Manual de Servicio L3E

SERVICE MANUAL
199616-H2100
for KUKJE MACHINERY CO.,LTD
March 2013
Pub. No. 99616-16100
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 diesel
engines.
A short summary describing the contents of each chapter is given in the CHAPTER INDEX page, and there is also a detailed
table of contents at the beginning of each chapter.
Regarding the procedures for operation and scheduled maintenance of the engine, refer to the Operation and Maintenance Man-
ual. For information on the engine components and ordering of service parts, refer to the Parts Catalogue. Structure and func-
tion of the engine are described in the relevant training manuals.
If you have an inquiry, please check the engine model and serial number, and contact our service department.
Description format
(1) Index numbers allotted to parts in exploded views are not only a call-out of part names listed in the text but also an indica-
tion of the sequence of disassembly.
(2) Inspections to be conducted during disassembly process are indicated in boxes in the relevant exploded views.
(3) Maintenance standards required for inspection and repair works are indicated in the appropriate positions in the text. They
are also collectively indicated in the Chapter 2.
(4) The tightening torque with engine oil applied on the thread, is specified [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 quantitative requirement for dimension of a part, clearance between parts and performance.The values are rounded
off for the inspection job, and do not necessarily conform to the design values.
Limit value
means the value, which the measured value reaches, the part needs repair or replacement with a new one.
Abbreviations and Standards

BTDC : Before Top Dead Center
ATDC : After Top Dead Center
BBDC : Before Bottom Dead Center
ABDC : After Bottom Dead Center
TIR : Total Indicator Reading
API : American Petroleum Institute
ASTM : American Society for Testing and Materials
JIS : Japanese Industrial Standards
LLC : Long Life Coolant
MIL : Military Specifications and Standards (U.S.A.)
MSDS : Material Safety Data Sheet
SAE : Society of Automotive Engineers (U.S.A.)
P/N : Part Number
Unit of Measurement
Measurements are based on the International System of Units (SI), and their converted metric values are indicated in { } and
U.S. customary values are in [ ].For the conversion, the following rates are used.
Pressure :1 MPa = 10.197 kgf/cm2
Torque :1 N•m = 0.10197 kgf•m
Force :1 N = 0.10197 kgf
Output power :1 kW = 1.341 HP = 1.3596 PS
Pressure (mercury column) :1 kPa = 0.7 cmHg
Pressure (water column) :1 kPa = 10.197 cmH2O (cmAq)
Rotation speed:1 min-1 = 1 rpm
III
Foreword
Safety Cautions
Fire and Explosion Precautions
Keep Flames Away Pay Attention to Fuel, Oil and Exhaust Gas
Do not use flames near the engine (in Leak
the engine room).The flame is dan- If any fuel, oil or exhaust gas leakage is found, imme-
gerous to ignite combustibles and diately take corrective measures to stop it.Such leak-
cause a fire.Wipe off spilled fuel, oil ages, if left uncorrected, can cause fuel or engine oil to
and LLC immediately and thor- reach hot engine surfaces or hot exhaust gas to con-
oughly.Spilled fuel, oil and LLC may ignite and cause a tact flammable material, may results in a fire, personal
fire.Store the fuel and engine oil in a well ventilated injury and damage to the equipment.
area. Make sure that the fuel and engine oil container
Use Explosion-Proof Light
caps are tightly fastened.
When inspecting fuel, engine oil, coolant, battery elec-
Tidy up around the engine. trolyte, etc., use an explosion-proof light.If the lighting
Do not place combustible or explosive material, such is not an explosion-proof type, it may ignite and cause
as fuel, engine oil, LLC or explosive powder near the an explosion.
engine.Such substances can cause a fire or explo-
Prevent Electrical Wires from Short Circuit
sion.Thoroughly remove dust, dirt and other foreign
Avoid inspecting or servicing the electrical system with
material collected on the engine and the area around
the battery cable connected to the battery. Otherwise,
the engine.Such material can cause a fire or the
a fire could result from short circuit.Be sure to discon-
engine to overheat.In particular, clean the top surface
nect the battery cable from the negative (-) terminal
of the battery thoroughly.Dust can cause a short cir-
before starting work.A loose terminal and a damaged
cuit.Always place the engine at a position at least 1 m
cable or wire may result in a short circuit and a
[3.28 ft.] apart from buildings and other equipment to
fire.Inspect, and if any defect is found, repair or
prevent a possible fire caused by engine heat.
replace it before starting work.
Keep Fire Extinguishers and First-Aid Kit

Handy
Keep fire extinguishers handy, and
become familiar with their
usage.Keep a first-aid kit at the desig-
nated place to be ready for use in an
emergency.Make counteract proce-
dures against a fire or an accident. Provide the contact
person and means of communication in case of emer-
gency.
IV
Foreword
Stay Away From Rotating and Moving Parts
Install Protective Covers Over Rotating Lockout and Tagout

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

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

rotating parts, serious injury will result.
V
Foreword
Be Careful of Exhaust Gas Poison- Be Careful of Falling

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

Do not climb onto the engine, nor step on any engine
parts on the engine sides.To work on parts located
high on the engine, use a ladder, footing, and others to
prevent from slipping and falling.Climbing onto the
engine may result in engine part damage and your
injury by falling down.
VI
Foreword
Be Careful When Handling Fuel, Be Careful of Burns

Engine Oil or Coolant
Do Not Touch the Engine During or Immedi-
Use Specified Fuel, Engine Oil and Coolant ately After Operation
Only Do not touch any parts of the engine
Use the fuel, oil and coolant specified in this manual during or immediately after opera-
only, and handle them carefully.Use of material other tion.You can get burned.Before start-
than specified one, or improper handling may cause ing the maintenance and inspection
various engine defects and malfunctions.Get the work, check the water temperature meter to make sure
MSDS issued from the fuel, oil and coolant suppliers, that the engine is cooled down.
and follow the directions in the MSDS for proper han- Be Careful to Open and Close the Radiator
dling. Cap
Be Careful with Coolant Never open the radiator cap while the engine is run-
When handling coolant, wear rubber gloves and a pro- ning or immediately after the engine stops.Stop the
tective face mask.If the coolant contacts your skin, or engine and give a sufficient time to allow the coolant to
get into your eyes or mouth, it may cause injury of skin cool down before opening the cap.When opening the
or eyes, or poisoning.If coolant is accidentally swal- radiator cap, slowly open the cap so as to release
lowed, induce vomiting immediately and seek medical internal pressure.To prevent hot steam scalds, wear
attention.If coolant enters your eyes, flush them imme- thick rubber gloves, or cover the cap with a cloth.When
diately with plenty of water and seek medical atten- closing the radiator cap, tightly close the cap.Do not
tion.If coolant contacts your skin or clothing, wash it open the radiator cap during engine running or imme-
away immediately with plenty of water.Keep flames diately after engine stop. Otherwise hot steam and
away from coolant.Coolant can catch flames and coolant gush out and can cause burns.
cause a fire.Drained coolant is a hazardous material. Refill Coolant Only After the Coolant Tem-
Do not discard it in an unauthorized procedure.Prac-
perature Dropped
tice the applicable law and regulations when discard
Refill the coolant after the coolant temperature drops
drained coolant.
to a room temperature.Replacement job immediately
Proper Procedure to Discard Waste Oil and after the engine stop may cause burns.
Coolant
Do not discard waste engine oil or coolant in an unau-
thorized procedure.Such a way of disposal is strictly
prohibited by laws and regulations.Discard waste oil,
coolant and other environmentally hazardous waste in
accordance with the applicable laws and regulations.
VII
Foreword
Battery When Abnormality Occurs
Be Careful with Battery Stop Overheated Engine After Cooling Run

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

If tampered, the warranty is totally void even in the After starting the engine, run the engine at a low idling
warranty period.Tampering with the engine can not speed for warming-up. Start the work after the coolant
only damage the engine but also may lead to personal temperature is raised. Warm-up operation circulates
injury. lubricant in the engine, and works for the longer ser-
vice life and economical operation. Do not conduct the
Wear Proper Work Clothing and Protective
warm-up operation for longer than necessary. Long
Gears
warm-up operation causes carbon deposits in the cyl-
Wear a hard hat, face shield, safety shoes, dust mask,
inders, and may lead to incomplete combustion.
gloves, ear plugs and other protective gears as
needed.When using compressed air, wear ear plugs, Do Not Operate the Engine in an Over-
safety goggles, a hard hat, gloves and other neces- loaded Condition
sary protective gears.Works without wearing proper If the engine shows an overloaded condition such as
protective gears may result in serious injury. black exhaust smoke, reduce the load immediately to
an appropriate load condition.Overloading causes not
Never Break the Seals
only high fuel consumption but also excessive carbon
To ensure the proper engine operation, the fuel injec-
deposits inside the engine. Carbon deposits cause
tion pump, governor, handle and fuel control link are
various problems and will shorten the service life of the
provided with seals that protect the fuel injection vol-
engine.
ume and rotation speed settings against tampering. If
the engine is operated with the seal tampered, no Cool Down the Engine Before Stop
guarantee will be provided. The defects shown below Cool down the engine at a low idling for five to six min-
may occur if the seal is tampered. utes before stopping it.Stopping the engine immedi-
Rapid wear of moving and rotating parts ately after high-load operation will cause local heat up
Engine troubles such as seizure and damage of of engine parts and shorten the service life of the
engine parts engine.During the cooling operation, check the engine
Sudden increase of fuel and lubricating oil consump- for abnormalities.
tion
Do Not Continue Low Load Operation
Deterioration of engine performance due to improper
Low load continuous operation (less than 30%) must
balance between fuel injection volume and governor
be limited within one hour.Long warm-up operation
control, or a serious accident due to overrunning of
the engine causes carbon deposits in the cylinders, and may lead
to incomplete combustion.Also, after low load opera-
Break-in the Engine
tion for approx one hour, run the engine at a 30% or
To break-in a new engine or overhauled engine, oper-
higher load for five minutes or more.
ate the engine at a speed lower than the rated speed
in a light load condition during the first 50 hours of Use Care to Protect Engine from Water
operation.Operating a new engine or overhauled Use care to protect engine from water such as rain
engine in a severe condition during the break-in period entering through the air inlet or exhaust openings.Do
shortens the service life of the engine. not wash the engine while it is running.Cleaning fluid
or water can be sucked into the engine.Starting the
engine with water inside the combustion chambers
can cause the water hammering, and may result in
engine inner parts damage and serious accident.
IX
Foreword
Air cleaner or Do Not Operate Starter for a Long Time

pre-cleaner is to be properly maintained Do not use the starter for more than 10 seconds at a
With foreign material in the intake air, excessive wear time. If the engine does not start, wait for at least 1
of the engine can result.Worn parts produce many minute before starting again.Continuous operation of
problems such as increase of oil consumption, the starter to start a stubborn engine may lead to a flat
decrease of output and starting difficulties.For effec- battery or starter burning out.
tive removal of dust from intake air, maintain the air Do Not Turn Off the Battery Switch During
cleaner/pre-cleaner according to the following instruc- Operation
tions. Do not turn off the battery switch during operation.If
Never perform maintenance of the air cleaner or pre- the battery switch is turned OFF when the engine is
cleaner during operation.Foreign material enters the running, not only various indicators will stop working
turbocharger and may result in a serious failure.
but also the diodes and transistors in the starter can
When removing the air cleaner or pre-cleaner, be
be damaged.
careful to prevent dust and foreign material collected
on the cleaner from entering the engine.After remov- Cautions for Engine Transportation
ing the air cleaner or pre-cleaner, immediately cover To road-transport the engine, consider the engine
the opening (inlet port of engine or turbocharger weight, width, and height, and obey applicable laws
silencer) with plastic sheet or similar means to pre- and regulations such as road traffic laws, vehicle road
vent foreign materials from entering the engine. acts, and vehicle restriction ordinances.
An air cleaner with a dust indicator gives an alarm
Pay Attention to Engine Room Ventilation
when it is clogged. Conduct maintenance when the
Always keep the engine room well-ventilated. Insuffi-
alarm is given.
cient intake air amount of the engine can cause an
Observe Safety Rules at Work Site
increase in the engine temperature, and could result in
Observe the safety rules established at the workplace
a decrease in the output power and poor performance.
when operating and maintaining the engine.Do not
It is highly recommended to calculate the required
operate the engine if you are in bad health. Consult
amount of air supply to the engine and install an ade-
your supervisor about your condition.Operation of the
quate ventilation system before installing the engine.
engine with decreased attention may cause improper
Do Not Touch High Pressure Fuel Jet.
operation and results in an accident. When working in
Do not touch fuel jet leaked or sprayed from the high
a team of two or more people, use specified hand sig-
pressure injection pipe.Fuel in the fuel injection pipe
nals to communicate among workers.
has a high pressure and if the fuel impinges your skin,
Use Proper Tools for Maintenance Work
it goes through the skin and can cause serious injury.
Always keep in mind to select most appropriate tools
for the work and use them correctly.If a tool is dam-
aged, replace with new tool.
X
Foreword
Warning Labels
Maintenance of Warning Labels

Make sure all warning/caution labels are legible.
Clean or replace the warning or caution label when the description or illustration is not clear to read.
For cleaning the warning/caution labels, use a cloth, water, and soap. Do not use cleaning solvent, gasoline, or
other chemicals to prevent the label from fading and peering.
Replace a damaged or missing label with a new one.
If any engine part, to which warning label is attached, 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
XI
Foreword
Points on Disassembling and As- Points on Assembling

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

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

1. General tools
2. 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. Piston, Connecting Rod, Crankshaft and Cylinder block - 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. Cylinder block and Crankshaft - Inspect and Repair
Chapter 7 ASSEMBLY OF BASIC ENGINE

1. Piston, Connecting Rod, Crankshaft and Cylinder block - Assemble
2. Front Mechanism - Assemble
3. Rear Mechanism - Assemble
4. 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
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 ELECTRICAL SYSTEM

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

1. Engine - Adjust
2. Break-In Operation
3. Performance Test
Chapter 14 TROUBLESHOOTING
1. Troubleshooting
Chapter 1 GENERAL
1. External View ........................................................................................................... 1-3
2. Outline of Systems .................................................................................................. 1-4
2.1 Outline of Fuel System ............................................................................................................. 1-4
2.2 Outline of Lubrication System................................................................................................... 1-4
2.3 Outline of Cooling System ........................................................................................................ 1-5
2.4 Outline of Inlet and Exhaust System......................................................................................... 1-5
3. Engine Serial Number ............................................................................................. 1-6
4. Engine Model Code and Displacement.................................................................. 1-6
5. Specifications .......................................................................................................... 1-7
1-1
Chapter 1 GENERAL
1. External View
Chapter 1 GENERAL
Oil filler
Thermostat
Rear hanger
Alternator
Exhaust manifold
Fan pulley
Front Rear
Belt
Oil pan
Crankshaft pulley
Gear case
Oil drain plug
Left Side View
Fuel injection nozzle Front hanger
Inlet manifold Fuel injection pump
stop solenoid
Water pump
Rear Front
Oil filler
Coolant drain plug
Oil filter Oil level gauge
Right Side View
1-3
Chapter 1 GENERAL
2. Outline of Systems
2.1 Outline of Fuel System
Fuel leak-off pipe

Fuel injection nozzle
Fuel injection pipe
To fuel tank
From fuel pump
Fuel injection pump

Fuel filter
Outline of Fuel System
2.2 Outline of Lubrication System
Rocker shaft
Camshaft
Oil main gallery
Oil filter
Oil pump
Crankshaft
Relief valve Oil screen
Oil drain plug
Outline of Lubrication System
1-4
Chapter 1 GENERAL
2.3 Outline of Cooling System
Water pump Water bypass pipe
Thermostat
Radiator
Cooling fan
Outline of Cooling System
2.4 Outline of Inlet and Exhaust System
Inlet
Exhaust Air breather pipe Blow-by gas
(blow-by gas return)
To muffler
From air cleaner
Inlet cover
Exhaust manifold
Outline of Inlet and Exhaust System
1-5
Chapter 1 GENERAL
3. Engine Serial Number

The engine serial number is stamped on the injection pump
mounting portion (upper part of tie rod cover) of cylinder
block.
Engine serial number
Engine serial number location

4. Engine Model Code and Displacement
Engine model code and displacement is displayed on the
injection pump mounting section side of cylinder block.
Engine model code and displacement
1-6
Chapter 1 GENERAL
5. Specifications
Engine model L3E-61KR

Type Water-cooled, 4-stroke cycle diesel
No. of cylinders 3
Combustion system Swirl chamber
Valve mechanism Overhead
Cylinder bore × stroke 76 × 70 mm [2.99 × 2.76 in.]
Main
Total displacement 0.952 L [58.10 cu.in.]
specifications
Compression ratio 23: 1
Fuel ASTM diesel fuel No.2-D (JIS K2204 specification No.2 or 3 )
Firing order 1-3-2
Direction of rotation Counterclockwise as viewed from flywheel side
Dry weight Approx. 65 kg [143 lb.]
Compression ring:2
Piston ring No. of units
Basic engine Oil ring:1 (with expander)
Starting system Starter
Type ND-PFR
Manufacturer DENSO corporation
Fuel injection
Plunger outside diameter ø5.5 mm [0.22 in.]
pump
MS retard (crank angle) 8º
Cam lift 6 mm [0.24 in.]
Governor Operation system Centrifugal weight system
Fuel system Type Throttle type

Manufacturer DENSO corporation
Fuel injection
nozzle Spray angle 15º
+0.78 +8 +113
Valve opening pressure 14.22 0 MPa {145 0 kgf/cm²} [2062 0 psi]
Fuel filter Type Cartridge type paper element
Type Electromagnetic plunger type
Fuel pump
Discharge rate 0.4 L [0.11 U.S.gal]/min or more (at 12V, 1.5A)
Lubrication method Forced circulation (oil pump pressure feed system)
Specification
Class CF or CH-4 oil
(API service category)
Engine oil
Approx. : 3.2 L [0.85 U.S.gal]
Capacity
(Maxmum: 2.7 L [0.72 U.S.gal]
Lubrication Type Gear type (tooth-to-tooth contacting area) housed in the gear case.
system Oil pump
Discharge rate 3 L [0.79 U.S. gal.]/min or more (at 1000 min-1)
Type Plunger valve type
Relief valve 0.34 ± 0.05 MPa {3.5 ± 0.5 kgf/cm2} [49.45 ± 7.25 psi]
Valve opening pressure
(at 1000 min-1)
Oil filter Type Cartridge type paper element
Cooling method Water-cooled, forced circulation
Coolant capacity (engine) 1.8 L {0.5 U.S. gal.]
Type Centrifugal
Cooling system Water pump 50 L [13.2 U.S. gal.]/min
Discharge rate
(at engine speed 4500 min-1)
Type Wax type
Thermostat
Valve opening temperature 76.5 ± 1.5 ºC [169.7 ± 2.7 ºF]
Inlet system Air cleaner Type Paper element
1-7
Chapter 1 GENERAL
Engine model L3E-61KR

Voltage, Grounding system 12V, negative (-) ground
Model number M001T68381
Manufacturer Mitsubishi Electric Corporation
Pinion engagement type Pinion shift (Reduction type)
Starter
Output 12 V, 1.7 kW
No. of units 1
No. of pinion tooth/ring gear tooth 14/106
Model number A007TA0171B
Type 3-phase alternating generator, Internal IC regulator
Manufacturer Mitsubishi Electric Corporation
Electrical Alternator
Output 12 V, 40 A
system
Rated speed 5000 min-1 (at 13.5 V, 37 A)
Regulator adjusting voltage 14.7 ± 0.3 V
Type Sheathed
Glow plug
Rated voltage - Armature current 11 V, 9.5 ± 1.0 A (applied voltage for 6 sec.)
Working
10 to 15 V
voltage
Insulating 100 MΩ or more at DC 500 V megger
Run off type resistance (at normal temperature, normal humidity)
Stop solenoid
(ETS:Energized to stop)
Stroke 10 ± 0.5 mm [0.39 ± 0.02 in.]
Ambient
-30 to 120ºC [-22 to 248ºF]
temperature
1-8
1. Maintenance Service Data ...................................................................................... 2-3
1.1 General Maintenance Service Data of Engine.......................................................................... 2-3
1.2 Maintenance Service Data of Engine Body .............................................................................. 2-3
1.3 Maintenance Service Data of Fuel System............................................................................... 2-5
1.4 Maintenance Service Data of Lubrication System .................................................................... 2-5
1.5 Maintenance Service Data of Cooling System ......................................................................... 2-6
1.6 Maintenance Service Data of Inlet and Exhaust System.......................................................... 2-6
1.7 Maintenance Service Data of Electrical System ....................................................................... 2-6
2. Tightening Torque Table......................................................................................... 2-7
2.1 Tightening Torque Specs for Engine Body ............................................................................... 2-7
2.2 Tightening Torque Spec for Fuel System ................................................................................. 2-7
2.3 Tightening Torque Specifications for Lubrication System......................................................... 2-8
2.4 Tightening Torque Specifications for Cooling System .............................................................. 2-8
2.5 Tightening Torque Specifications for Inlet and Exhaust System .............................................. 2-8
2.6 Tightening Torque Specifications for Electrical System............................................................ 2-8
2.7 Tightening Torque for Standard Bolts....................................................................................... 2-9
2.8 Tightening Torque for Standard Union Bolts .......................................................................... 2-10
2.9 Tightening Torque for Standard Union Nuts ........................................................................... 2-10
2-1
1. Maintenance Service Data

1.1 General Maintenance Service Data of Engine
Unit: mm [in.]
Item Nominal Standard Limit Remarks
Maximum speed
2500 ± 30 min-1
(based on rated speed)
Minimum speed 1400 ± 25 min-1
2.7 MPa {28 kgf/cm²} 2.2 MPa When oil and water temperatures
Compression pressure (at 280 min-1)
[398.85 psi] or above {22 kgf/cm²} [319 psi] at 20 to 30 °C [68 to 86 °F]
0.29 to 0.39 MPa
Rated speed {3.0 to 4.0 kgf/cm²}
[42 to 57 psi] Oil temperature at 60 to 70 °C
Engine oil pressure
[140 to 158 °F]
Approx. 0.098 MPa
Low idling speed
{1.0 kgf/cm²} [15 psi]
Open BTDC 18º
Inlet
Close ABDC 46º ± 2º
Valve timing When valve clearance is 0 mm [0 in.]
Open ABDC 46º (crank angle)
Exhaust
Close BTDC 18º
Inlet 0.25 [0.0098]
valve clearance When cold
Exhaust 0.25 [0.0098]
Fuel injection timing (BTDC) 15º
1.2 Maintenance Service Data of Engine Body

Unit: mm [in.]
ø12 12.013 to 12.035
Rocker arm inside diameter
[0.47] [0.4730 to 0.4738]
ø12 11.470 to 11.984
Rockers Rocker shaft outside diameter
[0.47] [0.4516 to 0.4718]
Clearance between rocker arm and 0.029 to 0.065 0.200
Replace rocker arm
rocker shaft (oil clearance) [0.0011 to 0.0026] [0.0079]
ø6.6 6.565 to 6.580 6.500
Inlet
Valve stem outside [0.260] [0.2585 to 0.2591] [0.2559]
diameter ø6.6 6.530 to 6.550 6.500
Exhaust
[0.260] [0.2571 to 0.2579] [0.2559]
ø6.6 6.600 to 6.615
Inlet
Valve guide inside [0.260] [0.2598 to 0.2604]
valve
diameter ø6.6 6.600 to 6.615
Exhaust
[0.260] [0.2598 to 0.2604]
0.020 to 0.050 0.100
Clearance between Inlet
[0.0008 to 0.0020] [0.0039] Replace valve and valve
valve stem and valve
0.050 to 0.085 0.150 guide
guide Exhaust
[0.0020 to 0.0033] [0.0059]
2-3
Unit: mm [in.]
Valve seat angle 44º
0.5 0.4 to 0.6 シート幅
Valve sinkage
[0.020] [0.016 to 0.024]
Valve seat and
valve 0.50
Valve margin 1.0 [0.039]
[0.0197]
弁座角
14 13.5 to 14.5 バルブ
Valve guide installed length
[0.55] [0.532 to 0.571] バルブマージン
沈み量
38.5
Free length 40 [1.57]
[1.516]
A
A = 2.0º or less Length B
Squareness B=1.4 [0.055] or less B=2.0
Lf
Valve spring Lf=40 [1.57] [0.079]
35.5 [1.398]/ 28 [1.10] /

