ASSEMBLY OF BASIC ENGINE."
1) Tighten it with a snug torque 147±7.4 N·m {15±0.75 kgf·m} [108±5 lbf·ft].
2) Then tighten the bolt to the angle of 45±3°.
2.2 Tightening Torque Spec for Fuel System

Description Remarks
Unit injector gland (nut) M16×1.5 127 ± 6.4 13 ± 0.7 94 ± 4.7 [Wet] Note (b)
Stud for unit injector gland Apply thread lock (Locktite 271 or
M16×2.0 127 ± 6.35 13 ± 0.65 94 ± 4.68
(Side to screw into cylinder head) equivalent).
Unit injector gauge stand M8×1.25 8.8 0.9 6.5
MUI M45×1.5
Unit injector body retaining nut 314 ± 10 32 ± 1 232 ± 7 [Wet] [2-time tightening method]
ECUI M42×1.5
Injection nozzle retaining nut M30×1.5 216 ± 5 22 ± 0.5 159 ± 3.7 [Wet] [2-time tightening method]
Fuel main pipe (union bolt) M10×1.25 15 ± 1.5 1.5 ± 0.15 11 ± 1.11
Priming pump and fuel filter (union bolt) M14×1.5 20 to 25 2.0 to 2.5 14 to 18.44
Priming pump bolt M16×1.5 34 ± 3.4 3.5 ± 0.35 25 ± 2.51
Fuel supply piping union bolt M20×1.5 59 ± 5.9 6.0 ± 0.6 44 ± 4.4
Fuel feed pump bolt M8×1.25 20 to 22 2.0 to 2.2 15 to 16
Fuel rack control lever M8×1.25 25 ± 2.5 2.5 ± 0.25 18 ± 1.84 [2-time tightening method]
Normally, bleed air from fuel main
Fuel filter breather plug M8×1.25 8 to 10 0.8 to 1.0 6 to 7
pipe.
Governor drive case M12×1.25 108 ± 10.8 11 ± 1.1 80 ± 8.0
Union bolt of fuel main pipe check valve M14×1.5 34 ± 4 3.5 ± 0.4 25 ± 3.0
Fuel main pipe check valve nut M12×1.25 56 ± 6 5.7 ± 0.6 41 ± 4.43
Cancel rod M10×1.25 33 ± 1.67 3.4 ± 0.17 24 ± 1.23
Cancel rod control lever (reamer bolt) M18×1.25 30 ± 1.52 3.1 ± 0.16 22 ± 1.12
Note:(e) Follow the procedure below to tighten the gland nut of unit injector.
1) First, tighten to 176±9 N·m {18±0.9 kgf·m} [130±7 lbf·ft] exceeding the specification for snug fitting of each con-
tact face.
2) Loosen the nut, then tighten to the specification 127±6.4 N·m {13±0.7 kgf·m} [94±5 lbf·ft].
2.3 Tightening Torque Spec for Lubrication System

Description Remarks
Oil pan M10×1.25 39±3.9 4±0.4 29±2.9
Oil pump M10×1.25 59±5.9 6±0.6 44±4.4
Oil pump cover M10×1.5 34 to 74 3.5 to 7.5 25 to 55
Safety valve plug M40×2.0 196±20 20±2 145±15
Oil cooler element (nut) M10×1.25 24.5±5 2.5±0.5 18.1±3.7
Oil cooler connecting pipe M10×1.5 39.2±5 4.0±0.5 28.9±3.7
Turbocharger lubrication pipe M10×1.5 59±3.0 6±0.3 44±2.2 Flange type
2-13
2.4 Tightening Torque Spec for Cooling System

Description Remarks
Dia x Pitch N·m kgf·m
Water pump M12×1.25 108±10.8 11±1.1 80±8.0
Water pump shaft pulley (nut) M30×1.5 392±20 40±2.0 289±14.8 For alternator driving
Fan pulley (cap nut) M30×1.5 392±39 40±4.0 289±29
2.5 Tightening Torque Spec for Inlet and Exhaust System

Description Remarks
Exhaust manifold M10×1.5 54±5 5.5±0.5 40±3.7
Coupling bolt M6×1.0 8.35±0.45 0.85±0.05 6.16±0.33
2.6 Tightening Torque Spec for Electrical System

Description Remarks
Starter mounting bolt M12×1.25 59±5.9 6±0.6 44±4.4
Starter terminal B M10×1.25 15.7 to 19.6 1.6 to 2.0 11.6±14.5
Alternator pulley M20×1.5 147±15 15±1.5 108±11.1
2-14
2.7 General Bolts and Nuts

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

10 x 1.5 14 [0.55] 32 3.3 23.9 58 5.9 42.67
12 x 1.75 17 [0.67] 57 5.8 42.0 102 10.4 75.2
Metric course screw
14 × 2 22 [0.87] 93 9.5 68.7 167 17.0 123.0
thread
16 × 2 24 [0.94] 139 14.2 102.7 251 25.6 185.2
18 × 2.5 27 [1.06] 194 19.8 143.2 350 35.7 258.2
20 × 2.5 30 [1.18] 272 27.7 200.4 489 49.9 361.0
22 × 2.5 32 [1.26] 363 37.0 267.6 653 66.6 482.0
24 × 3 36 [1.42] 468 47.7 345.0 843 86.0 622.0
27 × 3 41 [1.61] 686 70.0 506.3 1236 126.0 911.4
Note:(a) The tightening torque listed in this table is for standard bolts and nuts.
(b) The numerical values in the table are the values when spring washers are used.
(c) The table shows the standard values with a maximum tolerance value of ±10%.
(d) Use the tightening torque in this table unless otherwise specified.
(e) Do not apply oil to threaded portions.(Dry)
2-15
2.8 General Union Bolt

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

Cap nut thread size
Width across flats
Nominal Dia. × Pitch N·m kgf·m lbf·ft
(mm) [in.]
(M-thread)
63 14 × 1.5 19 [0.75] 39 4 28.76
80 16 × 1.5 22 [0.87] 49 5 36.14
100 20 × 1.5 27 [1.06] 78 8 57.53
120 22 × 1.5 30 [1.18] 98 10 72.28
150 27 × 1.5 32 [1.26] 157 16 115.80
180 30 × 1.5 36 [1.42] 196 20 144.56
200 30 × 1.5 36 [1.42] 196 20 144.56
220 33 × 1.5 41 [1.61] 245 25 180.70
254 36 × 1.5 41 [1.61] 294 30 216.84
(Maximum tolerance value: ±10%, dry condition)
2-16
1. Special Tools............................................................................................................ 3-3
3-1
1. Special Tools
Maintenance
Tool name Part No. Illustration Usage
item
Basic engine Eye bolt 45815-32301 Piston - Remove
M10 × 1.5
37591-02500 Lifting of cylinder head, main bearing

cap and others
M10 × 1.25
05930-00200 Lifting of cylinder head, gear case and

others
M12 × 1.25
Jack bolt 64362-68500 Fly wheel and damper removal
M12 × 1.25 - 95mm
Nozzle remover 36291-00900 Main bearing cap removal
M18×1.5
Adapter 32591-04300 Main bearing cap removal

M10 × 1.25
M18 × 1.5
Valve spring pusher assem- 35C91-04010 Valve spring installing and removal
bly
Valve guide remover 33591-04300 Valve guide removal

ø17 × L100 Applicable valve guide inside X out-
side diam
ø10× ø18 mm [ø0.39 × ø0.71 in.]
ø10 × L50
3-3
Maintenance
item
Basic engine Guide and seal installer 32591-10300 Valve guide and stem seal installing
Guide height : 27.5 mm [1.08 in.]
Stem seal height : 30.3 mm [1.19 in.]
Valve lapper 30091-08800 Valve lapping

Sucking disk ø40 [ø1.57 in.]
Valve lapper 30091-07500 Valve lapping

Sucking disk ø35 [ø1.38 in.]
Valve seat cutter 37591-06400 Valve seat refacing

(shaft) Guide shaft diam ø10 [ø0.39]
Width across flats : 32 mm [1.26 in.]
W1 1/8 -18
Valve seat cutter 37591-06430 Valve seat refacing

Seat angle θ=30°
Applicable seat inside/outside diame-
ter: ø45 to ø66 [ø1.77 to ø 2.60]
W1 1/8 -18
θ＝30°
Valve seat puller 32591-04200 Valve seat removal
Cupper tube pusher 35B91-06600 Cylinder head cupper tube removal

(MUI)
Cupper tube installer 35C91-21010 Cylinder head cupper tube installation

and caulking
(MUI)
Stainless steel tube installer 35C91-00600 Cylinder head stainless steel tube
installation and removal
(ECUI)
3-4
Maintenance
item
Basic engine Rocker bushing installer 35C91-01800 Rocker bushing replacement
Bushing inside and outside diameters
ø44×ø48 [ø1.73 × ø1.89 in.]
Follower bushing installer 35C91-01700 Cam follower bushing replacement

ø30×ø34 [ø1.18 × ø1.34 in.]
Idler bushing puller 32591-02500 Idler bushing replacement

ø50×ø55 [ø1.97 × ø2.17 in.]
Front seal installer assem- 37591-05010 Front oil seal installing

bly Applicable engine models: SH and SR
Rear seal installer assembly 35B91-06010 Rear oil seal installing
Ring expander 37191-03200 Piston ring installing and removal

Applicable diameter ø102 to ø177
[ø4.02 to ø6.97 in.]
Piston installer 37191-07100 Piston installing

Applicable piston diameter: ø89 to
ø178 [ø3.50 to ø7.01 in.]
Cylinder liner remover 32591-14100 Cylinder liner removal

Applicable liner inside diameter: ø145
to ø150 [ø5.71 to ø5.91in.]
Applicable engine models: SA and SH
Cylinder liner installer 32591-01800 Cylinder liner installing

Applicable liner inside diameter ø150
[ø5.91in.]
3-5
Maintenance
item
Basic engine Connecting rod bushing 32591-18010 Connecting rod bushing replacement
installer Bushing inside and outside diameters
ø55×ø59 [ø2.17×ø2.32 in.]
ø58 × ø62 [ø2.28×ø2.44 in.]
ø65× ø70 [ø2.56×ø2.76 in.]
Applicable engine models: SB, SA,
SH and SN
Crankcase grinder 32591-04050 Crankcase liner counterbore refacing

Applicable engine models: SA and SH
Cam gear stop bolt 35B91-16500 Cam gear retaining to pull out only
camshaft
M12×1.25
Cam bushing installer 35B91-02010 Cam bushing replacement
Unit injector puller 35C91-11400 Unit injector removal
Liner pusher assembly 37591-06020 Cylinder liner flange protrusion mea-

surement
3-6
Maintenance
item
Unit injector Clamp 48749-01000 Fixing to vice
(MUI)
Clamp 48493-01000 Fixing to vice

(ECUI)
Connector 48749-00101 Fuel injection valve opening pressure

adjustment
(MUI)
M45 × 1.5
M14 × 1.5
Connector 48493-00100 Fuel injection valve opening pressure

adjustment
(ECUI)
Unit injector Height gauge 35C91-01900 Tappet height adjustment to install to

engine
81 mm [3.19 in.] at BTDC120°
(ECUI)
Height gauge 35C91-11100 Fuel injection timing adjustment to

install to engine
80 mm [3.15 in.] at the specified fuel
injection timing
(MUI)
Lubrication Sys- Oil pump bushing puller MH061059 Oil pump bushing replacement
tem Bushing inside and outside diameters
ø40×ø44 [ø1.57 × ø1.73 in.]
(Press-in only for S12H engine)
3-7
Maintenance
item
Cooling system Spring snap pliers 37591-03100 Water pump cover hole snap ring
installing and removal
Applicable ring diameter ø180 to ø300
[ø7.09 to ø11.81 in.]
Impeller remover 37591-03200 Water pump impeller pull-out

Jack bolt hole of applicable impeller
PCD=ø72, ø54, ø44 [ø2.83, ø2.13 and
ø1.73 in.]
Ring remover 37791-03400 Pull-out of water pump unit seal (rota-

tion side) ring
Ring installer 37791-03300 Press-in and positioning of water

pump unit seal (rotation side) ring
Inside and outside diameters ø33×ø45,
L80 [ø1.30 × ø1.77, L3.15]
Unit seal installer 37191-06300 Water pump ynit seal (stationary side)
press-in
Applicable seal case outside diameter
ø52 [ø52 in.]
Test and adjust- Projection plate 37598-09201 Crankcase counter bore depth mea-
ment surement
L 230 × W 50 × T 15 [9.06 × 1.97 ×
0.59 in.]
3-8
Maintenance
item
Test and adjust- Connecting rod gauge 32691-01500 Connecting rod end play adjustment
ment Sheet thickness : 0.5 mm [0.02 in.]
Connecting rod gauge 32691-01600 Connecting rod end play adjustment

Sheet thickness : 0.6 mm [0.024 in.]
Nozzle tester 04239-00050 Injection valve opening pressure mea-

surement
Pressure range 0 to 50 MPa {0 to 510
kgf/cm2} [0 to 7252 psi]
Applicable engine models: SB, SA
and SH
Compression gauge 33A91-01700 Compression pressure measurement

Pressure range 0 to 7 MPa
{0 to 71 kgf/cm2} [0 to 1015 psi]
UNF 5/8 - 18
Gauge adapter 35C91-12200 Compression pressure measurement

UNF 5/8 - 18
Spacer 35C91-02100 Compression pressure measurement

Remove UI rocker arm to install
Leak tester assembly 35C91-03010 Cylinder head hydraulic pressure test
Rack set jig 35B91-03010 to adjust rack 0 position

(MUI)
3-9
1. Determining Overhaul Timing ................................................................................ 4-3
2. Compression Pressure - Measure.......................................................................... 4-4
4-1
1. Determining Overhaul Timing

In most cases, the engine should be overhauled when the compression pressure of the engine decreases. An increase in engine
oil consumption and blow-by gas should be considered when evaluating the engine condition.
Such symptoms as the output decrease, fuel consumption increase, oil pressure decrease, engine starting difficulty and noise
increase should be considered to evaluate overhaul timing, although these symptoms are often affected by various causes, and
may be a functional degrading of a specific part.
Decreased compression pressure shows symptoms as below:
(1) Output power decrease
(2) Fuel consumption increase
(3) Engine oil consumption increase
(4) Combustion gas leak increase by cylinder liner and piston ring wear, and as a result, blow-by gas increase through the
breather (Visually check the blow-by gas amount.)
(5) Gas leak increase due to poor seating of inlet and exhaust valves
(6) Difficult starting
(7) Noise increase from engine parts
(8) Increased smoke
The engine shows these symptoms in various combinations.
Some of these symptoms are directly caused by worn engine parts, while others are not.
The items (2) and (6) are largely affected by the fuel injection amount, injection timing, plunger wear and injector nozzle con-
dition.
The most valid reason to overhaul an engine is the decrease of compression pressure (decrease of output power) due to the worn
cylinder liner and piston rings, as described in item (4) and (5). And once this symptom is shown, it is reasonable to take other
symptoms into consideration for making the final decision.
4-3
2. Compression Pressure - Measure

Compression gauge
P/N:33A91-01700
(a) Be sure to measure the compression pressure of
all cylinders. It is not a clever way to measure Gauge adapter
P/N:35C91-12200
the compression pressure of only two or three
cylinders, and assume the compression pres-
sure of all other cylinders. Cylinders are all inde-
pendent.
(b) Also be sure to check the engine speed when
Spacer
measuring the compression pressure, as the P/N:35C91-02100
compression pressure varies depending on the Compression Pressure - Measure
engine speed.
(c) It is important to measure the compression pres-
sure at regular intervals, and know the change of
the pressure.
(1) Remove the rocker and shaft assembly from the cylin-
der to be measured.
(2) Remove the unit injector rocker assembly from the
rocker shaft assembly. Install the spacer and reassemble
the rocker and shaft assembly.
(3) Remove the unit injector from the cylinder head and
install the gauge adapter to the position. Connect the
compression gauge.
(4) Install the rocker shaft assembly to the rocker case, then
check and adjust intake and exhaust valve clearances.
(5) Stop the fuel line and crank the engine.
Read the engine speed and compression pressure while
the engine is running at a stable speed.
Note: Ensure the battery being fully charged when cranking
the engine with starter.
If the battery voltage is low, the proper compression
pressure can not be measured because of a low crank-
ing speed.
(6) If the measured value exceeds the limit, overhaul the
engine.
Revolution
speed at the
Item Standard value Limit value
standard pres-
sure
Compres- 2.4 MPa 1.9 MPa
sion pres- {24.4 kgf/cm2} {19.3 kgf/cm2} 120 min-1
sure [348 psi] [276 psi]
4-4
1. Cylinder Head and Valve Mechanism - Disassemble and Inspect ...................... 5-3
1.1 Valve Clearance - Inspect......................................................................................................... 5-5
1.2 Fuel Injection Timing - Inspect.................................................................................................. 5-5
1.3 Rocker Shaft, Rocker Arm and Push Rod - Remove................................................................ 5-6
1.4 Clearance Between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect... 5-6
1.5 Valve Bridge - Remove............................................................................................................. 5-7
1.6 Unit Injector - Remove .............................................................................................................. 5-7
1.7 Rocker Case - Remove ............................................................................................................ 5-7
1.8 Control Link (MUI) - Remove .................................................................................................... 5-7
1.9 Cylinder Head Assembly - Remove.......................................................................................... 5-8
1.10 Valve Sinkage - Measure.......................................................................................................... 5-8
1.11 Valve and Valve Spring - Remove............................................................................................ 5-8
2. Rear Mechanism - Disassemble and Inspect ........................................................ 5-9
2.1 Flywheel Face and Radial Runout - Measure......................................................................... 5-13
2.2 Flywheel - Remove ................................................................................................................. 5-13
2.3 Governor Drive and Cover - Remove ..................................................................................... 5-13
2.4 Fuel feed pump drive .............................................................................................................. 5-13
2.5 Timing Gear Case - Remove .................................................................................................. 5-14
2.6 Timing Gear Backlash and End Play - Measure..................................................................... 5-14
2.7 Rear Idler Gear - Remove ...................................................................................................... 5-14
2.8 Camshaft Gear - Remove....................................................................................................... 5-14
2.9 Rear Idler Shaft - Remove ...................................................................................................... 5-15
2.10 Rear Plate - Remove .............................................................................................................. 5-15
2.11 Cam Follower - Remove ......................................................................................................... 5-15
2.12 Control Link and Shaft (MUI) - Remove.................................................................................. 5-16
2.13 Front Mechanism of Left Side Camshaft - Remove................................................................ 5-16
2.14 Camshaft - Remove................................................................................................................ 5-17
3. Front Mechanism - Disassemble and Inspect..................................................... 5-18
3.1 Damper Face and Radial Runout - Measure .......................................................................... 5-19
3.2 Damper and Crankshaft Pulley - Remove .............................................................................. 5-19
3.3 Relief Valve - Remove ............................................................................................................ 5-19
3.4 Front Gear Case - Remove .................................................................................................... 5-20
3.5 Front Idler Gear Backlash and End Play - Measure ............................................................... 5-20
3.6 Front Idler Gear and Front Idler Gear Shaft - Remove ........................................................... 5-20
3.7 Water Pump Bearing Cover - Remove ................................................................................... 5-20
4. Cylinder Liner, Piston and Connecting Rod - Disassemble and Inspect ......... 5-21
4.1 Piston Protrusion - Measure ................................................................................................... 5-22
4.2 Connecting Rod End Play - Measure ..................................................................................... 5-22
4.3 Hard Carbon Deposits on the Upper Part of Cylinder Liner - Remove ................................... 5-22
4.4 Connecting Rod Cap - Remove.............................................................................................. 5-22
4.5 Piston - Remove ..................................................................................................................... 5-23
4.6 Piston Ring - Remove............................................................................................................. 5-24
4.7 Piston Pin and Piston - Remove ............................................................................................. 5-24
4.8 Cylinder Liner Inside Diameter - Measure .............................................................................. 5-24
4.9 Cylinder Liner Flange Protrusion - Measure ........................................................................... 5-24
4.10 Cylinder Liner - Remove ......................................................................................................... 5-25
5-1
5. Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect............. 5-26

5.1 Crankcase - Turn Over (Upend) ............................................................................................. 5-27
5.2 Crankshaft End Play - Measure.............................................................................................. 5-27
5.3 Piston Cooling Nozzle - Remove ............................................................................................ 5-27
5.4 Main Bearing Cap - Remove .................................................................................................. 5-27
5.5 Crankshaft - Remove.............................................................................................................. 5-28
5-2
1. Cylinder Head and Valve Mechanism - Disassemble and Inspect

Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the
efficient work.
Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with
any job.
Inspection of valve clearance
Inspection of fuel injection timing (UI tappet heigth)
Inspection of clearance between bottom face of valve bridge and top face of valve rotator
Measurement of valve sinkage
6 MUI
Wear on
both ends, 4 Oil leak
Bend, crack
5
2 1
16 12
17
3
18
19
7 Wear 11
Wear, 13
Oil hole clogging
9
Deformation, wear, crack
8 14
Wear on both ends

Contact, wear, crack
10
Fuel leak, gas intrusion

Rack sluggish movement
15
20
Replace: O-ring
Gasket Wear, corrosion, flaw
Packing Carbon deposit
Disassembling and inspection of cylinder head and valve mechanisms (MUI)

Disassembling sequence
1 Rocker cover 8 Plunger push rod 15 Cylinder head gasket
2 Rocker shaft 9 Gland 16 Cotter
3 Inlet and exhaust rocker arms 10 MUI assembly 17 Rotator
4 UI rocker arm 11 Rocker case 18 Valve spring
5 Inlet and exhaust push rods 12 Bracket, Lever,Cancel rod assembly 19 Valve stem seal
6 UI push rod 13 Cylinder head bolt 20 Inlet and exhaust valves
7 Bridge, Cap 14 Cylinder head (approx 33 kg [73 lb])
5-3
ECUI
7
4 Oil leak
5
1
16
Wear on 17
both ends, 3
Bend, crack 18
19 6
8 Wear
12
Wear 13
Oil hole clogging
10
Deformation, wear, crack 14
9
Wear on both ends
11
Contact, wear, crack
Fuel leak, gas intrusion
15
20
Replace : O- Ring
Gasket Wear, corrosion, flaw
Packing Carbon deposit
Disassembling and inspection of cylinder head and valve mechanisms (ECUI)

1 Rocker cover 8 Bridge, Cap 15 Cylinder head gasket
2 Rocker shaft 9 Plunger push rod 16 Cotter
3 Inlet and exhaust rocker arms 10 Gland 17 Rotator
4 UI rocker arm 11 ECUI assembly 18 Valve spring
5 Inlet and exhaust push rods 12 Rocker case 19 Valve stem seal
6 Spring seat 13 Cylinder head bolt 20 Inlet and exhaust valves
7 UI push rod, Helper spring 14 Cylinder head (approx 35 kg [77.2 lb])
5-4
1.1 Valve Clearance - Inspect

Inspect the valve clearance, and know the current condition.
For the inspection procedure, refer to "Valve Clearance -
Check and Adjust" of "ASSEMBLY OF BASIC ENGINE." Valve clearance
Valve Clearance - Inspect

1.2 Fuel Injection Timing - Inspect
Inspect the fuel injection timing (top height of UI tappet),
and know the current condition.
For the inspection procedure, refer to "Fuel Injection Tim-
ing - Inspect and Adjust" of "ASSEMBLY OF BASIC
ENGINE."
MUI ECUI
Fuel Injection Timing - Inspect
5-5
1.3 Rocker Shaft, Rocker Arm and Push Rod - Remove

(1) Remove the harness and terminal of the solenoid
beforehand. (ECUI)
(2) Loosen the adjusting screw of rocker arm.
(3) Remove the rocker shaft and rocker assembly from the
rocker case.
Note: Do not disturb the rocker bushing if it is not necessary.
(4) Remove push rod.
Remove the helper spring upper seat before removing
the push rod of unit injector. (ECUI)
Rocker Shaft Assembly - Remove
Rocker arm (Inlet)

Rocker arm (UI)
Rocker shaft
Push rod
(Inlet, exhaust)
Rocker arm
(Exhaust)
Help spring
Push rod Push rod

(MUI) (ECUI)
Rocker arm, Rocker shaft Push Rod - Disassemble

1.4 Clearance Between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect
Inspect the clearance between the bottom face of valve
Press top of bridge by hand.
bridge and the top face of valve rotator, and know the cur-
rent condition.
Valve bridge Bridge cap
For the inspection procedure, refer to "Clearance Between
Bottom Face of Valve Bridge and Top Face of Valve Rotator Clearance between Valve
- Inspect" of "ASSEMBLY OF BASIC ENGINE."
valve bridge bottom rotator
face and valve
rotator top face
Clearance Between Bottom Face of Valve Bridge and

Top Face of Valve Rotator - Inspect
5-6
1.5 Valve Bridge - Remove

Remove the valve bridge and bridge cap.
Note: Be careful not to drop the bridge cap into the cylinder
head.
1.6 Unit Injector - Remove
Bolt UI puller
Adjuster P/N: 35C91-11400
Be sure to fix the unit injector puller to the rocker
case then remove the gland and rock nut.
Plunger
If the gland and lock nut are removed before fixing Push rod
the unit injector puller, the unit injector may fly out.
(1) Remove the plunger push rod.
(2) Loosen the gland tightening nut. Do not remove the nut. Gasket
(3) Fix the unit injector puller on the rocker case. UI body Rocker
case
Pin
Unit Injector - Remove
(4) Insert pins of unit injector puller into the injector body
holes. Turn the adjuster to adjust the pin position to
secure.
(5) Remove the gland and screw of puller bolt to pull out
the injector slowly.
Note: Ensure that the ball bearing of rack lever is smoothly
dislocated without sticking. (MUI)
(6) Be sure to remove the gasket in cylinder head.
1.7 Rocker Case - Remove
Note: Remove the rocker case steering clear of the lever and
cancel rod for fuel rack control protruded from the cam
chamber. (MUI)
1.8 Control Link (MUI) - Remove
(1) Remove the rack control lever bracket from the cylin-
der head.
Rack lever
(2) Remove the reamer bolt of control lever at the cam
chamber side. Remove the lever from the control shaft. Bracket, bolt
Note: Pay attention not to drop the reamer bolt, special wash-
er and spring into the cam chamber. Cancel rod
(3) Remove the cancel rod, control lever and bracket as a
set.
Control lever
Control shaft
Reamer bolt
Cam chamber
Control Link (MUI) - Remove

5-7
1.9 Cylinder Head Assembly - Remove
Eye bolt
P/N:37591-02500
When removing the cylinder head gasket, be careful (M10 × 1.25)
not to damage the cylinder head or crankcase surface
with a screwdriver or the like.
(1) Remove cylinder head bolts.
(2) Remove the cylinder head by lifting it up using the
sling.
Note: Dowel pins are used to retain the cylinder head in a po- Eye bolt
P/N:05930-00200
sition. Therefore, pull the cylinder head vertical to the (M12 × 1.25)
mounting surface to remove. Cylinder Head Assembly - Remove
(3) Remove the cylinder head gasket.
1.10 Valve Sinkage - Measure
Measure the valve sinkage, and know the current condition.
For the measurement procedure, refer to "Valve Sinkage -
Measure" of "ASSEMBLY OF BASIC ENGINE."
1.11 Valve and Valve Spring - Remove

Using a valve spring pusher, compress the valve spring
P/N:35C91-04010
evenly and remove the valve cotters. Valve spring
pusher assembly
Note: If valves are reusable, mark the each valve seat and the
mating valve to identify their original positions. Do not
change the combination of the valve seat and the valve
when reassembling.
Valve and Valve Spring - Remove
5-8
2. Rear Mechanism - Disassemble and Inspect

efficient work.
any job.
Flywheel Face and Radial Runout - Measure
Timing Gear Backlash - Measure
Idler Gear and Camshaft End Play - Measure
MUI
12
1
3
4
Hydraulic
governor
Electronic
Crack, dowel hole defect governor
Wear on the lip,

Oil hole clogging,
Flaw, degradation
6 Wear
5 11 11
wear
7
Bushing wear
2 10
Flaw on 10
thread Gear tooth flaking, wear
Crack, dowel hole defect,

Gear flaw and wear
8 Replace : O-ring
Oil seal
9 Packing
Rear Mechanism (MUI) - Disassemble and Inspect

1 Pick-up 5 Timing gear case (approx 190 kg [419 lb]) 9 Idler gear
2 Flywheel (approx 105 kg [231 lb]) 6 Oil seal 10 Camshaft gear
3 Governor drive or Cover 7 Slinger 11 Idler shaft
(See "FUEL SYTEM") 8 Thrust plate 12 Rear plate
4 Fuel feed pump drive
(See "FUEL SYTEM")
5-9
ECUI
4
3
12
Crack, dowel hole defect
Wear on the lip,

Flaw, degradation 6 1
1 5
Flaking, wear
11
7
Flaking, wear
2
Bushing wear
10
wear 10
Gear tooth flaking, wear

Flaw on thread
Crack, dowel hole defect,

8
Gear flaw and wear Replace: O-ring
9 Oil seal
Packing
Rear Mechanism (ECUI) - Disassemble and Inspect

1 Pick-up 5 Timing gear case (approx 190 kg [419 lb]) 9 Idler gear
2 Flywheel (approx 105 kg [231 lb]) 6 Oil seal 10 Camshaft gear
3 Cover 7 Slinger 11 Idler shaft
4 Fuel feed pump drive 8 Thrust plate 12 Rear plate
(See "FUEL SYTEM")
5-10
Camshaft, Follower and UI Control Link (MUI) - Remove
14
13
11
12
Flaw, wear
10 9
Flaw, wear
8
Flaw, wear Flaw, wear

Flaw, wear 5
6
2
3
1 4
Camshaft, Follower and UI Control Link (MUI) - Remove

1 Case 6 Inlet cam follower assembly 11 Cancel rod, Lever, Bracket assembly
2 Coupling 7 UI cam follower assembly 12 Control shaft
3 Cam chamber side cover 8 Exhaust cam follower assembly 13 Needle gauge
4 Cam follower, Shaft assembly 9 Thrust plate 14 Control shaft bracket
5 Cam follower shaft 10 Camshaft (Approx 110 kg [243 lb])
5-11
Camshaft, Follower and UI Control Link (ECUI) - Remove
Replace
3 Flaw, wear
4
2
11
Flaw, wear
9
12 Flaw, wear
10
Flaw, wear
Replace
8 7
6 5
Flaw, wear
Camshaft, Follower and UI Control Link (ECUI) - Remove

1 Pick-up 5 Cam chamber side cover 9 UI cam follower assembly
2 Cam rotor 6 Cam follower, Shaft assembly 10 Exhaust cam follower assembly
3 Case 7 Cam follower shaft 11 Thrust plate
4 Coupling 8 Inlet cam follower assembly 12 Camshaft (Approx 110 kg [243 lb])
5-12
2.1 Flywheel Face and Radial Runout - Measure

Measure the face and radial runouts of the flywheel, and
know the current condition.
For the measurement procedure, refer to "Flywheel Face Face runout
measuring plane
and Radial Runout - Measure" of "ASSEMBLY OF BASIC
ENGINE." Radial runout
measuring plane

2.2 Flywheel - Remove
(a) Be careful not to drop or bump the flywheel. It can,

not only cause damage to parts, but also lead to
personnel injury. Lifting
sling
(b) Be careful not to cut your hands with the ring gear
when pulling-out the flywheel.
Jack bolt
M12×1.25
Be sure to remove the pickups before removing the
flywheel. Flywheel - Remove
(1) Hitch a sling to the flywheel to prevent it from falling.
(2) Screw two jack bolts evenly into the jack bolt holes,
and remove the flywheel.
2.3 Governor Drive and Cover - Remove
Remove the governor drive gear assembly from the rear
plate. (Hydraulic governor)
Remove the cover from the rear plate. (Hydraulic governor)
Note: (Refer to the chapter "FUEL SYSTEM" for disassem-
bly, inspection and assembly.)
2.4 Fuel feed pump drive
Remove the fuel feed pump drive gear assembly from the
rear plate.
Note: (Refer to the chapter "FUEL SYSTEM" for disassem-
bly, inspection and assembly.)
5-13
2.5 Timing Gear Case - Remove
Eye bolt
Be careful not to drop or bump the timing gear case. It P/N:05930-00200
(M12 × 1.25 mm)
can, not only cause damage to parts, but also lead to
personnel injury.
(1) Hitch a sling to the timing gear case to prevent it from
falling.
(2) Lift the timing gear case to disengage the dowel pins,
and remove the timing gear case.
(3) Remove the oil seal from the timing gear case. Timing gear case
Note: Replace the removed oil seal with a new one. Oil seal Timing Gear Case - Remove
can not be re-used.
2.6 Timing Gear Backlash and End Play - Measure
Measure the timing gear backlash and end play, and know
the current condition.
For the measurement procedure, refer to "Timing Gear
Backlash and End Play - Measure" of "ASSEMBLY OF
BASIC ENGINE."
Camshaft gear
Idler gear
Camshaft gear
Timing Gear Backlash and End Play - Measure

