Professional Documents
Culture Documents
Mitsubishi Diesel Engines: Service Manual
Mitsubishi Diesel Engines: Service Manual
MITSUBISHI
DIESEL ENGINES
S4S
ses
March 2002
J.. !!!!I'D'!S~~!~!.
Downloaded from www.Manualslib.com manuals search engine
Downloaded from www.Manualslib.com manuals search engine
Foreword
This service manual is written to familiarize you with the maintenance of your S4S and S6S Diesel Engine. If
the engine is carefully maintained it will deliver a long productive life and efficient performance marked by
power and economy.
Before you attempt to inspect, disassemble, or repair the engine, read this manual carefully to leam more about
the engine and how to care for it properly. AH descriptions, illustrations, specifications and serial numbers in
this manual are effective as of the date printing of this manual.
The information contained in this manual applies to the engine model produced at the time of publication.
It should be noted that specifications and design may change due to improvements made thereafter.
For items other than those in this publication, refer to the operation manual for a unit on which the
engine is mounted,
1. Parts in illustrations are numbered to correspond with references to these numbers in text.
2. Items or conditions to be inspected during disassembly are enclosed in a box in the disassembIed views:
4. The sequence in which parts are to be reassembled is summarized below eaeh assembIed view.
Sueh as:
@..... ~ .....@.....@.....CD
5. Tightening torque under wet conditions is indieated as "(wet)" in text, drawings, and tables. When so indieated
as (wet), apply engine oil to the threaded portion of the fastener. Unless indieated as such, the tightening
torque is to be assumed in the dry condition.
Notes, cautions, wamings, dangers are used in this manual to emphasize important or critical instructions or
advice.
Before you read this manual, note that the following special terms are used in dimensional and other specifications.
Assembly Standard Indicates the dimension of a part, the dimension to be attained at the
time of reassembly or the standard performance. The value is rounded
to the nearest whole number needed for inspeetion and is different from
the design value.
Repair Limit.. A part which has reached this limit must be repaired.
Service Limit A part which has reached this limit must be replaced.
Standard Clearance Indicates the clearance to be obtained between mating parts at reassembly.
Group Contents
1. General External view, engine serial number location, engine model and
application codes, specifications, tips on disassembly and reassembly.
4. Overhaul Instructions Determining when to overhaul the engine, testing compression pressure
5. Adjustments, Bench Test, Adjustment of valve clearance, fuel system bleeding, fuel injection
Performance Tests timing, no-load minimum and maximum speed setting, V-belt, bench
testing, performance tests.
6. Engine Auxiliaries Removal Removal and installation of turbocharger, fuel injection pump, alternator,
and Installation water pump, starter, etc.
7. Engine Main Parts Disassembly, inspeetion and reassembly of the main parts, to include
cylinder head and valve mechanism, flywheel, damper, timing gears and
camshaft, pistons, connecting rods, crankshaft, crankcase and tappets.
8. Inlet and Exhaust System Disassembly, inspeetion and reassembly of inlet and exhaust system
(exhaust manifold).
11.Fuel System Disassembly, inspeetion and reassembly offuel systern, to include fuel
filter and injection nozzles.
13.Workshop Tips Basic recommended assembly procedures: oil seals, O-rings, bearings,
split pins and spring pins.
1. Outline
Governor
Coolant drain plug
C'-I)
Oil drain plug
n on filter
<>-tt-++--Flywheel
I Left view
Oil filler
Thermostat
Exhaust manifold
Alternator
I Rear I IFront I
n
V-belt
Starter
IRight viewl
Remark: Direction of rotation of this engine is counterclockwise as seen from flywheel side.
1-2
[S4S-DT - Standard]
I
fT"i"T"i:
~ r~~ ~?n'\~
hl
vETRstopsolenoid
Water pump~ F -\.lIJ 11 (( --r
I ~ ;:, Ip,~ -~
):
! :;::
[l.l.AF::J"1"-
p
~
"/
~Governor
~
/ Coolant drain plug
rUi;!=~~o?J;»-~~'-.-i~0Ë=Q:~~:jl~~,\~~r-~-dn
Fuel feed pump -:
(I~I\
::n
.'
"
1111 ~f--Ij'---H--FI ywheel
on drain PIL
on filter
ILeft view I
Turbocharger
on filler
Thermostat
I Rear I IFront I
n
Starter
V-belt
(1-1\
Oil pan
IRignt viewl
Remark: Direction of rotation of this engine is counterclockwise as seen from flywheel side.
1-3
[868 - Standard]
Governor
Water pump
t:~~~ah~~::~~r Coolant drain plug
IFront I I Rear I
Flywheel
Oil filter
Oil drain plug Dipstick
I Left view
Oil filler
Thermostat
Exhaust manifold
Alternator
I Rear I IFront I
Starter
V-belt
Oilpan
IRight viewl
Remark: Direction of rotation of this engine is counterclockwise as seen from flywheel side.
1-4
[S6S-DT - Standard]
IFront I I Rear I
Flywheel
I Lef! view I
Turbocharger
Gil filler
Thermostat
Exhaust manifold
Alternator
I Rea.. I IFront I
Starter
V-belt
Gil pan
IRight viewl
Remark: Direction of rotation of this engine is counterclockwise as seen from flywheel side.
1-5
s D s - [Q][ïJ
~
T : Equipped with turbocharger
D : Direct injection type
Series code
Number of cylinders
Manufactured by Sagamihara machinery works
1-6
2. Specifieations
Model designation S4S S4S-DT
Type Water-cooled, 4-stroke cycle
No. of cylinders - arrangement 4- in line
Combustion chamber type Swirl chamber Direct injection
Valve mechanism Overhead
Cylinder bore x stroke mm[in.] 94 x 120 [3.70 x 4.72]
Piston displacement liter [cu in.] 3.331 [203]
";J
...
<Ll
Compression ratio 22: 1 17: 1
I:
<Ll Firing order 1-3-4-2
0
Direction of rotation Counterclockwise as viewed from flywheel side
Overall1ength
781 [30.7]
mm[in.]
Overall width
Dimension 593 [23.3]
mm[in.]
Overall height
710 [28.0] 821 [32.3]
mm[in.]