Installed length/load 64.1 to 71.0 170.1 to 189.4
-15%
(mm [in.]/N{kgf} [lbf]) {6.54 to 7.24} {17.41 to 19.31}
[14.4 to 16.0] [38.3 to 42.6]
0.3
Push rod Runout TIR
[0.012]
0.10
Cylinder head Distortion of bottom surface 0.05 [0.0020] or less Repair
[0.0039]
0.10
Distortion of top surface 0.05 [0.0020] or less Repair
[0.0039]
+1.0
Cylinder block ø76 76 0 +0.2
Inside diameter
[2.99] +0.039 [0.008]
[2.9921 0 ]
Cylindricity 0.01 [0.0004] or less
ø76.00 75.906 to 75.926
Standard
[2.9921] [2.9884 to 2.9892]
ø76.25 76.156 to 76.176
Outside diameter +0.25
[3.0020] [2.9983 to 2.9990]
ø76.50 76.406 to 76.426
+0.50
[3.0118] [3.0081 to 3.0089]
Piston
ø21 21.002 to 21.005
Piston pin outside diameter
[0.83] [0.8268 to 0.8270]
Clearance between piston pin bore and 0.007 to 0.015 0.08
piston pin outside diameter [0.0003 to 0.0006] [0.0031]
0.074 to 0.124 0.2 Repair or replace to
Clearance between piston and cylinder
[0.0029 to 0.0049] [0.008] oversize
No. 1 0.3
-
compression [0.012] Use the piston with
replacing the piston rings
Clearance between No. 2 0.05 to 0.09 0.2
until reaching the limits.
piston ring groove compression [0.0020 to 0.0035] [0.008]
When reaching the limits,
0.03 to 0.07 0.2 replace the piston.
Oil
[0.0012 to 0.0028] [0.008]
Piston ring
No. 1 0.15 to 0.30
compression [0.0059 to 0.0118]
No. 2 0.15 to 0.30 1.50
End gap Replace
compression [0.0059 to 0.0118] [0.0591]
0.15 to 0.35
Oil
[0.0059 to 0.0138]
Bend and twist 0.05/100 [0.0020/3.94] or less
Connecting rod 0.10 to 0.35 0.50
End play Replace connecting rod.
[0.0039 to 0.0138] [0.0197]
2-4
Unit: mm [in.]
ø43 42.965 to 42.980
Crankshaft journal outside diameter
[1.69] [1.6915 to 1.6921]
ø40 39.965 to 39.980 -0.70
Crankpin outside diameter
[1.57] [1.5734 to 1.5740] [-0.0276]
Crankshaft runout 0.06 [0.0024] or less TIR
Crankshaft Main bearing 0.030 to 0.075 0.100
Replace main bearing
Oil clearance [0.0012 to 0.0030] [0.0039]
Clearance between crankpin and 0.028 to 0.071 0.150 Replace connecting rod
connecting rod bearing [0.0011 to 0.0028] [0.0059] bearings
0.050 to 0.175 0.500
End play
[0.0020 to 0.0069] [0.0197]
0.010 to 0.141
Between crankshaft gear and idler gear
[0.0004 to 0.0056]
Timing gear 0.30
Between idler gear and camshaft gear Replace
Backlash 0.010 to 0.136 [0.0118]
Between idler gear and injection pump [0.0004 to 0.0054]
gear
27.37 27.27 to 27.47 26.37
Cam height of camshaft (major axis) Replace
[1.0776] [1.0736 to 1.0815] [1.0382]
Fuel injection pump camshaft 29.9 to 30.1 29
Replace
cam height (major axis) [1.177 to 1.185] [1.14]
0.50
Flatness of flywheel 0.08 [0.0031] or less Repair
[0.0197]
0.007 to 0.049 0.15
Clearance between tappet and tappet guide hole Replace tappet
[0.0003 to 0.0019] [0.0059]
0.050 to 0.100 0.150
Clearance between camshaft journal and camshaft hole Replace
[0.0020 to 0.0039] [0.0059]
0.030 to 0.066 0.200 Replace idler gear or idler
Clearance between idler gear and idler shaft
[0.0012 to 0.0026] [0.0079] shaft
1.3 Maintenance Service Data of Fuel System

14.22 MPa 14.22 to 15.00 MPa Adjust with washers. Standard
Fuel injection nozzle Injection start pressure {145 kgf/cm²} {145 to 153 kgf/cm²} value shows a value when it is
[2062 psi] [2062 to 2176 psi] new.
1.4 Maintenance Service Data of Lubrication System

Clearance between oil pump housing inside diameter and oil pump 0.100 to 0.196 mm 0.3 mm
Replace
outer gear outside diameter [0.0039 to 0.0077 in.] [0.0118 in.]
Difference between oil pump outer gear width and 0.040 to 0.100 mm 0.25 mm
Replace
oil pump housing [0.0016 to 0.0039 in.] [0.0098 in.]
0.29 ± 0.029 MPa {3.0 ±
Relief valve opening pressure 0.3 kgf/cm²} [42 ± 4.2 Replace
psi]
0.025 MPa
Oil pressure at which oil pressure switch illuminates Replace
{0.25 kgf/cm²} [3.6 psi]
2-5
1.5 Maintenance Service Data of Cooling System

Unit: mm [in.]
76.5 ± 1.5ºC
Valve opening temperature
[169.7 ± 2.7ºF]
Thermostat Replace
Temperature at which valve lift
90ºC [194ºF]
becomes 6 mm [0.23 in.] or more
Deflection amount of belt
(when it is pushed between crankshaft pulley and alternator 10 [0.39]
pulley with a force of approx. 98 N {10 kgf} [22 lbf])
1.6 Maintenance Service Data of Inlet and Exhaust System

Unit: mm [in.]
Distortion on mounting surfaces of inlet cover
0.15 [0.0059] or less Repair by grinding or replace.
and exhaust manifold
1.7 Maintenance Service Data of Electrical System

Unit: mm [in.]
0.5 to 2.0
Pinion gap Adjust by packing
[0.020 to 0.079]
Voltage 11 V
No-load characteris-
Current 110 A or less Inspection
tics
Rotational speed 2400 min-1
Brush length 16.5 [0.650] 10 [0.39] Replace
Starter
20.58 N 17.5 to 23.7 N 6.86 N
Brush spring load {2.10 kgf} {1.78 to 2.42 kgf} {0.70 kgf} Replace
[4.63 lbf] [3.92 to 5.34 lbf] [1.54 lbf]
Commutator runout 0.03 [0.0012] 0.10 [0.0039] Repair or replace.
Commutator outside diameter ø29.4 [1.158] 28.8 [1.134] Replace
0.75 0.5 to 1.0 0.2
Depth of undercuts between segments Repair
[0.0295] [0.020 to 0.039] [0.008]
IC regulator adjusting voltage (at 20°C [68°F]) 14.7 to 15.0 V
Voltage 13.5 V
2500 min-1 or less
Output characteris- Current 21 A or more
Inspection
tics (when hot) Voltage 13.5 V
Alternator 5000 min-1 or less
Current 37 A or more
Brush length 18.5 [0.728] 5.0 [0.197] Replace
4.8 to 6.0 N 2.2 N
Brush spring load {0.49 to 0.61 kgf} {0.22 kgf}
[1.08 to 1.35 lbf] [0.49 lfb]
0.15 to 0.20
Clearance between stop solenoid rack and plunger Repair
[0.0059 to 0.0079]
When applying
Rated voltage -
Glow plug 9.5 ± 1.0 A DC11 V for 6 sec-
Armature current
onds.
2-6
2. Tightening Torque Table

2.1 Tightening Torque Specs for Engine Body
Thread size Tightening torque

Description Remark
Dia. x Pitch N·m kgf·m lbf·ft
Cylinder head bolt (main) M 10 x 1.75 78.5 ± 5.0 8.0 ± 0.5 57.9 ± 3.6
Cylinder head bolt (sub) M 10 x 1.75 24.5 ± 4.9 2.5 ± 0.5 18.1 ± 3.6
Rocker cover bolt M 8 x 1.25 5.9 ± 1.0 0.6 ± 0.1 4.4 ± 0.7
Locker shaft assembly bolt M 8 x 1.25 18.2 ± 3.5 1.9 ± 0.4 13.4 ± 2.5
Main bearing cap bolt M 10 x 1.25 51.5 ± 2.4 5.3 ± 0.2 38.0 ± 1.7
Connecting rod cap nut M 9 x 1.0 32.9 ±1.4 3.4 ± 0.1 24.3 ± 1.0
Crankshaft pulley nut M 18 x 1.5 107.9 ± 9.8 11.0 ± 1.0 79.6 ± 7.2
Oil relief plug M 18 x 1.5 44.1 ± 4.9 4.5 ± 0.5 32.5 ± 3.6
Oil pump mounting bolt - 8.8 ± 1.0 0.9 ± 0.1 6.5 ± 0.7
Flywheel bolt M 10 x 1.25 88.3 ± 4.9 9.0 ± 0.5 65.1 ± 3.6
2.2 Tightening Torque Spec for Fuel System

Description Remark
Air bleeder screw
- 5.9 ± 1.0 0.6 ± 0.1 4.4 ± 0.7
(Fuel injection pump)
Hollow screw
M 12 x 1.25 12.3 ± 2.5 1.3 ± 0.3 9.1 ± 1.8
Delivery valve holder
- 36.3 ± 2.0 3.7 ± 0.2 26.8 ± 1.4
Lock plate screw
- 3.6 ± 0.4 0.4 ± 0.1 2.7 ± 0.2
Nozzle retaining nut M 16 x 0.75 36.8 ± 2.4 3.8 ± 0.2 27.1 ± 1.7
Nozzle holder M 20 x 1.5 54.0 ± 4.9 5.5 ± 0.5 39.8 ± 3.6
Fuel injection pipe nut M 12 x 1.5 27.0 ± 2.5 2.8 ± 0.3 19.9 ± 1.8
Torque spring set lock nut M 12 x 1.0 9.8 ± 2.0 1.0 ± 0.2 7.2 ± 1.4
Fuel return pipe nut M 12 x 1.5 22.6 ± 2.0 2.3 ± 0.3 16.7 ± 1.4
Torque spring set special nut M 12 x 1.0 19.6 ± 4.9 2.0 ± 0.5 14.5 ± 3.6
2-7
2.3 Tightening Torque Specifications for Lubrication System

Description Remark
Oil pressure switch PT 1/8 9.8 ± 1.9 1.0 ± 0.1 7.2 ± 1.4
Oil relief valve plug - 8.8 ± 1.0 0.9 ± 0.1 6.5 ± 0.7
Oil pump - 44.1 ± 4.9 4.5 ± 0.5 32.5 ± 3.6
2.4 Tightening Torque Specifications for Cooling System

Description Remark
Thermostat cover bolt M 8 x 1.25 24.5 ± 4.9 2.5 ± 0.5 18.1 ± 3.6
Thermo case bolt M 16 x 1.5 9.0 ± 1.0 0.9 ± 0.1 6.6 ± 0.7
2.5 Tightening Torque Specifications for Inlet and Exhaust System

Description Remark
Inlet cover bolt M 8 x 1.25 8.8 ± 1.0 0.9 ± 0.1 6.5 ± 0.7
Exhaust manifold bolt M 8 x 1.25 18.2 ± 3.5 1.9 ± 0.4 13.4 ± 2.5
2.6 Tightening Torque Specifications for Electrical System

Description Remark
Magnetic switch - 5.9 ± 1.7 0.60 ± 0.17 4.4 ± 1.2
Brush holder mounting bolt - 3.4 ± 1.0 0.35 ± 0.1 2.5 ± 0.7
Starter Through bolt - 5.8 ± 1.3 0.59 ± 0.13 4.3 ± 0.9

+2 +0.2 +1.4
B terminal M 8 x 1.25 9.8 0 1 0 7.2 0
M terminal - 10.7 ± 2.0 1.1 ± 0.2 7.9 ± 1.4

Stop solenoid fixing nut M 30 x 1.5 44.1 ± 4.9 4.5 ± 0.5 32.5 ± 3.6
Glow plug M 10 x 1.25 17.5 ± 2.5 1.8 ± 0.25 12.9 ± 1.8
Glow plug connection plate fixing nut M 4 x 0.7 1.25 ± 0.25 0.13 ± 0.03 0.92 ± 0.18
Alternator terminal B M 5 x 1.0 3.9 ± 1.0 0.4 ± 0.1 2.9 ± 0.7
2-8
2.7 Tightening Torque for Standard Bolts

2.7.1 Metric automobile screw thread
Thread size Strength classification
Width across flats
Dia. × Pitch
(mm) [in.] 4T 7T 10.9
(M-thread)
4 7 10
N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
6 × 1.0 10 [0.39] 4 0.4 2.95 9 0.9 6.64 13 1.3 9.59
8 × 1.25 12 [0.47] 12 1.2 8.85 18 1.9 13.28 30 3.1 22.13
10 × 1.25 14 [0.55] 21 2.15 15.49 35 3.6 25.81 60 6.1 44.25
12 × 1.25 17 [0.67] 35 3.6 25.81 64 6.5 47.20 108 11.0 79.66
2.7.2 Metric course screw thread

Thread size Strength classification
Width across flats
Dia. × Pitch
(mm) [in.] 7T 10.9
(M-thread)
N·m kgf·m lbf·ft N·m kgf·m lbf·ft

10 × 1.5 14 [0.55] 32 3.3 23.60 58 5.9 42.78
12 × 1.75 17 [0.67] 57 5.8 42.04 102 10.4 75.23
Note:(a) This table lists the tightening torque 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)
2-9
2.8 Tightening Torque for Standard Union Bolts

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

Cap nut thread size
Width across flats
Nominal Dia. × Pitch N·m kgf·m lbf·ft
(mm) [in.]
(M-thread)
63 14 × 1.5 19 [0.75] 39 4 28.76
80 16 × 1.5 22 [0.87] 49 5 36.14
100 20 × 1.5 27 [1.06] 78 8 57.53
120 22 × 1.5 30 [1.18] 98 10 72.28
150 27 × 1.5 32 [1.26] 157 16 115.80
180 30 × 1.5 36 [1.42] 196 20 144.56
200 30 × 1.5 36 [1.42] 196 20 144.56
220 33 × 1.5 41 [1.61] 245 25 180.70
254 36 × 1.5 41 [1.61] 294 30 216.84
(Maximum tolerance value: ±10%, dry condition)
2-10
1. General tools............................................................................................................ 3-3
2. Special Tools............................................................................................................ 3-4
3-1
1. General tools
1
5
No. Tool name Part No. Remarks

- Tool set MM413900 Includes parts No. 1 through 5
1 Spanner MK96008010 Width across flats (8 × 10 mm) [0.32 × 0.39 in.]
2 Spanner MK96012014 Width across flats (12 × 14 mm [0.47 x 0.55 in.])
3 Spanner MK96017019 Width across flats (17 × 19 mm [0.67 x 0.75 in.])
4 Screw driver MM300110 (-)
5 Tool bag MM300783
3-3
2. Special Tools
Tool name Part No. Illustration Remarks
Piston pin setting tool 30L91-10010 Piston pin removal/installation
Compression gauge adapter ST332270 Compression measuring
Oil pressure switch removal/

Oil pressure switch socket wrench (26) MD998054
installation
Piston ring pliers 31391-12900 Piston ring removal/installation
3-4
1. Definition of Overhaul ............................................................................................. 4-3
2. Determining Overhaul Timing ................................................................................ 4-3
3. Compression Pressure - Measure.......................................................................... 4-4
4-1
1. Definition of Overhaul
The overhaul is aprocess of disassembling, inspecting, repairing or reolacing parts, and restoring of engine to maintain the new
engine performance until the time of next overhaul.
Even a part satisfies the specification at the overhaul, the part must be replaced with a new one when the soundness of the part
is not ensured until the time of next overhaul.
2. Determining Overhaul Timing

In most cases, the engine should be overhauled when the compression pressure of the engine decreases. An increase in engine
oil consumption and blow-by gas should be considered when evaluating the engine condition.
Such symptoms as the output decrease, fuel consumption increase, oil pressure decrease, engine starting difficulty and noise
increase should be considered to evaluate overhaul timing, although these symptoms are often affected by various causes, and
are not always effective to consider overhaul timing.
Decreased compression pressure shows a variety of symptoms and engine conditions, thus making it difficult to accurately
determine when the engine needs an overhaul.
The following shows typical symptoms:
(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 amount.))
(5) Gas leak increase due to poor seating of inlet and exhaust valves
(6) Difficult starting
(7) Noise increase from engine parts
(8) Abnormal exhaust color after engine warm-up
The engine shows these symptoms in various combinations.
Some of these symptoms are directly caused by worn engine parts, while others are not.
Symptoms of items (2) and (6) are affected by improper fuel injection volume and timing of the fuel injection pump, worn
plunger, faulty nozzles and also faulty conditions of electrical devices such as battery and starter.
The most valid reason to overhaul an engine is the compression pressure decrease due to worn cylinder liner and piston ring, as
described in item (4). And once this symptom is shown, it is reasonable to take other symptoms into consideration for making
the final decision.
4-3
3. Compression Pressure - Measure
Compression gauge Compression

(a) Be sure to measure the compression pressure adapter gauge
P/N:ST332270
for all the cylinders. It is not a good practice to
measure the compression pressure for only one
cylinder, and to assume the compression pres-
sure is the same for all cylinders.
(b) Also be sure to check engine speed when mea-
suring the compression pressure, as compres-
sion pressure varies depending on engine
speed. Compression pressure - Measure
(c) Measuring the compression pressure at regular
intervals is important to obtain correct data.
(d) When measuring the compression pressure for
cylinders one by one, do not remove other fuel
injection nozzles from their positions, except for
the one being measured.
(1) Remove the injection nozzle from the cylinder head
where the compression pressure is to be measured.
(2) Remove the glow plugs from all cylinders.
(3) Attach the compression gauge adapter to the fuel injec-
tion nozzle mount and connect compression gauge.
(4) Stop the fuel supply.
(5) Crank the engine with starter. Read the engine speed
and compression pressure while the engine is running at
the specified speed.
Note: If the battery voltage is decreased, sufficient rotational
speed can not obtained, and thereby, compression
pressure cannot be measured correctly.
(6) If the measured value is lower than the limit, overhaul
the engine.
Basic
Item Standard Limit Rotational
speed
2.7 MPa 2.2 MPa
Compression pressure {28 kgf/cm2} {22 kgf/cm2} 280 min-1
[398.85 psi] [319 psi]
0.25 MPa
Tolerable difference {2.5 kgf/cm2}
- -
between cylinders [36 psi]
or less
4-4
1. Cylinder Head and Valve Mechanism - Disassemble and Inspect ...................... 5-3
1.1 Valve Clearance - Inspect......................................................................................................... 5-4
1.2 Fuel Injection Timing - Inspect.................................................................................................. 5-4
1.3 Rocker Shaft Assembly - Remove............................................................................................ 5-4
1.4 Cylinder Head Bolt - Remove ................................................................................................... 5-5
1.5 Cylinder Head Assembly - Remove.......................................................................................... 5-5
1.6 Valve Sinkage - Measure.......................................................................................................... 5-5
1.7 Valve and Valve Spring - Remove............................................................................................ 5-5
1.8 Valve Stem Seal - Remove....................................................................................................... 5-6
2. Rear Mechanism - Disassemble and Inspect ........................................................ 5-7
2.1 Flywheel - Remove ................................................................................................................... 5-8
2.2 Oil seal case - Remove............................................................................................................. 5-8
3. Front Mechanism - Disassemble and Inspect....................................................... 5-9
3.1 Tappet - Remove .................................................................................................................... 5-10
3.2 Crankshaft Pulley - Remove ................................................................................................... 5-10
3.3 Timing Gear Case - Remove .................................................................................................. 5-10
3.4 Timing Gear Backlash - Measure ........................................................................................... 5-11
3.5 Idler Gear - Remove ............................................................................................................... 5-11
3.6 Camshaft - Remove................................................................................................................ 5-11
3.7 Fuel injection pump camshaft - Remove ................................................................................ 5-12
3.8 Oil Pump - Remove ................................................................................................................ 5-12
3.9 Relief valve - Remove............................................................................................................. 5-13
3.10 Front plate - Remove .............................................................................................................. 5-13
4. Piston, Connecting Rod, Crankshaft and Cylinder block - Disassemble and
Inspect .................................................................................................................... 5-14
4.1 Oil pan - Remove.................................................................................................................... 5-15
4.2 Oil screen - Remove ............................................................................................................... 5-15
4.3 Connecting Rod End Play - Measure ..................................................................................... 5-15
4.4 Connecting Rod Cap - Remove.............................................................................................. 5-15
4.5 Piston - Remove ..................................................................................................................... 5-16
4.6 Piston Ring - Remove............................................................................................................. 5-16
4.7 Piston pin - Remove ............................................................................................................... 5-16
4.8 Cylinder inside diameter - Measure ........................................................................................ 5-16
4.9 Crankshaft End Play - Measure.............................................................................................. 5-17
4.10 Main Bearing Cap - Remove .................................................................................................. 5-17
4.11 Crankshaft - Remove.............................................................................................................. 5-17
5-1
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 the following before proceeding with any job.
Valve clearance - Inspect
Fuel injection timing - Inspect
Valve sinkage - Measure
Replace
3
4
Settling, flaw 6 5 Clogged oil hole, wear
Clogged oil hole, wear 7

8 Flaw in threaded portion
2
Wear and damage on both ends, bend
9
14
15 10
16
Settling, flaw
17
Replace
12
11 Valve guide wear, flaw
Crack, flaw, water leak, oil leak,

scale, gasket, carbon deposit
Valve seat face contact,
flaw, wear Local wear
13
18
Stem face local wear,
flaw, settling
Replace
19
Cylinder heads and Valve mechanisms - Disassemble and Inspect

Disassembling sequence
1 Rocker cover 8 Rocker shaft 15 Retainer
2 Grooved pin 9 Valve cap 16 Valve spring
3 Snap ring 10 Push rod 17 Valve stem seal
4 Exhaust rocker arm 11 Cylinder head bolt (main) 18 Valve
5 Rocker stay 12 Cylinder head bolt (sub) 19 Cylinder head gasket
6 Intake rocker arm 13 Cylinder head
7 Rocker shaft spring 14 Valve lock
5-3
1.1 Valve Clearance - Inspect

Inspect the valve clearance, and know the current condition.
For the inspection procedure, refer to "Valve Clearance -
Inspect and Adjust" of "ENGINE BODY - ASSEMBLE".
Valve Clearance - Inspect

1.2 Fuel Injection Timing - Inspect
Inspect the fuel injection timing, and know the current con-
dition.
For the inspection procedures, refer to "Fuel Injection Tim-
ing - Check and Adjust" of "ASSEMBLY OF BASIC
ENGINE."
Fuel flow out Fuel flow stop

