Nissan rf8

COOLING SYSTEM
CONTENTS
SERVICE DATA ............................................ EC-1-1 THERMOSTAT .............................................. EC-4-1
SPECIFICATIONS ......................................... EC-1-1 REMOVAL ..................................................... EC-4-1
SERVICE DATA ............................................. EC-1-1 INSPECTION ................................................. EC-4-1
TIGHTENING TORQUE ................................ EC-1-2 INSTALLATION ............................................. EC-4-1
TOOLS ............................................................. EC-2-1 RADIATOR AND COOLANT
WATER PUMP ............................................... EC-3-1 RESERVOIR TANK ..................................... EC-5-1
CONSTRUCTION .......................................... EC-3-1 FLUSHING COOLING SYSTEM ................... EC-5-1
REMOVAL ..................................................... EC-3-1 INSPECTION ................................................. EC-5-1
EXTERNAL APPEARANCE CHECK AND FAN CLUTCH ................................................ EC-6-1
CORRECTION .............................................. EC-3-1
CONSTRUCTION .......................................... EC-6-1
DISASSEMBLY ............................................. EC-3-2
REMOVAL ..................................................... EC-6-2
INSPECTION ................................................. EC-3-3
INSPECTION ................................................. EC-6-2
REASSEMBLY .............................................. EC-3-4
INSTALLATION ............................................. EC-3-6 INSTALLATION ............................................. EC-6-2
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
Engine model RF8TC
Item
Cooling method Water cooled z forced circulation
Radiator Corrugated fin
Type FD2300 (On-Off type)
Fan clutch
Changeover temperature of fan clutch °C (°F) 60 - 70 (140 - 158)
Type Centrifugal
Water pump
Drive Belt-driven type
Type Wax pellet
Thermostat 76.5 (170) x 1
Valve opening temperature °C (°F) x Number
82 (180) x 1
Cooling water capacity ! (Imp gal) 39 (8-5/8)
SERVICE DATA
Unit: mm (in)
Item Maintenance Service Remarks

standard limit
Outside diameter of shaft at impeller 20.051 - 20.060 —

(0.7894 - 0.7898)
Fit of impeller and shaft 0.023T - 0.053T — T: tight

(0.0009T - 0.0021T)
Outside diameter of shaft at pulley 25.002 - 25.015 —

(0.9843 - 0.9848)
Water pump
Fit of pulley and shaft 0.044T - 0.082T — T: tight
(0.0017T - 0.0032T)
To be measured in
Clearance between impeller and 0.6 - 1.2 — vertical direction in
body (0.024 - 0.047) relation to body sur-
face
Valve opening 76.5°C (170°F) 74.5 - 78.5 (166 - 173) 73.0 - 80.0 (163 - 176)
temperature
°C (°F) 82°C (180°F) 80.0 - 84.0 (176 - 183) 78.5 - 85.5 (173 - 186)
Thermostat Greater than Greater than
76.5°C (170°F) 10/90 (0.39/194) 8.5/90 (0.335/194)
Valve lift
mm/°C (in/°F) Greater than Greater than
82°C (180°F) 10/95 (0.39/203) 8.5/95 (0.335/203)
Valve opening pressure of coolant reservoir tank cap 49 - 69
kPa {kgf/cm2, psi} {0.5 - 0.7, 7 - 10} — Pressure side
Radiator leak test pressure kPa {kgf/cm2, psi} 98 {1.0, 14} — By compressed air
Fan clutch
changeover Fan dia. 700 mm 60 - 70 —
temperature °C (°F) (27.6 in) (140 - 158)
Entire periphery
Clearance between cooling fan and fan shroud 5.0 (0.197) — (when directly
mounted to engine)
Water pump to crank pulley 11 - 14 —