2.7 Rear Idler Gear - Remove
(1) Remove the oil seal slinger from the crankshaft.
Rear idler gear
(2) Remove the thrust plate.
(3) Remove the rear idler gears (right and left.)
Thrust plate
Rear idler gear

Slinger
Rear Idler Gear - Remove
2.8 Camshaft Gear - Remove
Remove the camshaft gear from the camshaft.
Camshaft gear
Camshaft Gear - Remove
5-14
2.9 Rear Idler Shaft - Remove

Remove the idler shaft with jack bolts.
Jack bolts
M10 × 1.25
Rear Idler Shaft - Remove

2.10 Rear Plate - Remove
Remove the rear plate from the crankcase.
Rear Plate - Remove

2.11 Cam Follower - Remove
(1) Remove the cam chamber side cover.
(2) Remove the cam follower and shaft assembly as a set
Follower
from the cam chamber.
(3) Remove snap rings at shaft both ends and disassemble
the assembly to the each follower assembly.
Cam Follower - Remove
5-15
2.12 Control Link and Shaft (MUI) - Remove

2.12.1 Cancel rod, Lever and Bracket Assembly
(1) Remove the rack control lever bracket from the cylin-
Rack lever
der head.
(2) Remove the reamer bolt of control lever at the cam Bracket, bolt
chamber side. Remove the lever from the control shaft.
Note: Pay attention not to drop the reamer bolt, special wash- Cancel rod
er and spring into the cam chamber.
(3) Remove the cancel rod, control lever and bracket as a
Control lever
set.
Control shaft
Reamer bolt
Cam chamber
Control Link (MUI) - Remove

2.12.2 Control Shaft
(1) Remove the control shaft front flange from the crank Control shaft
Bracket Needle bearing
case.
Rear
(2) Pull the control shaft slowly forward and remove two side
Front
halves of needle bearing (four in a bank) at the same side
time.
Note: Pay attention not to drop the needle bearing.
(3) Remove the control shaft bracket (two in a bank) from
Crankcase
the crankcase upper face. Control shaft
Needle bearing pull-out direction
Control Shaft (MUI) - Remove
2.13 Front Mechanism of Left Side Camshaft - Remove
(MUI)
(1) Remove the oil seal from the crankcase.
(2) Remove the coupling from the camshaft.
ECUI
(1) Remove the pick-up.
(2) Remove the cam rotor and rotor case.
(3) Remove the coupling from the camshaft.
5-16
2.14 Camshaft - Remove
Remove the camshaft supporting with a bar through

the cam chamber inspection window to avoid the Camshaft
damage to crankcase and bushing.
Thrust plate
(1) Remove the thrust plate.
(2) Remove the camshaft from the crankcase while sup-
porting it with a bar through the cam chamber inspec-
tion window.
Camshaft - Remove (1)
Camshaft
Bar
Camshaft - Remove (2)
5-17
3. Front Mechanism - Disassemble and Inspect

efficient work.
any job.
Damper Face and Radial Runouts - Measure
Front Idler Gear Backlash and End Play - Measure
Replace: O-ring
Packing
Oil seal
11
Lip wear
10
13
Oil hole clogging, Wear
12
Lip wear, flaw, aging
Flaking, flaw
Silicone oil leak, 9
7
Cover deformation,
discoloration
3
Vbelt groove
wear
2
5
3 3 6
Fan spec 1
Single damper spec
4
Front Mechanism - Disassemble and Inspect

1 Pointer 6 Front gear case (approx 60 kg [132 lb]) 10 Water pump, Bearing cover
2 Crank pulley (Approx 20 kg [44 lb]) 7 Oil seal 11 Oil seal
3 Damper (Approx 51 kg [112 lb]) 8 Oil pipe 12 Front plate
4 Relief valve (See "OIL SYTEM") 9 Idler gear 13 Idler shaft
5 Cover
5-18
3.1 Damper Face and Radial Runout - Measure

Measure the face and radial runout of the damper, and know
the current condition.
For the measurement procedure, refer to "Damper Face and
Radial Runout - Measure" of "ASSEMBLY OF BASIC
ENGINE."
Face runout
Radial runout
Damper Face and Radial Runout - Measure

3.2 Damper and Crankshaft Pulley - Remove
Crankshaft
Be careful not to drop or bump the damper. pulley
It can, not only cause damage to parts, but also lead
to personnel injury.
(1) Remove the pointer from the front cover. Guide bolt
(2) Install the guide bolt to damper mounting thread on the
crankshaft.
(3) Screw two jack bolts evenly into bolt holes, and remove
the crankshaft pulley. Jack bolt (M14 × 1.5 mm)
(4) While supporting the damper with a sling, screw two Crankshaft Pulley - Remove
jack bolts evenly into jack bolt holes, and remove the
Guide bolt
damper. (M22 × 1.5 mm)
Jack bolt
P/N: 64362-68500
(M12×1.25 mm)
Damper - Remove
3.3 Relief Valve - Remove
(1) Remove the plug from the gear case.
(2) Remove the relief spring and relief plunger.
Relief valve
Relief valve - Remove
5-19
3.4 Front Gear Case - Remove
When removing the front gear case, be careful not to

damage the oil seal or not to distort the pointer by
hitting.
(1) Hitch slings to the front gear case.
(2) Pull the front gear case to disengage the dowel pins,
and remove the front gear case.
(3) Remove the oil seal from the front gear case.
Front Gear Case - Remove

3.5 Front Idler Gear Backlash and End Play - Measure
Measure the front idler gear backlash, and know the current
condition.
Front idler gear
For the measurement procedure, refer to "Front idler gear
backlash - Measure" of "ASSEMBLY OF BASIC
ENGINE."
Front idler gear backlash - Measure

3.6 Front Idler Gear and Front Idler Gear Shaft - Remove
Remove front idler gear and front idler gear shaft from front
plate.
Front idler shaft
Front idler gear

Front idler gear, Front Idler Gear Shaft - Remove
3.7 Water Pump Bearing Cover - Remove
Remove pump bearing cover from front plate.
Water pump
Bearing cover
Water Pump Bearing Cover - Remove
5-20
4. Cylinder Liner, Piston and Connecting Rod - Disassemble and Inspect

efficient work.
any job.
Piston Protrusion - Measure
Connecting Rod End Play - Measure
Cylinder Liner Inside Diameter - Measure
Cylinder Liner Flange Protrusion - Measure
4
Wear, flaw
5
6 Deformation
9
Scraches on outside surface, crack,
flaw, wear, carbon deposit
8
11
7
Scratches on inside
face, wear, outside
o-ring groove rust,
10 cavitation
Wear on inside surface,

flaw, discoloration
Serration wear, crack Replace

3
1 Flaw
Crack, oil hole clogging
2 Flaw on inside and outside surfaces,

seizure, separation
Cylinder Liner, Piston and Connecting Rod - Disassemble and Inspect

1 Connecting rod bolt 5 No. 2 compression ring 9 Piston
2 Connecting rod cap 6 Oil ring 10 Connecting rod
3 Connecting rod bearing 7 Snap ring 11 Cylinder liner
4 No. 1 compression ring 8 Piston pin
5-21
4.1 Piston Protrusion - Measure

Measure the piston protrusion, and know the current condi-
tion.
For the measurement procedure, refer to "Piston Protrusion Piston protrusion
- Measure" of "ASSEMBLY OF BASIC ENGINE."
Piston Protrusion - Measure

4.2 Connecting Rod End Play - Measure
Measure the connecting rod end play, and know the current
Connecting rod
condition.
For the measurement procedure, refer to "Connecting Rod
End Play - Measure" of "ASSEMBLY OF BASIC
ENGINE."
Connecting rod end play

4.3 Hard Carbon Deposits on the Upper Part of Cylinder Liner - Remove
Hard carbon
Be sure to remove hard carbon deposits from the
upper part of the cylinder liner before pulling-out the
piston. Hard carbon deposits, if not removed, cause
damage to the piston and piston rings. Cylinder liner
Remove hard carbon deposits from the upper part of cylin-

der liner with carbon remover (scraper, sandpaper, etc.)
Note: Be careful not to damage the inner surface of the cyl-
inder liner.
Hard Carbon Deposits on the Upper Part of Cylinder
Liner - Remove
4.4 Connecting Rod Cap - Remove
Using a socket wrench, remove the connecting rod bolts
through the inspection window on the side of the crankcase, Connecting
and remove the connecting rod cap and connecting rod bear- rod cap
ings.
Note:(a) Be careful not to damage the connecting rod bear-
ings by dropping them into the oil pan.
(b) Make marks, such as cylinder number and upper or
lower, on the removed connecting rod bearings to
ensure the correct reassembly.
Connecting Rod Cap - Remove
5-22
4.5 Piston - Remove
When holding the connecting rod with your hand to prevent it from swinging, be very careful, as you may suffer
hand injuries from accidental movement of the connecting rod.
(a) When pulling-out the piston, be careful not to drop the upper connecting rod bearing.
(b) When removing piston, be careful not to damage cylinder liner by connecting rod runout.
(c) When only a few pistons remain in the cylinders, the crankshaft tends to turn by weight imbalance. Be sure to
hold the crankshaft to prevent it from rotating while removing pistons.
(d) Make sure that the connecting rod does not interfere with the piston cooling nozzle when removing the piston.
(e) When pulling the piston out of the cylinder liner, hold the piston by hand so that the piston does not rock.If piston
swings, it can result in piston inner surface hitting the connecting rod, causing damage to the piston.
4.5.1 Removing the Piston With Chain Block Lifting
Eye bolt
(1) Remove the connecting rod cap and rotate the crank- P/N:45815-32301
shaft to bring the piston to the top dead center position. (M10 × 1.5 mm)
(2) Install the eye bolt to the threaded hole on the piston
top, and support the piston to prevent it from falling
down.
(3) Rotate the crankshaft to place the crank pin slightly
near to the inspection window so that the connecting
rod big end does not contact the cylinder liner. Piston, Connecting rod
(4) Carefully pull-out the piston by making sure that the Unit weight:
Crankpin approx 15 kg [33 lb]
connecting rod big end slides into the cylinder liner. Removing the Piston With Chain Block Lifting
4.5.2 Removing the Piston With Pushing-up the Con-

Eye bolt
necting Rod Big End P/N:45815-32301 (M10 × 1.5 mm)
(1) Remove the connecting rod cap and rotate the crank-
shaft to bring the piston to the top dead center position.
(2) Install the eye bolt to the threaded hole on the piston
top, and support the piston to prevent it from falling
down.
(3) Rotate the crankshaft carefully until the crankpin is dis-
placed from the connecting rod and the lower bolt hole Weight of piston with
connecting rod:
can be seen trough the inspection window. Crank pin approx 15 kg [33 lb]
(4) Insert a bar wrapped with cloth, and push up the bottom
Crankshaft - Rotate
of connecting rod carefully, with the crankpin as a ful-
crum.
Note: Protect the crankpin and connecting rod big end with
cloth or rubber to prevent them from damage with the
bar.
(5) Push-up the connecting rod and piston while adjusting
the supporting position. Wrap in cloth
When the oil ring is slid out of the cylinder liner, care- Turning bar
fully put the piston on the top face of cylinder liner.
(6) Lift the piston with eye bolt on the piston top, and pull-
out the piston from cylinder liner.
Connecting Rod Big End - Push-Up
5-23
4.6 Piston Ring - Remove
Ring expander
When removing the piston ring, be careful not to be P/N : 37191-03200
pinched your hand between the piston and connecting
rod by piston swing.
A free swing of piston and its bump to connecting rod

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

4.8 Cylinder Liner Inside Diameter - Measure
Measure the cylinder liner inside diameter, and know the
current condition.
Cylinder liner
For the measurement procedure, refer to "Cylinder Liner
Inside Diameter - Measure" of "ASSEMBLY OF BASIC
ENGINE."
Cylinder Liner Inside Diameter - Measure

4.9 Cylinder Liner Flange Protrusion - Measure
Measure the cylinder liner flange protrusion, and know the Liner pusher
current condition. assembly
P/N: 37591-06020
For the measurement procedure, refer to "Cylinder Liner
Cylinder liner
Flange Protrusion - Measure" of "ASSEMBLY OF BASIC flange protrusion
ENGINE."
Tightening torque
98 N·m {10 kgf·m} [72.3 lbf·ft]
5-24
4.10 Cylinder Liner - Remove

(1) Set the cylinder liner remover to the cylinder liner.
Nut
Note: Use care not to hit the piston cooling nozzle when set-
Removing stroke
60 mm [2.36 in.]
ting the remover plate to the bottom of cylinder liner. Cylinder liner
(2) Screw the nuts, and remove the cylinder liner. remover
P/N:32591-14100
Cylinder liner
Cylinder Liner - Remove
5-25
5. Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect

efficient work.
any job.
Crankshaft End Play - Measure
Local contact on counter boring,

Rust in jacket, corrosion
crack, fletting on liner fitting
Oil hole deposit, surfaces, corrosion
clogging
11
Flaw on inside and outside

8 surfaces, corrosion, flaking
Wear, flaw, crack
Crack,
deformation
7
Local contact, wear, flaking
10
Valve movement,
9
Oil hole clogging Wear, flaking
5
4
2
Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect

Removing sequence
1 Main bearing cap bolt 5 Lower thrust plate 9 Check valve
2 Side bolt 6 Crankshaft 10 Piston cooling nozzle
3 Main bearing cap (Approx 375 kg [827 lb]) 11 Crankcase
(Approx 18 kg [40 lb]) 7 Upper main bearing (Approx 985 kg [2172 lb])
4 Lower main bearing 8 Upper thrust plate
5-26
5.1 Crankcase - Turn Over (Upend)

Using a turnover machine, turn over the crankcase. When
Crankcase, Crankshaft
the turnover machine is not available, hitch slings to the Unit weight: 1400 kg
crankcase using wood pieces and cloth pads, and raise the [3086 lb]
crankcase with a hoist or crane. Then lay it on the wooden
block with its side face downward. Then, change the posi-
tions of the slings, and turn over to upend the crankcase.
Crankcase - Turn Over (Upend)

5.2 Crankshaft End Play - Measure
Measure the crankshaft end play, and know the current con-
dition.
For the measurement procedure, refer to "Crankshaft End
Play - Measure" of "ASSEMBLY OF BASIC ENGINE."

5.3 Piston Cooling Nozzle - Remove
Remove the piston cooling nozzle from the crankcase.
5.4 Main Bearing Cap - Remove
Adapter Nozzle remover

P/N:32591-04300 P/N:36291-00900
When removing the main bearing cap, be careful not
to damage the main bearing or the thrust plate
attached to the cap. Also be careful not to drop those
parts from the cap, which may result in crankshaft
damage.
(1) Remove the main bearing cap bolts and side bolts. Main bearing
(2) Install the adapter to main bearing cap. cap bolt
Install the nozzle remover to adapter. Side bolt
(3) Remove the main bearing cap from the crankcase. Main Bearing Cap - Remove
(4) Remove the lower main bearing from the main bearing
cap.
(5) Remove the lower thrust plate from the rearmost main
bearing cap.
5-27
5.5 Crankshaft - Remove
(a) Before removing the crankshaft, remove the front

side upper thrust plate first, and be careful not to
drop it into crankcase.
(b) When placing the crankshaft onto a pallet or other
stands, be careful not to damage the crankshaft.
Once placed on a pallet, place some support to
prevent the crankshaft from moving.
(1) Push a mating face of the front upper thrust plate, and
rotate the thrust plate to remove. Crankshaft - Remove
(2) Suspend the crankshaft in a horizontal position, and
slowly lift the crankshaft upward.
Note: Do not hitch a chain directly onto crankshaft, as it
could damage the crankshaft. Place cloth belts or pads
in the positions before lifting crankshaft.
(3) Remove the upper main bearing from crankcase, pay-
ing attention to the lug position, and remove the upper
thrust plate on the rear side.
5-28
1. Cylinder Head and Valve Mechanism - Inspect and Repair................................. 6-3
1.1 Bushing Inside Diameter and Shaft Outside Diameter of Rocker - Measure............................ 6-3
1.2 Rocker Bushing - Replace ........................................................................................................ 6-3
1.3 Valve Stem Outside Diameter and Valve Guide Inside Diameter - Measure ........................... 6-4
1.4 Valve Guide - Replace.............................................................................................................. 6-4
1.5 Valve and Valve Seat Ring - Inspect ........................................................................................ 6-5
1.6 Valve - Reface .......................................................................................................................... 6-6
1.7 Valve Seat - Reface.................................................................................................................. 6-6
1.8 Valve Seat - Replace ................................................................................................................ 6-7
1.9 Valve and Valve Seat Ring - Lap.............................................................................................. 6-8
1.10 Valve Sinkage - Measure.......................................................................................................... 6-8
1.11 Valve Bridge, Bridge Cap, Valve Cotter and Valve Rotator - Inspect ....................................... 6-8
1.12 Squareness and Free Length of Valve Spring - Measure......................................................... 6-9
1.13 Push rod Runout - Measure...................................................................................................... 6-9
1.14 Nozzle Gland Stud and Bridge Guide - Inspect and Replace................................................... 6-9
1.15 Distortion of Cylinder Head Bottom Surface - Measure.......................................................... 6-10
1.16 Copper tube or Stainless Steel (SUS) Tube - Inspect and Replace ....................................... 6-11
2. Rear Mechanism - Inspect and Repair................................................................. 6-12
2.1 Rear idler bushing inside diameter and Rear idler shaft outside diameter - Measure ............ 6-12
2.2 Rear Idler Bushing - Replace.................................................................................................. 6-12
2.3 Camshaft - Inspect and Repair ............................................................................................... 6-13
2.4 Inside Diameter of Camshaft Bushing - Measure ................................................................... 6-14
2.5 Camshaft Bushing - Replace .................................................................................................. 6-15
2.6 Cam Follower Bushing Inside Diameter and Cam Follower Shaft Outside Diameter - Measure 6-
16
2.7 Cam Follower Bushing - Replace ........................................................................................... 6-16
2.8 Roller Tappet Assembly - Disassemble and Inspect .............................................................. 6-17
3. Front Mechanism - Inspect and Repair................................................................ 6-18
3.1 Damper - Inspect Visually....................................................................................................... 6-18
3.2 Front Idler Bushing Inside Diameter and Front Idler Shaft Outside Diameter - Measur ......... 6-18
3.3 Front Idler Bushing - Replace ................................................................................................. 6-18
4. Piston and Connecting Rod - Inspect and Repair .............................................. 6-19
4.1 Piston - Inspect Visually.......................................................................................................... 6-19
4.2 Piston Weight ......................................................................................................................... 6-19
4.3 Piston Outside Diameter - Measure........................................................................................ 6-19
4.4 Piston Ring Groove - Inspect.................................................................................................. 6-19
4.5 Piston Pin Bore Inside Diameter - Measure............................................................................ 6-20
4.6 Piston Ring - Inspect Visually ................................................................................................. 6-20
4.7 Piston Ring End Gap - Measure ............................................................................................. 6-20
4.8 Piston Pin Outside Diameter - Measure ................................................................................. 6-20
4.9 Connecting Rod Bushing Inside Diameter - Measure............................................................. 6-21
4.10 Connecting Rod Bushing - Replace........................................................................................ 6-21
4.11 Connecting Rod Assembly Weight Rank................................................................................ 6-23
4.12 Inside Diameter and Roundness of Connecting Rod Big-End Bore - Measure ...................... 6-23
4.13 Side Face Width of Connecting Rod Big-End - Measure........................................................ 6-23
4.14 Connecting Rod Big-End Serration and Bolt Holes - Inspect ................................................. 6-24
4.15 Connecting Rod Bearing - Inspect.......................................................................................... 6-24
4.16 Connecting Rod Bearing Spread - Measure........................................................................... 6-24
4.17 Connecting Rod Bearing Thickness - Measure ...................................................................... 6-25
6-1
4.18 Connecting Rod Bend and Twist - Inspect ............................................................................. 6-25

5. Crankcase and Crankshaft - Inspect and Repair ................................................ 6-26
5.1 Crankcase Top Surface Distortion - Measure......................................................................... 6-26
5.2 Inside Diameter of Main Bearing Housing Bore - Measure .................................................... 6-26
5.3 Cylinder Liner Fitting Bore in Crankcase - Inspect ................................................................. 6-27
5.4 Counterbore in Crankcase - Repair ........................................................................................ 6-27
5.5 Crankpin and Journal Outside Diameters - Measure.............................................................. 6-27
5.6 Width of Crankpin and Rearmost Crank Main Journal - Measure .......................................... 6-29
5.7 Crankshaft Runout - Measure................................................................................................. 6-30
5.8 Crankshaft Gear - Inspect....................................................................................................... 6-30
5.9 Crankshaft Gear - Replace ..................................................................................................... 6-31
5.10 Oil Seal Slinger - Inspect ........................................................................................................ 6-31
5.11 Oil Seal Slinger - Replace....................................................................................................... 6-32
5.12 Main Bearing - Inspect............................................................................................................ 6-32
5.13 Main Bearing Spread - Measure............................................................................................. 6-33
5.14 Thickness of Main Bearing Shell - Measure ........................................................................... 6-33
5.15 Thrust Plate - Inspect.............................................................................................................. 6-33
5.16 Thickness of Thrust Plate - Measure ...................................................................................... 6-34
5.17 Piston Cooling Nozzle - Inspect.............................................................................................. 6-34
6-2
1. Cylinder Head and Valve Mechanism - Inspect and Repair

1.1 Bushing Inside Diameter and Shaft Outside Diameter of Rocker - Measure
Measure the inside diameter of the rocker bushing and the
Measurement
outside diameter of the rocker shaft. If the measurement directions
exceeds the limit, replace the rocker bushing or rocker shaft
Measurement
with a new one. positions
Item Nominal Standard Limit value Measurement

value value directions
44.000 to
Rocker bushing inside 44.075 mm 44.125 mm
diameter [1.7323 to [1.7372 in.]
ø44 [ø1.73] 1.7352 in.]
mm [in.] 43.975 to
Rocker shaft outside 43.991 mm 43.930 mm Rocker Bushing Inside Diameter and Rear Idler Shaft
diameter [1.7313 to [1.7295 in.] Outside Diameter - Measure
1.7319 in.]
1.2 Rocker Bushing - Replace

(1) Remove the rocker bushing with the rocker bushing
installer.
(2) Install a new rocker bushing with the rocker bushing Notch
Rocker bushing
installer. installer
P/N:35C91-01800 Punch mark
Place the rocker arm punch mark side (hole 30°cham-
fered side) upward. Align the punch mark and bushing Rocker bushing Chamfered side
notch, and insert the bushing.
Note: The notch will be placed opposite side of the punch
mark side after assembling.
Rocker arm
Rocker Bushing - Insert
(3) Make sure the rocker arm is in the specified relational
Punch mark Notch (opposite side)
position to the rocker bushing.
(4) Measure the inside diameter of installed rocker bush-
ing.
If the value is not within the standard value, ream the
Oil hole
inside diameter to the standard.
Relational Positions of Rocker Arm and Bushing (Inlet

and Exhaust)
Punch mark Notch (opposite side)
Oil hole
Relational Positions of Rocker Arm and Bushing (UI)
6-3
1.3 Valve Stem Outside Diameter and Valve Guide Inside Diameter - Measure
Measure the outside diameter of valve stem and the inside
diameter of valve guide at the top and bottom sliding ends in Measurement
directions
mutually right-angle directions as shown, as the sliding sur-
faces tend to wear at the top and bottom ends. If the mea-
surement exceeds the limit, replace the valve guide or the
valve with a new one.
Note: Lap the valve and valve seat whenever a new valve is Measurement
installed. positions
Nominal
value Valve Stem Outside Diameter - Measure
Valve stem outside ø10 mm 9.94 to 9.96 mm 9.91 mm
diameter [0.39 in.] [0.3913 to 0.3921 in.] [0.3921 in.] Measurement directions
Valve guide inside ø10 mm 10.000 to 10.015 mm 10.060 mm
diameter [0.39 in.] [0.3940 to 0.3943 in.] [0.3960 in.]
Measurement
positions
Valve Guide Inside Diameter - Measure

1.4 Valve Guide - Replace
(1) Remove the valve guide with the valve guide remover.
Valve guide remover
P/N:33591-04300
Valve Guide - Remove

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

If a defect is found, repair or replace with a new one.
Seat width
Foreign material
Nominal Standard Limit inclusion, wear
Item
value value value
Valve seat angle 30° ±15'
2.2 to 2.4 mm
2.3 mm 2.8 mm
Seat angle
Seat width [0.087 to 0.095
[0.091 in.] [0.1102 in.]
in.]
2.9 to 3.1 mm Valve margin
3.0 mm 2.5 mm thickness
Valve margin thickness [0.114 to 0.122
[0.12 in.] [0.098 in.] Valve sinkage
in.]
Crack, corrosion
-0.1 to 0.1 mm
0 mm 0.5 mm
Valve sinkage [-0.004 to 0.004 Valve and Valve Seat Ring - Inspect
[0.00 in.] [0.020 in.]
in.]
1.5.1 Visual Inspection Valve lapper

P/N:30091-08800
(1) Valve
Carbon deposit on valve flange Tap only one time
Lapping
Step wear on seat surface compound
Foreign material inclusion on seat face
Corrosion of face and flange
Crack and flaking of seat and boundary of deposit
metal
(Liquid penetrant inspection)
Others Valve Seat Contact - Inspect
(2) Valve seat ring
Seat surface wear and edge deformation
Foreign material inclusion
Loose fitting
Others
1.5.2 Valve Seat Contact - Inspect
Apply an even and thin coat of coloring paste to valve seat
face. Tap the valve only once to the valve seat ring. Good Bad
Check the transferred paste mark on the valve seat ring.
1.5.3 Seat Width - Inspect Valve Seat Contact - Inspect
(1) Measure the paste mark width transferred in the "Seat
Contact - Inspect."
(2) Place a few pieces of pressure-sensitive paper (approx
30 mm [1.18 in.] in length and 3 mm [0.12 in.] in
width) around the seat ring and tap the valve only once.
Measure the discolored width of the paper.
6-5
1.6 Valve - Reface

When the valve is re-used by refacing, use valve refacer.
Note:(a) Grind the valve face with the valve refacer adjusted Valve refacer
to the specified angle.

(b) The valve margin is to be within the specified limit.
If the dimensions after refacing does not meet the
specified values, replace the valve with a new one.
Grind valve face
at the specified angle.
Valve Face - Reface

1.7 Valve Seat - Reface
(1) Reface the valve seat ring with valve seat cutter
(grinder). After refacing, insert sand paper of approx
400 grit between the cutter and valve, and grind the
valve seat lightly. Socket (width across flats
If the seat width exceeds the standard, grind the valve 32 mm [1.26 in.])
seat with a valve seat cutter having a different angle. Valve seat cutter
P/N:37591-06400 (shaft)
(2) Lap the valve and valve seat ring. 37591-06430 (cutter)
Note: Lap the seat with a minimum depth and measure the di-
mensions after refacing.
Valve Seat Ring - Reface
6-6
1.8 Valve Seat - Replace
Valve seat puller

P/N:32591-04200
Ensure the proper interference. Improper interference
will cause the valve seat ring to fall off or the cylinder
head to crack.
Note: Be careful not to damage the machined surface of cyl-
inder head when removing the valve seat ring.
1.8.1 Valve Seat Ring -
Remove with Valve Seat Puller
Remove valve seat ring with the valve seat puller.
Valve Seat - Remove With Valve Seat Puller
1.8.2 Valve Seat Ring - Remove by Welding
To remove the valve seat ring, weld a stud to the ring as
shown. Then, insert a shaft into the valve guide hole from
Welding
the top of cylinder head, and punch out the valve seat ring. Shaft
Note: Be careful not to allow spatters to adhere to the ma-
chined surface of the cylinder head during welding. Valve seat
1.8.3 Valve Seat Ring - Install

(1) Before installing valve seat ring, measure inside diame-
ter of valve seat counterbore in cylinder head and out-
side diameter of valve seat ring to make sure that the Stud, etc.
interference is within the range of standard value. If the Valve Seat Ring - Remove by Welding
value exceeds the standard, use oversize valve seat ring.
If inside diameter of valve seat counterbore in cylinder
head exceeds the limit, replace the cylinder head with a
new one.
Note: Oversized valve seat rings are available in 0.03 and
0.06 mm [0.0012 and 0.0024 in.] sizes.
Nomi- Inside diameter of valve seat

Limit
Item nal Standard value
value counterbore
value
55.10
ø55 mm 55.00 to 55.03 mm
Inside diameter of valve mm Valve Seat Counterbore
[ø2.17 [2.1654 to 2.1665
seat counterbore [2.1693
in.] in.]
in.]
55.10 to 55.13 mm
Standard [2.1693 to 2.1705
in.]
Valve
ø55 mm 55.13 to 55.16 mm Valve seat ring
seat ring Over size 0.03
[ø2.17 [2.1705 to 2.1716
outside mm [0.0012 in.]
in.] in.]
diameter
55.16 to 55.19 mm
Over size 0.06
[2.1716 to 2.1728
mm [0.0024 in.]
in.]
0.07 to 0.13 mm
Valve seat interference [0.0028 to 0.0051
in.]
Valve Seat - Install
(2) Chill valve seat ring at least for 4 minutes in liquid
nitrogen and keep cylinder head in a room temperature.
(3) Install valve seat ring to cylinder head with the valve
seat caulking tool.
6-7
1.9 Valve and Valve Seat Ring - Lap
Lap the valve seat whenever a defective contact on

the valve seat face is shown, or the valve, valve seat
ring or valve guide is replaced.
(1) Apply a thin coat of lapping compound evenly to valve
seat face.
Compound
Note:(a) Do not allow the compound to adhere to the valve
stem.
(b) The compound spreads more evenly when it is
mixed with a small amount of engine oil. Compound - Apply
(c) Use a medium-grain compound (120 to 150 mesh) Valve lapper
for the initial lapping, then use a fine-grain com- P/N:30091-08800
30091-07500
pound (200 mesh) for the finish.
(2) Lap the valve seat by tapping to the seat ring with the
valve lapper.
Rotate valve casually to change mating positions.
(3) Clean off the compound using diesel fuel.
(4) Apply engine oil to the mating surfaces, and lap for fin-
ishing.
(5) Check the valve mating face contact.
Valve and Valve Seat Ring - Lap
After the assembling of cylinder head and the maintenance of inlet and exhaust valves, measure the valve sinkage.
If the value exceeds the limit, check again or repair, or replace the parts with new ones.
Note: See "Valve and Valve Seat Ring - Inspect"
1.11 Valve Bridge, Bridge Cap, Valve Cotter and Valve Rotator - Inspect
(1) Inspect the contact surfaces between the valve bridge
Bridge cap
and the valve stem, and the sliding surfaces between the
valve bridge and the bridge guide. If significant wear or Bridge guide
Valve bridge
uneven contact is found, replace them with new ones. Valve rotator
(2) Check the bridge cap for wear. If significant wear is Valve stem
found, replace the bridge cap with a new one. Valve cotter
(3) Check the valve rotator for rotation. If any defect is
found, replace the valve rotator with a new one.
(4) Inspect the contact surfaces between valve cotter and
valve stem, and valve cotter and valve rotator. If uneven
Valve Bridge, Bridge Cap, Valve Cotter and Valve
wear or significant dent is found, replace them with
Rotator - Inspect
new ones.
6-8
1.12 Squareness and Free Length of Valve Spring - Measure

Measure the squareness and the free length of valve spring.
Squareness
If the free length or squareness exceeds the limit, replace the
valve spring with a new one.