Weight (dry) kg [Ib] 245 [540] 250[551]
Type of cylinder sleeve Integral with cylinder block
Ol:> Compression ring 2
No. of piston ring
~ Oilring 1 (w/spring expander)
0..
I:
.e; Open BTDC 30° BTDC 18°
a InIet valve
<Ll Close ABDC 50° ABDC 54°
I: Valve timing
·So Open BBDC 74° BBDC 66°
I: Exhaust valve
p:l
Close ATDC 30° ATDC 22°
Starting system Electric-starter
Starting aid G10w plugs
"0_",
§~e
"t).2
-><>-.
~lUtI'.:l
* Air cleaner
Turbocharger
Type
Model -
Paper-element
TD04HL
Type Force feed by oil pump
Specification Class CD oil (API Service Classification)
Engine oil Capacity (engine) Approx. 10 [2.6]
liter [U.S. gal] (Oil pan: 9 [2.4], Filter: 1 [0.3])
Type Trochoid
a
~
Speedratioto crankshaft 0.74
Ol:>
Oil pump
;>,
Ol:>
Capacity 28.6 [7.6] at 0.3MPa (3 kgf/cm") discharge pressure
I:
0
liter [U.S gal] of pump running at 2 230 min:'
.~
u Type Piston valve
·C
..0
::l
Re1ief va1ve Opening pressure
....:l 0.35 ± 0.05 (3.5±0.5) [50±7]
MPa (kgf/cm") [psi]
Water-cooled
Oil Cooler Type -
I multi-plate
Oil filter Type Cartridge of paper element
Opening pressure
Safety valve - 1.1 (11) [156]
MPa (kgf/cm") [psi] I
1-7
Ei
Voltage - polarity 12V - e ground
2'Jl Model M008T75171
;>,
'Jl
Type Pinion shift
ë<i
Cl
'5 Starter Output V-kW 12 - 2.2
Cl
Cl)
No. of pinion teeth/
ü3 lO/l22
flywheel ring gear teeth
1-8
1-9
1-10
1-11
1-12
This service manual covers recommended (1) Wash all engine parts, except oil seals, O-rings,
procedures to be followed when servicing diesel rubber seals, etc. in c1eaning solvent and dry
engines. It also contains information on special them with compressed air.
tools required and basic safety precautions.
(2) Use only the correct tools and instruments.
It is the responsibility of service personnel to be
familiar with these requirements, precautions and (3) Use only good quality lubricating oils and
potential hazards and to discuss these points with greases. Be sure to apply a coat of oil, grease,
their foreman or supervisor. or sealant to parts as specified. (Refer to section
3, of Group 2, "Maintenance Standards".)
Study this manual carefully and observe the
following general precautions to prevent serious (4) Use a torque wrench to tighten parts when
personal injury and to avoid damage to the specified tightening torques are required. (Refer
engine, equipment and parts. to section 2, of Group 2, "Maintenance
Standards".)
3.1 Disassembly
(5) Replace all gaskets and packing. Apply
(1) Use the correct tools and instruments. Serious appropriate amount of adhesive or liquid gasket
injury or damage to the engine can result from when required.
using the wrong tools and instruments.
1-13
2-2
Unit: mm [in.]
Repair Service
Group Inspeetion Point Nominal Assembly Standard Limit Limit Remark
Value (Standard Clearance) (Clearance) (Clearance)
...
~
0 Inside diameter
14.000 to 14.018 14.100
..0 [0.5512 to 0.5519] [0.5551]
Q)
0.. Clearance between (0.016 to 0.052) (0.08) If it exceeds the repair
0..
~ tappet and bore ([0.0006 to 0.0021)) ([0.0031)) limit, replace tappets.
~
Front (0.070 to 0.118)
'"
<Il and ([0.0028 to 0.0047)) If it exceeds the repair
~ ~ midd1e (without bushings)
§ 5 (0.15) limit, refinish bores
U
... ..0 Clearance
(0.070 to 0.110) ([0.0059)) and install bushings,
~ between
<Il
..0 Rear ([0.0028 to 0.0043)) or replace camshaft.
co camshaft
a
<Il journa1 and
(without bushings)
U (0.040 to 0.119) If it exceeds the repair
bore (0.15)
([0.0016 to 0.0047)) limit, rep1ace bushings.
([0.0059))
(with bushings) Ream if necessary.
'0
<Il
<) Warpage of gasket 0.05 [0.0020] 0.20 Regrind if warpage is
..c
...
<)
contact surface or less [0.0079] minor.
'0
.5 Compressed thickness 1.2 ±0.05
>-,
U of gasket [0.05] [±0.002]
Inlet 7.940 to 7.955 7.900
Diameter
va1ve 8 [0.3126 to 0.3132] [0.3110]
~
'0
ofva1ve
'5 stern Exhaust [0.31] 7.920 to 7.940 7.850
co
~
va1ve [0.3118 to 0.3126] [0.3091]
;>
(;J Inlet (0.065 to 0.095) (0.150)
;> Clearance
'0 between valve ([0.0026 to 0.0037)) ([0.0059])
=
<Il
guide and
~
;>
Exhaust (0.080 to 0.115) (0.200)
stern va1ve ([0.0032 to 0.0045)) ([0.0079))
~
Height to top of 11.5
±0.1 [±0.004]
va1ve guide [0.45]
'0
<Il
Ang1e 30°
~
..0 Inlet 0.4
...
~
~
'0 Valve va1ve [0.016] 1.0
.:::
;;, sinkage
±0.1 [±0.004]
[0.039] ':lè
ê<I Exhaust 0.5
U ~
'"
~
va1ve [0.020]
;>
IA 1.8
~ Width
[0.055]
±0.14 [±0.0055]
[0.071]
Valve
margin
Valve seat Va~e
angle sin age
Up to 1.83
Valve margin 2.13 [0.0839] [o.onO] by
refacing
48.85 47.60
Free length
[1.92] [ 1.87]
eo Squareness of ends
=
.t:: Squareness 1.50 or less with respect to center
0..
'" line
~
;>
Set length 43 [1.69]
~
176 to 196 147
Set force
(18 to 20) (15)
N (kgf) [lbf]
[40 to 44] [33]
2-3
Unit: mm [in.]