(0.43 - 0.55) When applied with
V-belt tension 98 N {10.0 kgf, 22 lbf}
Crank pulley to cooler compressor 10.5 - 13.5 — force at midpoint.
pulley (0.41 - 0.53)
EC-1-1
SERVICE DATA
TIGHTENING TORQUE
Unit: N·m {kgfzm, ftzlbf}
Tightening point Tightening torque
Water pump mounting bolt 10 - 13 {1.0 - 1.3, 7 - 9}
Cooling fan 21 - 26 {2.1 - 2.7, 15 - 20}
Fan clutch assembly (with cooling fan) 34 - 49 {3.5 - 5.0, 25 - 36}
Grease nipple (out) 10 - 15 {1.0 - 1.5, 7.2 - 10.8}
COOLING SYSTEM DIAGRAM
EEC2-001F
EC-1-2
SERVICE DATA
COOLING CIRCUIT
EEC2-001J
EC-1-3
TOOLS
TOOLS
WATER PUMP [TOOL KIT: 99742 97500]
Tool name and number Description Shape
Impeller and pulley puller Used to remove impeller and pulley.
99749 97500
ET14-093B
Drive shaft remover Used to remove drive shaft.

99758 97500
ET14-129
Bearing replacer Used to remove ball bearing.

99757 97500
ET14-130
Water seal replacer Used to remove/install water seal.

99753 97000
ETL2-009
Oil seal replacer Used to remove/install oil seal or remove water seal.
99759 97500
ETL2-011
EC-2-1
TOOLS

Drive shaft guide Used to install drive shaft.
99789 97500
ET14-131
Impeller replacer Used to install impeller.

99749 97502
ETL2-007
EC-2-2
WATER PUMP
WATER PUMP
CONSTRUCTION
ZEC039A
REMOVAL
1. Drain the engine cooling water.
2. Loosen the mounting bolts and nuts for the V-belt rigid ten-
sioner, then remove the V-belt from the water pump pulley.
3. Disconnect the hoses connected to the water pump.
4. Remove the water pump and O-ring.
EXTERNAL APPEARANCE CHECK AND CORRECTION
1. If water leakage or any trace of it is noticed at the hole on the
underside of the pump body, check the condition of the water
seal and impeller. If even only one of them is damaged, both
should be replaced as a unit in principle.
2. If grease leakage is noticed at the hole on the underside of the
pump body or on the pulley side, replace the ball bearing on the
side where leakage is noticed.
3. Check for interference of the impeller with the vehicle body or
the bearing’s axial play due to wear of the ball bearing. If even
only one of them is excessive, replace the two ball bearings as
a unit.
EC-3-1
WATER PUMP
DISASSEMBLY
ZEC040A
.>j
1 Impeller >.j6 Ball bearing >.j
11 Oil seal
.j
2 Pulley >.j7 Spacer j
12 Body
j
3 Dust cover >j8 Ball bearing >j
13 Grease nipple (in)
j
4 Snap ring j9 Washer j
14 Grease nipple (out)
>.j
5 Shaft >.j
10 Water seal assembly
Marks ‘‘.’’ and ‘‘>’’ indicate that the key points of operation are explained in the text.
NOTE: Numbers before part names do not indicate the disassembly sequence.
Key point of disassembly

j
1 Impeller
Using a puller (99749 97500), remove the impeller.
EEC2-005
j
2 Pulley
Using a puller (99749 97500), remove the water pump pulley.
Remove the dust cover and snap ring.
EEC2-006
EC-3-2
WATER PUMP
j5 Shaft
Using a drive shaft remover (99758 97500), remove the shaft
assembly with the ball bearing and spacer.
EEC2-007
j6 Ball bearing, j
7 Spacer
Using a press tool, press out the ball bearing together with the
spacer and washer.
ZEC041A
j
10 Water seal assembly, j 11 Oil seal
Using an oil seal replacer (99759 97500), drive out the water seal.
Using an oil seal replacer (99759 97500), remove the oil seal.
Remove the water seal from the impeller.
EEC2-009
INSPECTION
Clean all the disassembled parts thoroughly with cleaning fluid.
Especially for the impeller and the inside of the body, remove water
scales and rust and, if necessary, clean them with caustic soda
solvent or the like, then wash thoroughly with water. While clean-
ing, inspect the parts for cracks and other damage carefully. If
faulty, replace with a new one.
Outside diameter of shaft at impeller
Unit: mm (in)
Maintenance standard Service limit
20.051 - 20.060 (0.7894 - 0.7898) —
Fit of impeller and shaft

Unit: mm (in)
Maintenance standard Remarks
0.023T - 0.053T (0.0009T - 0.0021T) T: tight
EC-3-3
WATER PUMP
Outside diameter of shaft at pulley