70.2 to 70.8 mm 69.0 mm
MUI
[2.7638 to 2.7874 in.] [2.7165 in.]
Free length Free length
75.2 to 75.8 mm 74.0 mm
ECUI
[2.9606 to 2.9842 in.] [2.9134 in.]
A = 1.5º or less A At the
B = 1.8 mm B whole
MUI [0.071 in.] or less length
Lf Squareness and Free Length of Spring - Measure
at Lf = 70.5 mm B = 2.5 mm
[2.776 in.] [0.098 in.]
Squareness
A = 1.5º or less A At the
B = 2.0 mm B whole
ECUI [0.079 in.] or less length
Lf
at Lf = 75.5 mm B = 2.6 mm
[2.972 in.] [0.102 in.]
61.8 mm [2.433 in.] / 254.5 to
281.3 N
MUI
{25.95 to 28.68 kgf}
Set length / [57.21 to 63.24 lbf]
load 61.8 mm [2.433 in.]/ 383.1 to
423.5 N
ECUI
{39.06 to 43.18 kgf}
[86.12 to 95.21 lbf]
1.13 Push rod Runout - Measure

Measure the runout of pushrod in the total indicator reading
(TIR). If the runout exceeds the standard, replace the push-
rod with a new one.
Item Standard value V-block　

Push rod
Runout (TIR) 0.5 mm [0.020 in.] or less
1/2 1/2
Surface plate
Pushrod Runout - Measure

1.14 Nozzle Gland Stud and Bridge Guide - Inspect and Replace
Do not disassemble the idler gear and idler shaft unless it is
Gland stud (MUI)
absolutely necessary.
Inspect the nozzle gland stud bolt for bending, or damage at
the threaded portion.
Inspect the bridge guide for uneven wear and damage on the
sliding surfaces. Bridge
guide
Gland stud (ECUI)

Location of UI Gland Stud Bolt and Bridge Guide
6-9
1.14.1 Stud Bolt of Unit Injector Gland - Replace

Apply a thread lock (Locktite 271 or equivalent) to the
thread to cylinder, and tighten to the specified torque.
Apply thread lock
127.4 ± 6.35 N·m
{13 ± 0.65 kgf·m}
(102) [94 ± 4.68 lbf·ft] (96)
(20) (14)
MUI ECUI
Gland Stud Bolt (UI) - Install
1.14.2 Bridge Guide - Replace
Press-in the bridge guide to the specified dimension. (MUI)
Tighten the bridge guide to the specified torque. (ECUI) (54.5)
(49.5)
39.2 N·m
{4.0 kgf·m}
<MUI> <ECUI>
Bridge Guide - Install
1.15 Distortion of Cylinder Head Bottom Surface - Measure
Straight edge
The refacing depth of cylinder head is to be mini-

mum. Excessive grinding of the cylinder head may
result in defects such as contact between piston and
valve.
With a straight edge placed on the bottom face of cylinder
Cylinder head
head, measure the bottom face distortion with thickness
gauges. If the value exceeds the limit, replace the cylinder
head with a new one, or repair by grinding.
Distortion of Cylinder Head Bottom Surface - Measure
After the grinding, record the maximum depth of grinding.
The maximum amount of total grinding, which includes Height of cylinder head
both grinding amount of the top of crankcase and the bottom
of cylinder head, must be 0.50 mm [0.020 in.] or less.
Nomi-
Limit
value
value
0.07 mm
Distortion of cylinder 0.03 mm [0.0010
[0.0028
head bottom surface in.] or less
in.]
155 mm
Height of cylinder head 154.9 to 155.1 mm
[6.10
(reference value) [6.098 to 6.106 in.] Height of Cylinder Head - Measure
in.]
6-10
1.16 Copper tube or Stainless Steel (SUS) Tube - Inspect and Replace
1.16.1 Cylinder Head Hydraulic Pressure Test
Compressed air inlet (Rc1/8)
(1) Install the leak tester assembly to cylinder head and
0.4 MPa {4.08kgf/cm²} [58.02 psi]
apply a pneumatic pressure of 0.4 MPa {4.08 kgf/cm2}
[58.02 psi] to cooling water passage.
(2) Inspect mounting faces of copper or SUS tube for leak
or any other defect.
1.16.2 Copper tube or SUS Tube - Inspect and
Replace
MUI Leak tester assembly
P/N: 35C91-03010
(1) Push the copper tube from the cylinder head combus-
Cylinder Head Hydraulic Pressure Test
tion face side with the copper tube pusher and remove
the copper tube. Cupper tube pusher
P/N: 35B91-06600
Clean the tube installing surfaces in the cylinder head.
Cylinder head
Note: Do not reuse the removed copper tube. Cupper tube bottom face
(2) Install O-rings in the cylinder head. Apply grease to the
O-ring sliding surfaces. And apply liquid gasket O-rings
(2 pieces)
(ThreeBond No. 1207C or equivalent) to the ø22.6
[ø0.89 in.] hole to the depth of approx 10 mm [0.39 in.]
from the combustion surface side.
Note: Apply the liquid gasket not to ooze out to the copper
tube seat face. Copper Tube (MUI) - Remove
(3) Install a new copper tube and the flange of tube installer
Copper tube installer
and tighten bolts to the specified torque. assembly
(4) Apply oil to the nozzle tube stamp and install it into P/N: 35C91-21010
copper tube. Screw in the nozzle tube bolt until the Flange
Apply liquid packing.
stamp can be pulled out from the cylinder head.
(5) Remove the tube installer and subject the cylinder head
to the hydraulic pressure test.
O-rings 10
ECUI
(2 pieces)
(1) Loosen the SUS tube screw with the SUS tube installer. Stamp
Remove the SUS tube and gasket. Clean the tube
Copper Tube (MUI) - Install
installing surfaces in cylinder head.
(2) Install O-rings in the cylinder head. Apply grease to the SUS Tube installer
P/N: 35C91-00600
O-ring sliding surfaces. And apply liquid gasket Torque
(ThreeBond No. 1207C or equivalent) to M24 × 1 hole O-rings (2 pieces)
to the depth of approx 10 mm [0.39 in.] from the com- Gasket
bustion surface side.
Note: Apply the liquid gasket not to ooze out to the SUS tube
seat face. 10
(3) Install a new gasket in the cylinder head and screw in
the SUS tube. Apply liquid packing.
Tighten to the specified torque with the SUS tube SUS Tube (ECUI) - Remove and Install
installer.
(4) Subject cylinder head to hydraulic pressure test.
6-11
2. Rear Mechanism - Inspect and Repair

2.1 Rear idler bushing inside diameter and Rear idler shaft outside diameter - Measure
Measure the rear idler bushing inside diameter and the rear
Measurement
idler shaft outside diameter. If the value exceeded the limit, directions
replace the rear idler gear assembly or rear idler shaft with a Measurement
positions
new one.
Note: When replacing the idler bushing only, finish the
bushing inside diameter by reaming.
Measurement
direction
Nominal Limit
Item Standard value
value value
Rear idler bushing 50.000 to 50.025 mm +0.06 mm
inside diameter ø50 mm [1.9690 to 1.9695 in.] [0.0024 in.]
[ø1.97 Rear Idler Bushing Inside Diameter and
Rear idler shaft in.] 49.950 to 49.975 mm 49.900
outside diameter [1.9665 to 1.9675 in.] mm [in.] Rear Idler Shaft Outside Diameter - Measure
2.2 Rear Idler Bushing - Replace

Note: Machine finish the idler bushing inside diameter after
Lower than the gear both end
installing the bushing. by 1 mm [0.04 in.]
If the machining is not available, the replacement of Puller
gear assembly is recommended. P/N: 32591-02500
1 mm
(1) Using the removing side of idler bushing puller, remove
the idler bushing.
(2) Using the installation side of idler bushing puller, push-
in the bushing to the 30°chamfered side until the bush-
ing end face becomes flush with the gear boss end face.
(3) Furthermore, lower the idler bushing end face from the chamfer
Left Rear Idler Bushing - Replace
gear boss end face by 1 mm [0.04 in.] with the removal
side of idler bushing puller. Lower than the gear both end
(4) Machine the inside diameter of installed bushing to the by 1 mm [0.04 in.]
Puller
specified dimension. P/N: 32591-02500
1 mm
Nominal Limit
Item Standard value
value value
Bushing inside ø50 mm 50.000 to 50.025 mm
+0.06
diameter [1.97 in.] [1.9690 to 1.9695 in.]
Coaxiality <ø0.05 mm [0.0020 in.]
Squareness <ø0.1 mm [0.0039 in.]
chamfer
Surface roughness Ra 0.4 μm [16 μin.]
Right Rear Idler Bushing - Replace
6-12
2.3 Camshaft - Inspect and Repair

2.3.1 Cam Height - Measure
Inlet-Exhaust Cam
Measure the major and minor diameters of inlet and exhaust
cam lobes, and measure the major diameter of UI cam lobe
Major diameter
to calculate the cam height.
Nominal Limit Minor diameter

Item Standard value
value value
UI cam
Inlet cam lift
14.35mm 14.30 to 14.40 mm 13.65 mm
(major diam -
[0.5650 in.] [0.5630 to 0.5669 in.] [0.5374 in.] Major
minor diam)
diameter
Exhaust cam lift
9.25mm 9.20 to 9.30 mm 8.55 mm
(major diam -
[0.3642 in.] [0.3622 to 0.3661 in.] [0.3366 in.]
minor diam) Cam Height of Camshaft - Measure
Injector cam
86.2 mm 86.16 to 86.24 mm 85.5 mm
height
[3.393 in.] [3.3921 to 3.3953 in.] [3.366 in.]
(major diam)
2.3.2 Outside Diameter of Camshaft Journal - Mea-

sure
Measure the diameter of each camshaft journal in two direc-
tions at right angles to each other. If the value exceeds the
limit, replace the camshaft with a new one.
Measurement directions
Nominal Limit
Item Standard value
value value
Camshaft journal ø100 mm 99.92 to 99.94 mm 99.86 mm
outside diameter [ø3.94 in.] [3.9339 to 3.9346 in.] [3.9315 in.]
Outside Diameter of Camshaft Journal - Measure

2.3.3 Camshaft Runout - Measure
Measure the runout of camshaft in TIR. If the value exceeds
the limit, correct the camshaft using a press, or replace the
camshaft with a new one.
Note: With a dial gauge set on the camshaft, rotate the cam-
shaft one turn and read the gauge indication.
Item Standard value Limit value 1/2 1/2

Runout (TIR) 0.1 mm [0.004 in.] or less 0.16 mm [0.006 in.]
Camshaft Runout - Measure
6-13
2.4 Inside Diameter of Camshaft Bushing - Measure

(1) Check the inside surface of each bushing for damage,
Measurement
corrosion, flaking and other abnormalities. If any defect
direction
is found, replace the camshaft bushing with a new one.
(2) Measure the camshaft bushing inside diameter with
bushing installed as installed in the crankcase. If the
value exceeds the limit, replace the camshaft bushing
with a new one.
Note: Be careful not to damage the inner surface of camshaft
bushing when measuring the inside diameter.
Nominal Inside Diameter of Camshaft Bushing - Measure

value
Bushing inside
diameter ø100 mm 100.020 to 100.095 mm 100.15 mm
(as installed in [ø3.94 in.] [3.9378 to 3.9407 in.] [3.9429 in.]
crankcase)
0.08 to 0.175 mm
Oil clearance
[0.0031 to 0.0069 in.]
6-14
2.5 Camshaft Bushing - Replace

Remove and install the bushing with the camshaft bushing installer assembly.
Do not fail to check the oil hole alignment after installing the bushing in the crankcase.
2.5.1 Cam Bushing - Remove

Installer
(1) Install the installer to the bush to remove. Install the P/N: 35B91-02010
stopper plate to the next bushing hole. Add the spacer Stopper plate
Without
(A) to stopper plate if bushing remains in the hole.
bushing
(2) Screw in the bolt into stopper plate and place its end to
the installer to push.
bolt
Ball bearing With

bushing
Spacer (A)
Cam bushing
Camshaft Bushing - Remove
Apply anti-seizure agent of molybdenum disulfide type
(ThreeBond 1910 or equivalent) to thread and ball bear- Sleeve
ing surfaces.
(3) Screw in bolt and push out cam bushing. Without
bushing
2.5.2 Cam Bushing - Insert
(1) Set the spacer (B), cam bushing and sleeve in this order
and install in the crankcase bushing hole. With
Place the cam bushing mating mark (notch) at the front Spacer (B)
bushing
top position. Spacer (A)
Cam bushing
(2) Install the stopper plate to the next bushing hole. Add
Cam Bushing - Insert
the spacer (A) to stopper plate if bushing is already in
the hole. Flush Right
(3) Screw in the bolt into stopper plate and place its end to
the installer to push. Apply anti-seizure agent of molyb-
denum disulfide type (ThreeBond 1910 or equivalent)
No.1 No.7
to thread and ball bearing surfaces. Front Flush Rear
(4) Screw in the bolt to press-in cam bushing until its end No.7
face becomes flush with end face of crankcase bushing
hole.
(5) The No. 7 cam bushing on the right bank must be
Left
placed its end face being flush with the crankcase rear Position of Cam Bushing End Faces in Crankcase
end face. Remove the spacer (B) from the installer and Bushing Holes
push-in the bushing as the removing procedure.
(6) Make sure that the oil holes in the camshaft bushing are
in alignment with the crankcase oil holes.
Place notch
at the top
Oil hole
From front
Position of Cam Bushing Notch and Oil Holes
6-15
2.6 Cam Follower Bushing Inside Diameter and Cam Follower Shaft Outside Diameter - Measure
Measure the cam follower bushing inside diameter and cam Measurement Measurement
point direction
follower shaft outside diameter. If the value exceeds the
limit, replace the cam follower assembly or the cam fol-
lower shaft with a new one.
Nomi-
Limit
value
value
30.12 mm
Cam follower bushing 30.000 to 30.075 mm
ø30 [1.1858
inside diameter [1.1811 to 1.1841 in.]
mm in.]
[1.18 29.93 mm
Cam follower shaft in.] 29.959 to 29.980 mm Cam Follower Bushing Inside Diameter and Cam
[1.1783
outside diameter [1.1795 to 1.1803 in.] Follower Shaft Outside Diameter - Measure
in.]
Note: When replacing the cam follower bushing only, finish

the bushing inside diameter by reaming.
2.7 Cam Follower Bushing - Replace

(1) Remove the cam follower bushing with the cam fol-
Follower bushing
lower bushing installer. Installer
(2) Use the cam follower bushing installer to press-in a P/N: 35C91-01700
new follower bushing. Follower
Bushing
Place the follower punch mark side (30° chamfered side Notch
of the hole) upward. Align the punch mark and bushing Punch mark Chamfered
side
notch, and insert the bushing.
Note: The notch will be placed in the opposite side of the
punch mark side after assembling.
(3) Check the alignment of cam follower and the follower
Follower Bushing - Insert
bushing oil holes.
(4) Measure the inside diameter of installed follower bush- Oil hole, notch
ing. If the value is not within the standard value, ream (opposite side)
the inside diameter to the standard. Punch mark
Joint
Follower and Bushing Positions
6-16
2.8 Roller Tappet Assembly - Disassemble and Inspect

Note: The roller tappet assembly is installed to the follower
with thread lock and caulking. Do not disassemble the
assembly unless it is absolute necessary.
If a defect is found, replacement with a new assembly
is recommended.
2.8.1 Roller Tappet Outside Diameter - Measure
Also visually inspect the surface pitting, wear of pin and
bushing and others.
Nominal
Item
value
Standard value Limit value Roller Tappet Outside Diameter - Measure
Roller tappet out- ø41 mm 40.95 to 41.05 mm 40.9 mm
side diameter [ø1.61 in.] [1.6122 to 1.6161 in.] [1.6102 in.]
2.8.2 Roller Tappet Assembly - Replace

Set screw apply thread lock. Roller tappet
(1) Loosen the ser screw and pull-out the roller pin. Caulk after tightening. assembly
Note: Check and retouch the set screw thread hole as the
screw was caulked.
(2) Install a new roller tappet assembly, place the roller pin
position and fix it with a new set screw.
Apply thread lock to the set screw, and caulk after tight-
ening. Roller tappet
Bushing Pin
Roller Tappet Assembly - Replace
6-17
3. Front Mechanism - Inspect and Repair

3.1 Damper - Inspect Visually
Silicone oil leak
Thermo label
Paint discoloring and peeling with heat temperature
Crack on welding indication
Separation at caulking Deformation
Case deformation (bulge) Paint discoloration,
peeling
Temperature indication with thermo-label
Others
Silicone oil leak
Separation at caulkng
Crack on
welding
Damper - Inspect Visually
3.2 Front Idler Bushing Inside Diameter and Front Idler Shaft Outside Diameter - Measur
Measure the front idler bushing inside diameter and the
Measurement
front idler shaft outside diameter. If the value exceeds the directions
limit, replace the front idler gear assembly or front idler
Measurement
shaft with a new one. positions
Nominal
value
Front idler bushing 50.000 to 50.025 mm 50.06 mm
inside diameter ø50 mm [1.9685 to 1.9695 in.] [1.9709 in.]
[ø1.97
Front idler shaft in.] 49.950 to 49.975 mm 49.900mm
outside diameter [1.9665 to 1.9675 in.] [in.]
Front Idler Bushing Inside Diameter and Front Idler
Note: When replacing the idler bushing only, finish the Shaft Outside Diameter - Measure
bushing inside diameter by reaming.
3.3 Front Idler Bushing - Replace

Note: Machine finish the idler bushing inside diameter after
installing the bushing. Puller
If the machining is not available, the replacement of P/N: 32591-02500
gear assembly is recommended.

(1) Using the removal side of idler bushing puller, remove
1
the front idler bushing.
(2) Using the installation side of idler bushing puller, push-
in the bushing to the 1C [0.04 in.] chamfered side until
the bushing end face becomes flush with the gear boss 1C chamfer
end face.
Front Idler Bushing - Replace
(3) Furthermore, lower the idler bushing end face from the
gear boss end face by 1 mm [0.04 in.] with the removal
side of idler bushing puller.
(4) Machine the inside diameter of installed front bushing
to the specified dimension.
Item Nominal value Standard value

50.000 to 50.025 mm
Bushing inside diameter ø50 mm [1.97 in.]
[1.9690 to 1.9695 in.]
Coaxiality <ø0.05 mm [0.0020 in.]
Squareness <ø0.1 mm [0.0039 in.]
Surface roughness Ra 0.8 μm [32 μin.]
6-18
4. Piston and Connecting Rod - Inspect and Repair

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

Top land
Ring groove
Piston pin
boss
Sliding face
Piston - Inspect Visually

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

Unit weight ±15 g [0.53 oz]
Weight difference in one engine within 30 g [1.06 oz]
Part No. (tail 5 digits)
ID Marks on Piston Top Face

4.3 Piston Outside Diameter - Measure
Measure the piston outside diameter of piston skirt in the
[1.18 in.]
30 mm
right angle to the piston pin. If the value exceeds the limit,
replace the piston with a new one.
Measurement
position
Nominal
value
Piston outside ø149.8 mm 149.78 to 149.82 mm 149.68 mm
diameter [ø5.898 in.] [5.8969 to 5.8984 in.] [5.8929 in.]
Piston Outside Diameter - Measure

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

Ring insert
the whole circumference of piston.
No.1 compression
(1) Remove all deposits such as carbon from the each ring ring groove
groove.
No.2 compression
(2) Visually check each the ring groove for wear or dam- ring groove
age. If defective, replace the piston with a new one.
Oil ring groove
Inspect the ring groove insert of No. 1 compression ring
groove by the dye penetration test for cracks and sepa-
ration. Piston Ring Groove - Inspect
6-19
4.5 Piston Pin Bore Inside Diameter - Measure

Measure the piston pin bore diameter. If the value exceeds
the limit, replace the piston with a new one.
Nominal
value
Piston pin bore ø58 mm 58.002 to 58.012 mm 58.04 mm Measurement Measurement
diameter [ø2.28 in.] [2.2835 to 2.2839 in.] [2.2850 in.] directions positions
Piston Pin Bore Diameter - Measure

4.6 Piston Ring - Inspect Visually
Check the sliding surface, the top and bottom surfaces for
seizing, abnormal wear, foreign material inclusion and plat-
ing flaking. If any defect is found, replace the piston ring
with a new one.
4.7 Piston Ring End Gap - Measure
Place the piston ring in the gauge or a new cylinder liner,
and measure the end gap. If the value exceeds the limit,
replace the piston rings with a new set of rings. Thickness gauge
Standard Limit
Item
value value
0.6 to 0.8 mm
NO.1 1.7 mm
[0.024 to
compression [0.067 in.]
0.032 in.]
0.5 to 0.7 mm 1.6 mm
Piston ring NO.2
[0.020 to [0.0630 Gauge diameter:
End gap compression
0.028 in.] in.] 150 ± 0 mm [5.91 ± 0 in.] End gap
0.5 to 0.7 mm Piston Ring End Gap - Measuring
1.3 mm
Oil [0.020 to
[0.051 in.]
0.028 in.]
4.8 Piston Pin Outside Diameter - Measure

Measure the piston pin outside diameter.
Measurement
If the value exceeds the limit, replace the piston pin with a directions
new one.
Nominal Limit
Item Standard value
value value
69.970 mm
Piston pin outside ø70 mm 69.987 to 70.000 mm
[2.7547
diameter [2.76 in.] [2.7554 to 2.7559 in.]
in.]
Measurement
positions
Piston Pin Outside Diameter - Measure
6-20
4.9 Connecting Rod Bushing Inside Diameter - Measure

Measure the inside diameter of the connecting rod bushing.
If the value exceeds the limit, replace the connecting rod Measurement
directions
bushing with a new one.
Measurement
positions
Nomi-
Limit
value
value
Inside diameter of ø58 mm 58.07 mm
58.02 to 58.04 mm
connecting rod bush- [2.28 [2.2862
[2.2842 to 2.2850 in.]
ing in.] in.]
Connecting Rod Bushing Inside Diameter - Measure

4.10 Connecting Rod Bushing - Replace
Use the connecting rod bushing installer assembly. This tool
can be used for many engine models. Use the "SA" marked
parts and positions.
4.10.1 Connecting Rod - Set
Connecting rod bushing installer
(1) Align the adapter and plate to the match marks on base, P/N:32591-18010
Base match mark
and install them. Base match mark (red ø4 mm [0.16 in.])
(red punch mark)
Adapter Plate
Adapter match marks Base Plate match marks
(red punch mark) (red ø4 mm [ø0.16 in.])
Connecting Rod Bushing Installer - Prepare
(2) Align the oil hole in big end and install the connecting
rod to the base. Attach the cap and hand-tighten bolts. Connecting rod cap
Connecting rod Plate
Note: Leave the connecting rod bearings uninstalled.
(3) Check the snug contact of connecting rod at the plate
face and the adapter slant face. Then tighten firmly the
rod cap bolts.
(4) Fix the connecting rod to the base with the bracket.
Base
Mark on the plate
Adapter Bracket
Oil hole of connecting rod
Connecting Rod - Install and Fix (1)
Adapter Plate
Even contact of faces
Connecting Rod - Install and Fix (2)
6-21
4.10.2 Connecting Rod Bushing - Remove

(1) Apply engine oil to the inside of connecting rod bush-
Mandrel
ing.
(2) Install the collar (A) to the mandrel. Align the match Collar (A)
mark (red stamp line) to the base match mark (red Connecting
stamp line), and install the mandrel to the connecting rod bushing
rod bushing.
(3) Apply a pressure gradually to the mandrel with a press
Adapter
machine to push-out the bushing.
Base
Connecting Rod Bushing - Remove
(with connecting rod bush installer)
4.10.3 Connecting Rod Bushing - Press - in
(1) Install the collar (B), new bushing and collar (A) to the
mandrel in this order. And finger tighten the nut.
(2) Check the alignment of match marks on the collar (A) Mandrel
and (B), and the match mark of the bushing oil hole
Match marks Collar B
when the slanted faces of the bushing contact snugly (Red line mark)
with the collar (A) and (B). Connecting
(3) Tighten the nut to integrate the mandrel, collar (B), rod bushing
bushing and collar (A).
(4) Insert the collar (A) into the connecting rod bushing Oil hole mach
mark (ø4 mm
hole. Align the match marks to the base and adapter [0.16 in.])
Nut
match marks, and press in the bushing slowly with a
Collar A
press machine.
Match marks
(Red line mark)
Adapter
Base
Connecting rod bushing - Press in
(5) Measure the inside diameter of connecting and bushing.
If the value is out of the standard ream the bushing
Bushing oil hole
inside.
Note: Check the alignment of the oil holes of connecting and
bushing.
Connecting rod oil hole
Connecting rod and bushing oil hole positions
6-22
4.11 Connecting Rod Assembly Weight Rank

When replacing a connecting rod, be sure to check the
weight rank of connecting rod. In one engine, all the con-
necting rods must be of the same weight rank.
Weight rank table

Allowable
Part No. Weight rank Weight
value
32619-81110 A 7100 g [250 oz]
32619-81210 B 7200 g [254 oz]
32619-81310 C 7300 g [257 oz] Weight rank mark location
32619-81410 D 7400 g [261 oz]
±20 g [0.71 oz] Connecting Rod Weight Rank Mark Location
32619-81510 E 7500 g [264 oz]
32619-81610 F 7600 g [268 oz]
32619-81710 G 7700 g [271 oz]
32619-81810 H 7800 g [275 oz]
Note: The weight rank of connecting rod assembled in the

engine is also stamped on the caution plate.
4.12 Inside Diameter and Roundness of Connecting Rod Big-End Bore - Measure
Measure the connecting rod bore diameter at the front and
rear ends respectively in the directions A, B and C as shown
in the illustration. The roundness is determined by subtract- A
B
ing the minimum value from the maximum value among
measurements of A, B and C. Front Rear
C
If the value exceeds the limit, replace the connecting rod
with a new one. Measurement
Measurement
point
direction
Round-
Nominal Standard ness
Item Limit value
value value Limit
value Connecting Rod Big-End Bore Diameter - Measure
Minimum:
110.000 to 109.95 mm
Connecting 0.1 mm
ø110 mm 110.022 mm [4.3287 in.]
rod big-end [0.004 in.]
[4.33 in.] [4.3307 to Maximum:
bore diameter or less
4.3316 in.] 110.05 mm
[4.3327 in.]
4.13 Side Face Width of Connecting Rod Big-End - Measure

(1) Visually inspect the side face of connecting rod big-
end. If any defect such as wear or flaw is shown,
replace the connecting rod with a new one.
Connecting rod
(2) Measure the side face width of connecting rod big-end. big end width across flats
If the value exceeds the limit, replace with a new one.
Item Standard value

53.7 to 53.8 mm
Side face width of connecting rod big-end
[2.11 to 2.12 in.]
Side Face Width of Connecting Rod Big-End -

Measure
6-23
4.14 Connecting Rod Big-End Serration and Bolt Holes - Inspect

Contact, scratch, cavitation erosion, ovelay flaking and
foreign matter inclusion on sliding face
Contact, fretting, plating layer migration, and foreign mat-
ter inclusion on back face
Fretting and wear on joint faces
Others
4.15 Connecting Rod Bearing - Inspect
Inspect the sliding surface, back surface and end surfaces of
the connecting rod bearing. If there is any defect such as
local contact, sliding scratches, corrosion and foreign mate-
rial inclusion, replace the bearing with a new one.
Flaw, corrosion, peeling
End face
Connecting Rod Bearing - Inspect

4.16 Connecting Rod Bearing Spread - Measure
Measure the spread (free length) of bearing.

111 to 112.5 mm 110 mm
Connecting rod bearing spread
[4.370 to 4.429 in.] [4.331 in.]
Spread
Connecting Rod Bearing Spread - Measure
6-24
4.17 Connecting Rod Bearing Thickness - Measure

Measure the thickness of the connecting rod at its center
position.
If the value exceeds the limit, replace both upper and lower
connecting rod bearing shells with new ones as a set.
Measure the center
When the crankshaft is re-ground due to wear of the crank position.
pin, use the undersize bearing.
For the crankshaft grinding procedure, refer to "Crankpin
and Crank Journal - Grind" of "INSPECTION AND
REPAIR OF BASIC ENGINE."
Note: Replacement shells for undersized connecting rod
Connecting Rod Bearing Thickness - Measure
bearing are available in sizes of 0.25, 0.50, 0.75 and
1.00 mm [0.0098, 0.0197, 0.0295 and 0.0394 in.].
Item Nominal value Standard value Limit value

3.000 mm 2.987 to 3.000 mm 2.950 mm
Standard
[0.1181 in.] [0.1176 to 0.1181 in.] [0.1161 in.]
0.25 mm 3.125 mm 3.112 to 3.125 mm 3.075 mm
[0.0098 in.] [0.1230 in.] [0.1225 to 0.1230 in.] [0.1211 in.]
0.50 mm 3.25 mm 3.237 to 3.250 mm 3.200 mm
Connecting rod bearing thickness at the center
[0.0197 in.] [0.1280 in.] [0.1274 to 0.1280 in.] [0.1260 in.]
Under size
0.75 mm 3.375 mm 3.362 to 3.375 mm 3.325 mm
[0.0295 in.] [0.1329 in.] [0.1324 to 0.1329 in.] [0.1309 in.]
1.00 mm 3.50 mm 3.487 to 3.500 mm 3.450 mm
[0.0394 in.] [0.1378 in.] [0.1373 to 0.1378 in.] [0.1358 in.]
4.18 Connecting Rod Bend and Twist - Inspect

(1) Measure the dimensions of C and L as shown in the
illustration to check the bend and twist of the connect- C C 0.05
ing rod. Straighten the connecting rod with a press L L 100
C 0.05
machine so that the measured value meets the standard. Piston
L 100 L
If the value exceeds the limit, replace with a new one. Pin
C
Note: Tighten the connecting rod cap to the specified torque
and check the bend and twist. Connecting rod Connecting rod
Bend twist
(2) To inspect the connecting rod with the piston installed,
Tightening torque
turn the piston upside down and place it on a surface 343 ± 17 N·m {35 ± 1.7 kgf·m} [253 ± 12.5 lbf·ft]
plate. Insert a round bar having the same diameter as 2-time tightening [Wet]
Bend and Twist of Connecting Rod - Measure
the crankpin into the big-end bore, and measure the
height of the bar with a dial gauge.
Item Standard value

D
0.05/100 mm [0.0020/3.94 in.]
Connecting rod bend and twist (C/L)
or less C
C 0.05 [0.0020]
D 100 [3.94]
Surface plate
Bend and Twist of Connecting Rod - Measure
(Piston Installed)
6-25
5. Crankcase and Crankshaft - Inspect and Repair

5.1 Crankcase Top Surface Distortion - Measure
The refacing depth of the crankcase is to be minimum.

Excessive grinding may result in defects such as
defective combustion and contact between piston and
valve.
Apply a straight edge to the top surface of the crankcase and
measure its distortion with thickness gauges. If the value
exceeds the limit, replace the cylinder head with a new one, Straight edge
or repair by grinding.
After the grinding, record the maximum depth of grinding. Crankcase Top Surface Distortion - Measure
Note that the total grinding amount, which includes the
grinding depth of the bottom surface of the cylinder head,
must be 0.50 mm [0.0197 in.] or less.