Fuel Injection Timing - Inspect
1.3 Rocker Shaft Assembly - Remove
(1) Loosen the rock nat and loosen the rocker arm adjusting
Rocker shaft assembly
screws by rotating about one turn.
(2) Loosen the rocker stay bolts and remove the rocker
shaft assembly.
Note: Keep the removed rocker shaft assembly together with
the bolts.
(3) Remove grooved pin with pliers.
Rocker stay bolt

Grooved pin
Rocker shaft assembly - Remove
(4) Remove the snap ring. Then disassemble the rocker
Rocker arm
shaft assembly into the rocker arms, rocker stay, rocker
Rocker stay
shaft spring and rocker shaft.
Rocker shaft spring
Snap ring
Rocker shaft
Snap ring
Rocker shaft assembly - Disassemble
5-4
1.4 Cylinder Head Bolt - Remove

Loosen cylinder head bolts in the numerical order as shown
in the illustration. Cylinder head bolt (main)
1 5 7
2
4
3 8 6
10 11 9
Cylinder head bolt (sub)

Cylinder Head Bolt - Remove
1.5 Cylinder Head Assembly - Remove
When removing the cylinder head gasket, be careful

not to damage the cylinder head or cylinder block
surface with a screwdriver or the like.
(1) Lift up the cylinder head assembly, and remove the cyl-
inder head assembly from the cylinder block.
Note: If the cylinder head assembly cannot be removed due
to crimping of the cylinder head gasket, tap the thick
area on the side of the cylinder head using a plastic
hammer to give a shock. Cylinder head assembly - Remove
(2) Remove the cylinder head gasket.
Note: If there is a cylinder head problem, check the bolts for
tightness with a torque wrench before removing the
cylinder head bolts.
1.6 Valve Sinkage - Measure

Measure the valve sinkage, and know the current condition.
For the measurement procedure, refer to "Valve Sinkage -
Measure" of "ENGINE BODY - ASSEMBLE".
1.7 Valve and Valve Spring - Remove

(1) Using a valve lifter, compress the valve spring evenly
and remove the valve lock. Valve lifter
(2) Remove the retainer, valve spring and valve.
Note: If valves are reusable, mark each valve seat and the
mating valve guide for identifying their original posi-
tions. Do not mix valve seats. Valve
Valve lock
Retainer
Valve spring
Valve and valve spring - Remove
5-5
1.8 Valve Stem Seal - Remove

Grab the valve stem seal with pliers and remove.
Note: Be sure to replace the valve stem seal with a new one Valve stem seal
when assembling the valve and valve spring.
Valve Stem Seal - Remove
5-6
2. Rear Mechanism - Disassemble and Inspect
1
Flaw
Oil seal war, flaw, aging
Replace
Friction surface striation,

stepped weal, crack,
3 ring gear flaw,
abnormal wear
Rear equipment - Disassemble and Inspect

1 Flywheel 2 Rear plate 3 Oil seal case, oil seal
5-7
2.1 Flywheel - Remove
(a) Be careful not to cut your hands with the ring gear
when pulling-out the flywheel.
(b) Be careful not to drop or hit the flywheel.Doing so
may not only cause damage to the flywheel but
also lead to personnel injuries.
(c) The personnel who holds the pulley must pay due
Prevent the flywheel Guide bolt
attention to safety.Also, personnel must closely from rotating (M101.25 mm)
communicate with each other during the work. using a wrench.
(1) One personnel must firmly hold the pulley with a Flywheel - Remove
wrench to prevent the flywheel from rotating.
(2) Remove one bolt from the flywheel.
(3) Screw a guide bolt into the threaded hole of the bolt that
has been removed.
(4) Remove remaining bolts from the flywheel.
(5) Hold the flywheel firmly with both hands, and by mov-
ing it back and forth, pull it out straight.
Note: The ring gear is shrink-fitted to the flywheel. Do not
remove the ring gear unless it is defective.
2.2 Oil seal case - Remove
Be careful not to damage the oil seal. Oil seal case
(1) Remove bolts from the oil seal case.

(2) Pry out the oil seal case from the cylinder block using a
screwdriver.
Oil seal case - Remove
5-8
3. Front Mechanism - Disassemble and Inspect

efficient work.
Timing gear backlash - Measure
9 Wear of cam contact face and

10 outer circumference contact face
Replace 1
Settling, crack 8 16 Weight portion wear, flaw
15
Sliding sleeve wear, flaw

5 4
Flaw, wear 7 Rotation,condition
19
Sliding shaft contact 20
portion wear, flow 21
17 18
Replace
12 Replace
Replace 25
Flaw, wear, key groove defect
14
13
Peeling, wear, key groove defect
11
23 Clogged oil hole
Settling,
crack
22
Replace
Peeling, wear, key groove defect
24
3
Crack, dowel hole defect, clogged oil hole
2
Lip face wear, flaw, aging
Front equipment - Disassemble and Inspect

1 Tappet 10 Speed control lever 17 Fuel injection pump camshaft gear
2 Crankshaft pulley (Refer to the section of "FUEL 18 Ball bearing
3 Timing gear case, SYSTEM" for disassembly, 19 Snap ring
Oil seal inspection and assembly.) 20 Ball bearing
4 Grooved pin 11 Idler gear 21 Fuel injection pump camshaft
5 Governor shaft 12 Camshaft gear (Remove 19 to 23 as an assembly)
6 Tension lever 13 Ball bearing 22 Oil pump housing
7 Governor lever 14 Camshaft 23 Oil pump outer gear
8 Governor spring lever (Remove 14 to 16 as an assembly) 24 Oil pump inner gear
9 Grooveed pin 15 Sliding shaft 25 Front plate
16 Governor weight
5-9
3.1 Tappet - Remove

Remove the tappet from the cylinder block using the push
rods.
Note: Be sure to pull out the tappet. The tappet may fall in to
Push rod
oil pan, if the camshaft is pulled out before pulling out Tappet
the tappet.
Tappet - Remove
3.2 Crankshaft Pulley - Remove
Crankshaft pulley
The bar that stops the crankshaft from rotating may
come off. Pay due attention to safety.
(1) Screw two guide bolts into the threaded holes at the rear
end of the crankshaft. Stick a bar across the guide bolts
to prevent the crankshaft from rotating.
(2) Remove the crankshaft pulley.
(3) Take out the woodruff key of the crankshaft. Prevent the crankshaft
from rotating.
Crankshaft pulley - Remove
3.3 Timing Gear Case - Remove
The lower bolts secure also the oil pan.
The front plate is bolted to the cylinder block from Bolts on front: 8 pcs.
inside the gear case. Do not attempt to remove the Bolts on rear: 4 pcs.
front plate together with the gear case by tapping.

(1) Remove the bolts, and remove the water pump.
(2) Remove the cover from the timing gear case.
(3) Remove the timing gear case from the front plate.
Bolt on rear
(4) Remove the front oil seal from the timing gear case.
Note: Bolts have different lengths. Pay attention to the posi- Bolt on front
tions of bolts to ensure correct assembling.
5-10
3.4 Timing Gear Backlash - Measure

Measure the timing gear backlash, and know the current
condition.
For the measurement procedure, refer to "Timing Gear
Backlash - Measure" of "ENGINE BODY - ASSEMBLE".
Timing Gear Backlash - Measure

3.5 Idler Gear - Remove
(1) Remove the snap ring.
(2) Remove idler gears. Snap ring
Idler gear
Idler gear - Remove
3.6 Camshaft - Remove
When pulling out the camshaft, be careful not to cause

damage to the cam portion of the camshaft and the
cam hole of the cylinder block.
(1) Remove camshaft stopper washer.
Camshaft
stopper washer
Camshaft - Remove (1)
(2) Remove camshaft and camshaft gear ball bearing
as a set. Camshaft
Cam
Camshaft gear
5-11
3.7 Fuel injection pump camshaft - Remove
Sliding shaft
When pulling out the fuel injection pump camshaft, be
careful not to cause damage to the cam portion of the
fuel injection pump camshaft and the cam hole of the
cylinder block.
(1) Remove sliding shaft and governor weight.
Governor weight
Sliding shaft and

Governor weights - Remove
(2) Remove camshaft stopper washer.
Camshaft
stopper washer
Fuel injection pump

camshaft gear
Fuel injection pump
(3) Remove fuel injection pump camshaft as set of fuel
injection pump camshaft gear and ball bearing.
Fuel injection pump

3.8 Oil Pump - Remove
Remove oil pump housing and then oil pump outer gear and
oil pump inner gear. Oil pump inner gear Oil pump housing
Gear case Oil pump outer gear
Oil pump - Remove
5-12
3.9 Relief valve - Remove

(1) Remove the plug from the gear case.
(2) Remove the relief spring and relief plunger.
Relief plunger
Relief
Gear case Plug
spring
Relief valve - Remove
3.10 Front plate - Remove
Remove the bolts, and remove the front plate from cylinder
block.
Note: If it is difficult to remove the front plate, lightly tap it
with a plastic hammer paying attention not to bend.
Fixing bolts of front plate: 7

Front Plate - Remove
5-13
4. Piston, Connecting Rod, Crankshaft and Cylinder block - Disassemble and Inspect
efficient work.
Connecting rod end play - Measure
Crankshaft end play - Measure
Cylinder inside diameter - Measure
7
Piston ring wear, Peeling, scratches,
flaw, end gap 8 13
seizure
9 Connecting rod bend,
twist, big end thrust
Piston wear, sticking, 10 clearance
striation, ring groove wear
12
6
Cylinder flaw,
stepped wear 5 Peeling, scratches,
seizure
Top face distortion 11
Replace
16
Replace
Flaw in plug & dowel pins,

clogging or contamination
of oil/water holes 15
Peeling, scratches, seizure

14
Crankshaft gear teeth

flaw, sticking to bearing
Peeling, scratches, seizure 1
4
Flaw in journal & pin,
local wear, crack, bend, 3
clogged oil hole
Piston, Connecting rod, Crankshaft and Cylinder block - Disassemble and Inspect
1 Oil pan 7 No. 1 compression ring 12 Main bearing cap
2 Oil screen 8 No. 2 compression ring 13 Lower main bearing
3 Connecting rod cap 9 Oil ring 14 Crankshaft
4 Lower connecting rod bearing 10 Piston 15 Upper main bearing
5 Connecting rod (Remove parts 5 thru 10 as a unit) 16 Cylinder block
6 Piston pin 11 Upper connecting rod bearing (Approx. 22 kg [49 lb.])
Note: When replacing the cylinder block, carefully remove parts (relief valve, etc.) mounted on the reusable cylinder block so
that they can be reused.
5-14
4.1 Oil pan - Remove
Do not remove the oil pan inserting chisel or drive

between oil pan and cylinder block. When inserting
chisel or driver, oil pan flange will deform.
(1) Invert the engine.
(2) Remove bolts from the oil pan.
(3) To remove oil pan, tap bottom corners of the oil pan
with a plastic hammer.
Oil pan - Remove

4.2 Oil screen - Remove
Loosen the nut, and remove the oil screen.
Oil screen - Remove

4.3 Connecting Rod End Play - Measure
Measure the connecting rod end play, and know the current
condition.
For the measurement procedure, refer to "Connecting Rod
End Play - Measure" of "ENGINE BODY - ASSEMBLE".
Connecting Rod End Play - Measure

4.4 Connecting Rod Cap - Remove
(1) Mark the cylinder number on the connecting rod and
connecting rod cap so that their combination is not
changed when assembling.
(2) Remove the connecting rod caps.
Note: Mark the cylinder numbers and upper/lower on con-
necting rod bearings to ensure correct assembling.
Connecting Rod Cap - Remove
5-15
4.5 Piston - Remove

(1) Rotate the crankshaft to bring the piston to top dead
center.
(2) Using a piece of wood such a hammer handle, push the
mating surface of the connecting rod cap, and remove
the piston and connecting rod upward from the cylin-
der.
Connecting rod
Piston - Remove
4.6 Piston Ring - Remove
Remove the piston rings using piston ring pliers.
Piston Ring - Remove

4.7 Piston pin - Remove
Do not try to remove the piston pin by tapping. If a Push rod

Identification mark
great force is required to remove piston pin due to
Connecting rod
seized piston pin, replace piston pin and/or connecting Piston pin
rod with a new one after removing the piston pin.
Piston pin
Remove the piston pin with a piston pin setting tool. setting tool
P/N: 30L91-10010
Piston pin - Remove

4.8 Cylinder inside diameter - Measure
Measure the cylinder inside diameter, and recognize the cur-
Measuring
rent condition. directions
A
For the measurement procedure, refer to "Cylinder inside
diameter - Measure" of "ASSEMBLY OF BASIC B
Approx. 10 mm [0.39 in.]
ENGINE." from top end
Center
Bottom
Measuring
points
Cylinder inside diameter - Measure
5-16
4.9 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 "ENGINE BODY - ASSEMBLE".
Crankshaft End Play - Measure

4.10 Main Bearing Cap - Remove
(1) Remove the main bearing cap bolt.
(2) Remove the main bearing cap.
Wrap a screw driver with waste cloth. Place its tip in
the oil hole of front / rear bearing cap. Pry out the cap
by utilizing the balance weight as fulcrum.
Note:(a) Be careful not to damage the main bearings.
(b) Mark the bearings for their cylinder numbers.
Wrap a screw
driver with waste
cloth
Main bearing cap - Remove
4.11 Crankshaft - Remove
Be careful not to damage bearings when removing the

crankshaft.
(1) Slowly lift the crankshaft straight up.
(2) Arrange the bearings in the order of disassembly so that
their original positions are restored when assembling.
Note:(a) Do not attach a metal chain or other hoisting devic-
es directly onto the crankshaft, as they could dam-
age the crankshaft. Place cloth belts or pads in
position where a chain or other hoists are hooked Crankshaft - Remove
before raising crankshaft.
(b) Mark the bearings for their cylinder numbers.
5-17
1. Cylinder Head and Valve Mechanism - Inspect and Repair................................. 6-3

1.1 Clearance Between Rocker Arm and Rocker Shaft - Measure ................................................ 6-3
1.2 Valve Stem Outside Diameter and Valve Guide Inside Diameter - Measure ........................... 6-3
1.3 Valve Guide - Replace.............................................................................................................. 6-4
1.4 Valve Face - Inspect ................................................................................................................. 6-5
1.5 Valve Face - Reface ................................................................................................................. 6-5
1.6 Valve and Valve Seat Ring - Lap.............................................................................................. 6-6
1.7 Squareness and Free Length of Valve Spring - Measure......................................................... 6-6
1.8 Pushrod Runout - Measure....................................................................................................... 6-7
1.9 Distortion of Cylinder Head Bottom Surface - Measure............................................................ 6-7
2. Rear Mechanism - Inspect and Repair................................................................... 6-8
2.1 Flatness of Flywheel - Measure................................................................................................ 6-8
2.2 Ring Gear - Inspect................................................................................................................... 6-8
2.3 Ring Gear - Replace ................................................................................................................. 6-8
3. Front Mechanism - Inspect and Repair.................................................................. 6-9
3.1 Clearance Between Idler Gear and Idler Shaft - Measure........................................................ 6-9
3.2 Idler Shaft - Replace ................................................................................................................. 6-9
3.3 Cam Height of Camshaft - Measure ......................................................................................... 6-9
3.4 Cam height of Fuel Injection Pump Shaft - Measure ................................................................ 6-9
3.5 Clearance Between Camshaft Journal and Camshaft Hole - Measure .................................. 6-11
3.6 Clearance Between Tappet and Tappet Guide Hole - Measure............................................. 6-11
3.7 Tappet - Inspect...................................................................................................................... 6-11
4. Piston and Connecting Rod - Inspect and Repair .............................................. 6-12
4.1 Piston Outside Diameter - Measure........................................................................................ 6-12
4.2 Piston Ring Groove - Inspect.................................................................................................. 6-12
4.3 Piston Pin Bore Diameter and Piston Pin Outside Diameter - Measure ................................. 6-13
4.4 Piston Ring End Gap - Measure ............................................................................................. 6-13
4.5 Clearance Between Connecting Rod Bearing and Crankpin - Measure................................. 6-14
4.6 Connecting Rod Bend and Twist - Inspect ............................................................................. 6-15
5. Cylinder block and Crankshaft - Inspect and Repair ......................................... 6-16
5.1 Cylinder Inside Diameter - Measure ....................................................................................... 6-16
5.2 Cylinder block Top Surface Distortion - Measure ................................................................... 6-16
5.3 Crankshaft Runout - Measure................................................................................................. 6-17
5.4 Crankshaft Gear - Replace ..................................................................................................... 6-17
5.5 Clearance between main bearing and crank journal - Measure ............................................. 6-18
6-1
1. Cylinder Head and Valve Mechanism - Inspect and Repair

1.1 Clearance Between Rocker Arm and Rocker Shaft - Measure
Measure the inside diameter of the rocker arm and outside
Measuring
diameter of the rocker shaft. Replace the rocker arm or
direction
rocker shaft if the clearance exceeds the limit. Measuring
position
Item Nominal Standard Limit
12.013 to
ø 12 mm 12.035 mm
Rocker arm inside diameter - Measuring
[0.47 in.] [0.4730 to
0.4738 in.] direction
11.470 to
ø 12 mm 11.984 mm
Rocker shaft outside diameter -
[0.47 in.] [0.4516 to
0.4718 in.]
Clearance between rocker arm and rocker shaft
0.029 to - Measure
Clearance between rocker 0.065 mm 0.200 mm
-
arm and shaft [0.0011 to [0.0079 in.]
0.0026 in.]
1.2 Valve Stem Outside Diameter and Valve Guide Inside Diameter - Measure
Measure the outside diameter of the valve stem and the
inside diameter of the valve guide at the top and bottom
Measuring
ends in orthogonal direction as shown, as the sliding area directions
tends to wear at top and bottom ends. If the outside diameter
is less than the limit, or the clearance exceeds the limit,
replace either the valve or the valve guide with a new one.
Note: Lap the valve and valve seat whenever new valve is in- Measuring
points
stalled.

6.565 to Valve stem outside diameter - Measure
ø 6.6 mm 6.580 mm 6.500 mm
Inlet
[0.260 in.] [0.2585 to [0.2559 in.]
Valve stem 0.2591 in.] Inside Measuring
outside micrometer directions
diameter 6.530 to
ø 6.6 mm 6.550 mm 6.500 mm
Exhaust
[0.260 in.] [0.2571 to [0.2559 in.]
0.2579 in.]
0.020 to
0.050 mm 0.100 mm
Inlet -
Clearance [0.008 to [0.0039 in.]
between valve 0.0020 in.]
stem and valve 0.050 to
guide 0.085 mm 0.150 mm Measuring
Exhaust -
[0.0020 to [0.0059 in.] points
0.0033 in.]
Valve guide inside diameter - Measure
ø 6.6 mm 6.600 to
Inlet
Valve guide [0.260 in.] 6.615 mm
-
Inside diameter ø 6.6 mm [0.2598 to
Exhaust 0.2604 in.]
[0.260 in.]
13.5 to
Valve guide installed 14 mm 14.5 mm
-
length [0.55 in.] [0.532 to
0.571 in.]
6-3
1.3 Valve Guide - Replace

(1) Remove the valve guide with a punching tool pressing
Unit: mm [in.]
from the cylinder head bottom surface. Puller Puller
65
20 [2.56]
[0.79]
ø10
ø6 [0.39]
[0.24]
Valve guide
Valve guide - Remove

(2) When press-fitting the new valve guide, press-fit the
valve guide with a press from the stopper head top sur- ø12.5 [0.492] (ø25 [0.98])
face.
14 ± 0.1 [0.55 ± 0.004]

+0.015
(ø12 [0.47]) (ø6.6 0 )
[0.260 +0.00059 ]
(3) After press-fitting the valve guide, insert the valve and
0
[0.55 ± 0.020]
check the movement.
(4) Check contacts between valves and valve seats after
14 ± 0.5
replacing valve guides.
ø24 [0.94]
Stopper Unit: mm [in.]
Valve guide - Press fit
6-4
1.4 Valve Face - Inspect

Apply a thin lead-free coloring paste on the valve face, and
strike the valve face against the valve seat using a valve lap-
per to check for contact condition. If the contact is not even,
or any defects are found, or if the specified limit is Valve lapper
exceeded, reface or replace the valve.

Note:(a) Inspect the valve face after the valve guide is in- Lead-free
spected or replaced. coloring paste
(b) Do not rotate the valve when pressing the valve face
coated with lead-free coloring paste against the
valve seat.
Valve face - Inspect
(c) Lap the valve and valve seat whenever the valve is
refaced or replaced.