Repair Service
Group Inspeetion Point Nominal Assembly Standard Limit Limit Remark
Value (Standard Clearance) (Clearance) (Clearance)
Unit: mm [in.]
Repair Service
Graup Inspeetion Point Nominal Assembly Standard Limit Limit Remark
Value (Standard Clearance) (Clearance) (Clearance)
I::
Q) Cl) (0.07 to 0.11) (0.200)
No.1 ring
~ .S ([0.0028 to 0.0043]) ([0.0079])
v~f-----~---+':':--------::+-----j-':'::------=':+----------j
..0 I:: 2.0 (0.045 to 0.085) (0.150)
Q)
U
o:l No.2 ring
Q) [0.079] ([0.0018 to 0.0034]) ([0.0059])
§>t-------j-"--..........::.-+--------..........::.+----+-----+-----------i
~ g 4.5 (0.025 to 0.065) (0.150)
~ 5i:J Gil ring
U [0.177] ([0.0010 to 0.0026]) ([0.0059])
~
30 29.994 to 30.000
Diameter
[U8] [l.l809 to l.l8 II]
Clearance between (0.020 to 0.051) (0.080)
pin and bushing ([0.0008 to 0.0020]) ([0.0032])
Inside diameter of 30 30.020 to 30.045
bushing [U8] [l.l819 to l.l829]
0.10/100
0.15
"0
Bend and twist [0.0039/3.94]
[0.0059]
...o
Cl)
or less
.S Clearance between
~I:: crankpin and conneet-
(0.030 to 0.090) (0.200)
I:: ([0.0012 to 0.0035]) ([0.0079])
o ing rad bearing
U
33 (0.15 to 0.35) (0.50) Replace connecting
Endplay
[1.30] ([0.0059 to 0.0138]) ([0.020]) rad.
Rad weight difference JO g [0.35 oz]
per engine orless
Flatness 0.15 [0.0059] 0.50
Face runout or less [0.020]
0.02 [0.0008] 0.05 Straighten by cold
Deflection
or less [0.0020] working or replace.
Tcr
46.916:'2) 6.684 6.184
U SC
[1.8471:'2~1 [0.2632] [0.2435]
E
o:l
A=
U 46.878::;N 6.722 6.222
DI
11.8456:'2~1 [0.2647] [0.2450] B
Exhaust
valve A=
46.880:'2) 6.720 6.220
SC
[1.8457:'2~1 [0.2646] [0.2450]
2-5
Unit:mm [in.]
Repair Service
Group Inspeetion Point Nominal Assembly Standard Limit Limit Remark
Value (Standard Clearance) (Clearance) (Clearance)
...
.::l
..0
Clearance between (0.13 to 0.15) (0.20)
::I outer and inner rotors ([0.0051 to 0.0059]) ([0.0079])
....l
Clearance between (0.04 to 0.09) (0.15) Replace cover or
rotors and cover ([0.0016 to 0.0035]) ([0.0059]) case.
0.35±0.05
Valve
Relief valve (3.5±0.5)
opening
[50±7]
pressure,
MPa(kgfïcm')
Safety valve [psi] 1.1 (11) [156] With oil cooler
2-6
2-7
Unit: mm [in.]
Repair Service
Group Inspeetion Point Nominal Assembly Standard Limit Limit Remark
Value (Standard Clearance) (Clearance) (Clearance)
~
....
Thrust clearance of
pinion shaft
O.S
[0.020]
o or more
-ao O.S to 2.0
oE l§
()
CZJ Pinion clearance [0.020 to
Il.l 0.079]
~
No-laad characteristics Locked characteristics Magnetic switch
Torque
Voltage Current Speed Voltage Current Switch-in
Nrn (kgf.m)
V A min:' V A voltage V
[lbf.ft]
2S.0 (2.S5)
180 3800 lOS0
11 2 [1804] 8 or less
or less or more or less
or more
2-8
2. Tightening Torques
2.1 Important Bolts and Nuts
Thread Width Tightening Torque
Description Dia. x Pitch across flats, Remark
(M-thread) mm N·m kgf-rn IbHt
Cylinder head M12 x 1.75 19 113 to 123 11.5 ta 12.5 83 ta 90
Rocker cover M8 x 1.25 12 10.0 to 13.0 1.0 ta 1.3 7.23 to 9.40
Rocker shaft brackets M8 x 1.25 12 10.0 ro 20.0 1.0 to 2.0 7.23 ta 14.5
Main bearing caps M14x2 22 98 to 108 10.0 to 11.0 72 ta 80
Connecting rod caps MlO x 1.25 14 49.0 ta 59.0 5.0 to 6.0 36.2 ta 43.4
Flywheel M12x 1.25 17 78.5 ta 88.3 8.0 ta 9.0 57.9 to 65.1
Camshaft thrust plate M8 x 1.25 12 10.0 to 13.0 1.0 ta 1.3 7.23 ta 9.40
Front plate M8 x 1.25 12 10.0 ta 13.0 1.0 to 1.3 7.23 to 9.40
Timing gear case M8 x 1.25 12 10.0 ta 13.0 1.0 to 1.3 7.23 to 9.40
Crankshaft pulley M30 x 1.5 46 480 to 500 49 ro 51 354 to 369
Idler gear thrust plate MlO x 1.25 14 29.0 to 39.0 3.0 to 4.0 21.7 ta 28.9
Oil pan M8 x 1.25 12 10.0 to 13.0 1.0 ta 1.3 7.23 ro 9.40 Press product
Cast oil pan
Oil pan M8 x 1.25 12 27.5 ta 33.4 2.8 to 3.4 20.3 to 24.6 for agricul-
tural tractor
Agricultural
Rear plate MlO x 1.25 14 54.0 ta 65.7 5.5 ta 6.7 39.8 to 48.5
tractor use
M14 x 1.5 22 34.0 ta 44.0 3.5 to 4.5 25.3 to 32.5
Oil pan drain plug
M20x 1.5 24 73.0 to 83.0 7.5 to 8.5 54.2 to 61.5
Fuel injection nozzle
M8 x 1.25 12 21.0 ta 23.0 2.0 ta 2.4 14.5 to 17.4
glands (direct injection type)
Fuel injection nozzles
M20x 1.5 21 53.0 to 64.7 5.4 ta 6.6 39.1 ta 47.7
(swirl chamber type)
Fuel injection pump
22 34.0 to 39.0 3.5 to 4.0 25.3 ta 28.9
delivery valve holders
Fuel leak-off pipe nut M12 x 1.5 17 20.6 to 24.5 2.1 ta 2.5 15.2 ta 18.1
Fuel injection pump gear
M14 x 1.5 22 76.5 to 86.3 7.8 ta 8.8 56.4 to 63.7
(distribution type)
Fuel injection pump gear
(in-line, swirl chamber type) M12 x 1.75 19 58.8 ta 68.6 6.0 ta 7.0 43.4 ta 50.6
(in-line, direct injection type) M14 x 1.5 22 83.4 to 98.0 8.5 to 10.0 61.5 ta 72.3
Glow plug
(swirl chamber type) MlO x 1.25 12 15.0 to 20.0 1.5 to 2.0 10.8 ta 14.5