Crankcase top surface distor- 0.15 mm 0.25 mm
tion [0.0059 in.] or less [0.0098 in.] 46
8.9
Height from crank journal
468.95 to 469.05 mm 5㨪
center to crankcase top surface 46
[18.4626 to 18.466 in.]
(reference value)
9.0
5
Height from Crank Journal Center to Crankcase Top

Surface
5.2 Inside Diameter of Main Bearing Housing Bore - Measure
(1) Assemble the main bearing cap in crankcase in accor-
dance with the specified method. 490 ± 24.5 N·m {50 ± 2.5 kgf·m}
[362 ± 18.1 lbf·ft] [Wet]
Note: For tightening procedure for main bearing cap, refer to
"Main bearing cap - Install" of "ASSEMBLY OF BA-
SIC ENGINE."
(2) Measure the housing diameter in vertical and two diag-
onal directions.
147 ± 7.4 N·m
Nominal Standard {15 ± 0.75 kgf·m}
Item Limit value
value value [108 ± 5.4 lbf·ft] [Wet]
147.000 to
Inside diameter of main ø147 mm 147.025 147.045 mm Inside Diameter of Main Bearing Housing Bore -
bearing housing bore [ø5.79 in.] [5.7874 to [5.7892 in.] Measure
5.7884 in.]
6-26
5.3 Cylinder Liner Fitting Bore in Crankcase - Inspect

(1) Inspect the counterbore in the crankcase. Check for
counterboring
cracks in edges, uneven contact between the counter- (seat)
bore and the bottom face of the cylinder liner flange. If Jacket
any defect is found, reface the counterbore in the crank-
case. Liner fitting
faces
(2) Inspect the cylinder liner fitting faces in the crankcase. O-ring
Check for the defects such as fretting and corrosion.
Cylinder Liner Fitting Bore in Crankcase - Inspect

5.4 Counterbore in Crankcase - Repair
If local contact is shown on the counterbore in the crank-
Grinder
case, grind and repair. Grind the counterbore with the crank-
case grinder to correct the depth differences at four
directions in circumference to be less than 0.05 mm [0.0020
in.]
After the grinding of counterbore in the crankcase is com-
pleted, measure the cylinder liner flange protrusion.
Crankcase
Crankcase grinder counterbore
P/N:32591-04050
Counterbore in Crankcase - Repair

5.5 Crankpin and Journal Outside Diameters - Measure
(1) Measure the outside diameter of crankpins and crank
Measurement
journals. positions
If the value exceeds the limit, use the undersize bearing,
and grind the crankshaft to fit the undersize bearing.
If the value exceeds the limit even when the -1.00 mm
[-0.0394 in.] undersize bearing is used, replace the
Measurement
crankshaft with a new one. directions
Crankpin Outside Diameter - Measure

5.5.1 Crankpin and Crank Journal - Grind
When using the undersize bearing, grind to the standard
value corresponding to the undersize bearing to be used.
Do not change the fillet radius and the bearing journal width
when grinding. If a remarkable decrease in hardness is
found, quench the crankshaft again and inspect it with the Measurement Measurement
directions positions
magnetic particle inspection.
After the grinding, measure the width of crankpins and rear-
most crank main journal.
Crank Journal Outside Diameter - Measure
6-27
Item Size Nominal value Standard value

ø104.00 mm 103.90 to 103.92 mm
Standard
[ø4.0945 in.] [4.0905 to 4.0913 in.]
0.25 mm ø103.75 mm 103.65 to 103.67 mm
[0.0098 in.] [ø4.0846 in.] [4.0807 to 4.0815 in.]
0.50 mm ø103.50 mm 103.40 to 103.42 mm
Crankpin outside diameter
[0.0197 in.] [ø4.0748 in.] [4.0709 to 4.0716 in.]
Under size
0.75 mm ø103.25 mm 103.15 to 103.17 mm
[0.0295 in.] [ø4.0650 in.] [4.0610 to 4.0618 in.]
1.00 mm ø103.00 mm 102.90 to 102.92 mm
[0.0394 in.] [ø4.0551 in.] [4.0512 to 4.0520 in.]
ø140.00 mm 139.93 to 139.95 mm
Standard
[ø5.5118 in.] [5.5090 to 5.5098 in.]
0.25 mm ø139.75 mm 139.68 to 139.70 mm
[0.0098 in.] [ø5.5020 in.] [5.4992 to 5.5039 in.]
0.50 mm ø139.50 mm 139.43 to 139.45 mm
Crankshaft main journal outside diameter
[0.0197 in.] [ø5.4921 in.] [5.4894 to 5.4901 in.]
Under size
0.75 mm ø139.25 mm 139.18 to 139.20 mm
[0.0295 in.] [ø5.4828 in.] [5.4795 to 5.4803 in.]
1.00 mm ø139.00 mm 138.93 to 138.95 mm
[0.0394 in.] [ø5.4724 in.] [5.4697 to 5.4705 in.]
<0.01 mm
Parallelism
[0.0004 in.]
<0.01 mm
Roundness
[0.0004 in.]
<0.01 mm
Cylindricity
[0.0004 in.]
Pin and journal 7.0 to 7.2 mm
Pin R7 [R0.28]
[0.2756 to 0.2835 in.]
Fillet radius
7.0 to 7.2 mm
Journal R7 [R0.28]
[0.2756 to 0.2835 in.]
Hardness HV>620
Ra 0.2 μm
Finishing surface roughness
[8 µin.]
Angular deviation between pins ±0.3°
6-28
5.6 Width of Crankpin and Rearmost Crank Main Journal - Measure

(1) Inspect the ends of crankshaft for harmful flaw and
Rearmost crank
wear. journal width
Crankpin width
(2) Measure the width of crankpins and rearmost crank
journal.
When using oversize thrust plates due to wear of rear-
most crank journal width, grind crankshaft for use with
oversize thrust plates.
Width of Crankpin and Rearmost Crank Main Journal -

Measure
5.6.1 Rearmost Crank Journal Width - Grind
When using the oversize thrust plates, grind the rearmost
crank journal width to the standard value for use with over-
size thrust plates.
Do not change the fillet radius when grinding. Quench the
crankshaft if its surface hardness is significantly decreased,
and after quenching do the magnetic particle inspection.
Ensure that the finishing surface roughness after grinding is
in the standard value.
Note: The difference between the front and the rear thrust
plate in thickness must be 0.25 mm [0.0098 in.] or less.
Item Size Nominal value Standard value Limit value

108.0 mm 108.2 to 108.3 mm 108.4 mm
Crankpin width
[4.2520 in.] [4.2598 to 4.2638 in.] [4.2677 in.]
58.00 mm 58.00 to 58.03 mm
Standard
[2.2835 in.] [2.2835 to 2.2846 in.]
0.25 mm 58.25 mm 58.25 to 58.28 mm
[0.0098 in.] [2.2933 in.] [2.2933 to 2.2945 in.]
0.50 mm 58.50 mm 58.50 to 58.53 mm
[0.0197 in.] [2.3031 in.] [2.3031 to 2.3043 in.]
0.75 mm 58.75 mm 58.75 to 58.78 mm
Rearmost crank journal width
[0.0295 in.] [2.3130 in.] [2.3130 to 2.3142 in.]
Over size
1.00 mm 59.00 mm 59.00 to 59.03 mm
[0.0394 in.] [2.3228 in.] [2.3228 to 2.3240 in.]
1.25 mm 59.25 mm 59.25 to 59.28 mm
[0.0492 in.] [2.3327 in.] [2.3327 to 2.3339 in.]
1.50 mm 59.50 mm 59.50 to 59.53 mm
[0.0591 in.] [2.3425 in.] [2.3425 to 2.3437 in.]
6-29
5.7 Crankshaft Runout - Measure

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

0.08 mm [0.0031 in.] 0.2 mm
Crankshaft runout TIR
or less [0.008 in.]
5.8 Crankshaft Gear - Inspect

If there is any defect on the crankshaft gear teeth, such as
flaking, wear, or local contact, replace the crankshaft gear
with a new one.
6-30
5.9 Crankshaft Gear - Replace
Use protective gloves when you touch hot parts.

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

With a gear puller, remove the gear from the crankshaft.
Note: When removing the crankshaft gear by heating, the
heating temperature is 180°C [356 °F] or less.
Crankshaft gear
Crankshaft Gear - Remove
5.9.2 Crankshaft Gear - Install
Align.
(a) Check the correct installing direction and position
of crankshaft gear.
(b) To shrinkage-fit the crankshaft gear to the crank-
shaft, heat the crankshaft gear evenly to the spec-
ified temperature.
(1) Measure the outside diameter of crankshaft and the

inside diameter of crankshaft gear, and check the inter-
ference. Crankshaft Gear - Install
(2) Heat the crankshaft gear evenly to the specified temper-
ature. After checking gear direction and position, install Fitting direction Fitting direction
the crankshaft gear.
Standard interference Standard interference

value: value:
0.106 to 0.171 mm 0.14 to 0.209 mm
[0.0042 to 0.0067 in.] [0.0055 to 0.0082 in.]
Front Rear
Crankshaft Gear Installation Direction
5.10 Oil Seal Slinger - Inspect
If any defect such as dent, damage, wear and looseness that
can lead to oil leakage is found, replace the oil seal slinger Front cover Timing gear case
with a new one.
Oil seal Oil seal slinger
slinger
Oil seal
Oil seal
Front Rear
Oil Seal Slinger - Inspect
6-31
5.11 Oil Seal Slinger - Replace
Use protective gloves when you touch hot parts. Oil seal slinger
Handling with bear hands could result in burns.
5.11.1 Oil Seal Slinger - Remove

Using a gear puller, pull out the oil seal slinger from crank-
shaft.
Note: When removing the oil seal slinger by heating, the
heating temperature is 100°C [212°F] or less.
Oil Seal Slinger - Remove
5.11.2 Oil Seal Slinger - Install
ID mark ID mark
(1) Measure the outside diameter of crankshaft and inside (37425-08201) (41020-01500)
diameter of oil seal slinger, and check the interference.
(2) Heat the oil seal slinger evenly to the temperature of
Tight contact with gear
110ºC [230°F] or less. After checking the correct direc-
tion and position of slinger, install the slinger.
Interference Interference
0.210 to 0.294 mm 0.319 to 0.394 mm
[0.0083 to 0.0116 in.] [0.126 to 0.155 in.]
Front Rear
Oil Seal Slinger - Install
Slinger
Installer
Front Oil Seal Slinger - Install

5.12 Main Bearing - Inspect
the main bearing. If any defect such as local contact, sliding
scratches, corrosion and foreign material inclusion is found,
replace the main bearing with a new one.
Flaw, corrosion, peeling
End face
Main Bearing - Inspect
6-32
5.13 Main Bearing Spread - Measure

Measure the spread (free length) of bearing.

148.25 to 150.25 mm 147 mm
Main bearing spread
[5.837 to 5.915 in.] [5.79 in.]
Spread
Main Bearing Spread - Measure

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

3.500 mm 3.467 to 3.480 mm 3.450 mm
Standard
[0.1378 in.] [0.1365 to 0.1370 in.] [0.1358 in.]
0.25 mm 3.625 mm 3.592 to 3.605 mm 3.575 mm
[0.0098 in.] [0.1427 in.] [0.1414 to 0.1419 to in.] [0.1407 in.]
0.50 mm 3.750 mm 3.717 to 3.730 mm 3.700 mm
Main bearing thickness at the center position
[0.0197 in.] [0.1476 in.] [0.1463 to 0.1469 in.] [0.1457 in.]
Under size
0.75 mm 3.875 mm 3.842 to 3.855 mm 3.825 mm
[0.0295 in.] [0.1526 in.] [0.1513 to 0.1518 in.] [0.1506 in.]
1.00 mm 4.000 mm 3.967 to 3.980 mm 3.950 mm
[0.0394 in.] [0.1575 in.] [0.1562 to 0.1567 in.] [0.1555 in.]
5.15 Thrust Plate - Inspect

the thrust plate. If any defect such as local contact, sliding
Upper and lower surfaces
scratches, corrosion and foreign material inclusion is found, fletting, wear
replace the thrust plate with a new one.
Dowel pin hole

uneven wear
Sliding face
flaw, corrosion, peeling
Thrust Plate - Inspect
6-33
5.16 Thickness of Thrust Plate - Measure

Measure the thickness of thrust plate.
If the value exceeds the limit, replace the thrust plate with a
new one. When the crankshaft is re-ground due to wear, use
the oversize thrust plates.
For the crankshaft grinding procedure, refer to "Rearmost
Crank Journal Width - Grind" of "INSPECTION AND
REPAIR OF BASIC ENGINE."
Thickness of Thrust Plate - Measure

5.00 mm 4.78 to 4.85 mm 4.76 mm
Standard
[0.1969 in.] [0.1882 to 0.1909 in.] [0.1874 in.]
0.25 mm 5.25 mm 5.03 to 5.10 mm 5.01 mm
[0.0098 in.] [0.2067 in.] [0.1980 to 0.2008 in.] [0.1972 in.]
Thickness of thrust plate
0.50 mm 5.50 mm 5.28 to 5.35 mm 5.26 mm
Over size
[0.0197 in.] [0.2165 in.] [0.2079 to 0.2106 in.] [0.2071in.]
0.75 mm 5.75 mm 5.33 to 5.40 mm 5.31 mm
[0.0295 in.] [0.2264 in.] [0.2098 to 0.2126 in.] [0.2090 in.]
5.17 Piston Cooling Nozzle - Inspect
If the oil jet pipe of piston cooling nozzle is bent or

deformed, it will reduce the cooling performance, and
can lead to the piston seizure.
Inspect the piston cooling nozzle.
Interfere Check movement
If there is any defect such as valve malfunction and oil hole Oriffice by pushing with
clogging a fine rod.
clogging, replace the piston cooling nozzle with a new one.
Crack
Item Standard value
Valve opening pressure of pis- 0.29±0.03 MPa
ton cooling nozzle {3±0.3 kgf/cm2} [435.1±43.5 psi]
Foreign material
inclusion Body deformation
Piston Cooling Nozzle - Inspect
6-34
1. Crankshaft and Main Bearing - Install ................................................................... 7-3
1.1 Crankcase - Turn Over (Upend) ............................................................................................... 7-3
1.2 Piston Cooling Nozzle - Install .................................................................................................. 7-3
1.3 Upper Main Bearing - Install ..................................................................................................... 7-3
1.4 Rear Upper Thrust Plate - Install .............................................................................................. 7-4
1.5 Crankshaft - Install.................................................................................................................... 7-4
1.6 Front Upper Thrust Plate - Install.............................................................................................. 7-4
1.7 Lower Main Bearing Shell and Lower Thrust Plate - Install ...................................................... 7-5
1.8 Main Bearing Cap - Install ........................................................................................................ 7-6
1.9 Crankshaft End Play - Measure................................................................................................ 7-7
1.10 Crankcase - Turn Over ............................................................................................................. 7-7
2. Cylinder Liner, Piston and Connecting Rod - Assemble ..................................... 7-8
2.1 Cylinder Liner Protrusion - Measure ......................................................................................... 7-8
2.2 Cylinder Liner Flange Protrusion - Calculate (When Cylinder Liner Not Installed) ................... 7-8
2.3 Cylinder Liner - Install ............................................................................................................... 7-9
2.4 Cylinder Liner Flange Protrusion - Measure (When Cylinder Liner Installed)......................... 7-10
2.5 Cylinder Liner Inside Diameter - Measure .............................................................................. 7-10
2.6 Piston and Connecting Rod - Assemble ................................................................................. 7-11
2.7 Piston Ring - Install................................................................................................................. 7-11
2.8 Crankshaft - Turn.................................................................................................................... 7-12
2.9 Piston Installation - Prepare.................................................................................................... 7-12
2.10 Upper Connecting Rod Bearing - Install ................................................................................. 7-12
2.11 Piston - Install ......................................................................................................................... 7-13
2.12 Connecting Rod Cap - Install.................................................................................................. 7-15
2.13 Connecting Rod End Play - Measure ..................................................................................... 7-16
2.14 Piston Protrusion - Measure ................................................................................................... 7-16
3. Front Mechanism - Assemble............................................................................... 7-17
3.1 Front Plate - Install.................................................................................................................. 7-17
3.2 Front Idler Shaft - Install ......................................................................................................... 7-17
3.3 Front Idler Gear - Install.......................................................................................................... 7-17
3.4 Front Idler Gear Backlash and End Play - Measure ............................................................... 7-17
3.5 Water Pump Bearing Cover - Install ....................................................................................... 7-18
3.6 Front Gear Case - Install ........................................................................................................ 7-18
3.7 Front Oil Seal - Install ............................................................................................................. 7-18
3.8 Damper and Crankshaft Pulley - Install .................................................................................. 7-19
3.9 Damper Face and Radial Runouts - Measure ........................................................................ 7-19
3.10 Pointer - Install and Adjust...................................................................................................... 7-19
3.11 Relief Valve - Install ................................................................................................................ 7-19
4. Rear Mechanism - Assemble ................................................................................ 7-20
4.1 Rear Plate - Install .................................................................................................................. 7-20
4.2 Rear Idler Shaft - Install .......................................................................................................... 7-20
4.3 Camshaft - Install.................................................................................................................... 7-20
4.4 Camshaft Gear - Install........................................................................................................... 7-21
4.5 Rear Idler Gear - Install .......................................................................................................... 7-21
4.6 Timing Gear Backlash and End Play - Measure..................................................................... 7-21
4.7 Timing Gear Case - Install ...................................................................................................... 7-22
4.8 Rear Oil Seal - Install.............................................................................................................. 7-22
4.9 Flywheel - Install ..................................................................................................................... 7-23
4.10 Flywheel Face and Radial Runout - Measure......................................................................... 7-23
7-1
5. Cylinder Head and Valve Mechanism - Assemble .............................................. 7-24

5.1 Control Shaft (MUI) - Install .................................................................................................... 7-24
5.2 Cylinder Head Assembly - Assemble ..................................................................................... 7-25
5.3 Valve Sinkage - Measure........................................................................................................ 7-25
5.4 Liquid Gasket - Apply.............................................................................................................. 7-26
5.5 Cylinder Head Gasket - Install ................................................................................................ 7-26
5.6 Cylinder Head Assembly - Install............................................................................................ 7-26
5.7 Cylinder Head Bolt - Tighten................................................................................................... 7-27
5.8 Rack Control Link (MUI) - Install............................................................................................. 7-27
5.9 Camshaft - Install.................................................................................................................... 7-28
5.10 Rocker Case - Install .............................................................................................................. 7-28
5.11 Unit Injector - Install ................................................................................................................ 7-29
5.12 Rack Control Link (MUI) - Connect......................................................................................... 7-29
5.13 Bridge and Bridge Cap - Install............................................................................................... 7-30
5.14 Valve Bridge and Adjusting Screw - Adjust ............................................................................ 7-30
5.15 Clearance Between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect. 7-30
5.16 Rocker and Shaft Assembly - Install....................................................................................... 7-31
5.17 Valve Clearance - Check and Adjust ...................................................................................... 7-32
5.18 Valve Timing - Inspect ............................................................................................................ 7-33
5.19 Fuel Injection Timing - Inspect and Adjust.............................................................................. 7-34
7-2
1. Crankshaft and Main Bearing - Install

1.1 Crankcase - Turn Over (Upend)

the turnover machine is not available, hitch slings to the Weight:
crankcase using wood pieces and cloth pads, and raise the approx 985 kg [2172 lb]
block with its side face downward. Then, change the posi-
tions of the slings, and turn over to upend the crankcase.
Crankcase - Turn Over (Upend)

1.2 Piston Cooling Nozzle - Install
34 ± 1.7 N·m
{3.5 ± 0.17 kgf·m}
Be sure to tighten the piston cooling nozzle to the
[7.64 ± 0.38 lbf·ft]
specified torque using a torque wrench. If it is exces- Piston
sively tightened, it could cause the check valve mal- cooling nozzle
function, and may lead to the piston seizure.
Install the piston cooling nozzle onto the crankcase and
tighten the check valve to the specified torque.
Piston Cooling Nozzle - Install

1.3 Upper Main Bearing - Install
(a) Do not apply engine oil on the back face of bearing and the bearing housing bore in the crankcase when
installing the main bearing. Install the main bearing after cleaning off foreign material, oil and grease.
(b) Be careful not to confuse the upper shell with the lower shell.
The upper shell is identified by a machined oil hole. The lower shell has no oil hole nor groove. If the lower
main bearing shells are installed in upper shell positions, or vice versa, the crankshaft will be damaged.
(c) Be careful not to damage the bearing when installing.
(1) Clean the main bearing housing and the main bearing
cap mating surfaces using cleaning solvent, and make
sure that these surfaces are free from any foreign mate-
rial.
(2) Make sure that the main bearing is free from damage or Lug slot
contamination.
(3) Fit the upper main bearing shell in the crankcase bore
aligning the lug on the shell with the lug slot in the
Oil hole
crankcase.
Note:(a) Make the main bearing crush heights even at both Upper main bearing
ends.
Upper Main Bearing - Install
(b) The oil hole in the upper main bearing shell is
aligned with the oil hole in the crankcase by align-
ing the lug on the upper shell with the lug slot in the
crankcase.
(4) Apply an even coat of clean engine oil to the sliding
surface of upper main bearing shell.
7-3
1.4 Rear Upper Thrust Plate - Install
Be careful not to damage the thrust plate when

installing.
(1) With the oil grooves of the thrust plate facing outside,
install the rear upper thrust plate to the dowel pins on
the crankcase rearmost main journal.
(2) Apply engine oil evenly to the sliding surface.
Note: Front upper thrust plate is to be installed after the
Oil
crankshaft installation. grooves
Rear Upper Thrust Plate - Install
1.5 Crankshaft - Install
(1) Make sure that the sliding surfaces of the upper main
Apply a small amount of
bearing shells installed in the crankcase are evenly engine oil to journal after
cleaning.
coated with clean engine oil.
(2) Thoroughly clean the crankshaft with cleaning oil, and
blow off the oil with compressed air. Then, apply an
even coat of clean engine oil to the crankshaft journals.
Note: When cleaning the crankshaft, be sure to thoroughly
Blow pressurized air
clean the crank journals, crankpins, and oil holes and after cleaning.
make sure that the crankshaft is free from foreign ma-
terial such as machining chips and dirt. Make sure that
Crankshaft - Clean
oil holes are free from burrs.
(3) Lift the crankshaft keeping it in a horizontal attitude,
and slowly install into the crankcase.
Note: When lifting the crankshaft, use fiber slings or pads to
avoid any damages to the crankshaft.
(4) Slowly rotate the crankshaft to verify a smooth rotation
of the crankshaft.
Crankshaft - Install
1.6 Front Upper Thrust Plate - Install
Be careful not to damage the front upper thrust plate

Front upper thrust plate
when installing.
(1) Push the installed crankshaft softly toward the engine
front direction to contact the installed rear upper thrust
plate with the crank journal web face.
(2) With the oil grooves on the front upper thrust plate fac- Insert the plate into
the clearance
ing outside, insert the front upper thrust plate into the between crankshaft
clearance between the crankshaft and crankcase. and crankcase.
(3) Move the crankshaft back and forth to verify the proper Front Upper Thrust Plate - Install
end play.
7-4
1.7 Lower Main Bearing Shell and Lower Thrust Plate - Install
(1) Install the lower main bearing shell, aligning the lug
Main bearing
with the lug slot in the main bearing cap. lower
Note: Make the crush heights even.
(2) Apply an even coat of clean engine oil to the sliding Thrust plate
lower
surfaces of lower main bearing shells. Lug slot
(3) Install the lower thrust plates aligning with the dowel
Thrust plate
pins on the rearmost main bearing cap. lower
Note: Install the lower thrust plates to place the oil grooves
facing outward. Main bearing cap
Oil groove Dowel pin
Lower Main Bearing and
Lower Thrust Plates - Install
7-5
1.8 Main Bearing Cap - Install
Be sure to observe the specified tightening sequence

when tightening the main bearing cap bolts and side
bolts.
(1) Make sure that the main bearings and thrust plates
"FRONT" mark
installed to main bearing caps are evenly coated with
clean engine oil.
(2) Install the main bearing caps so that their stamp num-
bers are arranged in numerical order from engine front
to rear, and all lugs are aligned on the same side, which Bearing caps
No.1 to No.7
shows the embossed mark of "FRONT" faces toward
the engine front.
(3) Apply oil to the main bearing cap bolts and washers and
hand tighten them.
Main Bearing Cap - Install
(4) Tap the main bearing caps with a soft-head hammer
evenly to install them in position.
(5) Apply oil to the side bolts and O-rings and hand tighten
them.
(6) Snug tighten the main bearing cap bolts and side bolts
Tighten to the specified Main bolts 1. 2. 3. 4 at the first time:
except the rearmost ones, to the half of specified torque torque in two steps (Wet) 245 ± 12.2 N·m
{25 ± 1.2 kgf·m}
in the specified tightening sequence as shown in the [181 ± 9.0 lbf·ft]
Side bolts 5, 6: 74 ± 3.7 N·m
illustration. {7.5 ± 0.38 kgf·m}
[54.6 ± 2.7 lbf·ft]
Bottom 1 2 3 4
Main bolts 1. 2. 3. 4 at the
(7) Tighten the main bearing cap bolts and side bolts second time: 490 ± 24.5 N·m
except the rearmost ones to the specified torque in the 5 6
{50 ± 2.5 kgf·m}
[361 ± 18 lbf·ft]
specified sequence shown in the illustration. Side bolts 5, 6: 147 ± 7.4 N·m
{15 ± 0.75 kgf·m}
(8) Hand tighten the rearmost cap bolts and side bolts to Top
[108 ± 5.5 lbf·ft]
Right side Left side
make the rearmost main bearing be lightly seated. View from engine rear side
Tightening Sequence of Main Bearing Cap Bolts
Measure the crankshaft end play in this condition.
490 ± 24.5 N·m

{50 ± 2.5 kgf·m}
147 ± 7.4 N·m
[362 ± 18.1lbf·ft]
{15 ± 0.75 kgf·m}
[Wet]
[108 ± 5.4 lbf·ft]
[Wet]
Main bearing cap bolt - Install
7-6
1.9 Crankshaft End Play - Measure

(1) Verify the smooth rotation of crankshaft.
(2) Apply dial gauge plunger to the rear end face of crank-
shaft.
(3) With a bar, move the crankshaft fully to front and rear,
and read each measurement. The end play is the differ-
ence between the front and rear measurements.
If the value exceeds the standard, inspect the thrust
plates and crankshaft.
If the end play is less than the standard value, loosen
the rear most bearing cap bolts and move crankshaft
back and forth, and measure the end play again.
(4) After tightening the rearmost main bearing cap to the
specified torque, measure the end play again to verify.
(5) Again, verify the crankshaft smooth rotation.
(6) Verify again all the main bearing cap bolts and side
bolts to make sure that they are tightened properly.
Limit
Item Standard value
value
Crankshaft end play 0.3 to 0.495 mm 0.7 mm
(at shaft thrust bearings) [0.012 to 0.020 in.] [0.028 in.]
1.10 Crankcase - Turn Over

the turnover machine is not available, hitch slings to the Unit weight:
approx. 1,500 kg
crankcase using wood pieces and cloth pads, and raise the
[3307 lb]
block with its side face downward. Then, change the sling
positions. Turn over the crankcase on the wooden blocks to
turn it to the normal position.
Crankcase - Turn Over
7-7
2. Cylinder Liner, Piston and Connecting Rod - Assemble

2.1 Cylinder Liner Protrusion - Measure
(1) Place a dial gauge probe on the top surface of cylinder
liner flange, and adjust the dial to zero. protrusion height
(2) Place the probe to measure the protrusion of the cylin-
der liner at four places.
(3) If the value exceeds the limit, or if the ridge is cracked,
Cylinder
replace the cylinder liner with a new one.
Liner top face
Item Standard value

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

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

pressure of cylinder head gasket is low, and it can
result in gas and water leakages.
(1) Inspect the cylinder liner contact surface of the crank-
case. If uneven contact is shown, reface the counterbore
with the crankcase grinder to correct the difference of Projection plate
depth at four places in circumference to be less than P/N:37598-09201
0.05 mm [0.0020 in.]. Counterbore depth

For the repair procedure, refer to "Counterbore in
Crankcase - Repair" of "INSPECTION AND REPAIR
OF BASIC ENGINE."
(2) Make sure that the top and bottom faces of cylinder
liner flange, the top surface of crankcase, and the fitting
Depth of Counterbore in Crankcase - Measure
surfaces of cylinder liner and crankcase are clean
before measurement.
(3) Measure the depth of counterbore in crankcase.
Item Standard value

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

15.15 to 15.19 mm
Thickness of Cylinder Liner Flange
[0.5965 to 0.5980 in.]
Cylinder liner
Thickness of Cylinder Liner Flange
7-8
(5) Calculate the cylinder liner flange protrusion by sub-

tracting the depth of counterbore in crankcase from the Crankcase
Shim
thickness of cylinder liner flange. Cylinder liner
If the value exceeds the limit, insert a shim under the
cylinder liner flange. Select a shim which makes the
cylinder liner flange protrusion largest within the toler-
ance.
Note:(a) Shims are available in thickness: 0.05, 0.10 and
0.15 mm [0.0020, 0.0039 and 0.0059 in.]
(b) Do not double the shims.
Shim - Insert
Item Standard value
0.10 to 0.19 mm
Cylinder liner flange protrusion
[0.0039 to 0.0075 in.]
2.3 Cylinder Liner - Install
Apply engine oil to the O-ring sliding surface in the Crankcase to prevent O-rings from twisting.
Do not apply engine oil to the O-ring grooves on cylinder liner.
(1) Install the O-rings to the cylinder liner.
Apply engine oil.
(2) Insert the shim to the cylinder which needs the adjust-
ment of the cylinder liner flange protrusion.
(3) Apply engine oil to the O-ring sliding surface in the
Crankcase and on the cylinder liner O-rings. Shim
O-ring
Cylinder Liner O-Rings - Install

(4) Slowly insert the cylinder liner into the bore in the
crankcase. With a correct cylinder liner installer, lightly Installer
P/N32591-01800
tap the cylinder liner until its flange contacts snugly on
the seating surface of the crankcase. Then, lightly tap
the liner several times to verify the stable seating. Shim
Note: To verify the correct O-rings installation, measure the Cylinder liner
roundness of inside diameter of the cylinder liner (es-
pecially O-ring installing position.)
Cylinder Liner - Install
7-9
2.4 Cylinder Liner Flange Protrusion - Measure (When Cylinder Liner Installed)
(1) Remove dust and dirt from the crankcase top face and Liner pusher
the cylinder liner top face. assembly
P/N: 37591-06020
(2) Place the liner pushers on equally spaced 4 positions of
Cylinder liner
the cylinder liner upper rim and tighten the pusher bolts flange protrusion
evenly to make a close contact of the cylinder liner and
the crankcase.
(3) Apply a dial gauge probe to the top face of the crank-
case, and adjust the gauge to zero.
(4) Slide the probe to measure the flange protrusion at four Tightening torque
places on the top of the cylinder liner, and calculate the 98 N·m {10 kgf·m} [72.3 lbf·ft]
mean value.
(5) If the mean value of the protrusion is smaller than the
standard, insert a shim under the cylinder liner flange.
For the shim and the standard value, refer to "Cylinder
Liner Flange Protrusion - Calculate (When Cylinder
Liner Not Installed)" of "ASSEMBLY OF BASIC
ENGINE."
2.5 Cylinder Liner Inside Diameter - Measure

Measure the cylinder liner inside diameter after installing
the cylinder liner in the crankcase.
Cylinder liner
Measure the inside diameter at the three positions of upper
(top ring position at TDC), middle (outer O-ring position)
and lower (liner fitting position) respectively in the pin and
the perpendicular to pin directions.
Nominal
value
ø150 mm 150.00 to 150.04 mm 150.1 mm
Inside diameter
[ø5.91 in.] [5.9055 to 5.9071 in.] [5.9094 in.]
Circularity and 0.02 mm [0.0008 in.] Cylinder Liner Inside Diameter - Measure
cylindricity or less
Measurement point Measurement direction
26mm [1.02 in.] Direction square to pin
Direction parallel
to pin
135mm
[5.32 in.]
250mm
[9.84 in.]
Cylinder Liner Measuring Positions
7-10
2.6 Piston and Connecting Rod - Assemble

(1) Apply engine oil to the piston pin, and assemble the
Right bank AView Piston Left bank
piston and the connecting rod. The orientation of the Weight
piston and the connecting rod is as shown in the illus- A A
tration.
Note: The piston and the piston pin are made for a clearance Camshaft
fit. However, the piston pin is more easily inserted into
Part No. Matching
the piston if the piston is warmed up with a heater or Mark
Direction mark
with hot water. “F( Front )”
(2) Install the snap ring with ring pliers. Make sure that the Engine front
snap ring is fully inserted into the ring groove.