Valve seat
44° - -
angle
Valve
seat 0.4 to 0.6 mm
0.5 mm Good Bad
Valve sinkage [0.016 to -
[0.020 in.]
0.024 in.]
Contact
1.0 mm 0.50 mm (must be at face center)
Valve margin
[0.039 in.] [0.0197 in.]
Contact condition between valve seat and valve
Valve head Valve head

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

(b) The valve margin is to be within the specified lim-
it.If the dimensions after refacing do not meet the
specified values, replace the valve with a new one.
Grind the valve face
using the valve refacer
at the specified angle.
Valve Face - Reface
6-5
1.6 Valve and Valve Seat Ring - Lap

Lap the valve and valve seat ring whenever the valve seat
ring is refaced or the valve is replaced, or the contact sur-
faces fail to keep a pressure in the pressure test after assem-
bling.
(1) Apply a thin coat of lapping compound evenly to valve
seat face.
Note:(a) Do not allow the compound to adhere to the valve
Compound
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 (125 to 150 mesh)
for initial lapping, then use the fine-grain com-
pound (200 mesh) for finishing.
(2) Use a valve lapper for lapping.Tap the valve against the
Valve lapper
valve seat while rotating the valve little by little.
(3) Clean off the compound using diesel fuel.
(4) Apply engine oil to mating surfaces, and lap for finish-
ing.
(5) Apply a thin coat of lead-free coloring paste on the
valve face, and tap the valve face against the valve seat
using a valve lapper to check the contact condition. Valve and Valve Seat Ring - Lap
1.7 Squareness and Free Length of Valve Spring - Measure

Measure the squareness and free length of valve spring. If
the specified limit or standard value is exceeded, replace the Squareness of the spring
valve spring with a new one.
Nominal Standard Limit

38.5 mm
Free length 40 mm [1.57 in.]
[1.516 in.]
Free length
A A=2.0° or less
Length
B B=1.4 mm
Squareness B= 2.0 mm
Lf [0.055 in.] or less
[0.079 in.]
Lf=40 mm [1.57 in.]
35.5 mm [1.398 in.]/ 28 mm [1.10 in.]/ Squareness and free length of spring - Measure
Installed 64.1 to 71.0 N 170.1 to 189.4 N
-15 %
length/load {6.54 to 7.24 kgf} {17.41 to 19.31 kgf}
[14.4 to 16.0 lbf] [38.3 to 42.6 lbf]
6-6
1.8 Pushrod Runout - Measure

Measure the runout of push rod by TIR. If the run out
exceeds the limit, replace the push rod with a new one.
Item Limit Remarks

Pushrod runout 0.3 mm [0.012 in.] TIR V-block
Push rod
1/2 1/2
Surface plate
Pushrod runout - Measure

1.9 Distortion of Cylinder Head Bottom Surface - Measure
Measuring points
Refacing of cylinder head should be minimum.

Excessive grinding of the cylinder head may result in
defects such as defective combustion and contact
between piston and valve.
With a straight edge placed on the bottom face of the cylin-
der head, measure the bottom face distortion using a thick-
ness gauge. If the distortion exceeds the limit, grind the
cylinder head.
Distortion of cylinder head bottom surface - Measure
Item Standard Limit
Bottom surface of the 0.05 mm 0.10 mm
cylinder head distortion [0.0020 in.] or less [0.0039 in.]
6-7
2. Rear Mechanism - Inspect and Repair

2.1 Flatness of Flywheel - Measure
Place the flywheel on a surface plate and move a dial gauge
onto the friction surface of the flywheel to measure the flat-
ness. Grind the friction surface of the flywheel if the limit is
exceeded.
Item Standard Limit

0.08 mm 0.50 mm
Flatness of flywheel
[0.0031 in.] or less [0.0197 in.]
Flatness of flywheel - Measure

2.2 Ring Gear - Inspect
Inspect the ring gear for a missing tooth or wear on teeth,
and if any defect is found, replace the ring gear.
2.3 Ring Gear - Replace

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

2.3.2 Ring gear - Install
(1) Heat the ring gear evenly up to approx. 260 to 288°C
[500 to 550 °F] with an appropriate heater.
(2) Install the ring gear onto the flywheel with the no-gear
chamfering side faced to the flywheel.
Note: Do not heat the ring gear excessively.
6-8
3. Front Mechanism - Inspect and Repair

3.1 Clearance Between Idler Gear and Idler Shaft - Measure
Measure the inside diameter of the idler gear and outside
diameter of the idler shaft. Replace the idler gear or idler Measuring directions
shaft if the clearance exceeds the specified limit.
Measuring
Item Standard Limit points
Clearance between idler gear 0.030 to 0.066 mm 0.200 mm
and idler shaft [0.0012 to 0.0026 in.] [0.0079 in.]
Clearance between idler gear and idler shaft -

Measure
3.2 Idler Shaft - Replace
Press-fit the idler shaft into the cylinder block to the dimen-
sion in the illustration. 23.3 +0.3 +0.12
0 mm [0.917 0 in.]
Idler shaft - Replace

3.3 Cam Height of Camshaft - Measure
Measure the major axis of cam. If the measured value is less
than the specified limit, replace the camshaft with a new
one.
Measuring Measuring
Item Nominal Standard Limit directions points
Cam height of
27.37 mm 27.27 to 27.47 mm 26.37 mm
camshaft
[1.0776 in.] [1.0736 to 1.0815 in.] [1.0382 in.]
(major axis)
Cam height of camshaft - Measure

3.4 Cam height of Fuel Injection Pump Shaft - Measure
Measure the cam height. Replace the camshaft with a new
one if the height is less than the limit.
Item Standard Limit Measuring Measuring

Cam height of fuel injection pump directions points
29.9 to 30.1 mm 29 mm
camshaft
[1.177 to 1.185 in.] [1.14 in.]
(major axis)
Cam height of fuel injection pump camshaft - Measure

6-9
3.5 Clearance Between Camshaft Journal and Camshaft Hole - Measure

Measure the clearance between the outside diameter of cam-
shaft journal and the inside diameter of cylinder block cam-
shaft. If the clearance exceeds the limit, replace either
camshaft or cylinder block with a new one. Measuring Measuring
directions points
Item Standard Limit
Clearance between camshaft 0.050 to 0.100 mm 0.150 mm
journal and camshaft hole [0.0020 to 0.0039 in.] [0.0059 in.]
Outside diameter of camshaft journal - Measure
Inside diameter of cylinder block camshaft hole -

Measure
3.6 Clearance Between Tappet and Tappet Guide Hole - Measure
Measure clearance between the tappet and tappet hole. If the
Measuring Measuring
specified limit is exceeded, replace the tappet with a new points directions
one.
Item Standard Limit

Clearance between tappet 0.007 to 0.049 mm 0.15 mm
and tappet guide hole [0.0003 to 0.0019 in.] [0.0059 in.]
Clearance between tappet and tappet guide hole

- Measure
3.7 Tappet - Inspect
Inspect the tappet sliding face to cam for even wear. If the
surface is defective, replace the tappet with a new one.
Flaw, local wear Flaw, local wear
Good Bad Bad
Tappet Sliding Face to Cam - Inspect
6-10
4. Piston and Connecting Rod - Inspect and Repair

4.1 Piston Outside Diameter - Measure
Using a micrometer, measure the piston outside diameter at
the skirt perpendicular to the piston pins as shown in the Direction at right
angles to piston pin
illustration.
If the specified limit is exceeded, replace it with a new one.
Measuring
Item Nominal Standard Limit point
75.906 to
ø 76.00 mm 75.926 mm
Standard
[2.9921 in.] [2.9884 to
2.9892 in.]
76.156 to
Piston outside ø78.25 mm 76.176 mm
Size +0.25
diameter [3.0020 in.] [2.9983 to Piston outside diameter - Measure
2.9990 in.]
76.406 to
ø76.50 mm 76.426 mm
+0.50
[3.0118 in.] [3.0081 to
3.0089 in.]
4.2 Piston Ring Groove - Inspect
Remove carbon deposits from pistons and inspect the

entire circumference of the piston.
(1) Remove all deposits such as carbon from each ring
groove.
(2) Check each ring groove for wear or damage. If faulty,
replace the piston with a new one.
(3) Insert the piston ring into the piston ring groove. Apply
a straight edge and insert thickness gauges to measure
the clearance between ring and ring groove. Piston ring groove - Inspect
If the specified limit is exceeded, find the causal parts,
and replace them with new ones.
Item Standard Limit

No.1 0.3 mm
-
compression [0.012 in.]
Clearance
between piston No.2 0.05 to 0.09 mm 0.2 mm
ring and ring compression [0.0020 to 0.0035 in.] [0.008 in.]
groove
0.03 to 0.07 mm 0.2 mm
Oil
[0.0012 to 0.0028 in.] [0.008 in.]
6-11
4.3 Piston Pin Bore Diameter and Piston Pin Outside Diameter - Measure
Measure the piston pin bore diameter and piston pin outside
diameter. If the limit is exceeded, replace it with a new one.

21.002 to
ø21 mm 21.005 mm
Piston pin outside diameter -
[0.83 in.] [0.8268 to
0.8270 in.]
Clearance between the
0.007 to
inside deameter of piston
0.015 mm 0.08 mm
pin hole and the outside -
[0.0003 to [0.0031 in.]
deameter of piston pin Measuring points Measuring directions
0.0006 in.]
Piston pin bore diameter and Piston pin outside
diameter - Measure
4.4 Piston Ring End Gap - Measure
(a) When replacing rings without boring (honing),

measure the end gap at the bottom of the cylinder Piston
where the wear is minimum.
Cylinder
(b) When replacing the ring, use the ring of the same
size as the piston.
Insert the piston ring into the cylinder bore and push it with
the piston to achieve squareness. Then measure the end gap
Ring
with thickness gauges. Replace the piston ring if the limit is
exceeded. Piston ring end gap - Measure
Item Standard Limit

No.1 0.15 to 0.30 mm
compression [0.0059 to 0.0118 in.]
Piston ring No.2 0.15 to 0.30 mm 1.50 mm
end gap compression [0.0059 to 0.0118 in.] [0.0591 in.]
0.15 to 0.35 mm
Oil
[0.0059 to 0.0138 in.]
6-12
4.5 Clearance Between Connecting Rod Bearing and Crankpin - Measure
Measuring Measuring 32.9 ± 1.4 N·m

directions points {3.4 ± 0.1 kgf·m}
When grinding crankpins, be sure to grind all the pins
[24.2 ± 1.1 lbf·ft]
to the same size. Finish the fillet radius to the speci-
fied dimension.
(1) Assemble the bearing into the big end of the connecting
rod.
(2) Tighten the connecting rod cap to the specified torque.
(3) Measure the inside diameter of the connecting rod bear-
ing.
(4) Measure the crankpin outside diameter. Connecting rod bearing inside diameter - Measure
(5) Calculate the clearance from the difference between the
inside diameter of the connecting rod bearing and out-
side diameter of the crankpin.
(6) If the clearance exceeds the limit, replace the connect-
᷹ቯᣇะ ᷹ቯ▎ᚲ
ing rod bearing with a new one.
(7) Measure the clearance between the connecting rod
bearing and the crankpin again. Use the undersize bear-
ing if the limit is exceeded.
(8) If an undersize bearing is used, grind the crankpin to
the specified undersize.
Crankpin outside diameter - Measure
39.965 to
ø40 mm 39.980 mm -0.70 mm
Crankpin outside diameter
[1.57 in.] [1.5734 to [-0.0276 in.]
1.5740 in.]
0.028 to
Clearance between
0.071 mm 0.150 mm
crankpin and connecting - 0
R2-0.2 mm
[0.0011 to [0.0059 in.]
rod bearing 0
[0.08-0.008 in.]
0.0028 in.]
Item Undersize Finishing dimension

-0.020
0.25 mm ø39.75 -0.035 mm
[0.0098 in.] -0.0008 Finish dimension of fillet radius
[1.5650 -0.0014 in.]
Crankpin undersize
-0.020
0.50 mm ø39.50 -0.035 mm
[0.0197 in.] -0.0008
[1.5551 -0.0014 in.]
6-13
4.6 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 0.05
[
0.0020
]
L 100 3.94
ing rod. Straighten the connecting rod with a press so C 0.05
[
0.0020
]
L 100 3.94
that the measurement value meets the standard. C
L
If the value exceeds the limit, replace the connecting L
rod with a new one. Piston C
pin
Note: Before checking bend and twist, tighten the connecting
Connecting rod twist
rod cap to the specified torque.
(2) To inspect the connecting rod with the piston installed, Connecting rod bend Unit: mm [in.]
turn the piston upside down and place it on a surface
Connecting rod bend and twist - Inspect
plate. Insert a round bar having the same diameter as
the crankpin into the big-end bore, and measure the
height of the bar using a dial gauge. D
C
Item Standard
Connecting rod bend and twist 0.05/100 mm
(C/L, C/D) [0.0020/3.94 in.] or less A B
Measuring with a dial gauge
6-14
5. Cylinder block and Crankshaft - Inspect and Repair

5.1 Cylinder Inside Diameter - Measure
Use a cylinder gauge to measure the inside diameter and
Measuring
cylindricity of the cylinder at three locations in the A and B directions
A
directions as shown in the illustration. If any one of the cyl-
inders exceeds the repair limit, bore all the cylinders and B
replace the pistons and piston rings with oversize ones. from top end
Piston, Center
Cylinder inside diameter
piston ring type
Bottom
Size Size mark Standard Limit
+1.0 Measuring
ø76 0 mm points
Standard - +0.039
[2.99 0 in.] Cylinder inside diameter - Measure
+1.0 Standard
ø76.25 0 mm
+0.25 25 +0.039
+0.2 mm
[3.0020 0 in.] [+0.0079 in.]
+1.0
ø76.50 0 mm
+0.50 50 +0.039
[3.0118 0 in.]
0.01 mm
Cylindricity of cylinder -
[0.0004] or less
Clearance between 0.074 to 0.124 mm 0.2 mm
piston and cylinder [0.0029 to 0.0049 in.] [0.008 in.]
5.2 Cylinder block Top Surface Distortion - Measure
Measuring points and directions

Refacing of cylinder block should be kept to an abso-
lute minimum.
Excessive grinding of the cylinder block may result in
defects such as defective combustion and contact
between piston and valve.
Measure the distortion of the crankcase top surface with a
straight edge and thickness gauge. If the measurement
exceeds the limit, grind the top surface with a surface
grinder. Cylinder block top surface distortion - Measure
Item Standard Limit

Cylinder block top surface 0.05 mm 0.10 mm
distortion [0.0020 in.] or less [0.0039 in.]
6-15
5.3 Crankshaft Runout - Measure

Support the crankshaft at the front and rear journals with V-
blocks, and measure the crankshaft runout at the center jour-
nal using a dial gauge. If the runout deviates slightly from
the standard, grind the crankshaft. If the runout exceeds the
specified standard considerably, straighten the crankshaft
using a press.
If the crankshaft has been repaired by grinding or pressing,
inspect the crankshaft for cracks and other harmful damage
using a magnetic particle method.
Item Standard Remarks Crankshaft runout - Measure

Crankshaft runout 0.06 mm [0.0024 in.] or less TIR
5.4 Crankshaft Gear - Replace
ࠡࡗࡊ࡜࡯
Use protective gloves when you touch hot parts.
Touching hot parts with bare hands can result in
burns.
5.4.1 Crankshaft gear - Remove

Using a gear puller, remove the gear from the crankshaft.
Crankshaft gear - Remove

5.4.2 Crankshaft Gear - Install
(1) Install the key on the crankshaft.
(2) Heat the gear, and press-in the gear fully aligning with
the key.
วࠊߖ૏⟎
Crankshaft Gear - Install
6-16
5.5 Clearance between main bearing and crank journal - Measure
51.5 ± 2.4 N·m

(a) When grinding crank journals, be sure to grind all {5.3 ± 0.2 kgf·m}
[38.0 ± 1.7 lbf·ft]
the journals to the same size.
(b) Finish the fillet radius to the specified dimension.
(1) Install the main bearings.
(2) Secure the main bearing cap to the specified torque.
(3) Measure the inside diameter of the main bearings.
(4) Measure the outside diameter of the crank journal. Measuring Measuring
(5) Calculate the clearance between the inside diameter of directions points
the main bearing and outside diameter of the crank Main bearing inside diameter - Measure
journal.
(6) If the clearance exceeds the limit, replace the main
bearing.
(7) Measure the clearance between the main bearing cap
and the crank journal again. Use the undersize bearing
Measuring Measuring
if the limit is exceeded. directions points
(8) If an undersize bearing is used, grind the crank journal
to the undersized specification.

ø43 mm 42.965 to 42.980 mm Crank journal outside diameter - Measure
Journal diameter -
[1.69 in.] [1.6915 to 1.6921 in.]
0.030 to 0.075 mm 0.100 mm R2 mm R2 mm
Oil clearance -
[0.0012 to 0.0030 in.] [0.0039 in.] [0.08 in] [0.08 in]
Item Size Standard

-0.020
ø42.75-0.035 mm
-0.25 -0.0008
[1.6831-0.0014 in.]
Crank journal
-0.020
ø42.50-0.035 mm
-0.50 -0.0008
[1.6732-0.0014 in.]
Width of crankshaft thrust bearing surface
6-17
1. Piston, Connecting Rod, Crankshaft and Cylinder block - Assemble................ 7-3
1.1 Upper Main Bearing - Install ..................................................................................................... 7-3
1.2 Crankshaft - Install.................................................................................................................... 7-3
1.3 Main bearing cap bolt - Install................................................................................................... 7-3
1.4 Main Bearing Cap - Install ........................................................................................................ 7-4
1.5 Main bearing cap bolt - Install................................................................................................... 7-4
1.6 Crankshaft End Play - Measure................................................................................................ 7-5
1.7 Side Seal - Insert ...................................................................................................................... 7-5
1.8 Piston and Connecting Rod - Assemble ................................................................................... 7-6
1.9 Piston Ring - Install................................................................................................................... 7-7
1.10 Piston and connecting rod - Install............................................................................................ 7-7
1.11 Connecting Rod Cap - Install.................................................................................................... 7-8
1.12 Connecting Rod End Play - Measure ....................................................................................... 7-8
1.13 Oil screen - Install ..................................................................................................................... 7-8
1.14 Oil pan - Install.......................................................................................................................... 7-9
2. Front Mechanism - Assemble............................................................................... 7-10
2.1 Relief valve - Install................................................................................................................. 7-10
2.2 Oil Pump - Install .................................................................................................................... 7-10
2.3 Front Plate - Install.................................................................................................................. 7-10
2.4 Crankshaft - Turn.................................................................................................................... 7-10
2.5 Fuel injection pump camshaft - Install .................................................................................... 7-12
2.6 Camshaft - Install.................................................................................................................... 7-12
2.7 Idler Gear - Install ................................................................................................................... 7-12
2.8 Timing Gear Backlash - Measure ........................................................................................... 7-13
2.9 Governor weights and sliding shaft - Install ............................................................................ 7-13
2.10 Front Oil Seal - Install ............................................................................................................. 7-13
2.11 Timing Gear Case - Install ...................................................................................................... 7-14
2.12 Air-Conditioner Pulley and Crankshaft Pulley - Install ............................................................ 7-14
2.13 Tappet - Install ........................................................................................................................ 7-14
3. Rear Mechanism - Assemble ................................................................................ 7-15
3.1 Oil Seal Case - Install ............................................................................................................. 7-15
3.2 Flywheel - Install ..................................................................................................................... 7-15
4. Cylinder Head and Valve Mechanism - Assemble .............................................. 7-16
4.1 Cylinder head bottom surface - Clean .................................................................................... 7-16
4.2 Valve Stem Seal - Install......................................................................................................... 7-16
4.3 Valve Spring - Install............................................................................................................... 7-16
4.4 Valve Lock - Install.................................................................................................................. 7-16
4.5 Cylinder Head Gasket - Install ................................................................................................ 7-18
4.6 Cylinder Head Assembly - Install............................................................................................ 7-18
4.7 Cylinder Head Bolt - Tighten................................................................................................... 7-18
4.8 Push Rod - Insert.................................................................................................................... 7-18
4.9 Rocker Shaft Assembly - Assemble ....................................................................................... 7-20
4.10 Rocker Shaft Assembly - Install.............................................................................................. 7-20
4.11 Valve Clearance - Check and Adjust ...................................................................................... 7-21
4.12 Fuel Injection Timing - Check and Adjust ............................................................................... 7-22
4.13 Rocker Cover - Install ............................................................................................................. 7-23
7-1
1. Piston, Connecting Rod, Crankshaft and Cylinder block - Assemble

To assemble, follow the disassembly sequence in reverse.
1.1 Upper Main Bearing - Install
(1) Fit the upper main bearing shell in the cylinder block
bore while aligning the notch on the shell with the lug
of the cylinder block.
Note: The oil hole in the upper main bearing shell will be
aligned with the oil hole in the cylinder block by align-
ing the notch of upper shells with the lug of the cylin-
der block.
(2) Apply an even coat of clean engine oil to the sliding
surface of upper bearing shells.
Upper main bearing - Install (1)
Flanged main bearing

mounting portion
Front
Upper main bearing - Install (2)

1.2 Crankshaft - Install
(1) Wash the crankshaft thoroughly with cleaning oil and
clean it completely by compressed air.
Note: When washing crankshaft, be sure to thoroughly wash
oil holes so that they are free from foreign substances,
dust and dirt.Make sure that oil holes are free from any
burrs.
(2) Hold the crankshaft horizontally and slowly install it to
the cylinder block.
(3) Apply a thin coating of engine oil to the crankshaft
journals.
Installing crankshaft
1.3 Main bearing cap bolt - Install
(1) Install the lower main bearing shell, aligning the lug
with the lug slot in the main bearing cap.
(2) Apply an even coat of clean engine oil to the sliding
surface of lower bearing shells.
7-3
1.4 Main Bearing Cap - Install
Apply ThreeBond 1212

The foremost and rearmost caps should be installed to corner of cap
so that they are flush with the cylinder block surface.

(1) Apply sealant to the mating surface of the foremost and
rearmost caps and the cylinder block mating faces Front
before installing the main bearing caps.
3
Sealant ThreeBond 1212 or 1211
(2) Install the main bearing caps so that their front marks
Installing position of main bearing cap
(arrow) and cap numbers are in numerical order from
the front of the engine.
(3) Temporarily tighten the bolts.
(4) Tap the front - most / rear - most cap face with a plastic
hammer to adjust the face to be flush with the cylinder
block face.
Flush
Main bearing cap - Install

1.5 Main bearing cap bolt - Install
(1) Tighten the main bearing cap bolts alternately and pro-
gressively to the specified torque.
(2) Make sure that the crankshaft rotates smoothly.
51.5 ± 2.4 N·m

{5.3 ± 0.2 kgf·m}
[38.0 ± 1.7 lbf·ft]
Main bearing cap bolt - Tighten
Crankshaft for rotation - Check
7-4
1.6 Crankshaft End Play - Measure

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

0.050 to 0.175 mm 0.500 mm
Crankshaft end play
[0.0020 to 0.0069 in.] [0.0197 in.]
Crankshaft end play - Measure

1.7 Side Seal - Insert
(1) Apply sealant (ThreeBond 1211) to the periphery of
Side seal
new side seal from the bottom to 2/3 height.
(2) With the round section of the side seals facing outward,
press them partway into the front and rear caps using
hands. Round portion Round portion
(3) When the side seals are installed partway into caps, use
a tool with flat surface such as flat-head screwdriver to
install completely, taking care not to bend them.
Side Seal - Insert
7-5
1.8 Piston and Connecting Rod - Assemble

(1) With the identification mark of connecting rod facing
upward, place the rod on the piston pin setting tool. Identification mark
Connecting rod
Piston pin setting tool

P/N: 30L91-10010
Piston and Connecting rod - Assemble (1)

(2) Set the piston pin push rod and guide to the piston pin.
Push rod Piston pin Guide

(3) Assemble the piston to the connecting rod with the
front mark (Δ) on the piston top and the identification Identification mark Pushrod
mark of the connecting rod facing upward. Install the Piston pin
Connecting rod
Front mark
piston pin from the piston pin guide. ٌ
Guide

(4) Press-in the piston pin with the push rod using hydrau-
lic press (pin press-in load 9807±4903 N {1000±500
kgf} [2205±1102 lbf]) until the guide contacts the pis-
ton setting tool.
(5) After assembling, make sure that the piston and the
connecting rod move lightly on the piston pin.
7-6
1.9 Piston Ring - Install
T
Every piston ring has a top mark near the end gap.
Top face mark No.1
Install piston rings with the mark facing upward. compression ring
If the rings are installed upside down, it could cause
malfunctions such as excessive oil consumption or No.2
compression ring
engine seizing.
(1) Install the piston rings to the piston with piston ring pli-
ers. Oil ring
(2) Install the oil ring with its end gap 180° away from the
joint of the coil spring, as shown in the illustration. Piston and Piston ring - Install
Coil spring joint
180°
Oil ring ends
Oil ring and coil spring assembling

1.10 Piston and connecting rod - Install
Oil ring end gap No.1 ring end gap

Do not forcefully insert the piston, as it may cause
damage to the piston rings and crankpin.
(1) Apply engine oil to the circumference of the piston and
Front
piston rings.
(2) Orientate the ring end gaps diagonally opposite each
other avoiding the piston pin direction and its right
Oil ring spring joint
angle direction. No.2 ring end gap
(3) Install the upper connecting rod bearing with its lug fit-
ted in the lug groove of connecting rod. Orientation of piston ring end gaps
(4) Turn the crankshaft to bring the crankpin of the cylin-
der to top dead center.
(5) Face the front mark (Δ) stamped on the piston top
toward the timing gear case side (front of the engine).
(6) Insert the piston from the top face of cylinder block
using a piston guide (commercially available).
Piston and connecting rod - Install
7-7
1.11 Connecting Rod Cap - Install

(1) When the big end of the connecting rod comes into
close contact with the crankpin, turn the crankshaft
180° while pressing the piston head.
(2) Install the lower connecting rod bearing with its lug fit-
ted in the lug groove of connecting rod.
(3) Install the cap to the connecting rod, aligning the mat-
ing marks made during disassembly.
Note: For new connecting rod on which there is no mating
Lug groove
mark, orient the lugs of upper and lower bearings on Cylinder No.
the same side as shown in the illustration.