Unit: mm (in)
25.002 - 25.015 (0.9843 - 0.9848) —
Fit of pulley and shaft

Unit: mm (in)
0.044T - 0.082T (0.0017T - 0.0032T) T: tight
REASSEMBLY
When reassembling the water pump, make sure new water seal
assemblies, oil seals and O-rings are used.
Key point of reassembly

j
11 Oil seal
Using an oil seal replacer (99759 97500), drive the oil seal into the
body.
EEC2-010
j5 Shaft
Set the drive shaft guide (99789 97500) on the body and insert the
drive shaft.
EEC2-011
j8 Ball bearing
Insert the washer, then press in the ball bearing on the impeller
side using the bearing replacer (99757 97500).
NOTE
+ Make sure the rolling contact surface of the bearing is filled
with grease.
EEC2-012
EC-3-4
WATER PUMP
j6 Ball bearing, j 7 Spacer

Insert the spacer, then press in the ball bearing on the pulley side
using the bearing replacer (99757 97500).
NOTE
+ Make sure the rolling contact surface of the bearing is filled
with grease.
Install the snap ring and dust cover.
Press the pulley onto the drive shaft using a press tool.
EEC2-012A
j
10 Water seal assembly
1. Apply bonding agent (Three Bond 1102) to the outer periphery
of the water seal, then press it into the pump body using a water
seal replacer (99753 97000).
EEC2-015
2. Press the water seal into the impeller.
EEC2-016
j1 Impeller
Using an impeller replacer (99749 97502), press in the impeller so
that the clearance between the body and the impeller is within the
maintenance standard.
Unit: mm (in)
0.6 - 1.2 (0.024 - 0.047) Measure perpendicularly to the body surface.
EEC2-017
j
13 Grease nipple
Using a grease gun, apply grease through the grease nipple until
grease flows out of the relief valve.
Approx. grease amount: 130 g (4.59 oz)
Recommended grease: Showa Sekiyu Sunlight #2
EEC2-052
EC-3-5
WATER PUMP
INSTALLATION
1. Install the water pump on to the cylinder block with the O-ring
in place.
2. Connect hoses to the water pump.
3. Place the V-belt for driving the pump on the water pump pulley,
then the adjust tension.
4. Add the specified amount of engine cooling water.
EC-3-6
THERMOSTAT
THERMOSTAT
REMOVAL
2. Disconnect the radiator hose from the water outlet, then

remove the water outlet and gasket.
3. Remove the thermostat.
EEC2-020C
INSPECTION
Check the operation of the thermostat, using a tool similar to that
shown at right.
Maintenance
Item Service limit
standard
74.5 - 78.5 73.0 - 80.0
Valve opening 76.5°C (170°F)
(166 - 173) (163 - 176)
temperature
80.0 - 84.0 78.5 - 85.5
°C (°F) 82°C (180°F) ES8-10
(176 - 183) (173 - 186)
Greater than Greater than
76.5°C (170°F) 10/90 8.5/90
Valve lift (0.39/194) (0.335/194)
mm/°C (in/°F) Greater than Greater than
82°C (180°F) 10/95 8.5/95
(0.39/203) (0.335/203)
INSTALLATION
1. Install the thermostat to the specified position in the thermostat
housing.
2. Install the water outlet and gasket, then connect the radiator
hose to the water outlet.
3. Add the specified amount of engine cooling water.
EC-4-1
RADIATOR AND COOLANT RESERVOIR TANK

FLUSHING COOLING SYSTEM
Including radiator (with the radiator in its mounted condition).
1. Drain approx. 5% of coolant while adding the same amount of
cleaning solvent, and allow the engine to idle for approximately
30 minutes.
NOTE
+ During this flushing operation, be careful to maintain the
temperature of the flushing fluid of a constant 80°C
(176°F).
2. Thoroughly drain the flushing fluid, and fill the radiator and
engine with clean tap water, and run the engine again for
additional flushing.
WARNING
+ Do not remove the radiator cap quickly. Otherwise, you
may be sprayed and scalded with hot flushing fluid.
NOTE
+ Cover the cap with a thick and heavy rag, and remove it
gradually.
3. Flush repeatedly with tap water until the water drained from the
cooling system is completely clean.
4. Remove any dirt and dust accumulated between the radiator
core fins and tubes.
INSPECTION
+ Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
+ If measurement indicates that the service limit has exceeded,
repair or replace faulty parts.
Radiator leak test pressure
Plug all openings with wooden taps or the like, dip the entire
radiator into a container of water, and direct compressed air of 98
kPa {1.0 kgf/cm2, 14 psi} into the radiator to determine if air
leakage is noticed. If air leakage is noticed, repair or replace the
radiator.
Valve opening pressure of coolant reservoir tank cap