Assembling Orientation of Piston and Connecting Rod
Right bank View A Piston Left bank

weight
A A
Camshaft
Part No. Match

marks
Direction mark
“F (Front)”
means
engine front
Piston and Connecting Rod - Assemble

2.7 Piston Ring - Install
Ring expander
P/N:37191-03200
Every piston ring has an upper face mark near the end
gap. Install the piston rings with the marks facing Up mark
upward. No.1
Be careful not to install the piston rings upside down. If compression ring
the piston rings are assembled incorrectly, it results in No.2
compression ring
defects such as engine seizure.
(1) Install the piston rings to the piston with ring expander. Oil ring
(2) Install the oil ring with its end gap 180° away from the Coil spring
joint of the coil spring, as shown in the illustration. Piston and Piston Ring - Install
Coil spring joint
180°
Oil ring gap
Oil Ring and Coil Spring Assembling
7-11
2.8 Crankshaft - Turn

(1) Install two bolts to flywheel mounting holes of crank-
shaft.
(2) Using the bolts, turn crankshaft with a bar.
Bolt
(M22 × 1.5 mm)
Crankshaft
Crankshaft - Turn
2.9 Piston Installation - Prepare
(1) Turn the crankshaft to a position where the connecting
rod big end does not hit the crankpin to install the pis-
ton.
Crankpin Place so that connecting rod

big-end does not hit crankpin.
Position of Crankpin - Adjust
(2) Clean the cylinder liner inner surface and the crankpin,
and apply engine oil to the cylinder liner.
Piston Installation - Prepare

2.10 Upper Connecting Rod Bearing - Install
Upper connecting rod bearing
Be careful not to put engine oil on the back face of Lug groove
upper connecting rod bearing.
Install the upper connecting rod bearing on the connecting
rod big end aligning the lug and the lug slot. Apply engine
oil to the sliding surface. Verify the alignment of the oil hole
of connecting rod and the oil hole of bearing.
Oil hole
Upper Connecting Rod Bearing - Install
7-12
2.11 Piston - Install

Eye bolt
P/N:
When installing the piston, install the eye bolt to the 45815-32301
(M10 × 1.5)
threaded hole on the piston top, and lift the piston with
chain block. When the installation work is done by
hand, be sure to take preventive measures so that pis-
Engine front
ton does not falling down, and be very careful not to “F” mark
hurt your hands and fingers or not to damage the
parts.
Do not hit.
Camshaft
Piston and Connecting Rod - Install
(a) Make sure that the punch mark on the piston top
faces the camshaft side.
No. 1 compression ring gap
(b) Checking through the inspection window on the Coil spring gap
side of crankcase, make sure that the connecting

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

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

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

(4) Verify again the positions of piston ring gaps.
Apply engine oil to the piston rings.
Apply engine oil to the inner surface of piston installer.
Verify the oil ring placed in the groove. Then, compress
the piston rings with piston installer.
Note: For piston ring placing, see above (2).
Piston installer
P/N:37191-07100
Piston Ring - Compress
7-13
(5) Install the piston into cylinder liner by tapping the pis-
ton head with soft-head hammer.
Note: Make sure that the piston is not caught in the cylinder
liner, or the connecting rod big end does not hit the
crank pin.
Use of a soft hammer
handle
Piston- Install
(6) Verify the proper placing of upper connecting rod bear-
Verification of connecting
ing shell through the inspection window on crankcase rod bearing position
side. If the bearing shell is not placed properly, push the
bearing upward with your hand to correct the position.
Connecting Rod Bearing - Installation Check

(7) If the upper connecting rod bearing is displaced from
connecting rod big end, rotate the crankshaft to make a
space between the connecting rod big end and crank-
pin.Then, insert the connecting rod bearing, sliding on
the crankpin, and make sure that the lug on the bearing
shell is correctly positioned in the lug slot of the rod.
Upper connecting
rod bearing
Lug Groove - Align
7-14
2.12 Connecting Rod Cap - Install

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

(5) Align the connecting rod and rod cap side faces to
ensure the rod end play.
Note: To ensure the minimum end play, the connecting rod
gauge may be inserted between the two connecting
rods for adjustment.
Ensure the end play
(6) Measure the connecting rod end play, and adjust the with a connecting
end play to the range of the standard value. rod gauge.
Connecting rod gauge

P/N 0.5 mm [0.020 in.] : 32691-01500
0.6 mm [0.024 in.] : 32691-01600
(7) Tighten the connecting rod bolts to the specified torque.
After tightening to the specified torque, loosen the bolts
completely and tighten again to the specified torque. (2-
time tightening method)
Measure the end play again.
Note: To tighten the connecting rod bolts with the angle con-
trol tightening, follow the steps below.
(a) Tighten the bolt to a snug torque of 147±7.4 N·m 343±17 N·m {35±1.8 kgf·m}
{15± 0.75kgf·m} [108±5.46 lbf·ft]. [148±13 lbf·ft] [Wet]
2 times tightening method
(b) Further rotate the bolt 45±3 degrees.
(c) Loosen all bolts, and then angle controlled tighten
them again.(2-time tightening method)
7-15
2.13 Connecting Rod End Play - Measure

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

0.6 to 0.9 mm 1.1 mm
[0.024 to 0.035 in.] [0.043 in.]

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

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

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

Piston protrusion 0.45 to 0.95 mm [0.0177 to 0.0374 in.]
Cylinder liner flange pro-
0.10 to 0.19 mm [0.0039 to 0.0075 in.]
trusion
Thickness of cylinder head
1.77 to 1.83 mm [0.0697 to 0.0720 in.]
gasket
Top Clearance 0.92 to 1.57 mm [0.0362 to 0.0618 in.]
7-16
3. Front Mechanism - Assemble

Note: Install the plug with O-ring to the oil filler hole at the crankcase front end in right bank, then assemble the front mechanism.
3.1 Front Plate - Install
(1) Apply sealant (ThreeBond 1211) to the front plate 108 ± 10.8 N·m
packing mounting surface of the crankcase, and install {11 ± 1.1 kgf·m}
the packing with the dowel pin. [80 ± 8.0 lbf·ft]
(2) Install the front plate with the dowel pin on the packing.
(3) Tighten the bolts to the specified torque.
(4) Make sure that the bottom face of the front plate is flush
with the bottom face of the crankcase. Trim excess
packing.
Front plate
Front Plate - Install
3.2 Front Idler Shaft - Install
Install the idler shaft with O-ring to the front plate by align-
ing with the guide bolt.
Note: After installing the idler shaft, connect the lubrication
pipe to the shaft rear end.
Front idler shaft
Press-fit
108 ± 5.4 N·m

{11 ± 0.55 kgf·m}
[80 ± 4.0 lbf·ft]
Front Idler Shaft - Install
3.3 Front Idler Gear - Install
(1) Apply engine oil to the front idler gear shaft.
(2) Install the front idler gear.
(3) Install the thrust plate, and tighten the bolt to the speci-
fied torque. Front idler gear
Thrust plate
216 ± 10.8 N·m {22 ± 1.1 kgf·m}

[159 ± 8.0 lbf·ft]
Front idler gear - Install
3.4 Front Idler Gear Backlash and End Play - Measure
Measure the backlash and end play of the front idler gear. If
the value exceeds the limit, find the causal parts, and replace
Front idler gear
them with new ones.

0.11 to 0.28 mm
Backlash 0.5 mm [0.020 in.]
[0.0043 to 0.0110 in.]
0.3 to 0.5 mm
End play 0.7 mm [0.028 in.]
[0.0118 to 0.0197 in.]
Front Idler Gear Backlash and End Play - Measure

7-17
3.5 Water Pump Bearing Cover - Install

(1) Install the oil seal and O-ring to the water pump bearing
cover. Water pump
Bearing cover
(2) Install the water pump bearing cover to the front plate.
Water Pump Bearing Cover - Install

3.6 Front Gear Case - Install
(1) Apply sealant (ThreeBond 1211) to the front gear case
M12 × 1.25 (Fasten case.)
packing mounting surface of the crankcase, and install 98 ± 9.8 N·m
{10 ± 1.0 kgf·m}
the packing. Apply the same sealant (ThreeBond 1211) [72.3 ± 7.2 lbf·ft]
to the packing, and then install the front gear case.
(2) Tighten the bolts evenly to the specified torque.
M12 × 1.25
(3) Make sure that the bottom face of the front gear case is (Fasten with plate and nut.)
flush with the bottom face of the crankcase. Cut off 69 ± 6.9 N·m
{7 ± 0.7 kgf·m}
excessive packing carefully. [51 ± 5.1 lbf·ft]
M16 × 1.5
255 ± 25.5 N·m
{26 ± 2.6 kgf·m} [188 ± 18.8 lbf·ft]
Front Gear Case - Install
3.7 Front Oil Seal - Install
With the front seal installer assembly, install the front oil
Insert bolt
seal.
Guide flange
(1) Apply clean engine oil evenly to the oil seal lip.
Insert
Note: Pay attention to the installing side of oil seal, and be
careful not to damage the oil seal. Socket bolt
(2) Install the guide flange to the crankshaft front end, and Bolt
secure it with the insert bolts.
(3) Set the oil seal to insert and install it to the guide flange. Front seal installer
assembly
Swing
washer P/N:37591-05010
Front Oil Seal - Install (1)
(4) Tighten the bolt on guide flange to insert the oil seal
15.5 mm 17.5 mm
into the front cover. [0.610 in.] [0.689 in.]
(5) Remove the installer assembly.
Oil seal
Slinger
Front seal installer

assembly
P/N:37591-05010
Front Oil Seal - Install (2)
7-18
3.8 Damper and Crankshaft Pulley - Install

(1) Install the guide bolt to the damper mounting thread on
crankshaft. With punch mark Without punch mark
(2) Aligning with the dowel pin, install the spacer, rear
damper, spacer, front damper, and crankshaft pulley, in Front damper Rear damper
correct positions, using the guide bolt.
(3) Tighten bolts to the specified torque. Spacer
Note: Make sure the correct installation positions and orien-
tations of dampers.
490 ± 24.5 N·m
{50 ± 2.5 kgf·m}
[361 ± 18 lbf·ft]
Damper Installation Position and Orientation
3.9 Damper Face and Radial Runouts - Measure
Measure the face and radial runouts of the damper.
If the value exceeds the limit significantly, check the assem-
bling condition such as a loose bolt or foreign material
adhesion on the mounting faces.
Note: For measurement, avoid the punch mark positions.
Item Standard value

Face runout (reference) 0.5 mm [0.020 in.] or less
Face runout
Radial runout (reference) 0.5 mm [0.020 in.] or less
Radial runout
Damper Face and Radial Runouts - Measure

3.10 Pointer - Install and Adjust
(1) Install a dial gauge on No1. cylinder piston top and turn
(1) Place the crankshaft position to the TDC.
crankshaft to the top dead center position of No.1 cylin-
der.
Note: For the checking procedure of the top dead center by
the piston movement, refer to "Piston Protrusion -
Measure" of "ASSEMBLY OF BASIC ENGINE."
(2) In this position, verify two punch marks on timing gear
TDC
case and a punch mark on flywheel are positioned (2) Place punch marks
equally spaced.
mutually the same distance.
(3) Allign the pointer
Note: After disassembling or replacing the concerned parts, to the TDC scale.
be sure to verify the punch mark.
TDC-Verify and Pointer -Align
(3) Install pointer to front gear case and fix it aligning to
No. 1 top dead center position on angle scale.
3.11 Relief Valve - Install

Install the relief valve assembly with O-ring to the front
gear case.
Relief valve
Relief Valve - Install
7-19
4. Rear Mechanism - Assemble

Note: Before assembling the rear mechanism, install the oil seal to the control shaft hole at the crank case rear end. (MUI)
4.1 Rear Plate - Install
(1) Apply sealant (ThreeBond 1211) to the crankcase pack-
ing installing area, and attach the packing.
(2) Apply sealant (ThreeBond 1211) on the packing as
above, and install the rear plate.
(4) Make sure that the lower ends of rear plate are flush
with the bottom face of crankcase. Cut off any excess
of the packing neatly.
Install the oil seal.
108 ± 5.4 N·m
{11 ± 0.55 kgf·m}
Rear plate - Install

4.2 Rear Idler Shaft - Install
Tap in the rear idler shaft into crankcase by aligning with a
Guide bolt
guide bolt. (M12 × 1.25 mm)
108 ± 5.4 N·m

{11 ± 0.55 kgf·m}
[80 ± 4.0 lbf·ft]
Rear idler shaft
Rear Idler Shaft - Install
4.3 Camshaft - Install
Install the camshaft while supporting it with a protec-

tive pad through the crankcase window. Be careful not Camshaft
to bump the camshaft to avoid the damage to cam
lobe and bushing.
(1) Apply engine oil to the inner surface of camshaft bush-
ing.
(2) Apply engine oil to the camshaft oil galleries, journals Bar
and lobes.
(3) Support the camshaft with a bar, and slowly insert the Camshaft - Install
camshaft into crankcase.
(4) Install thrust plate, and tighten bolts to the specified
torque. 108 ± 5.4 N·m
{11 ± 0.55 kgf·m}
(5) Make sure camshaft rotates. [80 ± 4.0 lbf·ft]
Camshaft
Thrust plate
Camshaft and Thrust Plate - Install
7-20
4.4 Camshaft Gear - Install

(1) Install the camshaft gear by aligning its hole with the
dowel pins on camshaft. 176 ± 8.8 N·m
{18 ± 0.9 kgf·m}
(2) Tighten the bolts to the specified torque. [ ± 6.5 lbf·ft]
(3) Verify the camshaft smooth rotation.
Camshaft gear
Camshaft Gear - Install
4.5 Rear Idler Gear - Install
(1) Turn the crankshaft to bring No. 1 cylinder to the top
Camshaft gear
dead center.
(2) Install the idler gear, aligning match marks.
33
(3) Install the thrust plate to the idler shaft.
44
2
22
4
(4) Make sure the match marks on timing gears are prop-
1
erly aligned as shown in the illustration. 11
(5) Press-in the rear oil seal slinger to the crankshaft rear
end.
Rear idler gear Rear idler gear
For installation, refer to "Oil Slinger - Inspect and
Crankshaft gear
Replace" of "INSPECTION AND REPAIR OF BASIC
Rear Idler Gear - Install
ENGINE."
Rear idler gear
Thrust plate
Rear idler gear

Slinger
Timing Gear Train
4.6 Timing Gear Backlash and End Play - Measure
Measure the backlash and end play of the timing gear. If the
value exceeds the limit, find the causal parts, and replace
them with new ones.
Nominal Standard
Item Limit value
value value Camshaft gear
0.11 to 0.26 mm [0.0043 to 0.5 mm
Backlash
0.0102 in.] [0.020 in.]
Idler gear
0.3 to 0.5 mm 0.7 mm
Idler gear
[0.0118 to 0.0197 in.] [0.028 in.]
End play Camshaft gear
0.2 to 0.4 mm 0.5 mm
Camshaft
[0.008 to 0.016 in.] [0.020 in.]
Timing Gear Backlash and End Play - Measure
7-21
4.7 Timing Gear Case - Install

M12 × 1.25 Eye bolts
(Fasten case.) P/N:05930-00200
Be careful not to drop or bump the timing gear case. It 98 ± 4.9 N·m (M12 × 1.25)
{10 ± 0.5 kgf·m}
will result in personnel injury as well as damage of the [72.28 ± 3.61 lbf·ft]
timing gear case.
(1) Apply sealant (ThreeBond 1211) to the rear plate pack-
ing mating surface, and install the packing. M12 × 1.25
(Fasten with plate
(2) Apply sealant (ThreeBond 1211) to the packing mating and nut.) M16 × 1.5
69 ± 3.5 N·m 255 ± 12.3 N·m
surface to timing gear case.
{7 ± 0.36 kgf·m} {26 ± 1.25 kgf·m}
(3) Set the lifting attachments to the timing gear case, align [50.89 ± 2.58 lbf·ft] [188.08 ± 9.07 lbf·ft]
the case with the dowel pins, and install the case. Timing Gear Case - Install
(5) Cut off excessive packing carefully from the bottom of
crankcase.
4.8 Rear Oil Seal - Install
Use the rear seal installer assembly to install the rear oil
seal. Insert bolt
(1) Apply clean engine oil evenly to the oil seal lip. Guide flange
Note: Pay attention to the installing side of oil seal, and be Insert
careful not to damage the oil seal. Socket bolt
(2) Install the guide flange to the crankshaft rear end face,
and fix it with insert bolts. Bolt
(3) Set the oil seal to insert and install it to the guide flange.
Rear seal installer
(4) Tighten the bolt on the guide flange to insert the oil seal assembly
into timing gear case. P/N: 35B91-06010 Swing washer
Rear Oil Seal - Install (1)
(5) Remove the installer assembly.
Timing 17.5 mm [0.689 in.]
gear case
Oil seal
slinger 21.5 ± 0.2 mm

[0.847 ± 0.008 in.]
Rear Oil Seal - Install (2)
7-22
4.9 Flywheel - Install
Be careful not to drop or bump the flywheel. It will

Lifting
result in personnel injury as well as damage of the fly- sling
wheel.
(1) Check the mounting surfaces of flywheel and crank-
shaft to make sure that they are free from any foreign
material or damage.
588 ± 29.4 N·m
(2) Hitch a sling to the flywheel. {60 ± 3 kgf·m}
(3) Install the flywheel by aligning its hole with the dowel [ Wet ]
pin on the crankshaft. Flywheel - Install

(4) Apply engine oil to the bolt threads and bolt seat sur-
faces, then tighten the bolts to the specified torque.
4.10 Flywheel Face and Radial Runout - Measure
Measure the face and radial runouts of the flywheel.
If the measured value deviates from the standard, check the
assembling condition such as loose bolt or foreign material Face runout
measuring plane
adhesion on the mounting faces.
Radial runout
measuring plane
Item Standard value
Face runout (reference) 0.28 mm [0.0110 in.] or less
Radial runout (reference) 0.13 mm [0.0051 in.] or less
7-23
5. Cylinder Head and Valve Mechanism - Assemble

5.1 Control Shaft (MUI) - Install
Install some parts of MUI control before assembling the cyl-
inder head and valve mechanism. Bracket
(1) Install the control shaft bracket with O-ring into the
upper cam chamber through the crankcase upper face
aligning with the dowel pin.
Note: Install two brackets on each bank. Front end
(2) Install the washer and snap ring to the control shaft
front end and insert the shaft into the crank case front
Needle bearing
end.
(3) Install the split bearings to four places before inserting
Control Shaft - Install
the control shaft to the specified position.
Apply grease to the needle bearings to avoid dropping-
off.
Needle bearings
(4) Insert the control shaft farther to the position where the
needle bearings are installed in the bracket and crank-
case, and untill the snap ring and washer at the front
end contact the crank case.
Note: Insert the shaft carefully to avoid the damage of oil seal
at the rear end of crank case.
Control shaft
(5) Install the cover to the control shaft hole at the crank
case front end. Needle Bearing - Install
7-24
5.2 Cylinder Head Assembly - Assemble
Guide and seal installer Valve stem

(a) When inserting the valve through the stem seal, P/N:32591-10300
be careful to avoid the damage of stem seal lip
Stem seal
with the edge of stem groove.
(b) Do not apply oil or liquid sealant to the fitting faces Valve guide
between the stem seal and the valve guide.
(c) Always replace the stem seal with a new one.
30.3 ± 0.1 mm
[1.193 ± 0.04 in.] Cylinder head
(1) Apply engine oil to the valve stem, and insert it into the
valve guide.
(2) Install the stem seal to the valve guide with the guide Stem Seal - Install
and seal installer. P/N:35C91-04010
Note: Place the valve in the valve guide before installing the Valve spring
pusher assembly
stem seal. The valve stem seal is centered with the
valve stem.
(3) Place the valve spring and rotator to the valve guide,
and then install the valve cotters with the valve spring
pusher.
Valve Cotter - Install

(4) Tap the top of valve stem lightly several times with a
soft-head hammer to ensure the valve spring and valve Valve cotter
cotters are properly installed and seated firmly. Valve step head
Valve spring
Valve - Install
Note: For the inspection procedure of valve sinkage, refer to
"Valve and Valve Seat Ring - Inspect" of "INSPEC-
TION AND REPAIR OF BASIC ENGINE."
7-25
5.4 Liquid Gasket - Apply
a 5 VQ8 mm Liquid gasket: ThreeBond1211

p P/N: 37594-01300
L [0.32 in.]
(a) Do not apply a liquid gasket to the grommet. If p i
l q
applied excessively, the grommet may be i u
c
deformed. Especially pay attention to the position a
i
d
A where the applying area is small. t
i g
o a
(b) Do not apply the liquid gasket around the combus- s
n
tion chamber. It results in gas leakage. k
a e
r t
(1) Wipe off oil, grease and other stains from both sides of e
a In this area,
the cylinder head gasket. A never apply liquid gasket
(2) Apply liquid gasket around the push rod hole and oil Liquid Gasket Application Area (Both sides)
passages on both sides of the cylinder head gasket.
Beads of liquid gasket are 5 to 8 mm [0.20 to 0.31 in.]
wide from the cylinder head gasket outer edge and 0.2
to 0.5 mm [0.008 to 0.020 in.] thick.
Note: After the application of the liquid gasket to the cylin-
der head gasket install the cylinder head before the liq-
uid gasket dries.
5.5 Cylinder Head Gasket - Install
(1) Wipe off oil, grease and other contaminants from the
Dowel pins
cylinder head bottom surface and the crankcase top sur- (3 places)
face.
(2) Install the cylinder head gasket coated with liquid gas-
ket onto the crankcase with the dowel pins and holes in
alignment.
Cylinder Head Gasket - Install

5.6 Cylinder Head Assembly - Install
(1) Apply engine oil to the cylinder head bolt threads, bolt
seats and washer surfaces. Eye bolt
Note: Do not apply excessive amount of engine oil. Remove
the excess before assembling.
(2) Install the eye nut to stud bolt, and lift the cylinder head
assembly.
(3) Slowly lower the cylinder head, and install the cylinder
head aligning dowel pins with holes. Make sure that the
dowel pins are inserted in the holes, hand tighten the
Apply engine oil here.
cylinder head bolts.
Cylinder Head Assembly - Install
7-26
5.7 Cylinder Head Bolt - Tighten

Two methods of cylinder head bolt tightening, torque tight-
ening and angle controlled tightening, are available.
5.7.1 Torque Tightening Method
Torque method
(1) Tighten cylinder head bolts progressively to the speci- 539 ± 27 N·m
{55 ± 2.75 kgf·m}
fied torque in the sequence shown in illustration. [398 ± 20 lbf·ft]
[Wet, 2-time tightening method] 4
(2) Tighten all the bolts, and then loosen them, and tighten 2
them again according to this torque method. (2-time
Angle method
tightening) 6
(1) Snug torque
5
5.7.2 Angle Controlled Tightening Method 294 ± 14.7 N·m
{30 ± 1.5 kgf·m}
(1) Tighten cylinder head bolts to the specified snug torque [217 ± 10.8 lbf·ft]
in the sequence shown in illustration. (2) Tighten by 65 ± 3° 1
[Wet, 2-time tightening method] 3
(2) Put a mark to cylinder head bolt.
Cylinder Head Bolt - Tighten
(3) Tighten the bolts by turning 65±3° in the specified
sequence.
(4) Loosen all bolts, and then angle controlled tighten them
again. (2-time tightening)
5.8 Rack Control Link (MUI) - Install

(1) Connect the bracket, rack lever, cancel rod assembly
and control lever each with needle bearings and hold
Rack lever
with snap rings.
(2) Insert the control lever of assembled link into the cam Bracket, Bolt
cahmber through the cylinder head, and connect it to
the control shaft with the reamer bolt. (2-time tighten- Cancel rod
ing)
(3) Install the rack lever bracket on the cylinder head top
Control lever
face.
Control shaft
Reamer bolt
30 ± 1.52 N·m
{3.1 ± 0.15 kgf·m}
[22.1 ± 1.12 lb·ft]
Cam chamber
Rack Control Link (MUI) - Install
7-27
5.9 Camshaft - Install

seats and washer surfaces.
Note: Do not apply excessive amount of engine oil. Remove
the excess before assembling.
88 ± 4.4 N·m
assembly. {9 ± 0.45 kgf·m}
5.10 Rocker Case - Install
M10×1.25: 60±3.0 N·m {6±0.3 kgf·m}
seats and washer surfaces. [44±2.2 lbf·ft]
Note: Do not apply excessive amount of engine oil. Remove M12×1.25: 108±5.4 N·m
{11±0.55 kgf·m}
the excess before assembling. [44±2.5 lbf·ft]
assembly.
7-28
5.11 Unit Injector - Install
Clean the fuel passages in the unit injector and cylin-

der head to be free from dust and dirt. O-ring
(1) Install the O-ring and nozzle gasket to the unit injector.
(2) Insert the unit injector into the cylinder head and slowly
press in the injector aligning with the dowel pin. Nozzle gasket
Note: In case of MUI, connect the control rack described in
the following section.
(3) Install the gland and fix the unit injector with the seat
and nut. O-ring and Nozzle Gasket - Install
Nut tightening procedure
(a)Apply oil to threads and bearing faces. (Wet)
(b)Tighten to 176 ± 9 N·m {18 ± 0.9 kgf·m} [130 ± 7
lbf·ft] exceeding the specification for snug fitting of
each contact face.
(c)Loosen the nut, then tighten to the specification 127 ±
6.4 N·m {13 ± 0.7 kgf·m} [94 ± 5 lbf·ft].
MUI ECUI
Positioning of Unit Injector
Nut First time: Higher than the

[Wet] specified torque
176 ± 9 N·m
{18 ± 0.9 kgf·m}
[129.8 ± 6.6 lbf·ft]
Second time: Specified torque

127 ± 6.4N·m
{13 ± 0.65 kgf·m}
[93.7 ± 4.7 lbf·ft]
Gland
Unit Injector - Tighten
5.12 Rack Control Link (MUI) - Connect
Align the rack lever of installed control link and the ball
Rack lever
bearing to the groove at the end of rack, and install the unit
Dowel pin hole
injector into the cylinder head.
Fix the unit injector with gland. Check the smooth move-
ment of link between the cam chamber control shaft and the
unit injector.
Rack
Ball bearing
Rack Control Link (MUI) - Connect
7-29
5.13 Bridge and Bridge Cap - Install

(1) Apply engine oil to the bridge guide.
(2) Install the bridge on the bridge guide. Place the screw-
Bridge cap
fitted end of bridge to the exhaust manifold side.
(3) Apply engine oil to the bridge contact area of the bridge
cap, and install the bridge cap. Be careful not to drop Valve bridge
the bridge cap into the crankcase through the push rod
hole.
Bridge and Bridge Cap - Install

5.14 Valve Bridge and Adjusting Screw - Adjust
Adjust the contact of valve stem top faces to ensure the
smooth sliding of bridge on the guide and the balanced
pushing to valves.
(1) Loosen the adjusting screw so that the screw top face Contacting faces
protrudes from the top face of nut by 6 to 7 mm [0.23 to Tighten further between valve
by 10° bridge and valve
0.27 in.].
(2) Press the top of bridge by hand so that the bridge solid
side (without the screw) contacts closely to the valve 55 ± 2.8 N·m
stem top face. {5.6 ± 0.29 kgf·m}
[12.4 ± 0.63 lbf·ft]
(3) Turn the adjusting screw slowly until the screw con-
Valve Bridge and Adjusting Screw - Adjust
tacts the top face of valve stem. Then, turn the screw
further by 10°, and tighten the lock nut to the specified
torque.
5.15 Clearance Between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect

Be sure to keep the standard clearance between the Bridge cap
valve bridge and the valve rotator. If the clearance is Valve bridge
Clearance between
smaller than the standard, the valve cotter may valve bridge bottom face
come off or get damage. Valve rotator and valve rotator
Push the valve bridge by hand to make the close contact of

top end face of valve stems. Then, check the clearance
between the bottom face of valve bridge and the top face of
valve rotator. If the clearance deviates from the standard,
find the causal parts, and replace them with new ones. Clearance Between Bottom Face of Valve Bridge and
Top Face of Valve Rotator - Inspect
Item Standard value
Clearance between bottom Adjusting

6.1 mm [0.240 in.]
face of bridge and top face screw side
of rotator Plane side 5.1 mm [0.201 in.]
7-30
5.16 Rocker and Shaft Assembly - Install

5.16.1 Push Rod - Install
Injector push rod installing (ECUI)
(1) Place the push rod with the spring seat on cam follower.
(2) Install the helper spring to the push rod top and hold it
in the rocker case.
Note: Place other push rods on cam followers and leave them
Upper spring
in the rocker chamber befor installing the rocker arm.
seat Rocker case
Cam follower
Injector push rod installing (ECUI)

5.16.2 Rocker and Shaft Assembly - Install
(1) Assemble the rocker assembly and rocker shaft in the Rocker (UI)
order of the inlet, UI then exhaust. Rocker
Rocker (inlet) (exhaust)
(2) Install the rocker and shaft assembly by aligning its
hole with the dowel pin in rocker case. Rocker
shaft
Note: Use the special bolt with lubrication oil hole to tighten
the rocker shaft.
Rocker and Shaft Assembly
hard washer
(ECUI only)
Rocker case
167 ± 8.4 N·m {17 ± 0.86 kgf·m} [123.2 ± 6.2 lbf·ft]

Rocker and Shaft Assembly - Install
7-31
5.17 Valve Clearance - Check and Adjust

Adjust the valve clearance when the engine is cold.
Note:(a) The inlet valves are on the left side and the exhaust
valves are on the right when the cylinder head is
viewed from the camshaft side.
(b) The valve clearance standard values are shown on
the caution plate on the No. 1 cylinder rocker cover.
Nominal
Item Standard value
value
1.6
0.6 mm 0.55 to 0.65 mm
Inlet
[0.024 in.] [0.0217 to 0.0256 in.]
Valve clearance
0.8 mm 0.75 to 0.85 mm No. 1 Cylinder Compression Top Dead Center - Check
Exhaust
[0.031 in.] [0.0295 to 0.0335 in.]
(1) Adjust the valve clearance in the firing order at the top
dead center (TDC) of compression stroke by turning the Screw
crankshaft in the normal direction.