(direct injection type) M12 x 1.25 12 20.0 to 30.0 2.0 ta 3.0 14.5 to 21.7
(terminal) M4xO.7 8 1.0 ta 1.5 0.10 ta 0.15 0.72 ta 1.08
Exhaust manifold
(balt only) M8 x 1.25 12 27.5 to 33.3 2.8 ta 3.4 20.3 to 24.6
(with spacer) M8 x 1.25 12 15.0 to 22.0 1.5 ta 2.2 10.8 to 15.9
Oil pressure relief valve M22 x 1.5 27 44.1 ta 53.9 4.5 to 5.5 32.5 to 39.8
Safety valve ar blind plug M18 x2 24 64.0 to 74.0 6.5 to 7.5 47.0 to 54.2
Coolant drain plug 1/4 - 18NPTF 14 35.3 to 43.1 3.6 to 4.4 26.0 ta 31.8
Fuel injection pipe nuts M12 x 1.5 19 26.5 to 32.4 2.7 to 3.3 19.5 ta 23.9
Fuel return pipe nuts MlO x 1.25 14 17.7 ta 21.6 1.8 to 2.2 13.0 ta 15.9
Oil pump gear MlO x 1.25 14 28.0 ta 38.0 2.9 ta 3.9 21.0 to 28.2
2-9
Remarks: 1. The torque values shown above are for the balts with spring washers.
2. Do not apply any oil to the bolt threads.
2-10
2-11
3-2
~
Gage adaptor 30691-21100 Compression pressure
~
(swirl chamber) measurement
3-3
4-2
. - - - - - - - - 4l NOTE J r - - - - - - - - ,
4-3
......-------i[&CAUTION JI-------.
(a) Measure the compression pressure at regular
intervals to obtain correct data.
4-4
1. Adjustments 5- 2
1.1 Valve Clearance 5- 2
1.2 Fuel System Bleeding 5- 3
1.3 Fuel Injection Timing 5- 4
1.4 No-load Minimum (Idling) Speed and Maximum Speed Setting 5- 5
1.5 V-belt Inspeetion and Adjustment 5-10
2. Bench Testing .. 5-11
2.1 Starting Up 5-11
2.2 Inspeetion After Starting Up 5-11
2.3 Bench Testing (Dynamometer) Conditions 5-11
2.4 Inspeetion and Adjustment After Bench Testing 5-11
3. Performance Tests 5-12
3.1 Engine Equipment Condition 5-12
3.2 Tests and Their Purposes 5-12
3.3 Other Inspections 5-12
3.4 Adjustment Engine Output 5-12
1. Adjustments
(l) Inspeetion
Unit: mm [in]
Width across flats of 46
crankshaft pulley nut [1.81]
5-2
(2) Adjusting
(c) Tighten the air vent plug when the fuel flows
without bubbles.
(c) Tighten the air vent plug when the fuel flows
without bubbles.
5-3
(a) Remove delivery valve holder from the No.l Delivery valve hOlde'--t """'
plunger of the injection pump. Remove Spring
delivery valve and spring from the holder.
Restore the holder to the pump. Delivery valve _.= ,,,-,
5-4
5-5
(a) Pull speedcontrolleverto the high speed side. Speed con trol lever
Operate the starter switch to crank the engine.
Govemor Low idle speed
(b) The engine will fire up at 150 min-lof set bolt - set screw
cranking speed. When the engine fires, hold Idle sub-spring
the engine speed between 800 and 1000 min-I. adjusting screw
...----------JLt,CAUTION 1 - - - - -__
If a critical speed (the speed at which the engine
excessively vibrates due to torsional resonance)
might exist, shift the setting to a lower or higher
idle speed level. Setting no-Ioad minimum (idle) speed
(c) If the engine speed tends to fluctuate, turn idle Idle sub-spring
sub-spring adjusting screw clockwise to bring adjusting screw
this spring into slight contact with the tension
lever for eliminating fluctuation.
...----------JLt,CAUTION 1 - - - - -__
Tightening the idle sub-spring adjusting screw
is likely to cause the engine to overspeed when Setting idle sub-spring adjusting screw
the load is removed during operation. Be sure to
tighten this adjusting screw just enough to
eliminate the unstable condition.
5-6
Settinggovernor(maximum speed)
5-7
From the values obtained in [1] and [2], above, N4 = initial speed, min-I, before load is
compute the speed regulation for each load applied
change. A total of four percent values of speed Ns = lowest speed, min-I, during transitional
regulation are to be determined by using the period
indicated forrnulas. N6 = speed, min-I, at which the engine settles
after load is applied
If the computer values are at varianee with the tz = stabilization time
prescribed values, "governor notch adjustment"
should be made to eliminate the varianee.
5-8
,---------i!hCAUTION 1 - - - - - - - - - ,
Never loosen the adjusting screw by more than
20 notches (5 turns) frorn the fully tightened
position, or the control action of the governor
will become hazardous.
5-9
5-10
5-11
3. Performance Tests
There are various performance test procedures, and here the procedures for "Earth moving machinery
Engines, Part 1 : Test code of net power (JIS D 0006-1)" and "Earth moving machinery Engines, Part 2 :
standard format of specifications and tests methods of diesel engines (JIS D 0006-2)" are described. Other
test items may be required on application. Engine performance is judged with integrated test results.
Engine must be equipped with such standard auxiliaries as cooling fan, air cleaner and altemator.