Connecting rod cap - Install
(4) Tighten the connecting rod cap nuts evenly and alter-
nately to the specified torque.
(5) Inspect the end play of the connecting rod.
32.9 ± 1.4 N·m

{3.4 ± 0.1 kgf·m}
[24.3 ± 1.0 lbf·ft]
Connecting rod cap nuts - Tighten

1.12 Connecting Rod End Play - Measure
Measure the connecting rod end play (clearance between
connecting rod width and crankpin width).
If the value exceededs the limit, find the causal parts, and
replace them with new ones.
Item Standard Limit

0.10 to 0.35 mm 0.50 mm
Connecting rod end play
[0.0039 to 0.0138 in.] [0.0197 in.]
Connecting rod end play - Measure

1.13 Oil screen - Install
(1) Invert the cylinder block to face up the oil pan mount-
ing surface.
(2) Make sure that the end of the screen does not contact to
oil pan, install the screen and tighten the nut to the
specified torque.
Oil screen - Install
7-8
1.14 Oil pan - Install

(1) Install the new oil pan gasket.
(2) Evenly and diagonally tighten oil pan bolts.
Oil pan - Install
7-9
2. Front Mechanism - Assemble

2.1 Relief valve - Install
Insert the relief plunger and relief spring into the gear case,
44.1 ± 4.9 N·m
and tighten the plug to the specified torque.
Relief plunger Plug {4.5 ± 0.5 kgf·m}
[32.5 ± 3.6 lbf·ft]
Gear case Relief spring
Relief valve - Install

2.2 Oil Pump - Install
Install the oil pump inner gear, oil pump outer gerto the gear
Oil pump inner gear
case, and tighten the mounting bolts to the specified torque. Oil pump housing
8.8 ± 1.0 N·m
{0.9 ± 0.1 kgf·m}
[6.5 ± 0.7 lbf·ft]
Oil pump - Install

2.3 Front Plate - Install
(1) Clean the mounting surface of the gasket.
(2) Apply sealant to the gasket to prevent it from falling.
(3) With aligning to the dowel pin, install the gasket and
the front plate.
(4) Secure the front plate with mounting bolts.
Fixing bolts of front plate: 7

Front plate - Install
2.4 Crankshaft - Turn
(1) Install two bolts to flywheel mounting holes of crank-
shaft.
(2) Use the bolts to turn the crankshaft with a bar. Turn the
crankshaft to bring the No.1 piston at the dead center.
Engine - Turn
7-10
2.5 Fuel injection pump camshaft - Install

(1) Insert the fuel injection pump camshaft (with the bear-
Camshaft
ing and gear installed) into the cylinder block hole. stopper washer
(2) Install the bearing into the cylinder block hole com-
pletely by tapping the gear with a plastic hammer.
(3) Make sure that the fuel injection pump camshaft rotates
lightly.
(4) Tighten the camshaft stopper bolts.
Fuel injection pump

camshaft gear
Fuel injection pump camshaft

Cover - Install
2.6 Camshaft - Install
Apply engine oil.

Be careful not to damage camshaft journals, cams and
camshaft holes during insertion.
(1) Apply engine oil to the camshaft journals and cams.
(2) Slowly insert the camshaft assembly.
(3) Install camshaft stopper.
(4) Make sure that the camshaft rotates lightly. Move the
camshaft gear back and forth, and check the end play.
Camshaft
stopper washer
Camshaft - Install
2.7 Idler Gear - Install

(1) Apply engine oil to the idler gear shaft.
(2) With aligning the timing mark, install the idler gear.

Camshaft gear
Fuel injection pump

camshaft gear Crankshaft gear
Timing gear train
(3) Fix idler gear shaft with snap ring.
(4) Move the idler gear back and forth, and check the end Snap ring
play.
Idler gear
Idler gear - Install
7-11
2.8 Timing Gear Backlash - Measure

Measure the backlash of the timing gears using either
method: measure the gear play with the dial gauge plunger
applied to a tooth flank on the pitch circle at a right angle to
the tooth axis, or measure the clearance between gears by
inserting a thickness gauge between the gears at the tooth-
to-tooth contacting area. If the specified limit is exceeded,
replace the gears with new ones. When replacement of oil
pump gear is required, replace the oil pump gear with the oil
pump as assembly.
Item Standard Limit Timing gear backlash - Measure

0.010 to
Between crankshaft gear and 0.141 mm
idler gear [0.0004 to
Timing 0.0056 in.]
0.30 mm
gear
Between idler gear and 0.010 to [0.0118 in.]
backlash
camshaft gear 0.136 mm
Between idler gear and [0.0004 to
camshaft gear 0.0054 in.]
2.9 Governor weights and sliding shaft - Install

Install gavernor weight and sliding shaft to fuel injection
Sliding shaft
pump cam shaft gear.
Governor weight
Governor weights and sliding shaft - Install

2.10 Front Oil Seal - Install
Install a new oil seal to the timing gear case with the
installer.Make sure the oil seal is flush with the gear case.
Installer
Front Oil Seal - Install
7-12
2.11 Timing Gear Case - Install

(1) Apply sealant to the case to prevent the packing from
dislocation. Align the dowel pin and pump gear holes, Bolts on front: 8 pcs.
Bolts on rear: 4 pcs.
and install the case to cylinder block.
(2) Apply engine oil to the oil seal lip.
(3) Install the timing gear case and tighten the bolts to the
specified torque.
Bolt on rear
Bolt on front
Timing Gear Case - Install

2.12 Air-Conditioner Pulley and Crankshaft Pulley - Install
Crankshaft pulley
The bar could come off. Be very careful.
(1) Screw two guide bolts into the threaded holes at the rear
end of the crankshaft. Place a bar across the two guide
bolts so that the crankshaft does not rotate.
107.9 ± 9.8 N·m
(2) Install the woodruff key on the crankshaft. {11.0 ± 1.0 kgf·m}
(3) Install the crankshaft pulley and tighten the nuts to the [79.6 ± 7.2 lbf·ft]
specified torque. Prevent the crankshaft
from rotating.
Crankshaft Pulley - Install
2.13 Tappet - Install
Apply engine oil to the tappet outside face, insert the tappet
into the tappet hole and place the tappet softly on the cam-
shaft.
Apply engine oil
Tappet - Install
7-13
3. Rear Mechanism - Assemble

3.1 Oil Seal Case - Install
Be careful not to damage the oil seal. Oil seal case
(1) Install the new oil seal gasket.

(2) After applying engine oil to the entire circumference of
the oil seal lips, install the oil seal case on the cylinder
block.
Oil seal case - Install

3.2 Flywheel - Install
The person holding the pulley must be very careful to

assure safety by communicating with the person who
is installing the flywheel.
(1) One person must firmly hold the pulley with a wrench
to prevent the crankshaft from rotating.
(2) Screw the guide bolt into the rear end of the crankshaft.
Prevent the flywheel 88.3 ± 4.9 N·m
(3) Align the bolt hole of flywheel with the guide bolt and from rotating {9.0 ± 0.5 kgf·m}
install the flywheel to the crankshaft. using a wrench. [65.1 ± 3.6 lbf·ft]
(4) Temporarily tighten the bolts. Flywheel - Install
(5) Remove the guide bolt and temporarily tighten the last
bolt.
(6) Tighten the bolts to the specified torque.
7-14
4. Cylinder Head and Valve Mechanism - Assemble

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

4.2 Valve Stem Seal - Install
Push on in these faces.

Do not apply oil or liquid sealant to the fitting faces
between the stem seal and the valve guide.
(1) Apply engine oil to the lip of new valve stem seal. Valve stem seal
(2) Push the shoulder of the valve stem seal and fit the
valve stem steal into the valve guide.
(3) Make sure the valve stem steal is fully inserted into the
valve guide.
Valve guide
Valve stem seal - Install
4.3 Valve Spring - Install
Install the valve spring with its white or yellow enamel
painted side facing upward. White or yellow
enamel painted side
Valve spring - Install

4.4 Valve Lock - Install
Valve lock
If valve spring is overcompressed, the lower end of
the retainer comes into contact with the stem seal,
and causes damage to the stem seal.
(1) Install the retainer on the valve spring.
(2) Using a valve lifter, compress the valve spring evenly
and install the valve lock.
Valve lock - Install

7-15
4.5 Cylinder Head Gasket - Install
Guide bolt
Do not use the liquid gasket to the cylinder head.
(1) Make sure that there is no dirt or dents on the top sur-
faces of the cylinder block and pistons.
(2) Install two guide bolts in the bolt holes of the cylinder
block.
(3) Place a new cylinder head gasket on the cylinder block
aligning to the guide bolts. Cylinder head
Note: Every gasket has the model name mark on the top face gasket
on the front side to discriminate it from those of other Cylinder head gasket - Install
models.
4.6 Cylinder Head Assembly - Install
Align the cylinder head to the locating guide bolts, and
install the cylinder head. Cylinder head
Cylinder head assembly - Install

4.7 Cylinder Head Bolt - Tighten
Progressively tighten the cylinder head bolts in the numeri-
Cylinder head bolt (main)
cal order and to the specified torque as shown in the illustra- 78.5 ± 5.0 N·m {8.0 ± 0.5 kgf·m}
tion. [57.9 ± 3.6 lbf·ft]
11 7 5
10
8
9 4 6
2 1 3
Cylinder head bolt (sub)

24.5 ± 4.9 N·m {2.5 ± 0.5 kgf·m}
[18.1 ± 3.6 lbf·ft]
Tightening Sequence of Cylinder Head Bolts
4.8 Push Rod - Insert
Be sure to clean the push rods and remove foreign

substances before insert them. Valve clearance can
not be correctly adjusted if a foreign substance
adheres to the push rod.
(1) Insert each push rod into its hole in the cylinder head.
(2) Make sure that the ball end of each push rod is placed
correctly on the tappet cup.
Push Rod - Insert
7-16
4.9 Rocker Shaft Assembly - Assemble

(1) Apply engine oil to the rocker shaft.
Rocker arm
(2) When assembling, install the rocker shaft assembly in
Rocker stay
the same position as it was.
Rocker shaft spring
Snap ring
Rocker shaft
Snap ring
Rocker shaft assembly - Assemble

(3) Align the rocker shaft oil hole to the rocker stay oil
hole, and install the grooved pin into the front rocker
stay.
Grooved pin
Note: Hammer the grooved pin until it comes into contact
with the inner side of the rocker shaft.
(4) After assembling, make sure the rocker arm move
smoothly.
Grooved pin - Install

4.10 Rocker Shaft Assembly - Install
(1) Install the valve caps to the valve heads.
(2) Install the rocker shaft assembly to the cylinder head.
2
Tighten the mounting bolts to the specified torque. 18.2 ± 3.5 N·m
3 {1.9 ± 0.4 kgf·m}
(3) Progressively tighten the rocker shaft assembly bolts in 1
[13.4 ± 2.5 lbf·ft]
the numerical order and to the specified torque as
shown in the illustration.
Rocker shaft assembly - Install
7-17
4.11 Valve Clearance - Check and Adjust

The valve clearance should be inspected and adjusted when
the engine is cold.
Item Standard
Inlet 0.25 mm
Valve clearance (when cold)
Exhaust [0.0098 in.]
(1) Inspect the valve clearance for all cylinders in the firing
Firing order Turning angle
order by turning the crankshaft to the specified degrees
1-3-2 240q
in the normal direction (clockwise when viewed from
engine front side) to bring each piston to compression
top dead center.
(2) Set No. 1 cylinder to compression top dead center in

Mark on
compression stroke. This position is where the timing gear case
mark on the crankshaft pulley aligns with the mark on
the gear case. TDC mark on
crankshaft pulley
Note: The compression top dead center is where the rocker
Crankshaft - Turn
arm does not move when the crankshaft is rotated in
the forward and backward direction by both 20° ap-
prox. If the rocker arm moves, it is top dead center in
exhaust stroke. Rotate the crankshaft another full turn
to set the No. 1 cylinder to compression top dead cen-
ter.
(3) Start adjusting the valve clearance from the No. 1 cylin-
der and adjust the valve clearance of other cylinders
according to the ignition order.
Note: To set the next cylinder to the compression top after
adjustment of No. 1 cylinder, rotate the crankshaft in No. 1 cylinder compression top dead center - Check
the forward direction (clockwise toward the timing
gear case) by the angle corresponding to the number of
cylinders.
(4) Insert the thickness gauge of the specified thickness
between the rocker arm and valve cap, then adjust the
clearance by turning the screw in either direction so that
the gauge is gripped softly between the rocker arm and
bridge cap.
(5) After adjustment, tighten the lock nut firmly. Then,
check the clearance again.
Valve clearance - Adjust
7-18
4.12 Fuel Injection Timing - Check and Adjust

4.12.1 Fuel injection timing - Inspect Valve
To prevent the outflow of fuel, stop the fuel supply

before removing the delivery valve. Delivery
valve Valve seat
(1) Remove the No. 1 fuel injection pipe.

(2) Remove the No. 1 delivery valve holder of the fuel
injection pump.
(3) Pull out the spring and delivery valve. Do not remove
the delivery valve seat.
(4) Install the delivery valve holder. Delivery valve - Remove
(5) Remove the tie-rod cover.
(6) Disconnect the tie rod from the control rack.
(7) Set the control rack to the medium position of the oper-
ating range.
(8) Feed fuel from the fuel hose and check that the fuel Tie rod clip
flows out from the delivery holder.

(9) Rotate the crankshaft forward (clockwise). The fuel
injection timing is the moment when the fuel stops
Tie rod
flowing from the delivery valve holder outlet.
Control rack
Note: When the fuel stops flowing, rotate the crankshaft
Tie rod and control rack - Separate
backward (counterclockwise) to allow the fuel flowing
again. And then, rotate the crankshaft forward (clock-
wise) to ensure the accurate timing when the fuel stops
flowing.
(10)It is normal that injection timing mark of the crankshaft
pulley aligns the mark on the gear case at the position
that fuel flow stopped.
Fuel flow out Fuel flow stop

Fuel injection timing - Check
Crankshaft pulley
19°
17°
15°
Mark on

gear case
15°
Fuel injection timing: BTDC 15°

Timing mark
7-19
4.12.2 Fuel injection timing - Adjust
When using the shim, apply sealant to both side of

the shim to prevent oil leakage.
(1) If the fuel injection timing does not meet the specified
value, increase or decrease the thickness of the fuel
injection pump adjusting shim to adjust the timing.
(adjusting value: standard value ± 1.5°)
Note: A change in thickness of the shim by 0.1 mm [0.004 Adjusting shim
in.] results in a change in the fuel injection timing by Shims for adjusting fuel injection timing
approx 1°. Shims are available in nine thicknesses
from 0.2 to 1.0 mm [0.008 to 0.039 in.]. Mark on Injection timing mark
timing gear (One division
(2) After adjusting, check that the fuel injection timing is case corresponds to 2°)
properly adjusted.
(3) Close the cock of the fuel filter, and assemble the deliv- Retarded
Advanced
ery valve, spring, fuel injection pipe. by this by this
angle
(4) With the delivery valve installed, check the fuel injec- angle
tion timing according the step 5 to 6.
Timing mark
Note: If the fuel injection pump and the engine are dirty, dust
Crankshaft pulley
and dirt may enter the fuel injection pump when the de-
livery valve is removed.
Reduce
(5) Remove the tie rod cover and disconnect the tie rod Add shims shims
from the control rack. (thicker) (thinner)
(6) Set the control rack to the medium position in the oper-
ating range and then remove the No. 1 fuel injection
pipe on the nozzle side. When the crankshaft is gradu-
ally rotated forward (clockwise), fuel begins to swell at
the tip of the delivery valve. This timing is the fuel
injection timing. In this case, the timing is delayed by Retard Advance
1° as compared to the normal fuel injection timing. Fuel injection timing - Adjust
4.13 Rocker Cover - Install

(1) Make sure that the gasket is firmly installed into the
rocker cover.
(2) Tighten the nut to the specified torque. 5.9 ± 1.0 N·m
{0.6 ± 0.1 kgf·m}
[4.4 ± 0.7 lbf·ft]
Rocker cover - Install
7-20
1. Fuel System - Remove and Inspect ....................................................................... 8-3
1.1 Fuel Injection Pipe - Remove and Inspect ................................................................................ 8-4
1.2 Fuel injection nozzle - Remove and inspect ............................................................................. 8-4
1.3 Fuel Injection Pump - Remove and Inspect.............................................................................. 8-4
2. Fuel System - Disassemble, Inspect and Assemble ............................................ 8-5
2.1 Fuel Injection Nozzle - Disassemble and Inspect ..................................................................... 8-5
2.2 Fuel Injection Nozzle - Inspect and Adjust................................................................................ 8-6
2.3 Fuel Injection Nozzle - Assemble ............................................................................................. 8-8
2.4 Fuel Injection Pump on engine - Inspect .................................................................................. 8-8
2.5 Fuel Injection Pump - Disassemble and inspect....................................................................... 8-9
2.6 Fuel Injection Pump - Assemble ............................................................................................. 8-12
2.7 Governor - Disassemble and inspect...................................................................................... 8-17
2.8 Governor Cover - Disassemble and inspect ........................................................................... 8-19
2.9 Governor Cover - Assemble ................................................................................................... 8-19
2.10 Torque Spring Set - Disassemble and Inspect ....................................................................... 8-20
2.11 Torque Spring Set - Assemble................................................................................................ 8-20
3. Fuel System - Install .............................................................................................. 8-22
3.1 Governor - Install .................................................................................................................... 8-23
3.2 Fuel Injection Nozzle - Install.................................................................................................. 8-26
8-1
1. Fuel System - Remove and Inspect
1
2
3
Replace
Fuel system - Remove and Inspect

Removing sequence
1 No.1 to 3 fuel injection pipe 4 Fuel injection nozzle
2 Fuel return hose 5 Fuel injection pump
3 Fuel return pipee 6 Adjusting shim
(a) Confirm the thickness of fuel injection timing adjusting shim.

(b) Cover the openings on the fuel injection pipe, nozzle inlet connector and fuel injection pipe to prevent dust from
entering the fuel system.
8-3
1.1 Fuel Injection Pipe - Remove and Inspect

Remove the fuel injection pipe and fuel leak-off pipe.
Fuel injection pipe - Remove

1.2 Fuel injection nozzle - Remove and inspect
Loosen the nozzle with a wrench, and remove the fuel injec-
tion nozzle and holder gasket.
Note: Remove the holder gasket from cylinder head with a
wire or screwdriver.
Fuel injection nozzle - Remove

1.3 Fuel Injection Pump - Remove and Inspect
Remove the fuel injection pump.
Note: Check the thickness of the fuel injection timing adjust-
ing shim.
Adjusting shim
Fuel injection pump - Remove
8-4
2. Fuel System - Disassemble, Inspect and Assemble

2.1 Fuel Injection Nozzle - Disassemble and Inspect
Wear
6
Settling, squareness
5
Wear, flaw
3
2
Carbon deposit,
clogged injection nozzle tip
Fuel injection nozzle - Disassemble and inspect

1 Nozzle retaining nut 4 Pin 7 Nozzle holder
2 Nozzle tip assembly 5 spring
3 Piece 6 Washer
8-5
2.2 Fuel Injection Nozzle - Inspect and Adjust

2.2.1 Fuel injection start pressure - Inspect and
adjust Nozzle tester
Never touch the fuel injection nozzle tip during nozzle

injection test.
(1) Mount the nozzle on the nozzle tester.

(2) Push down the handle at a speed of one stroke a second
and measure the pressure when injection starts. If it is
out of the standard, adjust it to the standard.
(3) To adjust the injection start pressure, remove the set Fuel injection start pressure - Inspect
screw on the nozzle holder, loosen the cap nut and turn
the adjusting screw with a screwdriver.
(4) After adjustment, tighten the cap nut and set screw to
the specified torque.
(5) After tightening the set screw, inspect the injection start
pressure again to make sure it is within the standard.
Item Nominal Standard

14.22 to 15.00 MPa
14.22 MPa
Fuel injection starting {145 to 153 kgf/cm2}
{145 kgf/cm2}
pressure [2062 to 2176 psi]
[2062 psi]
(the value when it is new)
2.2.2 Fuel Injection Nozzle Spray - Inspect

When adjusting the nozzle opening pressure with the nozzle Defective spray pattern
tester, inspect the nozzle orifice clogging, fuel spray pattern
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. Good Large After Deflected Branched
spray dribble spray spray
The spray is of fine fuel droplets without big drops. angle
No dripping is shown after injection.
Fuel Injection Nozzle Spray - Inspect
8-6
2.2.3 Defective injection - Clean and Replace
When pulling out the nozzle tip, be careful not to dam-

age the tip.
(1) Loosen the retaining nut, then remove the nozzle tip,
and clean the needle valve and body in clean diesel
fuel.
Needle
(2) After cleaning, assemble the needle valve and the body valve Body
in clean diesel oil.
Note: The needle valve and body are precision finished com- Nozzle tip - Clean
ponents. Handle them carefully, and never change the
combination of the valve and body.
(3) Tighten the nozzle tip tightening retainer nut to the
specified torque. Nozzle tip end
(4) If the spray pattern is still faulty after cleaning and
adjusting, change the nozzle tip with a new one.
Note: New nozzle tips are coated with vaseline to prevent
from rusting. Wash if off in clean diesel fuel before in-
stallation.
Nozzle tip - Replace
8-7
2.3 Fuel Injection Nozzle - Assemble
36.8 ± 2.4 N·m

{3.8 ± 0.2 kgf·m}
[27.1 ± 1.7 lbf·ft]
54.0 ± 4.9 N·m

{5.5 ± 0.5 kgf·m}
[39.8 ± 3.6 lbf·ft]
Fuel Injection Nozzle - Assemble
Be sure to tighten the retaining nut to the specified torque.The excessive tightening of retaining nut can harm
smooth movement of the needle valve and result in abnormal exhaust smoke or needle valve sticking.
Note: When assembling the nozzle tip on the nozzle holder, make sure to align the nozzle tip knock pin with the nozzle holder
hole.
2.4 Fuel Injection Pump on engine - Inspect
Do not disassemble the fuel injection pump unless it is absolutely necessary. If faulty, it is desirable to replace it as an assembly.
Inspection item Inspection procedure Judgment

Low idling Judgment by rotation speed Varies depending on specification
Observe exhaust color during sudden acceleration under no-load.
Exhaust color No remarkable black smoke is emitted.
Observe exhaust color under load.
Remove the nozzle from the cylinder head, and check the nozzle for spray
Nozzle injection condition condition in the condition when it is not installed on the cylinder head. The spray pattern must be good.
Rotate the starter to check the spray pattern.
8-8
2.5 Fuel Injection Pump - Disassemble and inspect
12
Replace
13
14 Settling, crack
Replace 15
16 Wear, flaw
17
Plunger contact, wear, flaw, rust, seizure 18
1 8
19
Operating condition 3
11
10
4
2 9
Settling, crack 7
6
Contact, wear
5
Fuel injection pump - Disassemble and Inspect

1 Swivel nipple 8 Plunger 15 Delivery valve spring
2 Stop wire bracket 9 Plunger spring 16 Delivery valve gasket
3 Control sleeve 10 Spring upper seat 17 Delivery valve
4 Tappet guide pin 11 Control sleeve 18 Plunger barrel
5 Tappet 12 Lock plate 19 Pump housing
6 Tappet shim plate 13 Delivery valve holder
7 Spring lower seat 14 O-ring
8-9
2.5.1 Swivel nipple - Remove

(1) Fix the flange of pump housing with a vise. Swivel nipple Pump housing
(2) Remove swivel nipple from pump housing.
Vise
Swivel nipple - Remove

2.5.2 Tappet - Remove
(1) With pump housing faced in opposite direction, fix it Stop wire Control rack
bracket
with a vise.
(2) Remove stop wire bracket and then remove control Pump housing
rack.
Stop wire bracket - Remove

(3) While pushing in the tappet, pull out the tappet guide
pin with tweezers.
(4) Remove the tappet.
Tappet guide pin Tappet
Tappet guide pin - Remove

2.5.3 Plunger - Remove
Tappet shim plate
Remove tappet shim plate, spring lower sheet, plunger,
Spring lower sheet
plunger spring, spring upper sheet and control sleeve from
pump housing with tweezers. Plunger
Plunger spring
Spring upper
sheet
Control sleeve
Plunger - Remove
8-10
2.5.4 Delivery valve - Remove
Pump Lock plate