(2) The TDC is a position where punch mark on damper
cylinder number and pointer are aligned, and both inlet
and exhaust valves are closed.
(3) Insert a thickness gauge between rocker arm and bridge
Lock nut
cap to measure clearance. Adjust screw to the tightness
where the movement of thickness gauge feels drag.
Valve Clearance - Adjust
(4) After adjustment tighten lock nut firmly to the specified
torque. Then, check the clearance again.
7-32
5.18 Valve Timing - Inspect

The specified valve timing is automatically made, when
Top dead center
gears are assembled by aligning match marks and valve q 55
5 5 q
clearances are adjusted to the specified value. To make sure, Inlet valve Exhaust valve
open closes
check the valve timing as follows:
Direction of
5.18.1 Valve timing at normal valve clearance (no rotation
thickness gauge insertion)
(1) Check that the valve clearance is adjusted to the specifi- Inlet valve Exhaust valve
cation. closes open
(2) Insert the thickness gauge, which has the same thick- 65 q
q 65
ness as the specified valve clearance, between the Bottom dead center
Valve Timing When Valve Clearance Is 0 mm
bridge cap and rocker arm. (Valve clearance 0 mm)
(3) Turn the crankshaft in normal direction little by little, Rocker arm
and find a position where the thickness gauge is tightly
gripped (valve open position) and a position where the
thickness gauge is released (valve closed position).
Standard valve clearance
(4) Verify the valve timing to the specification.
Bridge cap Thickness gauge

Valve Clearance 0 mm
5.18.2 Valve Timing When Valve Clearance Is 2 mm
Top dead center 14°14°
[0.08 in.] Exhaust valve
Inlet valve
open closes
Direction of
rotation
After inspecting the valve timing with 2 mm valve
clearance, adjust the valve clearance to the specifica-
tion.
If the valve clearance is not adjusted to the specifica- Inlet valve Exhaust valve
tion, the valve system may be damaged. closes 21° 27°open
Bottom dead center
Adjust the clearance to 2.5 mm [0.098 in.] to check the tim- Valve Timing When Valve Clearance Is 2 mm [0.08 in.]
ing where the valve moves rapidly and the measurement is
Rocker arm
more accurate.
(1) Insert a thickness gauge of 0.5 mm [0.020 in.] between
the bridge cap and rocker arm. (Valve clearance 2 mm
Valve clearance 2 mm [0.08 in.]
[0.08 in.])
0.5 mm [0.020 in.]
(2) Turn the crankshaft in normal direction little by little,
and find a position where the thickness gauge is tightly
gripped (valve open position) and a position where the
thickness gauge is released (valve closed position).
Bridge cap Thickness gauge
(3) Verify the valve timing to the specification.
Valve Clearance 2 mm [0.08 in.]
(4) Readjust the valve clearance to the normal value.
7-33
5.19 Fuel Injection Timing - Inspect and Adjust

MUI
Height gauge
The fuel injection timing differs according to the specifica- P/N: 35C91-11100
tion, check the timing with stamp mark on the plate stuck to
the No. 1 rocker cover.
(1) Rotate the crankshaft in normal direction, and align the
pointer with the damper line mark of the specified
injection timing.
(2) Install the height gauge on the gauge stand of unit injec-
[3.1496 ± 0.0004 in.]

tor.
80 ± 0.01 mm
Hold the gauge grip lightly by fingers, place the protru-
sion to measure the height of tappet upper face.
(3) Change the tappet height with the rocker arm adjust Gauge stand
screw. Tighten the lock nut at the position where the
height gauge protrusion contacts lightly the tappet
upper face.
(4) Adjust all cylinders in the same procedure.
Injection Timing (MUI) - Inspect and Adjust
ECUI
Height gauge
The fuel injection timing differs according to the specifica-
P/N: 35C91-11100
tion. The ECUI adjusts the timing.
After installing the injector, adjust the tappet height at the
base circle position of injector cam.
(1) Rotate the crankshaft in the normal direction and align
the pointer with the 120°position before top dead center
.
[3.1890 ± 0.0020 in.]
Note: The anglar scale on damper shows the top dead center
81 ± 0.05 mm
position of multiple cylinders. Pay attention to the cor-

rect cylinder No. and its position.
(2) Install the height gauge on the gauge stand of unit injec-
tor.
Hold the gauge grip lightly by fingers, place the to mea-
sure the height of tappet upper face.
(3) Change tappet height with rocker arm adjust screw.
Injection Timing (ECUI) - Inspect and Adjust
Tighten lock nut at the position where height gauge
protrusion contacts lightly the tappet upper face.
(4) Adjust all cylinders in the same procedure.
7-34
1. Fuel System - Remove and Inspect ....................................................................... 8-3
1.1 Unit Injector - Remove and Inspect .......................................................................................... 8-3
1.2 Fuel Filter and Fuel Pipe - Remove and Inspect ...................................................................... 8-3
1.3 Feed Pump and Accessory Drive - Remove and Inspect ......................................................... 8-4
1.4 Governor and Actuator (MUI) - Remove and Inspect ............................................................... 8-5
1.5 Stop Slenoid and Rack Control Solenoid - Remove and Inspect (MUI) ................................... 8-8
1.6 Fuel control link (MUI)............................................................................................................... 8-9
2. Fuel System - Disassemble, Inspect and Assemble .......................................... 8-10
2.1 Fuel Filter (Wire Element) - Disassemble, Inspect and Assemble.......................................... 8-10
2.2 Fuel Filter (Paper Element) - Disassemble, Inspect and Assemble ....................................... 8-11
2.3 Unit Injector - Disassemble and Inspect ................................................................................. 8-12
2.4 Unit Injector - Inspect and Adjust............................................................................................ 8-14
2.5 Unit Injector - Assemble.......................................................................................................... 8-17
2.6 Feed Pump Drive - Disassemble and Inspect ........................................................................ 8-18
2.7 Feed Pump Drive - Assemble................................................................................................. 8-19
2.8 Feed Pump Drive - Install ....................................................................................................... 8-19
2.9 Governor Drive (MUI) - Disassemble and Inspect .................................................................. 8-20
2.10 Governor Drive - Assemble .................................................................................................... 8-21
2.11 Check Valve - Disassemble, Inspect and Assemble .............................................................. 8-22
3. Fuel System - Install .............................................................................................. 8-23
3.1 Unit injector............................................................................................................................. 8-23
3.2 Governor and Actuator (MUI) ................................................................................................. 8-23
3.3 Control Device (MUI) .............................................................................................................. 8-23
3.4 Solenoid - Install ..................................................................................................................... 8-26
8-1
1. Fuel System - Remove and Inspect
(a) Make sure that there is no flame around the area before handling fuel system.
(b) Pay attention not to splash fuel. Wipe of fuel if splahed.
1.1 Unit Injector - Remove and Inspect

For the removal of unit injector, refer to "Unit Injector - Remove" of "ENGINE MAIN PARTS - DISSASSEMBLE AND
INSPECT."
1.2 Fuel Filter and Fuel Pipe - Remove and Inspect
12 14
Replace: seal washer 11
ECUI
5
14 MUI
Feed pump
4 9
13 10 8
Valve opening 3
pressure
Fuel leak Feed pump
5
7
6
11
2
17
1
8
13
15
1
Fuel leak
16
Fuel leak
Primary filter Changeover-type filter
Fuel Filter and Fuel Pipe - Remove and Inspect
Removing sequence
1 Flexible pipe 10 Primimg pump bracket
2 Return pipe (connecting right and left banks) 11 Fuel feed pipes (right and left)
3 Check valve 12 Fuel main pipes
4 Return pipe (connecting right and left banks) 13 Filter assembly
5 Feed pump inlet and outlet pipes 14 Filter bracket
6 Priming pump inlet and outlet pipes 15 Primary filter outlet pipe
7 Priming pump 16 Primary filter assembly
8 Filter inlet pipe 17 Primary filter bracket
9 Connector
8-3
1.3 Feed Pump and Accessory Drive - Remove and Inspect
Replace: O-ring
Contact, wear
1
2
5
Spline,
key way wear
Wear 6
4
Oil, fuel leak

from inspection hole
Fuel filter and fuel pipe - Remove and inspect

Removing sequence
1 Left fuel pipe 4 Right fuel pipe
2 Left fuel pipe 5 Fuel filter assembly
3 Right fuel pipe 6 Fuel filter bracket
8-4
1.4 Governor and Actuator (MUI) - Remove and Inspect
Ball joint wear Hydraulic governor spec
Serration wear
1
3
Spline wear Replace: O-ring

Contact, wear ‫ޓޓޓ‬Packing
Woodward make PSG type governor
Hydraulic Governor (PSG) - Remove and Inspect
Removing sequence
1 Feed and return pipes 3 Governor assembly
2 Rod assembly 4 Governor drive and gear assembly
Ball joint wear

Hydraulic governor spec
3
1
Loose pin,
wear, open circuit 2
4 Serration wear
L
RO D
NT W A R
CO O D NG
AL W O WARNI
IGIT
1D
72
Spline wear
Replace: O-ring
Contact, wear 2 Packing
Woodward make EG-3P type governor
Hydraulic Governor (EG-3P) - Remove and Inspect
Removing sequence
1 Connector and cable 4 Governor assembly
2 Feed and return pipes 5 Governor drive and gear assembly
3 Rod assembly
8-5
Actuator spec
Serration wear
2 3
Joit wear
Terminal flaw
4 Cushion crack, deformation 1

Woodward make DYNA8200 type actuator
Actuator (DYNA8200) - Remove and Inspect
Removing sequence
1 Connector cable 3 Actuator
2 Rod assembly 4 Bracket
Actuator spec
Serration wear
3
2
1
Ball joint wear

Loose pin,
Wear, open circuit
Cushion crack,
deformation
Toho Seisakusho make SG4030 actuator

Actuator (SG4030) - Remove and Inspect
Removing sequence
1 Connector cable 3 Actuator
8-6
Actuator spec
2
Loose pin,
Wear, open circuit
1
Ball joint wear

4 3
Serration wear
Cushion crack, deformation

Woodward make PROACT 2 type actuator
Actuator (PROACT2) - Remove and Inspect
Removing sequence
1 Connector cable 4 Plate
3 Actuator
8-7
1.5 Stop Slenoid and Rack Control Solenoid - Remove and Inspect (MUI)
Stop solenoid RUN ON, RUN OFF spec

3
3
Cushion crack,
deformation
Bearing wear
1
4
Bearing wear
1 4
2
2
Ball joint wear
Ball joint wear
Terminal flaw
RUN ON RUN OFF

Stop Solenoid - Remove and Inspect
Removing sequence
1 Rod assembly 3 Stop lever
2 Stop solenoid 4 Bracket
rack control solenoid RUN ON, RUN OFF spec

5
5
3 4
1
2 1
Ball joint Ball joint
wear wear
RUN OFF RUN ON

Rack Control Solenoid - Remove and Inspect
Removing sequence
1 Rod and crevice 3 Solenoid 5 Bracket
2 Rod 4 Lever
8-8
1.6 Fuel control link (MUI)
(a) Many positions of the fuel control link are protected with the wire and tamper-proof nut. Do not break or tamper
these protection unless it is absolutely necessary.
(b) Breaking the protection and re-protection must be done by personnel and in a facility under an accord with our
company.
(c) The tamper-proof nut is impossible to loosen in a double structure with free spining outer nut. To remove the
nut, cut the outer nut and use the special tool to loosen the inner nut.
4
5 2
6
3
Hydraulic
governor
9 1
Bearing wear
3
Ball joint wear
3
2
7
6
Electronic
governor Actuator
7
11
8
10
7 PROACT
Replace
8
10
Hydraulic governor
Fuel Control Link - Remove and Inspect (MUI)

Removing sequence
1 Governor rod (adjustable length) 7 Tamper-proof nut and self-locking not
2 Cancel lever 8 Stopper bracket
3 Right lever 9 Bearing cover
4 Right rod (adjustable length) 10 Control shaft
5 Left lever 11 Pipe
6 Left rod (fixed length)
Note: For the removal of fuel control link (control shaft to unit injector), refer to "Cylinder head, valve mechanism - disassemble
and inspect" and "Rear mechanism - disassemble and inspect" in "BASIC ENGINE - DISASSEMBLE." )
8-9
2. Fuel System - Disassemble, Inspect and Assemble

2.1 Fuel Filter (Wire Element) - Disassemble, Inspect and Assemble
Replace: Seal washer

Air bleed plug
Packing
Turning effort
O-ring
2.5 N·m
{0.25 kgf·m}
[1.81 lbf·ft] or less
Clean
Contact with element
4 2
Pull-out direction
Left-hand thread
7.5 N·m Tighten.

{0.76 kgf·m}
[5.53 lbf·ft] 5
6
Loosen.
Insert ø4 [0.16 in.]
pin (tool). Clean
1
3
Fuel Filter (Wire Element) - Disassemble, Inspect and Assemble

1 Drain plug 5 Element
2 Lower case 6 Scraper assembly
3 Nut and retaining washer 7 Cover
4 Rod and handle
8-10
2.2 Fuel Filter (Paper Element) - Disassemble, Inspect and Assemble
Replace: O-ring Use filter wrench only to loosen.

Seal washer
Packing
Do not use. (See note.)
Air bleed plug

9 ± 1 N·m
{0.9±0.1 kgf·m} Filter wrench
[6.64±0.72 lbf·ft]
Thread deformation
4 2
5
5
Thread
deformation
1
1
Clogging, deformation,
crack
Changeover-type filter Standard filter
Fuel Filter (Paper Element) - Disassemble, Inspect and Assemble

1 Cartridge filter 4 Cock
2 Pin 5 Filter bracket
3 Cover
2.2.1 Cartridge Filter - Install
(a) When installing the cartridge filter, do not use a filter wrench. Tighten it by the hand.
(b) Do not deform or damage the cartridge filter surface.
(1) Clean the mounting surface of the filter.
(2) Apply clean fuel on the filter gasket.
(3) After the filter gasket contacts with base surface, tighten the filter by 3/4 to 1 turn by hand.
Note:(a) For the prevention of cartridge filter damage, install the filter after the maintenance job and immediately before the test
operation.
(b) Bleed air from fuel after installing at the bleeder pipe on fuel pipe, not at the filter bracket to avoid the thread damage
of bleeder plug by over-tightening.
8-11
2.3 Unit Injector - Disassemble and Inspect
Replace: O-ring
5
Crack, corrosion, deformation
4
3
9 Needle valve seating face wear
Carbon deposit, oriffice clogging,

cavitation, gas intrusion,
upper porttion of neddle valve wear,
8 Clean
1
Replace
Replace
Unit Injector (MUI) - Disassemble and Inspect

1 Nozzle retaining nut 6 Spring seat
2 Nozzle tip 7 Shim
3 Distance piece 8 Body retaining nut
4 Lower retainer 9 Spring cage
5 Needle valve spring
(a) Do not disassemble the unit injector body, plunger, rack (MUI) or solenoid (ECUI) as it needs the dedicated
facilities.
(b) Place the unit injector parts identifying each cylinder number to avoid mixing-up and keep cleanliness.
8-12
Replace : O -ring
5
Crack, corrosion, deformation
4
3
Needle valve seating face wear
2
9
Carbon deposit, oriffice clogging,

cavitation, gas intrusion,
upper porttion of neddle valve wear,
Clean
1
8
Replace
Replace
Unit Injector (ECUI) - Disassemble and Inspect

1 Nozzle retaining nut 6 Spring seat
2 Nozzle tip 7 Shim
3 Distance piece 8 Body retaining nut
4 Lower retainer 9 Spring cage
5 Needle valve spring
(1) Place the unit injector between the clamps and fix in a
vise to disassemble or assemble. Clamp
(2) For the cleaning of the unit injector use clean diesel fuel P/N:48749-01000 (MUI)
P/N:48493-01000 (ECUI)
or cleaner. After the cleaning, immerse the needle valve
and body assembled as a set to avoid rust and sticking.
Vise
Unit injector- Clamp
8-13
2.4 Unit Injector - Inspect and Adjust

2.4.1 Injection Starting Pressure - Inspect and Adjust
Fuel
Connector
P/N: 48749-00100
Never touch the fuel jet during nozzle injection test.
Body
(1) Install the spring cage to the connector and tighten the retaining nut
body retaining nut to the specified torque. (wet, 2-time 314 ± 10 N·m
{32 ± 1.0 kgf·m}
tightening method) [232 ± 7.4 lbf·ft]
(2) Install the shim, spring seat, spring, lower retainer, dis-
Shim
tance piece and nozzle tip to the spring cage, and Spring cage Spring seat
tighten the nozzle retaining nut to the specified torque.
Nozzle
(wet, 2-time tightening method) retaining nut
(3) Install the connector with nozzle tip to the nozzle tester. 216 ± 5 N·m
Lower retainer {22 ± 0.5 kgf·m}
Move the lever at a speed of one down stroke per one
[159 ± 3.7 lbf･ft]
second, and measure the injection starting pressure.
Distance piece
Item Nominal value Standard value Nozzle tip
Fuel injection start-

29.4 MPa 28.9 to 30.9 MPa Unit Injector Injection Starting Pressure Measurement
{300 kgf/cm2} {295 to 315 kgf/cm2} (MUI) - Prepare
ing pressure
[4264 psi] [4191 to 4482 psi]
Connector Fuel
(4) Select the shim thickness to adjust the injection starting
P/N: 48493-00100
pressure.
The pressure change to the shim thickness is shown
below Body
retaining nut
314 ± 10 N·m
Shim MUI valve open- ECUI nozzle Shim
{32 ± 1.0 kgf·m}
Thick- ing pressure opening pressure Spring seat [232 ± 7 lbf·ft]
Part number ness {kgf/ {kgf/
mm MPa cm2} MPa cm2} Nozzle
[in.] [psi] [psi] Spring cage
retaining nut
{-32.6} {-49.0} 216 ± 5 N·m
48742-00311 0.4 -3.19 -4.80 {22 ± 0.5 kgf·m}
[-463] [-696]
{-16.3} {-32.6} [159 ± 3.7 lbf･ft]
- 321 0.5 -1.60 -3.19
[-232] [-463] Lower retainer
0 (Stan- 0 (Stan- {-16.3} Distance piece
- 331 0.6 -1.60
dard) dard) [-232]
{16.3} 0 (Stan- 0 (Stan- Nozzle tip
- 341 0.7 1.60
[232] dard) dard)
Unit Injector Injection Starting Pressure Measurement
{32.6} {16.3}
- 351 0.8 3.19
[463]
1.60
[232]
(ECUI) - Prepare
{49.0} {32.6}
- 361 0.9 4.80
[696]
3.19
[463]
Nozzle tester
P/N:04239-00050
{65.3} {49.0}
- 371 1.0 6.40 4.80
[928] [696]
{81.6} {65.3}
- 381 1.1 8.00 6.40
[1160] [928]
{97.9} {81.6}
- 391 1.2 9.60 8.00
[1392] [1160]
(5) After the adjustment of the injection starting pressure

and all the inspections such as fuel spray as shown
below, assemble the unit injector.
Injection Starting Pressure - Measure
8-14
2.4.2 Fuel Spray - Inspect

When adjusting the nozzle opening pressure with the nozzle
tester, inspect the nozzle orifice clogging, fuel spray pattern
Good Faulty spray
and dripping. If the spray condition is faulty, clean or
replace the nozzle tip.
Checking points of the fuel spray are as follows:
Injection spray is straight.
Large After Intermittent Whirling
The spray is of fine fuel droplets without big drops. angle dribble spray spray
No dripping is shown after injection. spray
Fuel Spray - Inspect

2.4.3 Nozzle Spring - Inspect
Contact and wear of seat face Squareness
Cavitation and corrosion
Deformation and crack
Others
Item Standard value

Free length
Free length 27.6 mm [1.087 in.]
A
A = 0.65º or less B
Squareness B = 0.31 mm [0.0122 in.] or less at
Lf
Lf = 27.6 mm [1.087 in.]
Squareness and Free Length of Nozzle Spring -
Measure
25.8 mm [1.016 in.] / 489.6 to 612.4 N
Set length / load
{49.93 to 62.45 kgf} [110.07 to 137.67 lbf]
2.4.4 Lower Retainer - Inspect

Inspect the lower retainer visually. If its spring seat wears Uneven
unevenly, the needle valve contact surface wears remark- wear on spring
seat face
ably, or the cavitation occurs under the tapered area, replace
the lower retainer with a new one.
Cavitation
Needle valve
contact face wear
Lower Retainer - Inspect
2.4.5 Distance Piece - Inspect
Inspect the distance piece visually. If its needle valve con- High pressure seal face
tact surface or high pressure seal surface wears remarkably,
replace the distance piece with a new one.
Note: When the nozzle tip is replaced, replace the distance
piece and the nozzle spring with new ones.
High pressure
seal face Needle valve contact surface
ø6 mm [0.236 in.]
Distance Piece - Inspect
8-15
2.4.6 Spring Cage - Inspect

High pressure seal face
Contact of high pressure fuel sealing surface and fuel leak
Contact and wear of surface facing to outer circumferences
of spring and retainer
Contact, wear
MUI with spring ECUI
Spring Cage - Inspect
8-16
2.5 Unit Injector - Assemble
Nozzle tip
Lower retainer
Distance piece
Lower retainer
Needle valve spring
Spring cage
216 ± 5 N·m Spring seat
{22 ± 0.5 kgf·m} 216 ± 5 N·m
Shim
[159 ± 4 lbf･ft] {22 ± 0.5 kgf·m}
(wet, 2-time [159 ± 4 lbf･ft]
tightening method) (wet, 2-time tightening
method)
Spring cage
314 ± 10 N·m
{32 ± 1 kgf·m}
[232 ± 7 lbf·ft]
(wet, 2-time tightening
O-ring method)
314 ± 10 N·m
{32 ± 1 kgf·m}
[232 ± 7 lbf·ft]
(wet, 2-time tightening
method)
MUI ECUI
Unit Injector - Assemble
Be sure to tighten the retaining nut to the specified torque. The excessive tightening of retaining nut can harm
smooth movement of the needle valve and result in abnormal exhaust smoke or needle valve sticking.
Note: To assemble the unit injector, be sure to align the positioning dowel pins provided on many faces.
8-17
2.6 Feed Pump Drive - Disassemble and Inspect
6
Replace :O-Ring
Oil seal 7
4
3
Wear
1
5
10
11
12
Deformation,
crack, replace
2
Contact, wear
Key way wear Wear
Spline wear
Feed Pump Drive - Disassemble and Inspect

1 Oil seal case 5 Drive gear , Shaft assembly 9 Snap ring, Washer
2 Adapter shaft 6 Snap ring 10 Rubber
3 Oil seal 7 Ball bearing 11 Drive gear, Pin
4 Snap ring 8 Drive case 12 Drive shaft assembly
Note: The pin on drive gear, and the pin and ball bearing on drive shaft assembly are press fitted. Do not disassemble these parts
unless necessary.
8-18
2.7 Feed Pump Drive - Assemble

(1) Press in the pin to be flush with the drive gear.
(2) Drive shaft assembling. rubber (4 pieces)
Press in the gear side ball bearing and install pins to the
dive shaft.
(3) Assembling of drive gear assembly
Press in the drive gear to the outer race of ball bear- Pin
Pin (Drive gear)
ing installed on the drive shaft assembly. (Drive shaft)
Drive shaft
Insert new rubber between the shaft and pin and hold
with the washer and snap ring.
(4) Press in two ball bearings and hold with the snap ring.
(5) Insert the drive gear assembly shaft into the drive case
and hold with the snap ring.
Drive gear Drive case

5.5
Oil seal Case
Adapter shaft
Feed Pump Drive - Assemble and Install

2.8 Feed Pump Drive - Install
(1) Connect the feed pump shaft and adapter shaft through
the woodruff key.
Place the adapter shaft end at a position 5.5 mm from
the feed pump, and finger tighten the set screw.
(2) Install the feed pump with adapter to the oil seal case
and hand tighten the bolts.
Note: Chack that the adapter shaft and oil seal are to be nor-
mal.
(3) Inserting the prallel spline at the end of adapter shaft
into the drive shaft, assemble the drive case and oil seal
case.
(4) Check the adapter shaft visually through the oil case
inspection window and velify that the drive gear rotates
lightly.
(5) Tighten the set screw and mounting bolts to the specifi-
cation.
8-19
2.9 Governor Drive (MUI) - Disassemble and Inspect
Replace: O-ring 1
Packing
12
Bearing wear 4
10
Contact, wear
11
9
7 5
8
6
Wear at needle bearing sliding face,
governor serration
Deformation, crack, replace
Needle bearing wear
Governor Drive (MUI) - Disassemble and Inspect

1 Seal cap 7 Drive gear
2 Snap ring 8 Needle bearing
3 Idler shaft assembly 9 Rubber
4 Plate 10 Snap ring
5 Drive gear assembly 11 Ball bearing
6 Snap ring, Washer 12 Drive case
Note:(a) To disassemble the idler shaft assembly from the drive case, dislocate the snap ring through the opening of idler gear,
push the shaft end from the seal cap side.
Snap ring is hold freely between the gear and ball bearing.
(b) The ball bearings are press-fit and the gear is shrinkage fit to the idler shaft assembly. Do not disassemble the assembly
unless necessary.
(c) The pin and (ball and needle) bearings are press-fit to the drive gear assembly. Do not disassemble unless necessary.
8-20
2.10 Governor Drive - Assemble
O-ring Drive case

Ball bearing
Idler gear
Snap ring
(Hold with pliers
through gear hole.)
Seal cap
Idler shaft
Pin (shaft side) Washer
Snap ring
Needle bearing
Pin (shaft side)

Drive shaft
Snap ring
Washer
Drive gear
Stud bolt
Rubber
Plate
Snap ring
Fuel Injection Nozzle - Disassemble and Ispect

Disassembling Sequence
1 Set screw, sealing washer 6 Nozzle tip
2 Cap nut, sealing washer 7 Spacer
3 Adjusting screw 8 Push rod, nozzle spring, spring seat
4 O-ring 9 O-ring
5 Retaining nut 10 Nozzle holder
Note: Nozzle tip, spacer, and nozzle spring must be replaced with new ones as a set.
8-21
2.11 Check Valve - Disassemble, Inspect and Assemble
Replace: O-ring
Seal washer
Deformation, break
1 6 3 4
2 5
Ball
wear, leak
Seat
wear, leak
56 ± 6 N·m
14.7 mm [0.0102in.] {5.7 ± 0.6 kgf·m}
(ID mark F3) [41.3 ± 4.4 lbf·ft] 34 ± 4 N·m
{3.5 ± 0.4 kgf·m}
[25.08 ± 2.95 lbf·ft]
Check Valve - Disassemble, Inspect and Assemble

1 Self lock nut 4 Valve spring
2 Screw 5 Ball valve
3 O-ring 6 Valve body
2.11.1 Valve Opening Pressure - Inspect and Adjust
(1) Attach a pressure gauge to the fuel pipe. Press feed the
fuel and measure the valve opening pressure.
Item Nominal value Standard value

0.49 MPa 0.49±0.025 MPa
Valve opening pressure {5.0 kgf/cm2} {5.0±0.25 kgf/cm2}
[71.07 psi] [71.07 to 3.6 psi]
(2) If the opening pressure is out of the standard, adjust

with the screw or replace with a new one.
Note: If the fuel leaks between the ball and seat or the pres-
sure decreases significantly, replace the check valve
assembly with a new one.
8-22
3. Fuel System - Install

Install the parts in the reverse order of the disassemble sequence. (Refer to the illustration for disassembling.)
Clean and dry well the fuel passages.
3.1 Unit injector
Refer to the section "Cylinder Head and Valve Mechanism - Assemble" in "BASE ENGINE - ASSEMBLE."
3.2 Governor and Actuator (MUI)

Refer to the section "Governor and Actuator (MUI) - Remove and Inspect."
3.3 Control Device (MUI)

3.3.1 Shaft and Link of Each Cylinder - Install
Refer to the section "Cylinder Head and Valve Mechanism - Assemble" in "BASE ENGINE - ASSEMBLE."
3.3.2 Right-and-Left Control Shaft - Install

Standard specification
Pipe
(1) Insert the pipe with O-ring into the timing gear case
from right to left.
(2) Install the ball bearing and cover to the timing gear case
left side.
(3) Insert the right-and-left connecting shaft through the
Right-and-left
pipe from right to left and press into the left side ball connecting shaft
O-ring
bearing.
Cover
(4) Press in the ball bearing to the timing gear case right
Control Shaft (Left Side) - Install
side and install the cover and stopper bracket. Thighten
them together with locking wire bolts.
Pipe
Actuator PROACT specification
(1) Insert the pipe with O-ring into the timing gear case
from right to left.
(2) Install the ball bearing and cover to the timing gear case
left side.
(3) Screw in the stud bolt (thread lock applied) to the tim-
ORing Right-and-left
ing gear right side and tighten to the specified torque. connecting shaft
Cover
(4) Insert the right-and-left connecting shaft through the
pipe from right to left and press into the left side ball Standard Control Shaft (Right Side) - Install
bearing.
6.7 ± 0.6 N·m 20 ± 1.0 N·m
(5) Press in the ball bearing to the timing gear case right {0.68 ± 0.06 kgf·m} {2.0±0.1 kgf·m}
[4.94 ± 0.44 lbf·ft] [14.8±0.74 lbf·ft]
side and install the cover and stopper bracket. Thighten 17 ± 1.7 N·m
{1.73 ± 0.17 kgf·m}
them together with tamper-proof nuts.
[12.5 ± 1.3 lbf·ft]
Tighten the tamper-proof nut to the specified torque and
verify the free spining of outer nut. Tighten the self-
locking nut to fix.
Self lock nut
Tamper-proof nut
PROACT 2 Control Shaft - Install
(Right Side)
8-23
3.3.3 Rack Scale - Adjust

(1) Connect the left side lever and the fixed length link to Link Rack set jig
(fixed-length) Right-and-left P/N: 35B91-03010
the control shaft, and fix the rotation angle of shaft with connecting shaft
the rack set jig.
(2) Adjust the rack scale to "0" on left bank unit injectors
(No.7 through No.12) with each cancel rod.
(3) Connect the right side lever and adjustable link to the
control shaft. Adjust the rack scale to "0" on right bank
unit injectors (No.1 through No.6). 7
8
9
First, adjust the adjustable link length to bring the rack

5
Lever
3
scale to almost "0" on all right bank cylinders. Then

finely adjust with each cancel rod.
Cylinder connecting control shaft
(4) Remove rack set jig.
Left side Rear side
(5) Rotate the control shaft. Verify the smooth movement
Left Side Lever and Link Connection
of each unit injector rack from the "0" position to the Rack Set Jig - Install
maximum. Readjust if necessary.
Note:(a) The protrusion of each cancel rod thread is approx
7mm.
(b) The turning effort of actuator lever to move the Rack position
whole control link is 19.6 N {2 kgf} [4.41 lbf] at the De- Increase
crease
position 75 mm [2.95 in.] from the lever rotation
center.
(c) Screw in the ball joints evenly to the both ends
Approx
(right and left hand threads)of adjustable length 7 mm
[0.276 in.]
link.
Cancel rod
Rack "0" positon - Adjust
Lever
Link (adjustable length)
Lever
OP
ST
Cylinder connecting control shaft

Right Side Rear side
Right Side Lever and Link Connection
8-24
3.3.4 Governor/Actuator and Link - Connect and Cancel lever A 45°

Adjust STO
P
(1) Install the governor lever referring to the angle in illus-

Cancel lever B
tration placing the governor/actuator output to "0" (no
Link (adjustable length)
injection) position.
(2) Install the lever or cancel lever to the right-and-left con-
trol shaft, and insrtall the stop lever.
Horizontal
Cancel lever specification
Install the ball bearing and snap ring to the cancel lever
Governor lever
B. Press in the lever to the controll shaft and install the
Governor Lever and Link - Install (PSG and EG3P)
spacer.
Install the cancel lever A to the control shaft aliginig its Lever SG4030 10°
Angle
serration to bring the cancel lever B angle as shown in DYNA Standard 10°
the illustration when the unit injector rack scale shows 8200 1800 min-1 Horizontal
"0". Link
ST
OP
(adjustable length)
(3) Place the unit injector rack to "0", the governor actuator
Actuator lever
output shaft to "0", and install the adjustable length
link.
Note: Screw in the ball joints evenly to the both ends (right
and left hand threads)of adjustable length link.
(4) Adjust the adjustable length link to bring the unit injec- Governor Lever and Link - Install
tor rack scale to be "0.5" when the governor/actuator (SG4030, DYNA8200)
position is "0". Lever
STO
P
Link
(adjustable length)
Actuator
lever
51°
Governor Lever and Link - Install

(DYNA8200 1500 min-1 Specification)
Lever
Link
(adjustable length)
ST
OP
Actuator
lever
25°
Governor Lever and Link - Install

(PROACT)
8-25
3.4 Solenoid - Install

3.4.1 Stop Solenoid - Install and Adjust
(1) Install the stop solenoid to the right side of timing gear Stop lever
End plate
case.
Bracket
(2) Assemble the stoper lever assembly and install it to the
bracket.
(3) Install the stop solenoid to the bracket and connect to
the stop lever through the adjustable length link.
Note: The installing positions differ depending on the sole- Snap ring
noid specification (RUN ON or RUN OFF). Ball bearing
(4) Stop Solenoid - Adjust
Stop Lever Assembly - Install
RUN ON Specification
In the not-excited (engine stop) conditioon, adjust the 1 mm [0.04 in.]
clearance between the stop lever and follower to 1mm
[0.039 in.] when the actuator output shaft position is
"0".
RUN OFF Specification
In the excited (engine stop) conditioon, adjust the clear-
ance between the stop lever and follower to 1mm Follower OP
ST
[0.039 in.] when the actuator output shaft position is