Conduct this test to evaluate engine output, torque, fuel consumption rate and governor performance under
various load conditions.
Operate the engine continuously for 10 hours at 90% load (continuous load application) of nominal net
brake power while engine speed is maintained at revolutions corresponding to the nominal brake power. In
this test, evaluate fuel consumption rate and operating condition and confinn continuous engine operation.
Conduct this test to confinn that the engine can operate stably at the specified no-load minimum idle
speeds.
During performance testing, inspeet for leakage of gases, coolant, lubricating oil, or fuel, and for noise or
hunting. Make adjustment, as needed.
Diesel engine output is affected by atmospheric pressure, temperature, and humidity. Therefore, the engine
output should be set for standard atmospheric conditions.
5-12
Multiply the measured brake power or torque by the calculated diesel engine correction factor (see below)
to obtained a corrected value.
Dry atmospheric pressure (Pd): 80 kPa (600 mmHg) ~ Pd ~ 110 kPa (825 mmHg)
CD Natural aspiration engine and engine with mechanically driven air charger
fa =( ~) •(l ) 0.7
Pd 298
@ Turbocharged engine without air cooler (after cooler) or with air-to-air cooler
99 ) 0.7
fa = ( _ T
• ( _ ) 1.2
Pd 298
@ Turbocharged engine with air-to-liquid cooler
99
fa =(_)0.7. T
(_)07
Pd 298
fm = 0.036 qc - 1.14
q
CD qc (Corrected fuel supply volume) =-r
(z) x (Fuel flow rate gIs)
q =(Stroke volume f) x (Engine idle speed min-I)
37.2 ~ qc ~ 65 mg/(f-cycle)
5-13
1. Preparation 6- 2
2. Engine Auxiliaries Removal 6- 2
3. Engine Auxiliaries Installation 6- 7
1. Preparation
(c) Loosen the oil pan drain plug and drain engine
oil.
.-------....,( NOTE ) 1 - - - - - - - - ,
Check the drained oil for contamination.
Removing turbocharger
6-2
,-------llLtCAUTION ) f - - - - - - - - .
Removing fuel injection pipes
Be sure to put rubber caps over the openings of
the injection pump and nozzle holders to prevent
dust from getting inside the fuel system.
6-3
./~
~ Nozzle
Gasket
---Glow plug
6-4
C13) Altemator
Removing alternator
6-5
(a) Remove the bolts that hold fan and pulley and
remove them.
(15) Starter
<>
<;
\~rter~
Disconneet harness from starter. Remove nuts
to remove the starter.
Removing starter
(16) Thermostat
Removing thermostat
L
~
~Bolt
on pan
Removing oil pan
6-6
6-7
1.1 Disassembly
IDisassembly sequence I
CD Rocker cover @ Exhaust valve rocker arm @ Valve cotter
® Adjusting screw ® Rocker shaft spring @ Valve retainer
® Bolt (short) (@ Rocker shaft ® Valve spring
@ Bolt (long) (jJ) Valve cap @ Valve
Remove @ through (@ as an © Valve pushrod ® Valve stem seal
assembly. (j]) Cylinder head bolt ®> Cylinder head gasket
@ Rocker shaft bracket Remove ® through @ as an
@ Snap ring assembly.
(j) Inlet valve rocker arm ® Cylinder head
7-2
(b) Loosen the bolts, short and long, that hold the
rocker shaft bracket to the cylinder head. Be
sure to loosen the short bolt first. Remove the
rocker shaft assembly from the cylinder head.
,-------l,&CAUTION 1 - - - - - - - - ,
Removing rocker shaft assembly
If the long bolt is loosened first, the rocker shaft
bracket might suffer damage.
,--------1 NOTE } - - - - - - - - ,
(a) Wh en removing the gasket from the
crankcase, be careful not to damage the
gasket contact surface of the crankcase
7-3
1.2 Inspeetion
19.010
Inside diameter
to 19.030
of rocker
[0.7484
bushings
19 to 0.7492]
[0.75] 18.980
Diameter of to 19.000
rocker shaft [0.7472
to 0.7480]
Clearance 0.010
between rocker to 0.050 0.070
bushing and [0.0004 [0.0028]
shaft to 0.0020]
7-4
~
diameter of the guide at its ends as shown in the
illustration to determine the clearance between
the guide and stem. If clearance exceeds the
service limit, replace the valve or guide
whichever is excessively wom. Unit: mm [in.]
-~.
7-5
.....--------iLLCAUTION 1 - - - - - - - ,
The installation depth for the valve guide is
specified; be sure to use the valve guide instalIer
to insure the correct depth.
Coat the valve face lightly with red lead. Use the
Valve lapper to inspeet the valve contacts with
its seat. If the contact is not uniform, or if the
valve is defective or if the repair limit is exceeded,
repair or replace the valve and valve seat.
,..---------1 NOTE 1--------,
Unit: mm [in.]
Assembly Repair
Item
Standard Limit
Angle 30° - Good Bad
0.4±0.1
Inlet
[0.016 ± 0.004]
ce
Q)
Valve
(inlet) 1.0
Valve contact pattern
'" Valve
Q)
;> sinkage 0.5±0.1 [0.039]
Exhaust
~ Valve
[0.020±0.004]
(exhaust)
1.4±O.14 1.8
Width
[0.O55±0.OO55] [0.071]
Up to 1.83
2.13
Valve margin [o.onO]
[0.0839]
by refacing
Valve margin
Valve sinkage
7-6
NOTE 1---------,
NOTE 1---------,
b) Replace the valve seat if the seat width is Refacing valve seat
more than the repair limit as a result of wear
or cutting.
7-7
46~~·OO25
[1.8I I -;;"'~']
Inlet valve Exhaust valve
seat bore seat bore
Valve seat dimensions
Tools needed
Insert caulking tooI Installing valve seat
(for inlet valve seat) 36791-00200
Insert caulking tooI
(for exhaust valve seat) 34491-03020
7-8
7-9
1.3 Reassembly
Valve
After installing the valve in position, install the Stem seal instalIer
seal to the valve guide with stem seal installer
(32A91-10200). Valve stem seal
7-10
...------I&CAUTION 1 - - - - - -
Do not use any sealant. Make sure the gasket
contact surface ofthe crankcase is free from any
defects. Installing cylinder head
No. of bolts: 17
7-11
No. of bolts: 25
7-12
2. Flywheel
2.1 Disassembly
Replace gasket.