(a) The delivery valve, plunger and plunger barrel are Housing
precision-machined parts. Do not smear or
scratch them.
(b) Do not change the combination of the plunger bar-
rel and plunger for each cylinder.
(1) With pump housing faced up, grab the housing with a
vise.
(2) Remove outer rock plate first, and remove center rock Rock plate - Remove
plate last.
(3) Remove the delivery valve holder. Delivery valve holder
Delivery valve holder - Remove

(4) Remove the delivery valve spring.
Delivery valve spring
Delivery valve spring - Remove

(5) Remove delivery gasket, delivery valve or plunger bar-
rel from pump housing with tweezers.
Delivery valve - Remove
8-11
2.6 Fuel Injection Pump - Assemble
3.6 ± 0.4 N·m

5.9 ± 1.0 N·m {0.4 ± 0.1 kgf·m}
{0.6 ± 0.1 kgf·m} [2.7 ± 0.2 lbf·ft] 36.3 ± 2.0 N·m
[4.4 ± 0.7 lbf·ft] {3.7 ± 0.2 kgf·m}
[26.8 ± 1.4 lbf·ft]
12.3 ± 2.5 N·m

{1.3 ± 0.3 kgf·m}
[9.1 ± 1.8 lbf·ft]
3.6 ± 0.4 N·m

{0.4 ± 0.1 kgf·m}
[2.7 ± 0.2 lbf·ft]
Fuel injection pump - Assemble
8-12
2.6.1 Plunger barrel - Install

Plunger barrel
Align the plunger barrel groove with the knock pin of the Groove
pump housing, and insert the plunger barrel into the pump Pump housing
housing.
Note: If the knock pin is not aligned with the plunger barrel
groove, the plunger barrel will not be installed correct- Control rack
ly. Make sure that O-ring is not protruded from the side
Knock pin
pump housing when the delivery valve holder is snug-
ly tightened.
Viewed from above
Plunger barrel - Install
2.6.2 Delivery valve - Install
Delivery valve holder

(a) Do not reuse the O-ring. O-Ring
(b) Carefully install a new O-ring so that it is not cut
Delivery valve
with threads of the valve holder. spring
Assemble the delivery valve, delivery valve gasket and

delivery valve spring. Then with the O-ring installed, tem- Delivery valve
porarily tighten the delivery valve holder. gasket
Delivery valve
Delivery valve - Install

2.6.3 Control sleeve - Install
(1) With pump housing faced in opposite direction, fix it
Pump housing
with a vise. Control sleeve
(2) When installing the control sleeve, the protrusion
should be installed on the control rack side (on the side Knock pin Protrusion
opposite to the knock pin) so that it can be seen through
the hole on the pump housing side. Control rack
side
Control sleeve - Install
8-13
2.6.4 Plunger - Install

(1) Install spring upper seat and plunger spring.
Plunger spring
Plunger
upper seat
Plunger spring - Install

(2) Place the punch mark of plunger flange on the opposite
side of control sleeve top ridge (opposite side of control Sleeve
Stamp
rack side). Then combine it with spring lower seat and
insert them into the control sleeve.
Control rack
side plunger Protrusion
Control sleeve
Plunger - Assembly direction

2.6.5 Tappet - Install
Groove
(1) Install the tappet shim plate.
(2) Install the tappet so that the grooved side is located in Tappet
the tappet guide pin hole side.
Tappet shim
plate
Tappet guide
pin hole
Tappet - Install
(3) While pushing the tappet, install the tappet guide pin.
Tappet
Tappet guide pin
Tappet guide pin - Install
8-14
2.6.6 Control rack - Install

(1) Adjust the control sleeve position so that the protrusion
Control sleeve
of control sleeve engages with the fork portion.
Protrusion
(2) Install control rack.
(3) Install stop wire bracket. Fork
(4) Tighten the plate screw to the specified torque.
Note: Apply thread lock sealant to the thread when reusing
the plate screw.
Control rack
Control rack - Install
2.6.7 Delivery valve holder - Install

Delivery valve
(1) With pump housing faced up, grab the housing with a holder
vise. 36.3 ± 2.0 N·m
{3.7 ± 0.2 kgf·m}
(2) Tighten the delivery valve holder to the specified Pump housing
[26.8 ± 1.4 lbf·ft]
torque.
Delivery valve holder - Install

2.6.8 Control rack for smooth operation - Inspect
(1) Remove the pump housing from the vise and check the
control rack for smooth movement. If the movement is
not smooth, the following defects will be found:
Element sliding movement is bad.
A foreign substance is present in the teeth of rack or
sleeve.
The valve holder is overtightened.
(2) Check the injection timing.
Control rack for smooth operation - Inspect

2.6.9 Lock plate - Install
(1) Fix the pump housing on a vise.
(2) Install the center rock plate first, and install the both
outside rock plates.
(3) Tighten the screw to the specified torque. Lock plate
Screw
3.6 ± 0.4 N·m
{0.4 ± 0.1 kgf·m}
[2.7 ± 0.2 lbf·ft]
Lock plate - Install
8-15
2.6.10 Swivel nipple - Install

(1) Install swivel nipple to the pump housing. Swivel nipple 12.3 ± 2.5 N·m
{1.3 ± 0.3 kgf·m}
(2) Tighten the hollow screw to the specified torque. [9.1 ± 1.8 lbf·ft]
Swivel nipple - Install
8-16
2.7 Governor - Disassemble and inspect
1
Replace
15
2 14 18
Replace
Replace 13
3 16
Settling, crack
11
17
9
10
7
5 Weight portion wear, flaw
Settling, crack Sliding sleeve wear, flaw

12
8
6 Sliding shaft contact portion wear, flaw
Flaw, wear
Replace
4
Governor - Disassemble and Inspect

1 Tie rod cover 8 Start spring 15 Speed control lever
2 Governor cover 9 Tie rod spring 16 Sliding shaft
3 Governor spring 10 Tie rod 17 Governor weight
4 Sealing cap 11 Tie rod clip 18 Torque spring set
5 Grooved pin 12 Governor lever (Rack set screw)
6 Governor shaft 13 Governor lever
7 Tension lever 14 Grooved pin
8-17
2.7.1 Tie rod and Control rack - Separate

(1) Remove the tie-rod cover.
(2) Remove the tie rod clip and separate the tie rod from
the control rack.
Tie rod clip
Tie rod
Control rack
Tie rod and Control rack - Separate
2.7.2 Governor shaft and speed control lever -
Remove Speed control
Governor shaft cover
(1) Remove the sealing cap from gear case side. lever
(2) Pull out the grooved pin A.

Grooved pin B Tension lever
(3) Remove the governor shaft and then remove the tension
Governor spring
lever and governor lever.
lever Sealing cap
(4) Remove the governor spring lever.
Governor lever
(5) Remove grooved pin B, and remove speed control Governor shaft
lever. Grooved pin A
(6) Remove the governor cover. Gear case
Governor shaft and speed control lever - Remove
8-18
2.8 Governor Cover - Disassemble and inspect
1
Settling, crack
2 Replace
Governor - Disassemble and Inspect

1 Set bolt 4 Stop lever 7 Lever
2 Set bolt 5 Return spring 8 Governor cover
3 Jam nut 6 Grooved pin
2.9 Governor Cover - Assemble
Governor cover - Assemble
8-19
2.10 Torque Spring Set - Disassemble and Inspect
1
7
2
3
4
5
6
Settling, crack
Torque spring set - Disassemble and Inspect

1 Lock nut 5 Torque spring
2 Adjusting screw 6 Torque spring case
3 Torque spring 7 Special nut
4 Spring stopper
2.11 Torque Spring Set - Assemble
9.8 ± 2.0 N·m

{1.0 ± 0.2 kgf·m}
[7.2 ± 1.4 lbf·ft]
Torque spring set - Assemble
8-20
2.11.1 Torque spring set - Assemble

Lock nut
To assemble torque spring set, follow the instruction below. Special nut 9.8 ± 2.0 N·m
{1.0 ± 0.2 kgf·m}
(1) Install the adjusting screw so that the end of spring Torque spring case [7.2 ± 1.4 lbf·ft]
stopper is protruded from the torque spring case by the Spring stopper
specified amount shown in the table.
(2) Tighten the lock nut to the specified torque, and fix the
adjusting screw.
Protrusion
(3) When the spring stopper is installed at step (1) above, amount
confirm that the spring stopper can be pressed into the
Torque spring Adjusting screw
end face of torque spring case.
Torque spring setting
(4) To confirm that the spring stopper protrusion is

adjusted properly, arrange torque spring set as shown in Dial gauge
illustration. Hold the dial gauge at the tip of spring
Push in
stopper and set the gauge to zero.
spring
Push the spring stopper, and then slightly slide the stopper.
torque spring set off to the side. Read the gauge for pro-
trusion from the end face of torque spring case.
Protrusion Identification color Torque spring

0.2 to 0.3 mm [0.0079 to 0.0118 in.] Pink Spring stopper case
Spring stopper protrusion - Measure
8-21
3. Fuel System - Install
27.0 ± 2.5 N·m

{2.8 ± 0.3 kgf·m}
[19.9 ± 1.8 lbf·ft]
22.6 ± 2.0 N·m

{2.3 ± 0.3 kgf·m}
[16.7 ± 1.4 lbf·ft]
Replace
Fuel System - Install
8-22
3.1 Governor - Install
Replace
19.6 ± 4.9 N·m

{2.0 ± 0.5 kgf·m}
[14.5 ± 3.6 lbf·ft]
Replace
Replace
Settling, crack
Weight portion wear, flaw
Settling, crack Sliding sleeve wear, flaw
Sliding shaft contact portion wear, flaw

Flaw, wear
Replace
Governor - Install
8-23
3.1.1 Speed control lever and governor shaft - Install

(1) Insert the governor shaft into the gear case while com- Speed control
Governor shaft cover
bining the governor lever with the tension lever. lever
(2) Hammer grooved pin A into the gear case.

Grooved pin B Tension lever
(3) Hammer new sealing cap into the gear case.
Governor spring
(4) Thoroughly apply the Shell Alvania Grease #2 or #3 to
lever Sealing cap
the governor shaft cover.
Governor lever
(5) Insert the governor shaft cover to the speed control Governor shaft
lever, and install new O-ring and insert it into the gear Grooved pin A
case. Gear case
Speed control lever and governor shaft - Install
(6) Hammer grooved pin B into the gear case.
Governor lever Grooved Protrusion
(7) Install the governor spring case. pin A approx. 2mm
Note: When installing, minimize the assembling angle be- Tension [0.08 in.]
lever A
tween speed control lever and governor spring lever.
Section AA
A
Sealing cap
Gear case
Speed control lever - Assemble

3.1.2 Tie rod - Connection
Connect the tie rod with fuel injection pump control rack,
then fix it with tie rod clip.
Tie rod clip
Tie rod
Control rack
Tie rod - Connection
8-24
3.1.3 Torque spring set - Install

For installation and adjustment
(Double spring, two point control)
Adjust torque spring set as shown below and then fix it.
(1) Adjust the speed control lever with high speed set bolt.
After setting high idle rotation speed, fix it.
(2) Screw the torque spring set with maximum torque rota-
Screw in the adjusting screw
tion speed. Then set the maximum torque and fix with at the rated engine speed.
special nut. Set it to the rated engine power
and secure with the special nut.
(3) Screw the adjusting screw with rated rotation speed.
Then set the rated output and fix with special nut. Screw in the torque spring set
at maximum torque engine speed.
(4) Install the torque spring set sealing cap to seal it. Set it to the maximum torque
and secure with the special nut.
Sealing cap Special nut

(Sealing after setting) 19.6 ± 4.9 N·m
{2.0 ± 0.5 kgf·m}
[14.5 ± 3.6 lbf·ft]
Torque spring set - Install

3.1.4 Rack set screw - Install
Torque set nut
Be sure not to adjust the rack set screw unless it is

necessary because the torque spring set is adjusted
securely before shipping.
Adjust rack set screw as shown below and then fix it.
(1) Adjust the speed control lever with high speed set bolt. Screw in the rack set screw
at rated engine speed.
After setting high idle rotation speed, fix it. Set to the rated engine power
and secure with the torque set nut.
(2) Screw the rack set screw with the rated rotation speed,
then set the rated output. Sealing cap
(3) Secure the set bolt with the torque set nut. (Sealing after setting)
(4) Install the rack set screw sealing cap to seal.
Special nut
19.6 ± 4.9 N·m
{2.0 ± 0.5 kgf·m}
[14.5 ± 3.6 lbf·ft]
Rack set screw - Install
8-25
3.2 Fuel Injection Nozzle - Install

(1) Clean the nozzle holder hole of cylinder head.
(2) Install the gasket to the nozzle tip and tighten the fuel 54.0 ± 4.9 N·m
injection nozzle. {5.5 ± 0.5 kgf·m}
[39.8 ± 3.6 lbf·ft]
Fuel injection nozzle - Install
8-26
1. Lubrication system - Remove................................................................................. 9-3
1.1 Oil filter - Remove ..................................................................................................................... 9-4
1.2 Relief valve - Remove............................................................................................................... 9-4
1.3 Oil pressure switch - Remove................................................................................................... 9-4
1.4 Oil pump - Remove................................................................................................................... 9-4
2. Lubrication System - Disassemble, Inspect and Assemble ................................ 9-5
2.1 Oil Pump - Inspect .................................................................................................................... 9-5
2.2 Oil pressure switch - Inspect..................................................................................................... 9-5
2.3 Relief Valve - Inspect................................................................................................................ 9-7
3. Lubrication System - Install.................................................................................... 9-8
3.1 Oil Pump - Install ...................................................................................................................... 9-9
3.2 Oil pressure switch - Install....................................................................................................... 9-9
3.3 Relief valve - Install................................................................................................................... 9-9
3.4 Oil filter - Install ......................................................................................................................... 9-9
9-1
1. Lubrication system - Remove
Replace
Peeling, wear
Replace
5 10
6
7
2 3 4
8
Replace
Settling, crack
Lubrication system - Remove

Removing sequence
1 Oil filter 6 Oil pump housing
2 Plug 7 Oil pump outer gear
3 Relief spring 8 Oil pump inner gear
4 Relief plunger 9 Oil pan
5 Oil pressure switch 10 Oil screen
9-3
1.1 Oil filter - Remove

(1) Place a drip pan under the oil filter.
(2) Remove the oil filter using a filter wrench.
Oil filter
Oil filter - Remove
1.2 Relief valve - Remove
Remove the plug from gear case and then remove relief
spring and relief plunger. Relief plunger
Gear case Relief spring Plug
Relief valve - Remove

1.3 Oil pressure switch - Remove
Using an oil pressure switch socket wrench, remove oil
pressure switch. Oil pressure switch
socket wrench
P/N:MD998054
Oil pressure switch - Remove

1.4 Oil pump - Remove
(1) Removethe oil pump housing from gear case.
(2) Remove the oil pump housing gear and oil pump inner Oil pump inner gear Oil pump housing
gear.
Oil pump - Remove
9-4
2. Lubrication System - Disassemble, Inspect and Assemble

2.1 Oil Pump - Inspect
2.1.1 Clearance between oil pump housing inside
diameter and oil pump outer gear outside diam-
eter - Measure
Measure using thickness gauge. If the limit is exceeded,
replace gears or housing with a new one.
Item Standard Limit

Clearance between oil pump
housing inside diameter and 0.100 to 0.196 mm 0.3 mm
oil pump outer gear outside [0.0039 to 0.0077 in.] [0.0118 in.]
diameter
Clearance between oil pump housing inside diameter
and oil pump outer gear outside diameter - Measure
2.1.2 Measuring difference of oil pump outer gear

width and oil pump housing
Measure using thickness gauge. If the limit is exceeded,
replace gears or housing with a new one.
Item Standard Limit

Difference of oil pump outer
0.040 to 0.100 mm 0.25 mm
gear width and oil pump hous-
[0.0016 to 0.0039 in.] [0.0098 in.]
ing
Measuring difference of oil pump outer gear width and

oil pump housing
2.2 Oil pressure switch - Inspect
(1) Connect a tester (ohm range) between the terminal and
body to check for conduction. The switch is normal if Check for conduction.
electricity is conducted between them. If isolated,

replace the switch with a new one.
Oil pressure switch - Inspect (1)

(2) Insert a thin rod from the oil hole and lightly push it.
The switch is normal if isolated between them. If there
is continuity when the rod is pushed in, replace the
switch with a new one. Thin rod
(3) The switch is normal if isolated when air pressure of
0.05 MPa {0.5 kgf/cm2} [7.1 psi] is applied from the oil
hole. Also check for air leakage. If air leaks, the dia-
ǡ
phragm is damaged. Replace the switch.
Oil pressure switch - Inspect (2)

9-5
2.3 Relief Valve - Inspect

(1) Check the relief valve and valve seat for contact. Check
the spring for settling and damage. If any defects are Relief plunger
found, replace the relief valve with a new one.
(2) Measure the relief valve opening pressure. If the mea-
sured value does not meet the standard, replace the
relief valve with a new one.
Item Standard
0.29 ± 0.029 MPa Gear case Relief spring Plug
Relief valve opening pressure {3.0 ± 0.3 kgf/cm2}
[42 ± 4.2 psi]
Relief valve - Inspect
Note: When measuring engine oil pressure, measure it from
engine front (gear case).
Engine oil pressure

measuring port(PT1/8)
Engine oil pressure measuring port
9-6
3. Lubrication System - Install
8.8 ± 1.0 N·m

{0.9 ± 0.1 kgf·m}
Replace [ 6.5 ± 0.7 lbf·ft]
9.8 ± 1.9 N·m
{1.0 ± 0.1 kgf·m}
[7.2 ± 1.4 lbf·ft] Peeling, wear
Replace
Replace
Settling, crack
44.1 ± 4.9 N·m
{4.5 ± 0.5 kgf·m}
[32.5 ± 3.6 lbf·ft]
Lubrication System - Install
9-7
3.1 Oil Pump - Install

Install the oil pump inner gear, oil pump outer gerto the gear
Oil pump inner gear
case, and tighten the mounting bolts to the specified torque. Oil pump housing
8.8 ± 1.0 N·m
{0.9 ± 0.1 kgf·m}
[6.5 ± 0.7 lbf·ft]
Oil pump - Install

3.2 Oil pressure switch - Install
Oil pressure switch

(a) Do not apply sealant at the thread end. 9.8 ±1.9 N·m socket wrench
{1.0 ± 0.1 kgf·m} P/N:MD998054
(b) Do not overtighten. [7.2 ± 1.4 lbf·ft]
(1) Using an oil pressure switch socket wrench, tighten the

oil pressure switch to the specified torque.
(2) Apply a sealant to the threaded portion when installing
the switch.
Apply HERME SEAL H1 or
THREEBOND 1344N.
Oil pressure switch - Install

3.3 Relief valve - Install
Insert the relief plunger and relief spring into gear case, and
44.1 ± 4.9 N·m
tighten plug to the specified torque.
Relief plunger Plug {4.5 ± 0.5 kgf·m}
[32.5 ± 3.6 lbf·ft]
Gear case Relief spring
Relief valve - Install

3.4 Oil filter - Install
(1) Apply a light coating of engine oil to the filter gasket.
(2) Turn the filter by hand. When the filter gasket contacts
the mounting surface, turn the filter another rotation.
Apply
engine oil.
Oil filter - Install
9-8
1. Cooling System - Remove and Inspect ............................................................... 10-3
2. Cooling System - Disassemble, Inspect and Assemble .................................... 10-4
2.1 Thermostat - Disassemble and Inspect .................................................................................. 10-4
2.2 Thermostat - Inspect............................................................................................................... 10-5
2.3 Thermoswitch - Inspect........................................................................................................... 10-5
2.4 Water pump - Inspect ............................................................................................................. 10-5
3. Cooling System - Install ........................................................................................ 10-6
10-1
1. Cooling System - Remove and Inspect
Replace
Crack, water leak, flaw

6
2
1
Replace
Replace 4
3
Crack, elongation, wear, flaw Crack, water leak, flaw
Cooling system - Remove and Inspect

Removing sequence
1 Pulley 3 Thermostat case 5 Pipe
2 Belt 4 Thermoswitch 6 Water pump
10-3
2. Cooling System - Disassemble, Inspect and Assemble

2.1 Thermostat - Disassemble and Inspect
9 ± 1 N·m
{0.9 ± 0.1 kgf·m}
[6.6 ± 0.7 lbf·ft]
1
Replace
Thermostat - Disassemble and inspect

1 Thermostat cover 2 Thermostat 3 Thermostat case
10-4
2.2 Thermostat - Inspect
Stir hot water well

Be very careful of hot water and flames.
Otherwise, you may get burned or end up causing a
fire.
(1) Immerse the thermostat in a container filled with water.
(2) Heat the water while measuring the water temperature.
Record the temperature at which the valve start to open,
and at which valve lift becomes the standard value.
Replace the thermostat if a deviation from standard
temperature is significant. Thermostat - Inspect
Note:(a) Stir the hot water to maintain even temperatures
during the test.
(b) At assembly, confirm the valve opening tempera-
ture punched on its mounting flange.
Item Standard
76.5 ± 1.5°C
Valve opening temperature
[169.7 ± 2.7°F]
Temperature at which valve lift becomes
90°C [194°F]
6 mm [0.23 in.] or more
2.3 Thermoswitch - Inspect
Be careful of burns or fires when measuring tempera-

ture, especially if it involves a high-temperature and
open flame.

Immerse the thermo switch in a container filled with water.
Measure the water temperature by thermometer and mea-
sure the resistance value by heating water. If the resistance
extremely deviates from the standard, replace the thermo-
switch.
Thermoswitch - Inspect
Temperature Standard
120°C 30 mΩ
2.4 Water pump - Inspect

2.4.1 Water pump - Inspect
Check to make sure that the impeller and shaft of water
pump rotate smoothly without noise and irregularities. If
faulty, replace the water pump assembly.
Impeller and shaft for smooth rotation - Check
10-5
3. Cooling System - Install
Replace
Crack, water leak, flaw

6
2
1
Replace
5
24.5 ± 4.9 N·m
{2.5 ± 0.5 kgf·m}
[18.1 ± 3.6 lbf·ft]
Replace 4
3
Crack, elongation, wear, flaw Crack, water leak, flaw
Cooling System - Install
10-6
1. Inlet and Exhaust Systems - Remove and Inspect ............................................. 11-3
2. Inlet and Exhaust Systems - Disassemble, Inspect and Assemble .................. 11-4
2.1 Measure the distortion of the inlet cover and exhaust manifold.............................................. 11-4
3. Inlet and Exhaust Systems - Install...................................................................... 11-5
11-1
1. Inlet and Exhaust Systems - Remove and Inspect
Crack, flaw, contamination,

dirt/dust adhesion, corrosion Crack
1
2
Replace
Replace
Crack, corrosion
Inlet and exhaust systems - Remove and Inspect

Removing sequence
1 Inlet pipe 2 Inlet cover 3 Exhaust manifold
11-3
2. Inlet and Exhaust Systems - Disassemble, Inspect and Assemble

2.1 Measure the distortion of the inlet cover and exhaust manifold.
Using a straight edge and thickness gauge, measure distor-
tion across the cylinder head mounting surfaces of the inlet
cover and exhaust manifold. If the measured distortion
Thickness gauge
exceeds the limit, correct by grinding or replace the part.
Item Limit
Distortion in the mounting surfaces of inlet cover 0.15 mm
and exhaust manifold [0.0059 in.]
Straight edge
Exhaust manifold distortion - Measure
11-4
3. Inlet and Exhaust Systems - Install
Crack, flaw, contamination,

dirt/dust adhesion, corrosion Crack
Replace
Replace
8.8 ± 1.0 N·m
{0.9 ± 0.1 kgf·m}
[ 6.5 ± 0.7 lbf·ft] Crack, corrosion
18.2 ± 3.5 N·m

{1.9 ± 0.4 kgf·m}
[13.4 ± 2.5 lbf·ft]
Inlet and Exhaust Systems - Install
11-5
1. Electrical System - Remove and Inspect............................................................. 12-3
1.1 Alternator Before Removal - Inspect....................................................................................... 12-3
1.2 Alternator - Remove and Inspect ............................................................................................ 12-5
1.3 Stop solenoid - Remove and inspect ...................................................................................... 12-5
1.4 Glow Plug - Remove and Inspect ........................................................................................... 12-5
2. Electrical System - Disassemble, Inspect and Assemble.................................. 12-6
2.1 Starter Before Disassembling - Inspect .................................................................................. 12-6
2.2 Starter - Disassemble and inspect.......................................................................................... 12-8
2.3 Starter - Inspect and Repair.................................................................................................. 12-11
2.4 Starter - Assemble ................................................................................................................ 12-15
2.5 Alternator - Disassemble and inspect ................................................................................... 12-19
2.6 Alternator - Inspect and Repair............................................................................................. 12-22
2.7 Alternator - Assemble ........................................................................................................... 12-25
2.8 Glow Plug - Inspect and Repair ............................................................................................ 12-27
3. Electrical System - Install ................................................................................... 12-28
3.1 Glow plug - Install ................................................................................................................. 12-28
3.2 Stop solenoid - Install ........................................................................................................... 12-28
3.3 Alternator - Install.................................................................................................................. 12-30
12-1
1. Electrical System - Remove and Inspect

1.1 Alternator Before Removal - Inspect
1.1.1 Alternator operation - Inspect
Locate the cause of faulty charging from the malfunctions
described below. Do not remove the alternator for inspec-
tion and repair unless inspection cannot be performed with
the alternator installed on the engine.
Adjusted value of voltage regulator is high.