Stop lever assembly
"0".
Note:The excited condition can be simulated by pushing
Stop
the solenoid shaft strongly by hand.
Run OFF
Stop Solenoid - Install and Adjust (RUN ON)
1 mm [0.04 in.]
STO
P
Stop lever
Follower
assembly
Stop
Run ON
Stop Solenoid - Install and Adjust (RUN OFF)
8-26
3.4.2 Rack Control Solenoid - Install and Adjust

.]
RUN ON Specification in
. 18
(1) Install the rack control solenoid bracket to the left upper [1
m
m
side of timing gear case. 30
t to
(2) Assemble the lever assembly and install it to the us
j
bracket. Ad op
St Lever assembly
Note: The part construction is the same to the illustration
Link
"Stopper Lever Assembly - Install." (adjustable length)
(3) Install the rack control solenoid to the bracket, and con-
Control lever Crevice
nect the solenoid and the lever with the link adjusted to
the dimention as shown in the illustration.
(4) Connect the lever assembly and the control lever
through the adjustable length link and crevice.
(5) Adjustment of rack control solenoid
In the not-excited (rack controled) condition, adjust the
link length to 14 mm [0.55 in.] by moving the control Rack Control Solenoid - Install and Adjust (RUN ON)
lever to rack increase direction.
RUN OFF Specification
(1) Install the rack control solenoid bracket to the left upper
side of timing gear case.
(2) Install the rack control solenoid to the bracket and con-
nect to the control lever through the adjustable length Stop
link and crevice.
(3) Adjustment of rack control solenoid
In the excited (rack controled) condition, adjust the link
length to 14 mm [0.55 in.] by moving the control lever
to rack increase direction.
Rack Control Solenoid - Install and Adjust (RUN OFF)
8-27
1. Lubrication System - Remove and Inspect ........................................................... 9-3
1.1 Oil Pipes (Turbocharger and Fan Drive) - Remove and Inspect............................................... 9-3
1.2 Breather and Filler - Remove.................................................................................................... 9-4
1.3 Oil Filter and Oil Cooler - Remove............................................................................................ 9-5
1.4 Oil Pan, Oil Pump, Relief valve - Remove ................................................................................ 9-6
2. Lubrication System - Disassemble, Inspect and Assemble ................................ 9-7
2.1 Oil pump - Disassemble and Inspect ........................................................................................ 9-7
2.2 Oil Pump and Safety Valve - Inspect ........................................................................................ 9-8
2.3 Oil pump - Assemble .............................................................................................................. 9-10
2.4 Relief Valve - Disassemble, Inspect and Assemble ............................................................... 9-10
2.5 Oil Filter - Disassemble and Inspect ....................................................................................... 9-11
2.6 Oil Filter - Inspect.................................................................................................................... 9-11
2.7 Cartridge Filter - Install ........................................................................................................... 9-11
2.8 Governor Oil Filter (MUI) - Disassemble, Inspect and Assemble ........................................... 9-12
2.9 Oil Filter Alarm - Inspect ......................................................................................................... 9-12
2.10 Oil Cooler - Disassemble and Inspect .................................................................................... 9-13
3. Lubrication System - Install.................................................................................. 9-14
3.1 Oil Pump - Install .................................................................................................................... 9-14
3.2 Oil Pan - Install ....................................................................................................................... 9-14
9-1
1. Lubrication System - Remove and Inspect

1.1 Oil Pipes (Turbocharger and Fan Drive) - Remove and Inspect
Replace: O-ring
Packing
2
3
Timing
gear case
Crankcase
2
3 6
Fan drive
bracket
Idler
1
shaft
Crankcase
5
A
Crankcase 4
A
Front gear case
Oil Pipes (Turbocharger and Fan Drive) - Remove and Inspect

Removing sequence
1 Turbcharger lubrication pipe 4 Fan bracket lubrication pipes
2 Turbcharger lubrication pipes (F/R) 5 Fan bracket drain pipe (flexible)
3 Turbocharger drain pipes (F/R) 6 Fan idler gear lubrication pipe
9-3
1.2 Breather and Filler - Remove
1
Replace: Packing
2
No.7 8
MGS
No.7
Front breather speck
4
2
Rear breather spec

Breather and Filler - Remove
Removing sequence
1 Breather 4 Side cover 7 Filler pipe
2 Filler cap 5 Breather pipe 8 Cover
3 Oil filler 6 Stay
9-4
1.3 Oil Filter and Oil Cooler - Remove
5
4
Lifting eye bolt

Mounting bolt
M10 × 1.5
7
6
Hydraulic governor spec
1
2 1
Replace: O-ring
Woodward PSG type and EG-3P type governors ‫ޓޓޓ‬Packing
Oil Filter and Oil Cooler - Remove

Removing sequence
1 Oil filter assembly 5 Oil cooler inlet connector
2 Bypass oil filter assembly 6 Oil cooler outlet connector
3 Spacer 7 Oil cooler assembly (Approx 39 kg [86 lb])
4 Governor oil filter assembly
9-5
1.4 Oil Pan, Oil Pump, Relief valve - Remove
Replace: O-ring
Packing
Crankcase
installing face
10
8
Adapter
1
9 Timing
Gear case
Clogging, crack
2 Clean 4
Front
Gear case
3 5
6
Oil pump
Oil Pan, Oil Pump, Relief valve - Remove

Removing sequence
1 Oil pipe (oil cooler outlet) 6 Level gauge
2 Connector 7 Oil pan (Approx 70 kg [154 lb])
3 Relief valve assembly 8 Stay
4 Oil pipe (oil pump outlet) 9 Oil strainer
5 Connector 10 Oil pump assembly (Approx 33 kg [73 lb])
9-6
2. Lubrication System - Disassemble, Inspect and Assemble

2.1 Oil pump - Disassemble and Inspect
Contact and wear of gear teeth 1
6
Crack, flaw
Bushing flaw, wear
Contact and wear

of gear teeth 4
Bushing flaw, wear 3

Contact, wear
2
Contact, wear
Deformation, wear, crack
Gear sliding face contact, wear
Oil pump - Disassemble and Inspect

1 Pump drive gear 3 Pump gear (driven side) 5 Safety valve assembly
2 Pump cover 4 Pump gear (drive side) 6 Pump case
Note:(a) The pump dive gear and pump gear (drive side) are press-fit to the shaft. Do not disassemble unless necessary.
(b) The bushings are press-fit to the cover. Do not disassemble uncless necessary.
(c) The bushing inside diameter must be finished after fitting the busing and assembling the cover and case.
If the machining is not available, the replacement of case assembly is recommended.
The procedure to replace inevitably the bushing only is described later.
9-7
2.2 Oil Pump and Safety Valve - Inspect

2.2.1 Top Clearance Between the Gear Teeth and
Case - Measure
Measure the top clearance between drive and driven gear
teeth and case housing. If the value exceeds the limit,
replace the gear or the case with a new one.

Top clearance between gear 0.095 to 0.14 mm 0.2 mm
teeth and case [0.0037 to 0.0055 in.] [0.0079 in.]
Top Clearance Between the Gear Teeth and Case -

Measure
2.2.2 Side Clearance Between Gear Width and Case
- Measure
Measure the side clearance between the gear width and case
depth. If the value exceeds the limit, replace the gear or the
case with a new one.

Side clearance between gear 0.095 to 0.155 mm 0.25 mm
width and case face [0.0037 to 0.0061 in.] [0.0098 in.]
Side Clearance Between Gear Width and Case -

Measure
9-8
2.2.3 Gear Shaft Diameter and Bushing Inside Diam-

eter - Measure
Item
Nominal
Standard value Limit value
2
value Bushing press-in
depth
ø40 mm 40.000 to 40.016 mm 39.930 mm
Shaft diameter
[ø1.57 in.] [1.5748 to 1.5754 in.] [1.5720 in.]
68.137
Bushing inside ø40 mm 40.040 to 40.059 mm 40.140 mm
diameter [ø1.57 in.] [1.5764 to 1.5771 in.] [1.5803 in.] Y Z
2.2.4 Bushing - Replace +0.04

ø40 +0.059
(1) Remove all the bushings to the inside of case and cover.
Note: The inside faces of the bushings are machined as one
body. Replace all the bushings in one time.
(2) Press in the bushing to be flush with the case or cover Bushing puller (only to press-in)
P/N: MH061059
using the push-in end of bushing puller.
Bushings - Machine as One Body
The positions of oil holes and oil grooves are as shown
in the illutration.
(3) Furthermore, lower idler bushing end face 2 mm [0.08
in.] with removal side of the idler bushing puller. Place bushing
oil holes here.
(4) Assemble the case and cover aligning with the dwel
OUT IN IN OUT
pin. Machine the bushing inside diameter to the speci- Bushing oil grooves
fied value. (Axial direction)
At marked
positions)
( 8 places)
Nominal
Item Standard value
value View arrow Z
View aroow Y (Bushing press-in (Bushing press-in position
ø40 mm 40.040 to 40.059 mm position on case side) on cover side)
Bushing inside diameter
[ø1.57 in.] [1.5764 to 1.5771 in.]
Installation Positions of Bushings
Center distance 68.137 mm [2.6826 in.]
Coaxiality < ø 0.05 mm [0.0020 in.]
Squareness < ø 0.02 mm [0.0008 in.]
Surface roughness Ra 0.2μm [8μin.]
2.2.5 Safety Valve - Inspect

Shim Flaw on
t 2.6 mm sliding face
Item Standard value [0.1024 in.]
1.4±0.1 MPa
Valve opening pressure
{14±1.0 kgf/cm2} [203±14.5 psi]
Valve
Free length 93.7 to 94.3
A = 2.0º or less A
B = 3.3 mm [0.13 in.] B
Squareness
Spring or less Lf
Plug tightening torque
Lf = 94 mm [3.70 in.]
196 ± 20 N·m
Deformation, Contact and wear
73.4/902 to 1040 mm {20 ± 2 kgf·m}
Set length/load break [144.7 ± 14.5 lbf·ft] of seat face
{92 to 106 kgf}
Safety Valve - Inspect and Assemble
Shim adjust the valve opening pressure to the specification.
Use shims up to two pieces.
9-9
2.3 Oil pump - Assemble

(1) Install the pump gear (drive and driven) into the pump
34 to 74 N·m
case, and tighten the cover mounting bolts to the speci- {3.5 to 7.5 k·f·m}
Pump drive gear
fied torque. [25 to 55 lbf·ft]
Verify the gear pump smooth rotation.

(2) Press in the pump drive gear to be flush with the pump Gear pump Cover
(Drive side)
drive shaft.
(3) Install the safety valve, spring and shim, and tighten the Flush Gear pump
bolts to the specified torque. (Driven side)
Case
Oil Pump - Assemble
2.4 Relief Valve - Disassemble, Inspect and Assemble
Nominal
Item Standard value Limit value Spring deformation, Flaw on sliding face
value
break
Free 115 mm
Pilot hole
length [4.53 in.] Replace: O-ring
clogging
Spring Set 92 mm / 354 N
length {92 mm / 36.1 kgf}
/ load [3.62 in. / 79.6 lbf]
0.58 MPa ±0.05 MPa
Valve opening
{5.9 kgf/cm2} {±0.5 kgf/cm2}
pressure
[84.1 psi] [±7.25 psi]
0.58 MPa 0.53 to 0.63 MPa 0.39 MPa Plug
Engine Rat- {5.9 kgf/cm2} {5.4 to 6.4 kgf/cm2} {4.0 kgf/cm2}
oil- ing Sleeve Relief valve
[84.1 psi] [76.9 to 91.4 psi] [56.6 psi]
pres- Relief Valve - Disassemble, Inspect and Assemble
sure 0.25 MPa 0.20 to 0.30 MPa 0.10 MPa
(warm) Idling {2.5 kgf/cm2} {2.0 to 3.0 kgf/cm2} {1 kgf/cm2}
[36.3 psi] [29 to 42 psi] [14.5 psi]
Measure the main gallery oil pressure to inspect the valve R1/8
opening pressure when the engine is running and the oil is
warm.
If the pressure is out of the standard value, inspect the
causal part and replace.
Note: The cause of the abnormal pressure may be caused by
a part other than the relief valve.
Main Gallery Oil Pressure - Measure
9-10
2.5 Oil Filter - Disassemble and Inspect
6
Use filter wrench only to loosen.
Filter wrench
2
Clogging, deformation,
crack
Replace: O-ring, Seal washer Clogging, deformation,

‫ޓޓޓ‬Cartridge filter crack
1
Oil Filter - Disassemble and Inspect

1 Oil filter 3 Filter alarm 5 Bypass filter bracket
2 Bypass oil filter 4 Oil filter bracket 6 Spacer
2.6 Oil Filter - Inspect
When replacing the oil filter, sample the oil (500 ml [0.13
US gal]) and check for metal and other particles. If metal or
other particles are found, cut and unfold the element, and
inspect the color and shape of metal particles trapped in ele-
ment to identify the cause.
Oil Filter - Inspect

2.7 Cartridge Filter - Install
(a) When installing the cartridge filter, do not use a filter wrench. Tighten it by hand.
(b) Do not deform or damage the cartridge filter surface.
(1) Clean the mounting surface of the filter.
(2) Apply clean oil on the filter gasket.
(3) After the filter gasket contacts with the base surface, tighten the filter by 3/4 to 1 turn by hand.
Note: For the prevention of cartridge filter damage, install the filter after the maintenance job and immediately before the test
operation.
9-11
2.8 Governor Oil Filter (MUI) - Disassemble, Inspect and Assemble
Replace: Packing 9.8 ± 2 N·m

{1 ± 0.2 kgf·m} 6
Seal washer
Element [7.24 ± 1.45 lbf·ft]
Clogging, break
3
5
Deformation, crack
1 4
9.8 ± 2 N·m 34.3 ± 6.9 N·m

{1 ± 0.2 kgf·m} {3.5 ± 0.7 kgf·m}
[7.23 ± 1.48 lbf·ft] 2 [25.30 ± 5.09 lbf·ft]
Governor Oil Filter (MUI) - Disassemble, Inspect and Assemble
1 Drain plug 3 Element 5 Case
2 Center bolt 4 Spring, Seat 6 Cover
Do not deform or damage the filter case surface.

Note: Supply new oil through the bleeder plug after replacing the element. This will allow a quick response of the governor at
the initial start-up without air bleeding.
2.9 Oil Filter Alarm - Inspect
(1) Use a tester to check the alarm for insulation and conti-
nuity. If the alarm is defective, disassemble and repair.
If the bakelite or rubber insulations are deteriorated or
Filter inlet
damaged, replace the alarm.
pressure
(2) If the filter alarm activation pressure is out of the stan-
dard, replace the alarm with a new one.
Item Nominal value Standard value Filter

outlet pressure
Glow start pressure

0.15 MPa 0.15
+0.03
+0.3
0 MPa Ω
{1.5 kgf/cm2} {1.5 0 kgf/cm2}
(differential pressure)
[22 psi] +4
[22 0 psi] Oil Filter Alarm - Inspect
Note: If a defect is shown, replace the assembly without dis-

assembling.
9-12
2.10 Oil Cooler - Disassemble and Inspect
Replace: O-ring 1
Packing 39.2 ± 5 N·m 4 24.5 ± 5 N·m
{4.0 ± 0.5 kgf·m} {2.5 ± 0.5 kgf·m}
[28.9 ± 3.7 lbf·ft] [18.1 ± 3.7 lbf·ft]
Clogging, deformation, crack
Oil Cooler - Disassemble and Inspect

1 Pipe 2 Bypass valve 3 Element 4 Cover
2.10.1 Element-Inspect
Air
Apply pressurized air to the oil passage of element. Leak check 1.47 MPa
Check the air leak. ]15 kgfEm2_
Element - Inspect
2.10.2 Bypass Valve - Inspect
Flaw on Replace: O-ring Valve case
Nominal sliding face
Item Standard value
value
Free length 66.5
Spring 54.1 mm/ 145 N

set length / load {54.1 mm / 14.8 kgf}
[2.13 in. / 32.6 lbf]
0.44 MPa ±0.05 MPa
Valve opening pressure {4.5 kgf/cm2} {±0.5 kgf/cm2}
[63.82 psi] [±7.25 psi] Valve
Spring deformation, break
Snap ring
Bypass Valve - Inspect
9-13
3. Lubrication System - Install

Thoroughly clean and dry the oil passage.
3.1 Oil Pump - Install
(1) Install the oil pump assembly to the crankcase.
(2) Measure the backlash between crankshaft gear and oil
pump drive gear and shim adjust.
Shim t=0.1 mm
[0.0039 in.]
Item Nominal value Standard value Stay P/N: 35B35-00900
Bbacklash 0.11 to 0.26 mm [0.0043 to 0.0102 in.] Strainer 59 ± 5.9 N·m
{6 ± 0.6 kgf·m}
(3) Install the strainer pipe to the oil pump inlet and secure [44 ± 4.4 lbfft]
with the stay.
Backlash
Oil pump 0.11 to 0.26 mm
assembly [0.0043 to 0.0102 in.]
Oil pump - Install and Backlash - Adjust
3.2 Oil Pan - Install
(1) Apply liquid gasket (ThreeBond 1211 or equivalent) to
Front plate Rear plate
joints (4 places) of front and rear plates at crankcase
bottom face.
(2) Apply liquid gasket (ThreeBond 1211 or equivalent) to
joints (4 places) of the oil packing and place it on the Timing
Crankcase gear case
oil pan upper face. Liquid gasket
apply.
(3) Install the oil pan to the crankcase.
(4) Insert the connector into the opening at right rear posi-
Front Packing
tion of the oil pan, and connect it to the oil pump outlet.
gear case
Crankcase
Liquid Gasket on Oil Pan - Apply
39 ± 3.9 N·m
{4 ± 0.4 kgf·m}
[29 ± 2.9 lbf·ft] Connector
Oil Pan - Install
9-14
1. Cooling System - Remove and Inspect ............................................................... 10-3
1.1 Fan and Fan Drive - Remove and Inspect.............................................................................. 10-3
1.2 Waterpump, Thermostat and Water Pipe - Remove and Inspect ........................................... 10-4
2. Cooling System - Disassemble, Inspect and Assemble .................................... 10-6
2.1 Fan Drive - Disassemble, Inspect and Assemble ................................................................... 10-6
2.2 Water pump - Disassemble and Inspect................................................................................. 10-7
2.3 Water pump - Assemble ....................................................................................................... 10-10
2.4 Air cooler Water pump - Disassemble and Inspect............................................................... 10-13
2.5 Air cooler water pump - Assemble........................................................................................ 10-15
2.6 Thermostat Operation - Inspect ............................................................................................ 10-16
3. Cooling System - Install ...................................................................................... 10-17
3.1 Water pump Installing Position - Inspect .............................................................................. 10-17
3.2 Water pump for Air cooler..................................................................................................... 10-19
10-1
1. Cooling System - Remove and Inspect

1.1 Fan and Fan Drive - Remove and Inspect
Adapter
4
Deformation, crack
1
Wear, crack
Fan and Fan Drive - Remove and Inspect

Removing sequence
1 Fan (approx 50 to 80 kg [110 to 176 lb] depending on spec- 3 Fan belt
ification) 4 Fan pulley, Bracket assembly (approx 45 kg [99 lb])
2 Spacer
Note: Loosen, not remove, the bracket installing bolts to remove the fan belt. Then, loosen the push bolt under the barcket to
lower the bracket assembly.
10-3
1.2 Waterpump, Thermostat and Water Pipe - Remove and Inspect
Standard spec
Replace: O-ring 5
Packing
5
Air cooler (RH)
Timing gear case

7
Air cooler (RH)
7
8
Air cooler (LH)
10
6
6
4
10 Adapter
Ribbed belt spec ‫ޓ‬
1
1
Front gear case
3
Waterpump, Thermostat and Water Pipe - Remove and Inspect
Removing sequence
1 Pulley 6 Air cooler outlet pipes (right and left)
2 Bypass pipes (right and left) 7 Outlet pipes (right and left)
3 Water pump assembly 8 Thermostat assembly
4 Water pump outlet pipe 9 Stay
5 Air cooler inlet pipes (right and left) 10 Thermostat
10-4
PTAW (ECUI) spec

Replace: O-ring
1
7
8
Air cooler (RH)

2
Air cooler (LH)
5
Waterpump, Thermostat and Water Pipe - Remove and Inspect
Removing sequence
1 Water pump outlet pipe 5 Water pump assembly
2 Air cooler inlet pipes (right and left) 6 Bracket
3 Air cooler outlet pipes (right and left) 7 Thermostat assembly
4 Bypass pipes 8 Thermostat
10-5
2. Cooling System - Disassemble, Inspect and Assemble

2.1 Fan Drive - Disassemble, Inspect and Assemble
Replace: O-ring
Oil seal 2
392 ± 39 N·m Oil leak from

{40 ± 4.0 kgf·m} seal cap
[88 ± 8.8 lbf·ft]
Bearing wear
Wear of sleeve contact

face to oil seal
3 6
4 Belt tension
adjusting bolt
Fan Drive - Disassemble, Inspect and Assemble

1 Cap nut 3 Oil seal 5 Shaft, Bearing
2 Fan pulley assembly 4 Snap ring 6 Bracket
2.1.1 Sleeve - Inspect and Replace
Replace the sleeve if its chromeplating contacting to the oil
seal is weared.
(1) Cut or pry out the sleeve.
(2) Press in a new sleeve to be flush with the pulley.
Make flush
Interference Sleeve
0.016 to 0.073
Sleeve on Fan Pulley - Press-In
10-6
2.2 Water pump - Disassemble and Inspect
Replace: 㧻-ring 10
‫ޓޓ‬ Oil sea 11
Unit seal Wear 7
Rust, wear (at oil seal) 12
Wear 5
4 1
2
8
13
15
Corrosion, contact flaw
14 Wear flaw, water leak
Water pump - Disassemble and Inspect

1 Snap ring 6 Gear 11 Ball bearing
2 Cover 7 Snap ring 12 Shaft
3 Impeller 8 Ring for unit seal (rotational) 13 Unit seal
4 Sleeve 9 Shaft, Bearing set 14 Oil seal
5 Ball bearing 10 Snap ring 15 Pump case (weight: approx 28kg [62 lb])
10-7
2.2.1 Water pump Mounted on Engine - Inspect

Visually check the drain port at the bottom center of water
pump case with a finger.If water is oozing out, the unit seal
is defective, and if oil is oozing out, the oil seal is defective.
Water pump Mounted on Engine - Inspect

2.2.2 Impeller - Remove
Cover
(1) Remove the snap ring that holds the cover with water Snap ring pliers
pump pliers, and remove the cover. P/N:37591-03100
Snap ring
Water pump Cover - Remove

(2) Remove the impeller with impeller remover.
Impeller remover Impeller
P/N:37591-03200
Shaft
M10×1.5
Impeller - Remove
10-8
2.2.3 Water pump Shaft - Remove

(1) Remove the oil seal sleeve.
Gear puller
(2) Remove the gear and ball bearing together with a gear
puller.
(3) Remove the ball bearing snap ring on the water pump
impeller side.
(4) Insert the two half rings of ring remover between the
unit seal ring and the water pump case as shown in the
illustration.
(5) Install the outer ring to hold the half rings in the posi-
Water pump Gear - Remove
tion.
(6) Push the impeller end face of water pump shaft with a Ring remover Press
hand press, remove the unit seal ring from the shaft. P/N:37791-03400 Ring for unit seal
Inner (half)
Outer
Water pump Shaft - Remove
10-9
2.3 Water pump - Assemble
O-ring e
ranc
Clea 0.46 mm 1 in.]
± 8
1.04 9 ± 0.01 O-ring Apply engine oil to
. 0 4 0
[0 oil seal lip.
Pres-inn the oil O-ring
seat to be flush
with the case
face. Place 30°chamfer
to nut side.
Shaft and impeller
are flush.
80 ± 0.15 mm
[3.150 ± 0.0059 in.]
Apply sealant (Sealend

No. 7 or equivalent) to Thread of water check hole
threads. Torque 22.5 ± 2.25 N·m
{2.29 ± 0.23 kgf·m}
[16.60 ± 1.66 lbf·ft]
Apply thread lock
(Locktite #271 or equivalent).
Apply LLC to sliding faces between Apply liquid sealant (ThreeBond 1102
the cup perphery of rotary unit seal or equivalent) to the periphery of unit
and the mating ring. seal fixed side.
Water pump - Assemble
10-10
2.3.1 Oil Seal - Install

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

2.3.2 Unit Seal (Stationary Side) - Install
unit seal Installer
(1) Apply sealant (ThreeBond 1102) to the outer circum- Installer
P/N: 37191-06300
ference of unit seal (stationary side.)
(2) Tap-in the unit seal into the water pump case with the
unit seal installer.
Apply sealant.
Unit Seal (Stationary Side) - Install

2.3.3 Water pump Shaft - Install
When installing the water pump shaft, be careful not

to damage the oil seal and unit seal (stationary side)
inside the pump case with the shaft.
(1) Press-in the impeller ball bearing to the water pump

shaft.
(2) Press-in the water pump shaft slowly into pump case
until the end of ball bearing comes into contact with
pump case. Water pump Shaft - Install
(3) Securely install the snap ring to groove.
2.3.4 Unit seal ring and unit seal (rotating side) -

Shaft
Install
[3.15 ± 0.006 in.]
80 ± 0.15 mm
(1) Set the unit seal (rotating side) to the unit seal ring.
(2) Apply LLC to the unit seal (rotating side.) Ring installer
P/N: 37791-03300
(3) Press-in the unit seal with the installer and press, slowly
install the unit seal ring to the specified position.
Unit seal
Unit seal ring
(rotation side)
Unit seal ring and unit seal (rotating side) - Install
10-11
2.3.5 Oil Seal Sleeve - Install

(1) Insert the O-ring to the oil seal sleeve.
Sleeve
(2) With the chamfered edge on the outer periphery of 30º chamfer
sleeve facing outward (pulley side), install the oil seal Ball bearing
sleeve into the pump shaft.
Drive gear
Oil Seal Sleeve - Install

2.3.6 water pump impeller - Press-In
Press in the water pump impeller with a press tool. Place the Flush
water pump impeller boss face to be flush with the end face Impeller
of pump shaft.
Shaft
Nominal
Item Standard value
value
0 mm91 in.]
to 1.5 5
1.04 mm 0.58 to 1.50 mm 0.58 28 to 0.0
Impeller front clearance [0.02
[0.0409 in.] [0.0228 to 0.0591 in.]
Water Pump Impeller - Install
10-12
2.4 Air cooler Water pump - Disassemble and Inspect
PTAW spec
2
3
4
Corrosion, flaw
11
Replace
Replace
Wear, seal plate flaw
Corrosion, crack, flaw 10 7

5
1
6 9 8
Wear
Wear, flaw
Water pump for Air cooler - Disassemble and Inspect

1 Pulley 7 Ball bearing
2 Snap ring 8 Spacer
3 Cover 9 Ball bearing
4 Impeller 10 Unit seal (cassette type)
5 Snap ring 11 Case
6 Shaft, Ball bearing assembly
10-13
2.4.1 Pump Assembled to Engine - Inspect

Touch the drain pipe at the bottom of pump case. If water is
oozing out, the unit seal is defective. If grease, the seal plate
of ball bearing is defective.
2.4.2 Pump Pulley - Removal
Use pull-out thread holes to pull out the pulley from the
shaft.
Water pump Assembled to Engine - Inspect

2.4.3 Impeller - Remove
(1) Remove the snap ring and remove the pump cover. Impeller
(2) Use pull-out thread holes to pull out the impeller from Impeller remover
the shaft. Shaft

2.4.4 Shaft and Ball Bearing Assembly - Pull Out
(1) Remove the snap ring of pulley-side ball bearing. Push
the shaft from impeller side. Remove the shaft and ball
bearings as a set from the case.
Note: The cassette type unit seal is also removed. Do not re-
use the unit seal to avoid deformation or breakage.
Water Pump Impeller - Remove
(2) Remove the unit seal from the case.
Push the unit seal from the pulley side to the impeller
side.
10-14
2.5 Air cooler water pump - Assemble
One side sealed

ball bearing
Cover
Cassette type
unit seal
Flush
Impeller
11.3 ± 0.3 mm
[0.445 ± 0.012 in.]
O-ring
Spacer
0.8 ± 0.3 mm
Snap ring [0.032 ± 0.012 in.]
Fill grease (Kyodo Yushi WPH Snap ring

or equivalent) of 31g [1.09 oz]
Torque 12.3 ± 2.45 N·m

Thread of water check hole
{1.25 ± 0.25 kgf·m}
: 22.5 ± 2.25 N·m {2.29 ± 0.23 kgf·m}
[0.907 ± 1.8 lbf·ft]
[16.6 ± 1.66 lbf㨯ft]
Apply sealant
Apply thread lock (Locktite 271 or equivalent)
(Sealend No.7 or equvalent)
Waterpump for Air Cooler - Assemble
10-15
2.5.1 Pump Shaft and Ball Bearing Assembly - Install

Install the ball bearing, spacer and ball bearings as shown,
and push into the case.
Note: The bearings on both ends are with seal plate type.
Place the seal plates facing outsides.
2.5.2 Water Pump Shaft - Install
(1) Fill grease (Kyodo Yushi WPH or equivalent) of 31 g
[1.09 oz] in the space among the ball bearing rolling
surfaces and spacer outside diameter.
(2) Press in the shaft and ball bearing assembly into the
pump case, and hold with the snap ring.
(3) Press in the cassette type unit seal from impeller side. ø44 mm [1.73 in.]
Prepare the jig which can insert rotational and station- Prepare installer.
ø17 mm [0.67 in.]
ary parts in one time and install iin the position.
ø33 mm [1.30 in.] Press-in
2.5.3 Pulley and Pulley - Install simultaneously
[0.445 ± 0.012 in.]