IDisassembly sequence I
CD Flywheel Remove ® and CID as an assembly. @ Rear gasket
® Flywheel housing
CID Oil seal
7-13
...-------l[&CAUTION JI-------.
Do not cause damage to the oil seal.
2.2 Inspeetion
7-14
Assernbly Repair
Item
Standard Limit
Face and bore 0.15 [0.0059] 0.50
runouts of flywheel or less [0.020]
(Removal)
(b) Hit the ring gear all the way around with a
bar and a hammer to remove it. Removingring gear
(Installation)
.---------l( Lh CAUTION ) 1 - - - - - - - ,
Do not heat the ring gear excessively.
7-15
2.3 Reassembly
Apply grease, F1ywheel
(1) Installing oil seal (According to engine housing
specification)
Engine side F1ywheel side
Apply a thin coat of grease to the oil seal and <;::::J c:::)
install the oil seal to the flywheel housing with
an installer.
I ""H--_ Oil seal
. . - - - - - - - 1 NOTE 1 - - - - - - - - - ,
If the oil seal contact surface of the crankshaft is
excessively worn, use an oil seal with sleeve. Installing oi! sea!
(illCAUTION
During installation, signal to each other to avoid
personal injury.
7-16
3.1 Disassembly
Replace gasket
IDisassembly sequence I
CD Damper (S6S) @ Timing gear case Remove (j]) through © as an
® Crankshaft pulley (J) Oil pump gear assembly.
@ Cover @ Thrust plate (j]) Camshaft
@ Fuel injection pump ® Idler gear ® Camshaft gear
® Oilpan © Thrust plate
Cl]) Front plate
7-17
llliWARNING
Be to install the safety bars securely.
Removing damper
.--------1illCAUTION 1 - - - - - - - ,
Do not cause damage to the oil seal.
7-18
~-------I&CAUTION)1-----------,
7-19
7-20
3.2 Inspeetion
-9-~
To find the cam lift, use the procedure that
follows:
Unit: mm [in.]
Nominal Assembly Service
Item
Value Standard Limit
A= 6.62 6.182
DI 46.918tii:~1 [0.2631] [0.2434]
Inlet [1.8472tii:8?i]
valve A
A=
46.916tii:~1 6.684 6.184
SC
[0.2632] [0.2435]
Cam [1.8471tii:~]
lift C A=
DI 46.878tiiS
l 6.722 6.222
[0.2647] [0.2450]
Exhaust [1.8456tii:~]
valve A=
1 6.720 6.220
SC 46.88otiiS
[0.2646] [0.2450]
[1.8457tii:8?i]
DI - Direct injection SC - Swirl chamber
7-21
Unit: mm [in.]
Nominal Assembly Service
Item Value Standard Limit Measuring camshaft journals
No.l,2 53.94
(S4S) 54 to 53.96 53.90
Diameters No.l, 2,3 [2.13] [2.1236 [2.1220]
of cam- (S6S) to 2.1244]
shaft 52.94
journals
No.3 (S4S) 53 to 52.96 52.90
NoA (S6S) [2.09] [2.0842 [2.0827]
to 2.0850]
0.070
to 0.118
Front and [0.0028
middle to 0.0047]
(without
bushings) Measuring camshaft bushings
Clearance 0.070
between to 0.110 0.15
camshaft Rear [0.0028 [0.0059]
journals to 0.0043] (Repair
and bore (without limit)
bushings)
0.040
to 0.119
[0.0016
to 0.0047]
(with bush-
ings)
7-22
Timing gears
Backlash
NOTE f-----------,
7-23
Crankshaft pulley
If the top surface of the new belt sinks into the groove Inspecting V-belt groove
more than 1.6 mm [0.06 in.], replace the pulley.
7-24
3.3 Reassembly
r-------1&,CAUTION 1 - - - - - - - . ,
Do not cause damage to the lobes and bushings.
7-25
Injection pump
7-26
(b) Put a 0.05 mm [0.0020 in.] feeler gage Valve timing diagram (direct injection type)
between the top of the valve cap and the
rocker.
Rotatien
Exhaust valve
500 74°
Bottom dead center
Valve timing diagram (swirl chamber type)
Rotation
Inlet valve
7-27
(c) Tighten the bolts that hold the timing gear case
to the specified torque.
(c)
Three Bond 1207C (32A91-05100) from the
tube and put it on the oil pan flange.
7-28
Installing damper
7-29
4.1 Disassembly
Check for wear or darnage.
Check for
wear or
clogged oil
hole.
IDisassembly sequence I
CD Nut rJ) Snap ring @ Main bearing (lower halt)
® Connecting rad cap @ Piston pin @ Crankshaft
@ Connecting rad bearing CID Piston @ Main bearing (upper halt)
Remove @ through ®l as an ®l Connecting rod (j]) Check valve
assembly. ® Bearing cap bolt (direct injection with turbocharger)
@ Top compression ring ® Main bearing cap (j]) Tappet
@ Second compression ring ® Side seal ® Crankcase
@ ou ring CID Thrust plate
7-30
Removing piston
7-31
NOTE 1-------,
7-32
4.2 Inspeetion
Crankcase
Unit: mm [in.]
Assembly Repair
Item
Standard Limit
Flatness of gasket 0.05 [0.0020] 0.20
contact surface or less [0.0079]
E9
~~
«) lr)
7-
(a) Measure the inside diameter of the cylinder sti
at the top (ridged portion),middle and bottom, -0
- oe
~]
each in two directions parallel and transverse
to the crankshaft, as shown in the illustration.
Unit: mm [in.]
Assembly Repair Service
Item
Standard Limit Limit
94.000
Inside Measuring cylinder
to 94.035 94.200 94.700
diameter of
[3.7008 [3.7087] [3.7283]
cylinder
to 3.7022]
0.01
Circularity [0.0004]
or less
0.015
Taper [0.0006]
or less
7-33
~
(l) Measuring piston diameter
7-34
WEIGHTmark
FRONTmark
Forward
NOTE 1 - - - - - - - - - ,
Measuring cut clearance between ends of piston ring
Use the piston to put the ring in the gage or the
cylinder sleeve squarely.