Overcharge
Faulty battery.
Adjusted value of voltage relay is low.
Faulty alternator output.
Over discharge Electric power consumption is extremely high.
Special load is used.
Faulty wiring.
1.1.2 Handling precaution

Pay full attention when handling, as improper handling
could result in damage or failure.
(1) Never connect the battery terminal reverse.The B ter-
minal is (+) and the E terminal is (-).
(2) Do not use any high voltage tester such as a megger.
(3) Do not disconnect lead wire from B terminal of the
alternator while the engine is running.
(4) Battery voltage is constantly applied to B terminal of
the alternator. Do not ground at this terminal.
(5) Do not short circuit or ground at L terminal.
(6) When using a steam cleaner, be careful not to allow the
steam to come into contact with the alternator.
12-3
1.1.3 Regulated voltage - Inspect

(1) Disconnect (+) battery terminal and connect an amme-
Ammeter
ter across the line.
A
(2) Connect a voltmeter between terminal L and ground.
Switch
(3) The indication of the voltmeter must be 0 when the L

starter switch is OFF.
R Battery
The indication of the voltmeter must be considerably 12V
lower than the battery voltage when the starter switch is V Voltmeter
ON (engine OFF).
(4) Start the engine with the ammeter terminals discon-
Regulated voltage - Inspect
nected.
(5) Measure the indication (regulated voltage) of the volt-
meter.
Item Specification Standard Condition

Regulated voltage 12 V, 40 A 14.4 to 15.0 V 5000 min-1, 20ºC [68ºF]
1.1.4 Output - Inspect

(1) Disconnect the battery ground cable. Ammeter
(2) Connect B terminal of the alternator to the ammeter, A
then connect the voltmeter between B terminal and

B Charge
V Voltmeter lamp

ground.
L Battery
(3) Connect the battery ground cable.
R Switch
(4) Start the engine.
(5) Immediately apply all loads such as lamps.
(6) Increase the engine speed and measure the maximum
output current at the specified alternator rotation speed
Output - Inspect
with the specified value of voltmeter.
(7) If the measured value meets the standard, the output is
normal.
Standard
Item Specification
Terminal voltage/current Alternator rotation speed
13.5V/21A or higher 2500 min-1
Output characteristics (when hot) 12V, 50A
13.5V / 37A or higher 5000 min-1
12-4
1.2 Alternator - Remove and Inspect

(1) Remove the alternator.
(2) Remove the adjusting plate. Alternator
Adjusting plate
Flange bolt
Bolt
Alternator - Remove and Inspect
1.3 Stop solenoid - Remove and inspect
(1) Loosen the stop solenoid fixing nut.
(2) Remove the stop solenoid.
Stop solenoid
Nut
Stop solenoid - Remove

1.4 Glow Plug - Remove and Inspect
(1) Loosen the fixing nut and remove the connection plate.
Connection plate
(2) Remove the glow plug.
Glow plug
Glow Plug - Remove and Inspect
12-5
2. Electrical System - Disassemble, Inspect and Assemble

2.1 Starter Before Disassembling - Inspect
2.1.1 Magnetic Switch - Inspect (3) The magnetic switch is normal if the pinion pops out
Inspect the magnetic switch as described below. If faulty, when the switch is turned ON.
replace the magnetic switch with a new one.
Disconnect the connector.
Do not apply current continuously for longer than 10
seconds. 㧿
㧹
Pull-in test
㧗㧙
(1) Disconnect the connector of M terminal. Battery
(2) Connect the starter to the circuit as shown in the illus- 12V
tration.
Starter
Holding test
(1) Disconnect the connector of M terminal.
(2) Connect the starter to the circuit as shown in the illus-
tration. 㧿
㧹
(3) Turn ON the switch and pull out the pinion fully by
hand. 㧗㧙
The magnetic switch is normal if the pinion does not Battery
12V
return when it is released.
Starter
Holding test
Return test
(1) Disconnect the connector of M terminal.
(2) Connect the starter to the circuit as shown in the illus-
tration. 㧿
㧹
(3) Turn OFF the switch and pull out the pinion fully by
hand.The magnetic switch is normal if the pinion 㧗㧙
returns immediately when it is released. Battery
12V
Starter
Return test
12-6
2.1.2 Test at no-load rent or rotation speed does not meet the standard, disas-
semble, inspect and repair the starter.
(a) Use a thick wire as possible and firmly tighten
each terminal.
㧭 Ammeter Switch 㧮
(b) Be careful that the pinion pops out during opera-
㧿
tion when measuring the rotation speed at the tip
㧹
of the pinion.
㨂 Voltmeter
Battery
(1) Connect the starter to the circuit as shown in the illus- 12V
Starter
tration.
(2) In normal condition, the pinion pops out when the
switch is turned ON, and the starter rotates at more than
the specified rotation speed.If the terminal voltage, cur- Test at no-load
Item Standard
Starter model number M001T68381
Nominal output 12 V, 1.7 kW
Terminal voltage 11 V
No-load characteristics Current 110 A or less
Rotational speed 2400 min-1 or more
12-7
2.2 Starter - Disassemble and inspect
2
14
Magnetic switch open circuit, short
Commutator surface contamination,

seizure, wear
Replace
6
Replace
Replace
1
Gear wear, flaw
Open circuit,
Gear wear, flaw 12 11 ground
13 10
9
8
12
19
5
18 Bearing hole
3 wear
17
Replace
4
16 Brush powder deposit,
Replace local wear, brush
15 Overrunning clutch movement inside the
function holder, rust, deterioration,
Yoke open holder insulated condition
7 circuit, short
Starter - Disassemble and Inspect

1 Pinion set 8 Packing 15 Snap ring
2 Magnetic switch 9 Packing 16 Stopper
3 Rear bracket 10 Plate 17 Overrunning clutch
4 Brush holder 11 Ball 18 Internal gear
5 Brush assembly 12 Planetary gear 19 Gear shaft
6 Armature 13 Lever
7 Yoke 14 Front bracket
12-8
2.2.1 Preparation before disassembling

Put matching marks between the magnetic switch, front
bracket, yoke and rear bracket.
2.2.2 Pinion Set - Remove
SW1 B
The starter will generate heat if the current is being
S SW2
applied. Remove the pinion within 10 seconds. M
Battery
(1) Connect the starter to the circuit as shown in the illus- 12V Disconnect the lead
tration. with a terminal
connected to
(2) Turn the switches SW1 and SW2 ON to move the pin- terminal M.
ion out, and turn the SW2 OFF to stop the rotation of
the armature and the pinion.
(3) Place an appropriate tube on the pinion stopper.Tap the Connection to move the pinion forward
tube with a hammer to drop the pinion stopper to the
clutch side. This will expose the stopper ring.
Stopper ring
(4) Remove the stopper ring with pliers and remove the
pinion.
Pinion stopper
Note: Do not reuse the stopper ring and pinion stopper when
assembling.
Pinion
Pinion - Remove
2.2.3 Magnetic Switch - Remove
Remove the magnetic switch screws and the M terminal nut,
and remove the magnetic switch.
Screw
Magnetic switch
Magnetic Switch - Remove

2.2.4 Rear Bracket - Remove
(1) Remove the through bolts and brush holder screws.
(2) Remove the rear bracket. Screw
Rear bracket
Through bolt
Rear Bracket - Remove
12-9
2.2.5 Brush Holder and Brush Assembly - Remove

(1) Apply a socket (of the same diameter as the commuta-
tor) to the commutator of the armature. Socket
(2) Remove the brush holder and brush assembly by sliding
on the socket.
Brush holder
Brush assembly
Brush Holder and Brush Assembly - Remove

2.2.6 Armature and Yoke Assembly - Remove
(1) Remove the armature and yoke assembly. Packing
(2) Remove the packing from the internal gear. Plate
(3) Remove the packing and plate on the lever support.
(4) Remove the ball from the internal gear.
Armature
(5) Remove the planetary gears.
Yoke
Packing
Ball
Planetary gear
Armature and Yoke Assembly - Remove

2.2.7 Overrunning clutch - Remove
Pull out the internal gear, gear shaft, overrunning clutch and Lever
Overrunning clutch
lever as an assembly from the front bracket, and remove the
lever.
Internal gear
Gear shaft
Front bracket
Overrunning clutch - Remove
2.2.8 Gear shaft - Remove
(1) Remove the stopper ring and remove the stopper.
Internal gear
(2) Separate the overrunning clutch, internal gear and gear
shaft.
Stopper
Gear shaft
Overrunning clutch
Stopper ring
Gear shaft - Remove
12-10
2.3 Starter - Inspect and Repair

2.3.1 Magnetic switch coil continuity - Inspect
(1) Check for continuity between M terminal and C termi- Terminal M
nal. If there is no continuity, replace the magnetic
switch with a new one.
Tester
Terminal C
Continuity between M terminal and C terminal -

Inspect
(2) Check for continuity between M terminal and the case.
If there is no continuity, replace the magnetic switch Case
with a new one.
Tester
Terminal M
Continuity between M terminal and the case - Inspect

(3) Make sure there is no continuity between the M termi-
nal and the B terminal. If there is continuity, replace the Terminal M
magnetic switch with a new one.
Tester
Terminal B
Isolation between M terminal and B terminal - Inspect
2.3.2 Brush - Inspect for wear
Measure the length of the brushes.
If it is less than the limit, replace the brush holder assembly
and brush assembly with new ones.
Item Standard Limit

16.5 mm 10 mm
Brush length
[0.650 in.] [0.39 in.]
Brush - Inspect for wear
12-11
2.3.3 Brush spring load - Inspect

Using a new brush, measure the spring load at which the
spring lifts from the brush. If it is less than the limit, replace
the spring with a new one.
Item Standard Limit

17.5 to 23.7 N 6.86 N
Brush spring load {1.78 to 2.42 kgf} {0.70 kgf}
[3.92 to 5.34 lbf] [1.54 lbf]
Brush spring load - Inspect

2.3.4 Brush Holder Insulation - Inspect
Check the isolation between the brush holder and the brush Insulated brush holder
holder base.If continuity is detected, replace the brush
holder assembly with a new one.
Check the brush holders for looseness.
Brush holder base
Brush Holder Insulation - Inspect

2.3.5 Commutator outside diameter - Measure
Measure the commutator outside diameter. If the measured
value is less than the limit, replace the armature with a new Ou
tsi
one. de
dia
m
et
Item Nominal Limit er
ø29.4 mm 28.8 mm
Commutator outside diameter
[1.158 in.] [1.134 in.]
Commutator outside diameter - Measure

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

Commutator runout 0.03 mm [0.0012 in.] 0.10 mm [0.0039 in.]
Commutator runout - Measure
12-12
2.3.7 Undercut depth - Measure

Measure the depth of undercutting between the commutator
segments. If the measured value is less than the limit, repair Undercut
or replace the commutator. Segment

Mica
Item Standard Limit
0.5 to 1.0 mm 0.2 mm
Undercut depth
[0.020 to 0.039] [0.008 in.]
Undercut depth - Measure

2.3.8 Front Bracket - Inspect
If ball bearing does not rotate smoothly or an abnormal
noise is generated, replace the front bracket with a new one.
2.3.9 Armature Coil - Inspect

(1) Inspect the armature coil using a growler tester.
Iron plate
Place the armature on a growler tester, and attach a thin
sheet of iron (e.g. teeth of a saw) to the core of arma-
ture.While holding the iron sheet, rotate armature
slowly one revolution by hand.If the coil is shorted, the Growler tester
iron plate is sucked on that position.
If the coil is shorted, replace the armature with a new
one.
Armature coil - Check for short circuit

(2) Check that the commutator and the shaft (core) are iso-
lated.If there is continuity, replace the armature with a
new one.
Commutator and shaft (core) isolation - Inspect

(3) Check that there is continuity between each segment.If
there is no continuity, replace the armature with a new
one.
Continuity between segments - Inspect
12-13
2.3.10 Rear Bracket - Inspect

If the rear bearing box is worn, replace the rear bracket with
a new one.
2.3.11 Overrunning clutch operation - Inspect
The overrunning clutch is coated with grease, thus, do

not wash it in wash oil.
Make sure that, when attempting to turn the overrunning

clutch, it locks in one direction and rotates smoothly in the
opposite direction.
Overrunning clutch operation - Inspect

2.3.12 Pinion - Inspect
Inspect the pinion for wear and damage. If defective,
replace the pinion with a new one.
2.3.13 Starter gear - Inspect

Inspect each starter gear.If it is worn or damaged, replace
the gear with a new one.
12-14
2.4 Starter - Assemble
+2
5.9 ± 1.7 N·m
9.8 0 N·m {0.60 ± 0.17 kgf·m}
+0.2
{1 0 kgf·m} [4.4 ± 1.2 lbf·ft]
+1.4
[7.2 0 lbf·ft]
10.7 ± 2.0 N·m Apply Multemp PS2

{1.1 ± 0.2 kgf·m} (Kyoudo Yushi made).
[7.9 ± 1.4 lbf·ft]
5.8 ± 1.3 N·m

{0.59 ± 0.13 kgf·m}
[4.3 ± 0.9 lbf·ft]
Apply Multemp PS2

(Kyoudo Yushi made).
3.4 ± 1.0 N·m Apply Molykote AG-650

{0.35 ± 0.1 kgf·m} (Dow Corning Asia made).
[2.5 ± 0.7 lbf·ft]
Starter - Assemble
2.4.1 Grease - Apply
(a) To avoid mixing of different greases, remove old grease before applying new grease.
(b) Make sure that the starter mounting surface, brushes, commutator and other electric current conducting compo-
nents are free from grease.
When overhauling the starter, apply grease to the following sliding surfaces, gears and bearings.
(1) Areas to which Multemp #6129 (Kyodo Yushi made) or the equivalent is applied
Plunger surface (a small amount) Sliding area between lever and overrunning clutch
Shaft sliding area of overrunning clutch Bearing of gear shaft
Gear shaft Rear bearing
Pinion gear installing surface
(2) Areas to which MOLYKOTE AG-650 (Dow Corning Toray made) or the equivalent is applied
Ball Gear shaft, gear and internal gear of armature
12-15
2.4.2 Pinion - Install
Stopper ring
(a) Before assembling, apply grease to the inner race
groove of the front bracket bearing. Pinion stopper
(b) Be sure to use a new stopper ring and pinion stop-
per. Do not reuse the stopper ring and pinion stop-
Pinion
per that has been removed.
(1) Put the overrunning clutch through the front bracket.

(2) Install the pinion spring, pinion and pinion stopper in
this order onto the shaft of the overrunning clutch. Pinion - Install
(3) Install the stopper ring firmly to the shaft groove of
overrunning clutch.
(4) Using a gear puller, firmly pull the pinion stopper
closer to the stopper ring to fix.
2.4.3 Gear shaft - Install

Stopper
Stopper ring
Be sure to use a new stopper ring. Do not reuse the Shaft of
overrunning clutch
stopper ring that has been removed.
(1) Install the lever to the overrunning clutch. Pinion

(2) Fit the internal gear into the gear shaft.
(3) Put the gear shaft through the overrunning clutch and
install the stopper on it. Gear shaft
(4) Fit the stopper ring into the groove of the stopper ring
and firmly pinch it. Gear shaft - Install
(5) Using a gear puller, firmly pull the pinion and fit the
stopper into the stopper ring.
Note: The adjustment of play in the axial direction of the gear
shaft is not necessary because its required amount is
automatically secured.
2.4.4 Yoke and armature - Install
(1) Install the planetary gears on the gear shaft. Packing
(2) Install the packing on the internal gear. Plate
(3) Install the plate and packing.
(4) Install the yoke on the front bracket.
Armature
(5) Apply grease to the armature shaft end and install a ball
on it. Yoke
(6) Install the armature. Packing
Ball
Note: The adjustment of play in the axial direction of the ar-
Planetary gear
mature shaft is not necessary.
Yoke and armature - Install
12-16
2.4.5 Brush Holder and Brush Assembly - Install

(1) Attach the socket to the commutator of the armature.
(2) While sliding the brushes on the socket, install the Socket
brush holder and brush assembly on the armature.
Brush holder
Brush assembly
Brush Holder and Brush Assembly - Install

2.4.6 Rear bracket - Install
Screw
Install the rear bracket to the yoke, and tighten the through 3.4 ± 1.0 N·m
bolt and the brush holder screws. {0.35 ± 0.1 kgf·m}
Rear bracket [2.5 ± 0.7 lbf·ft]
Through bolt
5.8 ± 1.3 N·m
{0.59 ± 0.13 kgf·m}
[4.3 ± 0.9 lbf·ft]
Rear bracket - Install
2.4.7 Magnetic switch - Install
Magnet switch
(1) Install the magnetic switch and tighten the screws.
(2) Connect the lead to the terminal M and tighten it with 5.9 ± 1.7 N·m
{0.60 ± 0.17 kgf·m}
the fixing nut. [4.4 ± 1.2 lbf·ft]
Terminal M
10.7 ± 2.0 N·m
{1.1 ± 0.2 kgf·m}
[7.9 ± 1.4 lbf·ft]
Magnetic switch - Install
12-17
2.4.8 Pinion gap - Inspect
SW1 B
Do not apply current continuously for longer than 10
S SW2
seconds. M
Battery
(1) Connect the starter to the circuit as shown in the illus- 12V Disconnect the lead
tration. with a terminal
connected to
(2) When the switches SW1 and SW2 are turned ON, the terminal M.
pinion pops out to the cranking position and the arma-
ture starts to rotate.
(3) Turn the switch SW2 OFF to stop the rotation of the Connection for pinion gap inspection
armature.
(4) Gently push back the pinion in the out position with a Pinion
finger and measure the distance over which the pinion

has returned (pinion gap).
Gently push back
(5) If the measured value is out of the standard, increase or
the pinion.
decrease the number of packings between the magnetic
switch and the front bracket for adjustment, or replace
the lever with a new one.
Pinion gap
Item Standard 0.5 to 2.0 mm [0.020 to 0.008 in.]
0.5 to 2.0 mm Pinion gap - Inspect
Pinion gap
[0.020 to 0.079 in.]
12-18
2.5 Alternator - Disassemble and inspect
Slip ring contamination, flaw,

seizure, coil resistance 5
Rotation
4
Crack, flaw
3 Crack, flaw
7
Deformation, 10
flaw 2
Rotation
8
1
Rotation
6
9
Short, open circuit
Brush sliding condition, wear

Coil open circuit,
ground
Alternator - Disassemble and inspect

1 Nut 5 Rotor, bearing 9 Rectifier
2 Pulley, spacer 6 Stator 10 Nut set
3 Through bolt 7 Rear bracket
4 Front bracket, bearing 8 Regulator
12-19
2.5.1 Stator and Front bracket - Separate

Rear bracket
(a) Disassembly of alternator should be conducted

only when repair is necessary.
(b) Use care not to insert the screwdriver deeply. Oth-
erwise its tip may damage the stator.
(1) Remove the through bolts.

(2) Insert the tip of a flat-blade screwdriver between the
stator and front bracket, and separate them each other. Stator core Front bracket
Stator and Front bracket - Separate

2.5.2 Pulley - Remove
Pulley
When holding a rotor with a vice, be sure to hold at the Front bracket
base of claw with a vice. Holding the tip of claw can
cause damage.
(1) Wrap the rotor in cloth and clamp it in a vise.

(2) Remove the pulley nut, and then pull out the pulley and
spacer.
(3) Remove the rotor from the front bracket. Rotor
Pulley - Remove
2.5.3 Rear Bearing - Remove
Using the bearing puller, remove the rear bearing from the Rotor
Rear bearing
rotor.
Rear Bearing - Remove

2.5.4 Front Bearing - Remove
Remove the screw, and remove the bearing retainer and the Front bearing Front
front bearing from the front bracket. Screw bracket
Bearing retainer
Front Bearing - Remove
12-20
2.5.5 Stator - Remove
The solder must be removed in a short time. If the

heat is applied for a long time, the diode will be dam-
aged.
(1) Melt the solder of stator and rectifier, and remove the
stator from the rectifier. Stator core
(2) Unscrew the rectifier mounting screws, and dismount Rectifier
the rectifier. Soldering
Stator - Remove
2.5.6 Regulator Assembly - Remove
Screw
(1) Remove the screws from the regulator assembly.
(2) Melt the solder at the regulator and rectifier connec-
tions, and remove the regulator assembly.
Regulator
assembly
Regulator Assembly - Remove
2.5.7 Rectifier Assembly - Remove
(1) Remove the screws, mold and nuts from the rectifier.
Nut
(2) Remove the rectifier assembly.
Screw
Rear bracket
Rectifier assembly
Rectifier Assembly - Remove
12-21
2.6 Alternator - Inspect and Repair

2.6.1 Stator - Inspect
(1) Continuity between lead wires - Inspect
Check that there is continuity between a pair of lead
wires.If there is no continuity, replace the stator with a
new one.
Continuity between lead wires - Inspect

(2) Isolation between lead wire and core - Inspect
Check that there is no continuity between stator lead
wires and the stator core.If there is continuity, replace
the stator with a new one.
Note: The core cannot be replaced as a single item.
Isolation between lead wire and core - Inspect

2.6.2 Rectifier - Inspect
Check that the diodes in the rectifier function properly.
Inspection should be conducted at both positive and nega-
tive sides alternately, and if there is infinite resistance in
both sides, it means open circuit, and if there is zero ohm
indication, or close to zero ohm, it means short circuit.If
defective, replace the rectifier with a new one.
Note: Use the largest measuring range.The current that flows
during the test is much lower than the current that nor-
mally flows in the rectifier. Therefore, the tester may
not indicate resistance accurately in some cases. When Rectifier - Inspect
the measuring range is small, this tendency becomes

larger.
12-22
2.6.3 Rotor - Inspect

(1) Check for conduction between slip rings (rotor coils).If
isolated, replace the rotor with a new one.
Conduction between slip rings (rotor coil) - Inspect

(2) Check that the slip ring and the shaft (or core) are iso-
lated.If there is continuity, replace the rotor with a new
one.
Isolation between slip rings and shaft - Inspect

2.6.4 Brush - Inspect for wear
Measure the length of the brushes. If the specified limit is
exceeded, replace the brush with a new one.
Item Standard value Limit value

Brush length 18.5 mm [0.728 in.] 5.0 mm [0.197 in.]
Wear limit line
Brush - Inspect for wear
12-23
2.6.5 Brushes - Replace

(1) To remove the brush and the spring, unsolder the brush
lead. Soldering
Brush holder
Brushes - Replace
(2) To install a new brush, push the brush into the brush
holder as shown in the illustration, and then solder the Brush
lead to the brush.
Note: Pay attention to the brush insertion direction when in-
stalling.
Brush - Install
12-24
2.7 Alternator - Assemble
Alternator - Assemble
Note: Be sure to use proper harness.