11.3 ± 0.3 mm
(1) Press in the impeller to be flush with the shaft end.
Check the clearance between impeller and case.
Nominal
Item Standard value
value
0.8 mm 0.5 to 1.1 mm
[0.031 in.] [0.020 to 0.043 in.]
Cassette Type Unit Seal - Press In
(2) Press in the ribbed belt pulley to the shaft end opposite
to the impeller end.
2.6 Thermostat Operation - Inspect
(1) Immerse the thermostat in a electric pot or the like, and
raise the temperature.
(2) Check the water temperature to measure the tempera-
ture at which the valve start to open, and at which the
valve lift becomes the maximum.
Note: Check the valve opening temperature stamped on the
periphery seat of thermostat.
Nominal
Item Standard value
value
Valve opening temper- 71ºC 69 to 73 ºC
ature [106 ºF] [156 to 163 ºF]
Basic 85 ºC
valve lift becomes 9
engine [185 ºF]
mm [0.35 in.] or more
10 mm
Lift
[0.3937 in.]
Valve opening temper- 35ºC 33 to 37ºC
ature [95 ºF] [91.4 to 98.6 ºF]
50ºC
Air cooler valve lift becomes 9
[122 ºF]
[0.35] or more
10 mm
Lift
[0.3937 in.]
10-16
3. Cooling System - Install

Clean and dry well the cooling water passage.
3.1 Water pump Installing Position - Inspect
Check that the idler gear, bearing cover and oil seal are installed at the water pump installing position of front plate and front
gear case.
Refer to the section "Front Mechanism - Assemble" in "BASE ENGINE - ASSEMBLE."
3.1.1 Water pump - Install
ECUI (Y2PTAW)
392 ± 20 N·m
{40 ± 2 kgf·m}
108 ± 10.8 N·m

{11 ± 1.1 kgf·m}
Water pump - Install
10-17
(1) Screw in the stud bolts to the thread holes (3 places) for
water pump on front gear case.
Note: Apply liquid sealant (ThreeBond 1215 or equivalent)
to the thread of stud bolt (1 place) as shown in the il-
lustration.
(2) Install the joint and O-ring to the water inlet port of
Stud bolt Apply liquid sealant
front gear case.
(ThreeBond 1215 or
(3) Install the water pump assembly to the front gear case. equivalent) to this
bolt.
Press in the ball bearing into the bearing case and align
the joint and stud bolts.
Note: Press in the oil seal at the rear end of the bearing case Stud Bolt on Front Gear Case - Screw In
slowly to avoid damage.
(4) Install the pulley to the $$waterpump$ shaft, and
tighten the nut to the specified torque.
10-18
3.2 Water pump for Air cooler
Outlet
Inlet
Water pump
Tension bolt
Alternator
Water pump
Ribbed belt
Alternator Tension bolt
Water pump for Air cooler - Install
10-19
1. Inlet and Exhaust Systems - Remove and Inspect ............................................. 11-3
1.1 Air duct and Air cooler - Remove and inspect ........................................................................ 11-3
1.2 Turbocharger and Air Duct - Remove and Inspect ................................................................. 11-4
1.3 Exhaust Manifold and Insulator - Remove and Inspect .......................................................... 11-5
2. Inlet and Exhaust Systems - Disassemble, Inspect and Assemble .................. 11-6
2.1 Air cooler - Disassemble, Inspect and Assemble ................................................................... 11-6
3. Inlet and Exhaust Systems - Install...................................................................... 11-8
3.1 Joint and Seal Ring - Inspect and Assemble .......................................................................... 11-8
3.2 Joint Coupling - Tighten.......................................................................................................... 11-8
3.3 Installing Orientation of Exhaust Manifold Gasket .................................................................. 11-8
11-1
1. Inlet and Exhaust Systems - Remove and Inspect

1.1 Air duct and Air cooler - Remove and inspect
Replace: O-ring
‫ޓޓޓ‬Packing
RH
Local contact, air leak

Turbocharger
Turbocharger Deformation, air leak
2 3
1
LH
MUI
Air Duct and Air cooler - Remove and Inspect

Removing sequence
1 Boost balance pipe 3 Air duct
2 Joint 4 Air cooler assembly
11-3
1.2 Turbocharger and Air Duct - Remove and Inspect
Break, replace
Gas leak, inside 6

diameter local wear
250A
looseness, crack, peeling,

assembly replacement ‫ޓ‬
5 7
2
Replace
3 Gas leak 6
Contamination, Crean
200A
Turbocharger and Air Duct - Remove and Inspect
Removing sequence
1 Insulator 4 Turbocharger (Approx 29 kg [64 lb]) 6 Air duct (approx 25 kg [55 lb])
2 Pre-cleaner 5 Joint, Seal ring assembly 7 Stay
3 Silencer assembly
Note:(a) Do not disassemble the silencer to avoid the entry of foreign matter.
Visualy check. Replace as an assembly if defective.
(b) Refer to the separate-volume service manual of turbochrger.
11-4
1.3 Exhaust Manifold and Insulator - Remove and Inspect
Replace: Gasket
Joint gasket
1
6 4
5
Deformation,
gas leak
3
4
5
7
Deformation,
gas leak
8 Crack, break
2
Exhaust Manifold and Insulator - Remove and Inspect

Removing sequence
1 Insulator (RH) 4 Flexible joint 7 Exhaust manifold (LH)
2 Insulator (LH) 5 Joint gasket 8 Gasket
3 Coupling 6 Exhaust manifold (RH)
11-5
2. Inlet and Exhaust Systems - Disassemble, Inspect and Assemble

2.1 Air cooler - Disassemble, Inspect and Assemble
Replace: O-ring
Fin clogging,
‫ޓ‬ ‫ޓ‬Packing
deformation, leak
‫ޓ‬ ‫ޓ‬Gasket
1
2
Water leak at
water check hole Hole clogging
4
3
Peeling of sealant,
air leak
2
MUI
Fin clogging,
deformation, leak
Water leak at
water check hole
4 Hole clogging
Peeling of sealant, air leak

ECUI
Air Cooler - Disassemble, Inspect and Assemble

1 Connector, Pipe 3 Element (Approx 46 kg [101 lb]) 4 Inlet manifold (Approx 30 kg [66 lb])
2 Cover
11-6
2.1.1 Air cooler - Inspect
The Air cooler differs in material and structure depend-

ing on the application (fresh water or seawater). Pay
attention to the difference when handling the Air
cooler.This cooler is for fresh water.
2.1.2 Air cooler - Clean
Blow compressed air (at a pressure of 0.29 to 0.49 MPa {3
to 5 kgf/cm2} [43 to 71 psi] or less) through the air cooler in
the opposite direction to the normal air flow to remove the
accumulation of dust and dirt. Then, inspect for corrosion
and cracks.
Air cooler - Clean

2.1.3 Air cooler - Check for Leakage
Immerse the Air cooler in water. In this condition, blow
compressed air (at a pressure of 0.39 MPa {4 kgf/cm2} [57
psi]) to the coolant passage to check for air leakage.
Compressed air
Air cooler - Check for Leakage

2.1.4 Air cooler - Assemble
Plate Element
To assemble, follow the disassembly sequence in reverse.
Seal the clearance between the element and plate with
KE45-W (Shin-Etsu Chemical Co., ltd.) or equivalent sili-
cone sealant.
Fill sealant (Shin-Etsu KE45W or equivalent).

MUI ECUI
Application of Liquid Sealant
11-7
3. Inlet and Exhaust Systems - Install

Thoroughly clean and dry the inlet and exhaust passages.
3.1 Joint and Seal Ring - Inspect and Assemble
3.1.1 Seal Ring - Inspect
Nominal Limit
Item Standard value
value value
ø121 ø123
Inner ring inside diameter 119.5 to 121.0
[4.76 in.] [4.84 in.]
ø134.5 ø133.5
Outer ring outside diameter 134.5 to 136.0
[5.30 in.] [5.26 in]
3.1.2 Seal Ring - Assemble

Install the inner ring and outer ring alternately in the joint Install outer and inner
alternately.
ring groove.
Apply snti-seizure
compound Joint
(Molykote or
equvalent) to
seal rings.
Seal ring
(Outer)
Seal ring (inner)
joint and Seal Ring - Assemble

3.2 Joint Coupling - Tighten
(1) Assemble the exhaust manifold, joint gasket and flexi-
ble joit and install the coupling. 8.35 ± 0.45 N·m
(2) Apply anti-seizure compound (Molykote or equivalent) {0.85 ± 0.05 kgf·m}
[6.16 ± 0.33 lbf·ft]
to the thread and tighten the nut to the specified torque.
(3) Lightly shake the outer circumference of coupling to
make a snug contact between the mating face and the
coupling taper face.
(4) Re-tighten the nut to the specified torque.
Self lock nut
(5) Lightly shake again to verify the tightening to be free Apply anti-seizure compound
from looseness. (Molykote or equivalent) to threads.
Joint Coupling - Install
3.3 Installing Orientation of Exhaust Manifold Gasket
Place the turnback of gasket inside opening (exhaust port
area) to face the manifold.
Manifold side
2 mm
A A
Section A-A
Installing Orientation of Exhaust Manifold Gasket
11-8
1. Air Start System - Remove and Inspect............................................................... 12-3
1.1 Air Starter - Remove and Inspect ........................................................................................... 12-3
2. Air Start System - Install ....................................................................................... 12-3
12-1
1. Air Start System - Remove and Inspect

1.1 Air Starter - Remove and Inspect
Air starter mortor starting spec
Air tank
Reray valve
2
Air Starter - Remove and Inspect

Removing Sequence
1 Carble 3 Air motor (approx 22 kg [49 lb])
2 Air pipe
2. Air Start System - Install

12-3
1. Engine - Adjust ...................................................................................................... 13-3
1.1 Turning Gear - Use ................................................................................................................. 13-3
1.2 Valve Bridge and Adjusting Screw - Check ............................................................................ 13-4
1.3 Valve Clearance - Check ........................................................................................................ 13-4
1.4 Fuel Injection Timing - Check ................................................................................................. 13-4
1.5 Fuel System - Bleed Air .......................................................................................................... 13-4
1.6 Belt and Belt Tension - Inspect and Adjust............................................................................. 13-5
2. Break-in Operation ................................................................................................ 13-7
2.1 Preparation Before Engine Starting ........................................................................................ 13-7
2.2 Engine Start-up....................................................................................................................... 13-7
2.3 Break-in Operation.................................................................................................................. 13-7
3. Engine-Test and Adjustment ................................................................................ 13-9
3.1 Engine Performance Test ....................................................................................................... 13-9
3.2 Exhaust Gas Test ................................................................................................................... 13-9
3.3 Governor Performance Test ................................................................................................... 13-9
3.4 Alarm Action and Emergency Stop Tests ............................................................................... 13-9
3.5 Maximum Fuel Injection Volume (MUI) - Set .......................................................................... 13-9
4. Seal (MUI) ............................................................................................................. 13-10
4.1 Sealing with Wire and Seal................................................................................................... 13-10
4.2 Sealing with the Tamper Proof Nut....................................................................................... 13-10
13-1
1. Engine - Adjust
1.1 Turning Gear - Use
Before starting the engine, make sure that the turning gear is in the engine running position.If the engine is started
with the turning gear engaged (pushed-in position), it will result in personal injury as well as damage to ring gear.
(1) Loosen two bolts, and remove the plate from slot of
shaft.
Shaft
Bolt
Bolt
Plate
Turning Gear - Use (for Engine Running)

(2) Push-in the shaft all the way so that it engages with ring
gear.
Turning Gear - Use (Push-in)

(3) Using a socket and ratchet handle, rotate the shaft for
turning crankshaft. Socket
(4) After the turning, pull-out the shaft, insert the plate into
slot of shaft, and tighten the bolts.
Make sure that the plate is firmly fitted in slot of shaft.

Ratchet
handle
Turning Gear - Use (for Turning)
13-3
1.2 Valve Bridge and Adjusting Screw - Check

Check the adjustment of valve bridge and adjusting screw. If
it is not adjusted, adjust it to the standard value.
For the adjusting procedure, refer to "Valve Bridge and
Adjusting Screw - Adjust" of "ASSEMBLY OF BASIC
ENGINE."
1.3 Valve Clearance - Check
Check the valve clearance.
If it is not adjusted, adjust it to the standard value.
For the adjusting procedures, refer to "Valve Clearance -
Inspect and Adjust" of "ASSEMBLY OF BASIC ENGINE.
"
1.4 Fuel Injection Timing - Check
Check the fuel injection timing.
If it is not adjusted, adjust the timing to the specified value.
For the adjusting procedures, refer to "Fuel Injection Tim-
ing - Check and Adjust" of "ASSEMBLY OF BASIC
ENGINE. "
1.5 Fuel System - Bleed Air
[Unlock]
(a) Thoroughly wipe off fuel spilled out of the air vent [Priming]
plug. Spilled fuel can cause a fire.

(b) After the air bleeding, ensure the lock of priming Lock
Turn left.
pump cap. If the locking is loose, it can cause
Move back
damage to the priming pump and result in a fuel Cap
and forth.
leak and a fire.
Hold down and
To bleed air from the fuel system, start the air bleeding at turn right.
Priming pump
the place nearest to the fuel tank, from the primary filter,
cartridge filter to fuel pipe, while feeding fuel with the Priming Pump - Operate
priming pump.
Note:(a) Bleed air from fuel at the bleeder valve on fuel pipe, Fuel pipe
not at the cartridge filter bracket to avoid the thread Air bleed valve assembly
damage of bleeder plug by over-tightening.
(b) If the bleed plug is tightened before the priming
pump cap is locked, fuel pressure acts on the feed
pump, making it hard to press the pump. However, Cylinder head
the check valve operation condition can be checked
because the pressure is stabilized at the check valve
Check valve
opening pressure.
Fuel Pipe - Bleed Air
13-4
1.6 Belt and Belt Tension - Inspect and Adjust
If any defects such as separation or damage is found in the inspection, replace the belt with a new one.
Keep the belt free from oil and grease. Oil or grease causes the belt to slip and shorten the service life.
Excessive belt tension can cause rapid wear of the alternator bearing and shorten the service life of the belt. Adjust
the belt tension correct following the procedures below.
1.6.1 Belt - Inspect

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

(2) Adjust the belt tension by turning the adjusting bolt.
(3) Tighten the lock nut.
Adjusting bolt
Adjusting rod
Fixing bolt
Ribbed belt Width Approx
10 mm [0.39 in.]
Pressing
force
Fixing bolt
Gauge
Adjusting bolt
Fixing bolt
Belt Tension - Adjust
13-5
Ribbed belt tension (N) table

Belt straight distance (mm) [in.]
Number
Item 300 [11.81] or more than 300 to 400 more than 400 to 500 more than 500 to 600 more than 600
of ribs
below [11.81 to 15.75] [15.75 to 19.69] [19.69 to 23.62] [23.62]
74 N {7.55 kgf} 49 N {5.00 kgf} 37 N {3.77 kgf} 29 N {2.96 kgf} 25 N {2.55 kgf}
3
[16.64 lbf] [11.02 lbf] [8.32 lbf] [6.52 lbf] [5.62 lbf]
4
5
6
132 N {13.46 kgf} 88 N {8.97kgf} 66 N {6.73 kgf} 53 N {5.40 kgf} 44 N {4.49 kgf}
7
When a new [29.67 lbf] [19.78 lbf] [14.84 lbf] [11.91 lbf] [9.89 lbf]
belt is installed: 147 N {14.99 kgf} 98 N {9.99 kgf} 74 N {7.55 kgf} 59 N {6.02 kgf} 49 N {5.00 kgf}
8
9
10
11
12
3
4
5
6
7
When re- [20.91 lbf] [13.94 lbf] [10.34 lbf] [8.32 lbf] [6.97 lbf]
adjusted: 103 N {10.50 kgf} 69 N {7.04 kgf} 51 N {5.20 kgf} 41 N {4.18 kgf} 34 N {3.47 kgf}
8
9
10
11
12
The force when the middle point of belt straight line is pushed and deflected by 15 mm [0.59 in.].
13-6
2. Break-in Operation
2.1 Preparation Before Engine Starting
Check the levels of fuel, engine oil, and coolant, and also bleed air from the fuel system and the cooling system.
MUI
Inspect the link between governor or actuator output lever and the unit injector control rack. Check that the fuel control rack is
at the no-injection position when the engine is stopped. Check that the control rack is at the "0" position when the stop lever is
pulled.
Check the wiring of the electrical system (sensor, meter alarm panel, starter, alternator, stop solenoid, governor controller, and
battery), then check that there is no defect by turning ON the controller main switch. Set the governor controller so that the
engine runs at a low idle speed after the start-up.
MUI
Operate the stop solenoid, and make sure that the unit injector control rack moves to the no injection position.
Install the pressure gauge, thermometer and flow meter as required.
2.2 Engine Start-up
(1) Before starting the engine, check the levels of fuel, engine oil and coolant, and then bleed the fuel system and cooling sys-
tem.
(2) Stop the fuel supply, and crank the engine with the starter for 10 seconds to lubricate the engine.
(3) Move the control lever slightly in the fuel increase direction (but not to the "full injection" position), and then turn the
starter switch key to the [START] position to start the engine.
(4) After the engine has started, adjust the control lever to let the engine operate at a minimum no-load speed (low idle speed).
(5) Turn the starter switch key to the [OFF] position and make sure that the engine is stopped.
2.3 Break-in Operation
Be prepared to activate the emergency stop for unexpected trouble of engine operation.
2.3.1 Break-in Operation Load and Time

The rotating speed and load during break-in operation are to be increased progressively as shown in the table.
Note that the time shown in the table is the minimum time required to check the engine in a stable condition.
Break-in Operation
Loading factor
Rotating speed (min-1) Time (min)
(%)
1 Rotation speed of low idling 0 20
2 Rated speed × 0.6 to 0.7 0 10
3 0 10
4 25 % 20
5 Rated speed 50 % 20
6 75 % 30
7 100 % 20
13-7
2.3.2 Inspection while the engine is running

During the break-in operation, pay attention to followings and make sure that there is no abnormality.
Oil pressure and oil temperature
Coolant temperature and level
Leakage of oil, water, fuel and gas; especially oil from turbochrger pipe connection of lubricating oil.
Noise and vibration
Intake air pressure and temperature
Exhaust color and odor
Exhaust temperature
Differences between right and left banks
Blow-by gas (amount and color)
Rotational fluctuation
Face and radial runouts of rotating parts
Indication and operation of meter and alarm
2.3.3 Inspection and Adjustment After Break-in Operation
Valve clearance
Fuel injection timing
Bolts and nuts on the engine - Retighten
Belt tension
Inspection and repair of defects such as oil leak
13-8
3. Engine-Test and Adjustment
(a) Engine test, adjustment and seal shall be performed at the certified maintenance shop only.
When the seal of engine is to be done at a service shop other than the certified shops, ask a certified shop for
the presence of qualified person for the test, adjustment and seal.
(b) Performance check and adjustment of the engine shall be conducted when the water and oil temperatures
become stable after sufficient warm-up operation.
After the break-in operation is completed, and the engine runs normally, check and adjust the performance and functions of the
engine.
Record the test results referring to the engine data of delivery time.
3.1 Engine Performance Test
Fuel consumption rate, various temperatures and pressures, and exhaust color
3.2 Exhaust Gas Test
Exhaust gas analyses
3.3 Governor Performance Test
Minimum speed at no-load (low idle) - set
Maximum speed at no-load (high idle) - set
Load sudden application and rejection tests
Governor droop, hunting, and rotational fluctuation - check
Setting conditions of governor controller and others - check
3.4 Alarm Action and Emergency Stop Tests
Oil pressure decrease, water temperature increase, and overspeed
3.5 Maximum Fuel Injection Volume (MUI) - Set
(1) Operate the engine at the rated (maximum) load.
(2) Adjust the set bolt to touch lightly the control lever, and tighten the lock nut.
Note: The lock nut position in PROACT2 specification is under the stopper bracket.
Control lever Control lever Control lever

position at the
maximum load Control lever
Lock
nut
Lock nut Self lock

nut
Stopper Load
bracket Load increase
Lock nut increase Load Tamper proof
Set bolt nut
increase
PSG,EG3P DYNA8200,SG4030 PROACT2
Maximum Injection Amount - Set
13-9
4. Seal (MUI)
After all performance tests and adjustments are completed, stop the engine, and seal the specified parts from the governor or
actuator to the unit injector.
4.1 Sealing with Wire and Seal
Applied to PTA specification.
4.2 Sealing with the Tamper Proof Nut
Applied to Y1 and V2 (PROACT2) specifications.
Tighten to the torque of 20 ± 1 N·m {2 ± 0.1 kgf·m}
(1) Tighten the tamper-proof nut to the specified torque. [14.8 ± 0.7 lbf·ft] to separate the inner nut.
Verify the free turning of the nut with the separate off
Tamper-proof
innner nut. nut
(2) Fix the free turning nut with a self-locking nut.
Note: Apply conventional wires and seals to the other sealing Self lock nut
positions.
Tamper-proof
nut
Sealing with the Tamper Proof Nut
13-10
Engine inspection record sheet (SH series)
No. 1 Cylinder liner bore inside diameter - measure

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

Item to be
Nominal Standard Limit
measured
Cylinder liner φ150 150.00 to 150.04 150.1
inside diameter [5.91] [5.9055 to 5.9071] [5.9094]
Location
a 26 [1.02]
b 135 [5.32]
c 250 [9.84]
Measured value
Item Cylinder liner bore inside diameter Item Cylinder liner bore inside diameter
No. Direction A B C No. Direction A B C
X X
1 7
Y Y
X X
2 8
Y Y
X X
3 9
Y Y
X X
4 10
Y Y
X X
5 11
Y Y
X X
6 12
Y Y
Remark Approved by Checked by Measured by

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

Item to be measured Standard Limit
Cylinder liner 0.10～0.19 0.05
flange protrusion [0.0039 to 0.0075] [0.0020]
Measured value
Item Cylinder liner bore flange protrusion

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

INSPECTION RECORD SHEET No.3(1/2)
SH
Engine Model
Customer Serial No.
Date
Valve guide inside diameter and Valve stem outside
Item diameter -
Unit mm[in.]
Measuring Standard
location
Item to be measured Nominal Standard Limit
φ10 10.000 to 10.015 10.060
Valve guide inside diameter
[0.39] [0.3937 to 0.3943] [0.3961]
Valve stem outside φ10 9.94 to 9.96 9.91
diameter [0.39] [0.3913 to 0.3921] [0.3902]
Measured value
Item Valve guide inside diameter Valve stem outside diameter Clearance
A B A B A B
No. Direction
X Y X Y X Y X Y Max. Min. Max. Min.
a
Inlet
b
1
Exhaust
a
b
a
Inlet
b
2
Exhaust
a
b
a
Inlet
b
3
Exhaust
a
b
a
Inlet
b
4
Exhaust
a
b
a
Inlet
b
5
Exhaust
a
b
a
Inlet
b
6
Exhaust
a
b

No.3(2/2) INSPECTION RECORD SHEET
SH
Engine Model
Customer Serial No.
Date
Valve guide inside diameter and Valve stem outside
Item diameter -
Unit mm[in.]
Measuring Standard
location
φ10 10.000 to 10.015 10.060
Valve guide inside diameter
[0.39] [0.3937 to 0.3943] [0.3961]
Valve stem outside φ10 9.94 to 9.96 9.91
diameter [0.39] [0.3913 to 0.3921] [0.3902]
Measured value
Item Valve guide inside diameter Valve stem outside diameter Clearance
A B A B A B
No. Direction
X Y X Y X Y X Y Max. Min. Max. Min.
a
Inlet
b
7
Exhaust
a
b
a
Inlet
b
8
Exhaust
a
b
a
Inlet
b
9
Exhaust
a
b
a
Inlet
b
10
Exhaust
a
b
a
Inlet
b
11
Exhaust
a
b
a
Inlet
b
12
Exhaust
a
b

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

Valve seat angle 30° -
-0.1 to 0.1 0.5
Valve sinkage
[-0.0039 to 0.0039] [0.020]
2.2 to 2.4 2.8
Seat width
[0.087 to 0.095] [0.110]
2.9 to 3.1 2.5
Valve margin
[0.114 to 0.122] [0.098]
Measured value
Item Item
Valve seat Valve Valve seat Valve
Seat width Seat width
No. Direction angle sinkage No. Direction angle sinkage
a a
Inlet
Inlet
b b
1 4
Exhaust
Exhaust
a a
b b
a a
Inlet
Inlet
b b
2 5
Exhaust
Exhaust
a a
b b
a a
Inlet
Inlet
b b
3 6
Exhaust
Exhaust
a a
b b

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

Valve seat angle 30° -
-0.1 to 0.1 0.5
Valve sinkage
[-0.0039 to 0.0039] [0.020]
2.2 to 2.4 2.8
Seat width
[0.087 to 0.095] [0.110]
2.9 to 3.1 2.5
Valve margin
[0.114 to 0.122] [0.098]
Measured value
Item Item
Valve seat Valve Valve seat Valve
Seat width Seat width
No. Direction angle sinkage No. Direction angle sinkage
a a
Inlet
Inlet
b b
7 10
Exhaust
Exhaust
a a
b b
a a
Inlet
Inlet
b b
8 11
Exhaust
Exhaust
a a
b b
a a
Inlet
Inlet
b b
9 12
Exhaust
Exhaust
a a
b b

INSPECTION RECORD SHEET No.5
SH
Engine Model
Customer Serial No.
Date
Item Cylinder head bottom face distortion - measure Unit mm[in.]
Item to be
Standard Limit
measured
Distortion of
0.03 [0.0012] 0.07
cylinder head
or less [0.0028]
bottom surface
Measured value
Item Cylinder head bottom face distortion

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

No. 6(1/2) INSPECTION RECORD SHEET
SH
Engine Model
Customer Serial No.
Date
Connecting rod bushing inside diameter and connecting rod
Item big-end bore diameter - measure (1/2)
Unit mm[in.]
Measuring
location
Standard
Item to be measured Nominal Standard Limit Roundness
Connecting rod bushing φ58 58.02 to 58.04 58.07
-
Connecting rod big end φ110 110.000 to 110.022 Minimum: 109.95 [4.3287] 0.1
bore diameter [4.33] [4.3307 to 4.3316] Maximum: 110.05 [4.3327] [0.0039]
Measured value
Item Connecting rod bushing inside diameter Connecting rod big-end bore diameter
No. Direction X Y A B C
a
1
b
a
2
b
a
3
b
a
4
b
a
5
b
a
6
b

INSPECTION RECORD SHEET No. 6(2/2)
SH
Engine Model
Customer Serial No.
Date
Connecting rod bushing inside diameter and connecting rod
Item big-end bore diameter - measure (2/2)
Unit mm[in.]
Measuring
location
Standard
Item to be measured Nominal Standard Limit Roundness
Connecting rod bushing φ58 58.02 to 58.04 58.07
-
Connecting rod big end φ110 110.000 to 110.022 Minimum: 109.95 [4.3287] 0.1
bore diameter [4.33] [4.3307 to 4.3316] Maximum: 110.05 [4.3327] [0.0039]
Measured value
Item Connecting rod bushing inside diameter Connecting rod big-end bore diameter
No. Direction X Y A B C
a
7
b
a
8
b
a
9
b
a
10
b
a
11
b
a
12
b

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

Rocker bushing 44.000 to 44.075 44.125
inside diameter φ44 [1.7323 to 1.7352] [1.7372]
Rocker shaft [1.73] 43.975 to 43.991 43.930
outside diameter [1.7313 to 1.7319] [1.7295]
Measured value
Item Rocker bushing inside diameter Rocker shaft outside diameter Clearance
No. Direction X Y X Y Maximum Minimum
a
1
b
a
2
b
a
3
b
a
4
b
a
5
b
a
6
b

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

Rocker bushing 44.000 to 44.075 44.125
Rocker shaft [1.73] 43.975 to 43.991 43.930
Measured value
Item Rocker bushing inside diameter Rocker shaft outside diameter Clearance
a
7
b
a
8
b
a
9
b
a
10
b
a
11
b
a
12
b

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

Piston pin bore 58.002 to 58.012 58.04
Piston pin [2.28] 57.987 to 58.000 57.97
Measured value
Item Piston pin bore inside diameter Piston pin outside diameter Clearance
A
1 B
C - - - -
A
2 B
C - - - -
A
3 B
C - - - -
A
4 B
C - - - -
A
5 B
C - - - -
A
6 B
C - - - -

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

Piston pin bore 58.002 to 58.012 58.04
Piston pin [2.28] 57.987 to 58.000 57.97
Measured value
Item Piston pin bore inside diameter Piston pin outside diameter Clearance
A
7 B
C - - - -
A
8 B
C - - - -
A
9 B
C - - - -
A
10 B
C - - - -
A
11 B
C - - - -
A
12 B
C - - - -

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

Item to be measured Nominal Standard
0.6 0.55 to 0.65
Inlet
Valve [0.024] [0.0217 to 0.0256]
clearance (A) 0.8 0.75 to 0.85
Exhaust
[0.031] [0.0295 to 0.0335]
Measured value
Valve clearance Valve clearance
No. Inlet Exhaust No. Inlet Exhaust
Before Before
adjustment adjustment
1 After
7 After
Before Before
2 After
8 After
Before Before
3 After
9 After
Before Before
4 After
10 After
Before Before
5 After
11 After
Before Before
6 After
12 After

INSPECTION RECORD SHEET No. 10
SH
Engine Model
Customer Serial No.
Date
Item Fuel injection nozzle injection pressure - measure Unit MPa{kgf/cm2}[psi]

Item to be measured Nominal Standard
29.4 28.9 to 30.9
Valve opening
{300} {295 to 315}
pressure
[4264] [4191 to 4482]
Measured value
Injection pressure Service hours Injection pressure Injection pressure Service hours Injection pressure
No. (h)
No. (h)
Before adjustment After adjustment Before adjustment After adjustment
1 7
2 8
3 9
4 10
5 11
6 12

No. 11 INSPECTION RECORD SHEET
SH
Engine Model
Customer Serial No.
Date
Camshaft bushing inside diameter and camshaft journal
Item outside diameter (right side) - measure
Unit mm[in.]

Camshaft bushing 100.020 to 100.095 100.15
Camshaft journal [3.94] 99.92 to 99.94 99.86
bore [3.9339 to 3.9346] [3.9315]
Measured value
Item Camshaft bushing inside diameter Camshaft journal outside diameter Clearance
No. Direction X Y X Y Minimum Maximum
a
1
b
a
2
b
a
3
b
a
4
b
a
5
b
a
6
b
a
7
b

No. 12
SH
Engine Model
Customer Serial No.
Date
Camshaft bushing inside diameter and camshaft journal
Item outside diameter (left side) - measure
Unit mm[in.]

Camshaft bushing 100.020 to 100.095 100.15
Camshaft journal [3.94] 99.92 to 99.94 99.86
bore [3.9339 to 3.9346] [3.9315]
Measured value
Item Camshaft bushing inside diameter Camshaft journal outside diameter Clearance
No. Direction X Y X Y Minimum Maximum
a
1
b
a
2
b
a
3
b
a
4
b
a
5
b
a
6
b
a
7
b

No.13 INSPECTION RECORD SHEET
SH
Engine Model
Customer Serial No.
Date
Item Crankshaft end play - measure Unit mm[in.]
Measuring location
Standard
0.300～0.495 0.7
Crankshaft end play
[0.0118 to 0.0195] [0.0276]
Measured value
Before disassembly After reassembly

Revision History
Revision History
Mitsubishi Diesel Engine S12H
Title
SERVICE MANUAL
Pub. No. 29502-00120
Revision Issued Description
- March 2011 First edition issued.
Changed the document number, cover Pub. No. 99269-03120 (issued in

- June 2018
March 2011) and issued it as a new publication.
Mitsubishi Diesel Engine S12H
SERVICE MANUAL
Issued in March 2011

Pub. No. 29502-00120
Issued by Mitsubishi Heavy Industries Engine & Turbocharger, Ltd.

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

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

• Without written approval from the publisher, for all or some part of this manual, unauthorized reproduction,
copy, reprinting in any way or method are prohibited.
Printed in Japan
Copyright © 2018 MITSUBISHI HEAVY INDUSTRIES ENGINE & TURBOCHARGER, LTD. All Rights Reserved.
March 2011 SERVICE MANUAL Pub. No. 29502-00120

Service Manual: Pub. No. 29502-00120 Issued: March 2011

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SERVICE MANUAL

Issued: March 2011

Pub. No. 29502-00120

HOW TO USE THIS MANUAL

Terms used in this manual

Abbreviations and Standards

Pressure : 1 MPa = 10.197 kgf/cm2

gerous to ignite combustibles and an explosion.

Pay Attention to Fuel, Oil and

Be Careful of Engine Room Venti- Do Not Continue Low Load Opera-

Do Not Turn Off the Battery Switch engine.

During Operation Use Care to Protect Engine From

Abnormality during Engine acts and vehicle restriction ordinances.

Do Not Add Cooling Water Imme-

Maintenance of Warning Labels

Points on Disassembling and Assembling

Always keep the safety in mind. Points on Disassembling

Use Proper Tools for Maintenance Points on Assembling

absolutely necessary. Pay attention to matching marks and numbers to

Chapter 2 SERVICE DATA

Chapter 3 SERVICE TOOLS

Chapter 4 OVERHAUL INSTRUCTIONS

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

Chapter 7 ASSEMBLY OF BASIC ENGINE

Chapter 9 LUBRICATION SYSTEM

Chapter 10 COOLING SYSTEM

Chapter 11 INLET AND EXHAUST SYSTEMS

Chapter 12 AIR START SYSTEM

Chapter 13 ADJUSTMENT AND OPERATION

S12H-PTA with fan MUI spec

Thermostat case Thermostat case

Fuel main pipe,

Oil pan Damper

Engine Front View

S12H-PTA with fan MUI spec

Rotation speed sensor

Fuel feed pump

Engine Rear View

S12H-PTA with fan MUI spec

Air cooler Fuel filter

Water drain cock

Bypass oil filter

Oil level gauge

Left Side View

S12H-PTA with fan MUI spec

Turbocharger Coolant outlet

Right Side View

S12H-PTK without fan parallel cooling MUI spec

Fuel main pipe,

Engine Front View

S12H-PTK without fan parallel cooling MUI spec

Fuel feed Rotation

Engine Rear View

Turbocharger S12H-PTK without fan parallel cooling MUI spec

Bypass oil filter

Oil level gauge Fuel inlet

Left Side View

S12H-PTK without fan parallel cooling MUI spec

Air cooler Air cooler

Right Side View

Engine coolant outlet

Fuel main pipe,

Pressure : 1 MPa = 10.197 kgf/cm2

absolutely necessary. Pay attention to matching marks and numbers to