Unit: mm [in.]
Assembly Service
Item
Standard Limit
No.l
Cut and No.2 0.30 to 0.50 1.50
clearance rings [0.0118 to 0.0197] [0.0591]
Oi! ring
7-35
7-36
Unit: mm [in.]
Item Assembly Standard
Direct 0.05 to 0.45
Piston injection [0.0020 to 0.0177]
protrusion Swirl -0.25 to 0.15
chamber [-0.0098 to 0.0059]
Compressed thickness 1.2±0.05
of cylinder head gasket [0.05±0.002]
. - - - - - - - - 4l & CAUTION f - - - - - - - ,
Incorrect piston protrusion affects engine
performance and causes valve interference with
the piston.
7-37
Unit: mm [in.]
Nominal Assembly Service
Item Value Standard Limit
57.955 57.800
Diameter of 58 to 57.970 [2.2756]
crankpin [2.28] [2.2817 (Repair
to 2.2823] limit)
Clearance
0.030
between
to 0.090 0.200
connecting
[0.0012 [0.0079]
rad bearing and
to 0.0035]
crankpin
Measuring diagram
(2) Clearance between connecting rod bushing and
piston pin
7-38
Unit: mm [in.]
Nomina1 Assemb1y Service
Item Va1ue Standard Limit
30.020
Inside diameter
30 to 30.045
ofconnecting
[1.18] [1.1819
rad bushing
to 1.1829]
0.020
Clearance
to 0.051 0.080
between pin
[0.0008 [0.0032]
and bushing
to 0.0020]
(c) After installing the bushing, put the piston pin Installing connecting rad bushing
in position and make sure the pin rotates
freely.
Item
Assemb1y
Standard
Repair
Limit
t=;;=3- Twist
Bend
0.10/100
Bend or twisting 0.15
[0.0039/3.94]
of connecting rod [0.0059]
or 1ess Measuring connecting rad bend and twist
7-39
Unit: mm [in.]
Assembly Service Measuring connecting rad end play
Item
Standard Limit
End play of 0.15 to 0.35 0.50
connecting rod [0.0059 to 0.0138] [0.020]
7-40
Assembly
Item
Standard
Connecting rod weight difference per 10 g [0.35 oz]
engine or less
7-41
Crankshaft
Measuring diagram
-$-~
(I) Measuring joumal diameter
Measuring crankpins
7-42
Unit: mm [in.]
Nominal Assembly Service
Item Value Standard Limit
57.955
Crankpin 58 to 57.970 57.800
diameter [2.28] [2.2817 [2.2756]
to 2.2823]
Circularity 0.01
0.03
[0.0004]
Taper or less [0.0012]
7-43
Unit: mm [in.]
Assembly Repair
Item
Standard Limit
Crankshaft 0.100 to 0.264 0.300
end play [0.0039to 0.0104] [0.0118]
Unit: mm [in.]
Assembly Repair
Item Measuring crankshaft deflection
Standard Limit
Crankshaft 0.02 [0.0008] 0.05
deflection or less [0.0020]
r-------4
l& CAUTION )f--------,
Do not remove the gear by tapping with a
hammer.
7-44
sleeve.
Oil seal
running
surface
.--------iL'tCAUTION \ - - - - - - - - ,
Be careful not to cause damage to the sleeve when
installing it.
on seal
t-J=~~h Oil seal
1-t::===Lj sleeve
7-45
,------I&CAUTION 1 - - - - - - - - ,
Be careful not to cause damage to the crankshaft
when removing the sleeve.
Removing oil seal sleeve
Main bearings
(3) Replacement
7-46
Tappets
7-47
4.3 Reassembly
Installing crankshaft
7-48
98 to 108 N·m
Tightening torque for
(l0.0 to 11.0 kgf-m
main bearing cap bolts
[72 to 80 lbf-ft]
7-49
A
FRüNTmark ..
(~~IGm='k
ViewA
r-------I( NOTE 1 - - - - - - - - ,
Install the compression rings on the piston with
"R" or "T" mark toward the top of the piston.
~~Oilring
Instal1ing piston rings
7-50
(b) Install the oil ring with the joint of the coil
spring 1800 apart from those of the ring gap. Joint of coil spring
180
0
I
~ ""- En'" of oil ring
(d) Install the upper half of the connecting rod Tab and groove
bearing to the big end of the connecting rad,
making sure the locating lug fits into the notch
in the rad. Apply engine oil to the bearing.
V
End gap of <' End gap of oil
No.2 com- 60· ring
pression ring
Inlet valve side
Configuration of piston ring ends (direct injection type)
7-51
End gap of
Endgap of No. 2 oil ring
compression ring 60°
Inlet valve side ....
Configuration of piston ring ends (swirl chamber type)
(b) Install the cap to the rod and tighten the cap
nuts to the specified torque.
~-----IffiCAUTION f - - - - - - - - - ,
7-52
1. Description 8- 2
2. Exhaust Manifold 8- 2
Inspeetion 8- 2
--
1. Description
Muffler
Air cleaner
Cylinder
2. Exhaust Manifold
Inspeetion
Unit: mm [in.]
8-2
1. Description 9- 2
2. on Pump 9- 3
2.1 Disassembly 9- 3
2.2 Inspeetion 9- 4
2.3 Reassembly 9- 6
3. Oil Filter 9- 7
Disassembly and Inspeetion 9- 7
4. OH Cooler (Engine with OH Cooler) 9- 7
Disassembly and Inspeetion 9- 7
5. on Pressure Relief Valve 9- 8
Inspeetion 9- 8
6. Safety Valve (Engine with on Cooler) 9- 8
Inspeetion 9- 8
--
1. Description
Piston Turbocharger
Valve mechanism
Valve pushrod
üiljet
Tappet
Camshaft --+----t·r:u:rr:u:
Idler gear
üilpump
9-2
2. on Pump
2.1 Disassembly
Replace O-ring
IDisassembly sequence I
CD O-ring @ Pin @ Outer rotor
(g) Main shaft ® Inner rotor @ Pump case
9-3
2.2 Inspeetion
Unit: mm [ in.]
Unit: mm [in.]
9-4
Unit: mm [ in.]