If the harness is modified, the alternator will not function properly.
12-25
2.7.1 Rectifier assembly and

Regulator Assembly - Install Regulator
assembly
Install the rectifier assembly and regulator assembly to the
rear bracket.
Rectifier
assembly
Rectifier assembly and
Regulator Assembly - Install
2.7.2 Stator - Install
Solder must be applied in a short period of time.If the

heat is applied for a long time, the diode will be dam-
aged.
(1) Install the stator.

(2) Solder the lead wire of stator to the rectifier. Stator core
Rectifier
Soldering
Stator - Install
2.7.3 Front bearing - Install
(1) Install the front bearing to the front bracket. Front bearing Front
(2) Secure the bearing retainer with the screw. Screw bracket
Bearing retainer
Front bearing - Install

2.7.4 Rear bearing - Install
Install the rear bearing to the rotor. Rotor
Rear bearing
Rear bearing - Install
12-26
2.7.5 Pulley - Install

(1) Insert the rotor to the front bracket. Pulley
(2) Wrap the rotor in cloth and clamp it in a vise. Front bracket
(3) Install the pulley assembly and secure it with the nut.
Rotor
Pulley - Install
2.7.6 Rear bracket assembly and Front bracket
assembly - Assemble Rear bracket
(1) Insert a piece of wire to the hole of brush through the
Brush
small hole provided in the bracket, and raise the Wire
brushes. Install the rotor to the rear bracket, and remove
the wire.
Brush - Fix
(2) Assemble the front bracket, stator, and rear bracket, and
Front bracket
secure them with the through bolt.
Through bolt
Stator core
Rear bracket assembly and Front bracket assembly -

Assemble
2.8 Glow Plug - Inspect and Repair
2.8.1 Heating test of glow plug
Connect the wiring to the terminal and ground the body as
shown in the illustration. If the glow plug heats red, it is nor-
mal.
Item Standard Remarks

Rated voltage -
9.5 ± 1.0A Apply DC11V for 6 seconds.
Armature current
Heating test of glow plug
12-27
3. Electrical System - Install

3.1 Glow plug - Install
(1) Install the glow plug, and tighten it to the specified
torque. 1.25 ± 0.25 N·m Connection plate
{0.13 ± 0.03 kgf·m}
(2) Install the connection plate and tighten the fixing nuts [0.92 ± 0.18 lbf·ft]
to the specified torque. Glow plug
17.5 ± 2.5 N·m
{1.8 ± 0.25 kgf·m}
[12.9 ± 1.8 lbf·ft]
Glow plug - Install

3.2 Stop solenoid - Install
(1) Install the fixing nut to the stop solenoid.
(2) Install the stop solenoid and tighten the fixing nuts to
44.1 ± 4.9 N·m
the specified torque. {4.5 ± 0.5 kgf·m}
[32.5 ± 3.6 lbf·ft]
Stop solenoid
Nut
Stop solenoid - Install
12-28
3.2.1 Stop solenoid - Install
These areas must be

Nut Cylinder block free from a sealant.
44.1 ± 4.9 N·m
{4.5 ± 0.5 kgf·m} Control rack
[32.55 ± 3.61 lbf·ft]
Do not allow wash fluid to

enter the inside of the
solenoid from the clearance.
㧭
Rubber cap
Stop solenoid 0.15 to 0.20mm UP

[0.00591 to 0.0079 in.] PUSH
Shaft TO
Threaded portion: STOP
Apply a sealant.
Water drain hole
Stop solenoid - Install
Do not allow wash fluid to enter the terminal and the inside (cord and shaft) of the solenoid.
(1) Apply a sealant to the threaded portion of the stop solenoid.
Note: Apply the sealant up to the position where the stop solenoid is screwed into the governor case.
Sealant ThreeBond 1212 or 1211
(2) Temporarily assemble the stop solenoid and the nut to the governor case.
(3) Move the control rack of the fuel injection pump fully in the stop direction.
(4) Screw in the stop solenoid while pushing in the plunger until the shaft contacts the tie rod. At this position, the clearance of
A should be 0 mm [0 in.] (position at which the plunger rotates together by screwing in the stop solenoid).
(5) Turn the stop solenoid in the reverse direction by 30 to 45° from the above position and temporarily tighten the nut.
(6) Move the control rack side to side and make sure that there is play of approx. 0.15 to 0.20 mm [0.0059 to 0.0079 in.].
(7) Lastly, assemble the rubber cap with the arrow facing upward (water drain hole facing downward) as illustrated.
12-29
3.2.2 Checking after assembling stop solenoid

(1) Make sure that the stop solenoid activates and the engine stops when the starter switch is turned to OFF position after the
engine starts.
(2) Make sure that the stop solenoid activates and the engine stops when the starter switch key is turned to ON position during
engine start.
(3) By turning the engine key from OFF to ON to START, check that the stop solenoid activates when the key is placed in ON
position, and also check that the activation of stop solenoid immediately stops when the engine key is placed in START
position.
3.3 Alternator - Install

(1) Install the adjusting plate.
(2) Install the alternator. Alternator
Adjusting plate
Flange bolt
Bolt
Alternator - Install
12-30
1. Engine - Adjust ...................................................................................................... 13-3
1.1 Valve Clearance - Check ........................................................................................................ 13-3
1.2 Fuel Injection Timing - Check ................................................................................................. 13-3
1.3 Fuel System - Bleed Air .......................................................................................................... 13-3
1.4 No-Load Minimum Engine Speed (Idling) and No-Load Maximum Engine Speed - Check and
Adjust...................................................................................................................................... 13-4
1.5 Belt and Belt Tension - Inspect and Adjust............................................................................. 13-5
2. Break-In Operation ................................................................................................ 13-6
2.1 Engine Start-up....................................................................................................................... 13-6
2.2 Inspection While the Engine is Running ................................................................................. 13-6
2.3 Break-in Operation Time......................................................................................................... 13-6
2.4 Inspection and Adjustment After Bbreak-in Operation............................................................ 13-6
3. Performance Test .................................................................................................. 13-7
3.1 Engine Equipment Condition .................................................................................................. 13-7
3.2 Test Items and Purposes........................................................................................................ 13-7
3.3 Other Inspections ................................................................................................................... 13-7
3.4 Engine Output Adjustment...................................................................................................... 13-7
13-1
1. Engine - Adjust
1.1 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 "ENGINE BODY - ASSEMBLE".
1.2 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. "
1.3 Fuel System - Bleed Air
Wipe off fuel spilled from the air vent screw thoroughly
with a cloth. Spilled fuel can cause fires.
Air bleeding of the fuel system must be started from the
place closest to the fuel tank, i.e. from the fuel filter to the
fuel injection pump.
1.3.1 Fuel injection pump - Bleed air
Loosen the air vent screw of pump to discharge air in the
fuel pipe and fuel injection pump. Air vent screw
Note: Air in the fuel injection pipe and fuel injection nozzle
is automatically discharged by cranking the engine.
Fuel injection pump - Bleed air
13-3
1.4 No-Load Minimum Engine Speed (Idling) and No-Load Maximum Engine Speed - Check and Adjust
(a) The inspection and adjustment of no-load minimum speed and maximum speed should be conducted by the
appointed service shops only, as the set bolt of every engine is sealed after the confirmation of output using the
test bench.
(b) After the governor parts are adjusted, all external stoppers must be sealed. These seals, in case of engine trou-
ble, are very important, as they are one of key factors for claim judgment. Be sure to seal all the specified sec-
tions.
(c) Taking into consideration the engine overruns, be ready to operate the engine stop lever manually when
inspecting and adjusting.
1.4.1 Preparation
(1) Operate the engine to warm up until coolant tempera-
ture reaches 60 °C [140 °F] or higher.
(2) Make sure that valve clearance, fuel injection timing, Low idling set bolt
fuel injection start pressure, spray condition, and oil
tight are normal.
High speed set bolt
Engine speed - Adjust

1.4.2 No-load minimum engine speed - Adjust
(1) Loosen the lock nut of idling set bolt.
(2) By turning the bolt, adjust no-load minimum engine
speed.
(3) Secure the set bolt with the lock nut.
1.4.3 No-load maximum engine speed - Adjust
(1) Loosen the lock nut of high speed set bolt.
(2) By turning the bolt, adjust no-load maximum engine
speed.
(3) Secure the set bolt with the lock nut.
13-4
1.5 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.
1.5.1 Belt - Inspect

(1) Inspect the belt visually for separation or damage. If any defects are found, replace the belt with a new one.
(2) Inspect the deflection of belt.
Inspect the belt deflection by pressing it with approx. 98 N {10 kgf} [72 lbf] force at the center of its span. The belt deflec-
tion should be 10 mm [0.394 in.].
If the deflection is out of standard, adjust the belt tension.
1.5.2 Belt Tension - Adjust
Water pump Adjusting bolt
(1) Loosen all retaining bolts of the alternator and adjusting pulley
Alternator pulley
plate.
(2) Adjust belt tension properly. Approx.
10 mm
(3) Tighten all retaining bolts of the alternator and adjust- [0.39 in]
ing plate.
Retaining bolts
Deflection:approx. 10 mm [0.39 in]
Crankshaft
pulley (push force: approx. 98 N {10 kgf} [22 lbf])
Belt Tension - Adjust
13-5
2. Break-In Operation
After the engine is overhauled, connect the engine to the dynamometer, and run the engine for break-in operation and inspec-
tion.
2.1 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 (idling).
(5) Turn the starter switch key to the [OFF] position and make sure that the engine is stopped.
2.2 Inspection While the Engine is Running

During the break-in operation, check the following. If any abnormality is found, stop the engine, investigate the cause, and take
appropriate measures.
(1) The oil pressure should be the specified value.
(2) The coolant temperature should be the specified value.
(3) There should be no leaks of oil, water, fuel, and gas (air). Pay special attention to oil leaks from the turbocharger lube oil
pipe connections.
(4) Check for an abnormal noise.
(5) Check for smoke color and odors.
2.3 Break-in Operation Time
The relationship between the load in the break-in operation and the operation time is as shown below.
Break-in operation time

Time
Rotation speed (min-1) Load (PS)
(min)
1 Low rotation speed 600 to 900 No-load 5
Medium rotation
2 1000 to 1200 No-load 5
speed
3 High rotation speed 1400 to rated speed No-load 10
4 25 % 10
5 50 % 10
Rated speed
6 75 % 30
7 100 % 20
Note: Run the engine at appropriate speed and load for the break-in operation of your engine. Be sure to perform break-in oper-
ation after overhaul or installation.
2.4 Inspection and Adjustment After Bbreak-in Operation
(1) Valve clearance - Adjust
(2) Fuel injection timing - Inspect
(3) Exterior bolt and nut tightness - Inspect
13-6
3. Performance Test
The following describes the procedures specified in "Earth
moving machinery - Engines - Part 1: Test code of net
power (JIS D0006-1)" and "Earth moving machinery -
Engines - Part 2: Standard format of specifications and test-
ing methods of diesel engines (JIS D0006-2)."Other test
items may be required in some applications.All test results
should be evaluated comprehensively in order to determine
the engine performance.
3.1 Engine Equipment Condition
The engine must be equipped with standard auxiliary
devices such as the cooling fan, air cleaner and alternator.
3.2 Test Items and Purposes

3.2.1 Operation load test
Conduct this test to evaluate the engine output, torque, fuel
consumption rate and governor performance under various
load conditions.
3.2.2 Continuous load test
Operate the engine continuously for 10 hours at 90% load
(continuous load application) of nominal net brake power
while the engine speed is maintained at revolutions corre-
sponding to the nominal brake power. In this test, evaluate
the fuel consumption rate and operating condition, and con-
firm that the engine is capable of continuous operation.
3.2.3 No-load minimum engine speed test
Conduct this test to confirm that the engine can operate sta-
bly at the specified no-load minimum engine speed.
3.3 Other Inspections

Check for gas, coolant and oil leaks; abnormal odors; and
hunting. Make adjustments as needed.
3.4 Engine Output Adjustment

Diesel engine output is affected by atmospheric pressure,
temperature and humidity.Therefore, correction calculations
must be performed to obtain the value of engine output
under the standard atmospheric conditions.
3.4.1 Standard atmospheric conditions
Reference temperature298 K (25ºC)
Atmospheric total pressure:100 kPa (750 mmHg)
Reference atmospheric dry pressure:99 kPa (743 mmHg)
13-7
3.4.2 Calculation of corrected power

Multiply the measured brake power or torque by the calcu-
lated diesel engine correction factor to obtain a corrected
value.If the applicable range of the correction formula is
exceeded, indicate the corrected values and record the test
conditions on the test record.
Calculation output = Correction factor ( ) × Measured brake power

Atmospheric conditions during test
Temperature( ):283 K(10°C)[50°F] T 313 K(40°C )[104°F]
Dry atmospheric pressure( ):80 kPa(600 mmHg) 110 kPa(825 mmHg)
=( ) :Atmospheric factor :Engine factor
Range of correction equation use

The range of correction factor ( ) is as follows:
0.9 1.1.
Calculation of engine factor ( )
Calculation of correction factor ( ) =0.036 -1.14
Natural aspiration engine and engine with :Corrected fuel supply volume
mechanically driven air charger =
99 0.7
=( )·( ) ( ) × (Fuel flow rate g/s)
298 =
(Stroke volume ) × (Engine speed min-1)
Turbocharged engine without air cooler = 120000 (4-cycle engine)
or with air-to-air cooler :Ratio between pressure at turbocharger or
99 0.7 1.2 air cooler outlet and atmospheric pressure
=( ) ·( )
298 ( =1 for natural aspiration engine)
Turbocharged engine with air-to-liquid · Applicable range of engine factor ( )
cooler 37.2 65mg/( -cycle)
99 0.7 0.7 · 37.2mg/(l -cycle): =0.2 (constant)
=( ) ·( )
298 · 65mg/( -cycle) : =1.2 (constant)
13-8
1. Troubleshooting .................................................................................................... 14-3
1.1 Troubleshooting ...................................................................................................................... 14-3
1.2 Starting trouble ....................................................................................................................... 14-4
1.3 Knocking ................................................................................................................................. 14-5
1.4 Overheating ............................................................................................................................ 14-6
1.5 Excessive black smoke........................................................................................................... 14-7
1.6 Idling malfunction.................................................................................................................... 14-8
1.7 Low output .............................................................................................................................. 14-9
14-1
1. Troubleshooting
1.1 Troubleshooting
(a) For the fuel injection pump, the injection quantity

of each cylinder can be measured only with a
pump tester. Do not adjust or disassemble the fuel
injection pump even during troubleshooting unless
absolutely necessary.
(b) To inspect the combustion state of each cylinder,
loosen the fuel injection pipe of any cylinder to
stop injection, and compare the extent of a drop in
the engine speed with that of other cylinders.
(1) Troubles of the diesel engine often occur in combina-
tion of various problem causes, and therefore it is often
very difficult to determine the defect from a problem
phenomenon.
Especially a similar phenomenon occurs in troubles of
the fuel injection pump, fuel injection nozzles and com-
pression pressure. It is, therefore, necessary to conduct
a careful study to determine the cause.
From the reason above, troubleshooting described in
this section is summarized as the inspecting order from
items which are more likely to cause problems or items
easy to inspect in sequence.
(2) The diesel engine has the following characteristics from
its structure and combustion system. It is necessary to
fully understand these characteristics before performing
troubleshooting.
The engine produces unique combustion noise (die-
sel knock) in the normal condition.
The engine discharges slight black smoke at heavy
load.
High compression and high torque cause vibration
on a single unit of the engine.
14-3
1.2 Starting trouble

1.2.1 Check items before troubleshooting
(1) Clogging of air cleaner
(2) Coagulation of engine oil
(3) Use of poor quality fuel
(4) Drop in cranking speed
1.2.2 Problem: Starting trouble
NO Is power applied to the glow plug NO

Is the preheating Inspect key switch,
wire immediately after the key
device normal? wiring and glow signal
switch is turned ON?
YES
YES Inspect glow plug
If the preheating device is equipped with a NO

Is the electrical Inspect wiring
fuel pump, does the pump operate when
wiring normal? of fuel pump
the key switch is turned ON?
YES
NO Is fuel drained when the air bleeding NO

Does fuel flow in Inspect fuel filter,
screw of the fuel injection pump is
the fuel line? fuel pipe and fuel tank
loosened?
YES
Is the engine correctly adjusted NO

Adjust engine
(fuel injection timing and valve clearance)?
YES
Are fuel injection nozzles normal NO

(spray state and injection-valve opening Inspect fuel injection nozzles
pressure)?
YES
Is the compression pressure NO Inspect valves, pistons, piston rings

in cylinders normal? and cylinder head gasket
YES
Inspect fuel injection pump
Problem: Starting trouble
14-4
1.3 Knocking
The diesel engine rotates producing unique combustion noise (diesel knock) due to its combustion system. This knock noise is
normal unless it is especially loud.
(2) Use of poor quality fuel (low cetane number fuel such as kerosene)
1.3.2 Problem: Knocking
Is the fuel injection timing normal NO

Adjust fuel injection timing
(fuel injection timing is early)?
YES

Examine fuel injection nozzles
(drop in injection start pressure and faulty)
YES
Is the compression pressure NO Inspecting valves, pistons, piston rings

in cylinders normal? and cylinder head gasket
YES
Is the fuel injection pump normal (variations in injection amount)?
YES
Generation of mechanical noise (wear of and damage to main working parts)
Problem: Knocking
14-5
1.4 Overheating
(1) Quantity and leakage of coolant
(2) Loosening of fan belt
(3) Clogging of radiator fins
(4) Concentration of LLC
(5) Clogging of muffler
(6) Quantity and degradation of engine oil
(7) Swirling of cooling air
(8) Thermostat malfunction
1.4.2 Problem: Overheating
Overheat often occurs by engine load mismatching when the engine is set up. If the engine itself is normal and overheat occurs,
measure the ambient and coolant temperatures in the loaded condition (thermostat full open). If the temperature difference is
greater than 60°C [140°F], it is desirable to inspect items other than the engine.
NO
Does the engine run continuously under overload? Examine the cause of load
YES
Is the cooling system normal NO

(blow-by of cylinder head gasket, clogging of water pump, Repair cooling system
water hose and radiator, and faulty thermostat)?
YES
NO
Is the fuel injection timing normal? Adjust fuel injection timing
Problem: Overheating
14-6
1.5 Excessive black smoke

(3) Overload
1.5.2 Problem: Excessive black smoke
Is the smoke set amount of NO

Adjust smoke set
fuel injection pump normal?
YES
Is the engine correctly adjusted? NO

(Excessive valve clearance, Adjust engine
incorrect fuel injection timing)
YES
NO
Are fuel injection nozzles normal? (Spray Inspect fuel injection nozzles
condition, excessive injection starting pressure)
YES
NO
Is the compression pressure normal? Inspect valves, cylinder head gasket, pistons and piston rings
YES
Problem: Excessive black smoke
14-7
1.6 Idling malfunction

(1) Engine control system malfunction
(2) Viscosity of engine oil too high
1.6.2 Problem: Unstable idling

(engine idle speed, valve clearance and Adjust engine
fuel injection timing)?
YES
Are fuel injection nozzles normal (spray state, NO

Inspect fuel injection nozzles
injection-valve opening pressure too high)?
YES
Is the compression NO
Inspect valves, pistons and piston rings
pressure normal?
YES
Inspect fuel injection pump and governor system
Problem: Unstable idling
14-8
1.7 Low output

(1) Seizure of engine operating parts
(2) Viscosity of engine oil too high
(5) Clogging of muffler
(6) Malfunction of driving system
1.7.2 Problem: Low output
Does fuel including the fuel amount

NO in the fuel tank flow sufficiently in NO Inspect fuel filter,
Is fuel in the fuel line sufficient? the drop type?
fuel pipe and fuel tank
Does fuel flow with the switch turned
ON in the electromagnetic type?
YES
YES Fuel pump

Adjust engine
(valve clearance and fuel injection timing)?
YES

(spray state and injection-valve Inspect fuel injection nozzles
opening pressure)?
YES
Is the compression NO
Inspect valves, cylinder head gasket, pistons and piston rings
pressure normal?
YES
Problem: Unstable idling
14-9
March 2013 SERVICE MANUAL for KUKJE MACHINERY CO.,LTD Pub. No. 99616-16100
Printed in Japan Pub. No. 99616-16100

Manual de Servicio L3E

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Manual de Servicio L3E

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SERVICE MANUAL

for KUKJE MACHINERY CO.,LTD

HOW TO USE THIS MANUAL

Terms used in this manual

Abbreviations and Standards

Keep Fire Extinguishers and First-Aid Kit

Stay Away From Rotating and Moving Parts

Install Protective Covers Over Rotating Lockout and Tagout

Work tion and maintenance.Lockout and tagout are effective

parts.If clothes or a tool gets caught in

Be Careful of Exhaust Gas Poison- Be Careful of Falling

Do not Climb Onto the Engine

Be Careful When Handling Fuel, Be Careful of Burns

Battery When Abnormality Occurs

Be Careful with Battery Stop Overheated Engine After Cooling Run

Do Not Tamper Warm-up the Engine Before Use

Air cleaner or Do Not Operate Starter for a Long Time

Maintenance of Warning Labels

Points on Disassembling and As- Points on Assembling

Chapter 2 SERVICE DATA

Chapter 3 SERVICE TOOLS

Chapter 4 OVERHAUL INSTRUCTIONS

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

Chapter 7 ASSEMBLY OF BASIC ENGINE

Chapter 8 FUEL SYSTEM

Chapter 9 LUBRICATION SYSTEM

Chapter 10 COOLING SYSTEM

Chapter 11 INLET AND EXHAUST SYSTEMS

Chapter 12 ELECTRICAL SYSTEM

Chapter 13 ADJUSTMENT AND OPERATION

Left Side View

Fuel injection nozzle Front hanger

Inlet manifold Fuel injection pump

Oil filter Oil level gauge

Right Side View

Fuel leak-off pipe

From fuel pump

Fuel injection pump

Outline of Fuel System

2.2 Outline of Lubrication System

Relief valve Oil screen

Oil drain plug

Outline of Lubrication System

2.3 Outline of Cooling System

Water pump Water bypass pipe

Outline of Cooling System

2.4 Outline of Inlet and Exhaust System

From air cleaner

Outline of Inlet and Exhaust System

3. Engine Serial Number

Engine serial number

Engine serial number location

Engine model code and displacement

Engine model L3E-61KR

Fuel system Type Throttle type

Engine model L3E-61KR

Chapter 2 SERVICE DATA

1. Maintenance Service Data

1.2 Maintenance Service Data of Engine Body

35.5 [1.398]/ 28 [1.10] /

1.3 Maintenance Service Data of Fuel System

Item Nominal Standard Limit Remarks