9-5
2.3 Reassembly
Q)
---l1-----(3
h~==:;~ Flush
Flush
Reassembly sequence I
9-6
3. on Filter
Disassembly and Inspeetion
IDisassembly sequence I
CD Filter element
Replace gasket.
Replace O-ring.
I Disassembly sequence I
CD Cover <2> Element
9-7
9-8
1. Description 10-2
2. Water Pump (According to Engine Specification) 10-3
Inspeetion 10-3
3. Thermostat 10-4
Inspeetion 10-4
1. Descrlption
Cylinder head
Bypass pipe--'.----l.--Ill
Water pump---+---I=~
IO+-----t--Water jacket
Coolant inlet
Oil cooler
Cylinder head
Thermostat
Water pump
Coolant inlet
10-2
Inspeetion
Check V-belt
grooves for wear
ordamage.
Check fan blades for
distortion or cracks.
IDisassembly sequence I
CD Fan Q) Pulley @ Water pump assembly
(2) Spaeer @ V-belt @ Cover
10-3
3. Thermostat
Inspeetion
:"5 [0.3]
E.
~
8 UlI
" 'I
(1) Remove the thermostat from the engine. :El 0 76.5± 1.5 90
1: [170±2.7J[194]
~ Temperature, oe [OF]
(2) Hang the thermostat in the jar of water, as shown
in the illustration. Thermostat must be below the
surface of the water and it must be away from
the sides of the jar,
(3) Heat the water uniformly in the jar and measure Testing thermostat
a temperature at which the valve starts opening
and a temperature at which the valve lift is more
than 8 mm [0.3 in.]. If the valve does not start
opening at the correct temperature, or if it does
not open to correct lift, replace the thermostat.
,------iu:tCAUTION J I - - - - - - - - ,
a) Stir the water in the jar with a stick to
maintain its temperature uniform during test.
10-4
II1II
1. Descripûon
Direct injection type
Fuel filter
Iol--+----Retum pipe
Fuel filter-i-r_!.J..I.l-f-J_
Air vent plug
Injection pump_Lj]~~===::c~~~itl~f::::==\
pt.-----t--Retum pipe
Fuel inlet
Feed pump
11-2
o
o
(D-----I o
o
Check for clogging or tearing.
Replace every 500 service q o
(1 tJ
hours,
IDisassembly sequence I
GD Elernentassernbly ~ Bracket
11-3
3.1 Disassembly
Direct injection type
IDisassembly sequence I
CDRetaining nut @ Tip packing (j) Shims
~ Nozzle tip @ Pressure pin @ Nozzle body
@ Straight pin @ Pressure spring
\ Replace gasket.1
®
©---®
IChttk '"'WeM ~
Check for fatigue or squareness.
IDisassembly sequence I
CDRetaining nut @ Pin (j) Body
~ Nozzle tip assembly @ Spring @ Gasket
@ Piece @ Washer
11-4
3.2 Inspeetion
(1) Injeetion pressure (valve opening pressure)
11-5
11-6
(c) If the nozzle is still bad after the tip has been
washed, replace the tip.
Nwll'~
valve Body
11-7
3.3 Reassembly
Direct injection type
Reassembly sequence I
11-8
Retaining nut
Torque for body:
34.3 to 39.2 Nrn
(3.5 to 4.0 kgf-rn)
[25.3 to 28.9 lbf-ft]
Torque tor engine:
49.0 to 68.6 Nrn]
(5.0 to 7.0 kgf-rn)
[36.2 to 50.6 lhf·ft]
Reassembly sequence I
11-9
1. Starter 12- 2
1.1 Disassembly 12- 2
1.2 Inspeetion 12- 3
1.3 Reassembly : 12- 7
2. Altemator 12-10
2.1 Disassembly 12-10
2.2 Inspeetion 12-11
2.3 Reassembly 12-12
3. Glow Plugs 12-13
Inspeetion 12-13
4. Stop Solenoid (Option) 12-13
Inspeetion 12-13
1. Starter
1.1 Disassembly
[12 V-2.2 kW, 12 V-3 kW]
Wom or • \)
damaged ~
teeth.
IDisassembly sequence I
CD Switch assembly rJ) BalI © Install gear
® Rear bracket @ Packing set @ Overrunning clutch
CID Brush holder assembly CID Gear @ Front bracket
@ Yoke assembly @) Lever assembly @ Bearing
@ Armature (j]) Washer set ® Oil seal
® Bearing © Gear shaft (j]) Pinion set
12-2
1.2 Inspeetion
(1) Armature
12-3
~
Unit: mm [in.]
Assembly Repair Mode depth .
Item
Standard Limit Good Bad
Dept of commuta- 0.4 to 0.6 0.20 [0.008]
tor mild [0.016 to 0.024] or less
12-4
Unit: mm [in.]
Item Assembly Standard
Thrust clearance of 0.5 [0.020] or less
pinion shaft [Below 0 not permissible]
12-6
1.3 Reassembly
[12 V-2.2 kW, 12 V-3 kW]
Reassembly sequence
12-7
12-8
2) No-Ioad test
12-9
2. Alternator
2.1 Disassembly
5
Check slip rings for dirt buildup,
burning or ether defects, Check oil
seal contact surface of shaft for WeM.
IDisassernbly sequence I
CD Nut, washer @ Rotor assembly CID Rectifier assembly
~ Pulley, spaeer ® Stator ®l Nut set
C3> Screw (f) Rear bracket
@ Front bracket assembly @ Regulator assembly
12-10
2.2 Inspeetion
(1) Brushes
Testing rectifier
12-11
2.3 Reassembly
I ,Reassembly sequence I
Rotor
12-12
3. Glow Plugs
Inspeetion
If the glow plug glows red when the positive (+) wire
is connected to the portion A with the porti on B
grounded, the plug cao be used.
Inspeetion
Item
Rated voltage V 12V
Rated temp.,
20°C [68°P]
°C rF]
12-13
1.1 ou Seals
When installing an oil seal (metal-encased type),
observe the following points:
(1) Before installing the oil seal, make sure the lip is
not damaged and apply a thin coat of grease to
the press-fitted surface of the outer case of the
seal.
13-2
1.2 O-rings
O-ring guide
1.3 Bearings
Bearing driver
13-3