Unit: kPa {kgf/cm2, psi}
Maintenance standard Service limit Remarks
49 - 69 {0.5 - 0.7, 7 - 10} — Pressure side
ES8-11
EC-5-1
Engine coolant
Check density of anti-freeze solution or LLC (Long Life Coolant)
using a tester. If it is low, add anti-freeze solution or LLC as
required to suit the areas where the vehicle is to be operated.
ES8-12
EC-5-2
FAN CLUTCH
FAN CLUTCH
CONSTRUCTION
ZEC042A
EC-6-1
FAN CLUTCH
REMOVAL
1. Remove the fan shroud and shroud support.
2. Remove the fan and the fan clutch assembly as a unit.
3. Remove the fan from the fan clutch assembly.
EEC2040B
EEC2040C
INSPECTION
EXTERNAL APPEARANCE CHECK
After removing the fan clutch, inspect the exterior for cracks,
silicone oil leakage or any other damage. If faulty, replace the fan
clutch assembly. Never disassemble it.
NOTE
+ Care should be given lest the bimetal is damaged or
deformed during removal and inspection.
OPERATION TEMPERATURE CHECK
1. Install the fan on the fan clutch and rotate the fan drive shaft
continuously at a constant speed.
2. Install a thermometer and a drier, then blow hot air onto the
bimetal.
3. Check to make sure that the speed of the fan changes from low
to high when the thermometer indicates the following tempera-
ture.
Unit: °C (°F)
Maintenance
Item Service limit
standard
Fan clutch
60 - 70
changeover FD2300 On-Off type —
(140 - 158)
temperature
INSTALLATION
1. Install the fan onto the fan clutch assembly.
2. Install the fan clutch assembly with fan onto the fan clutch
adapter.
EC-6-2
ENGINE QUICK REFERENCE INDEX
SERVICE
MANUAL
MODEL
RF 8TC and RF8TD series
RF8TC : RF8-000766A∼
RF8TD : RF8-100001D∼
FOREWORD
This manual describes the service, by system, of the
RF8TC and RF8TD engine models.
In order for a vehicle to perform at its best, and to extend
vehicle life, maintenance should be performed properly. Also,
overhaul and repair should be effected in accordance with
prescribed service standards.
This manual should be kept readily available in the work-
shop as a helpful reference for those engaged in servicing
vehicles. Nissan Diesel Motor Co., Ltd. reserves the right to
make changes for improvement at any time without notice.
This manual is based on vehicles that were manufactured
on or before December 1, 1998. Revisions, if any, will be
introduced in the Technical Bulletin.
Printed: May 1999

Edition: Jan. 1999
© 1999 NISSAN DIESEL MOTOR CO., LTD. 9905K30-14150-SZ1(M)
HOW TO USE THIS MANUAL
c A quick reference index, a black tab is provided on the first page, so you can quickly find the first page of
each chapter by mating it to the chapter’s black tab.
c The contents are listed on the first page of each chapter.
c Construction illustration:
The assembled unit is indicated. The construction illustration includes the names of the major components,
items requiring adjustment after reassembling and their maintenance standards.
[EXAMPLE]
WLB002A
—1—
c Exploded illustration:
The number given to each part in the illustration corresponds to the number attached to each part name, and
the number is determined according to the operation sequence.
No. j 1 ,j 2 ,j 3 Disassembly sequence
Reassembly sequence is in the reverse order of disassembly.
The marks ‘‘.’’ and ‘‘>’’ affixed to the part name number indicate that the key points of operation
(precautions, technique, use of special tools, and other maintenance information) are explained in the text.
.: Key points of disassembly
>: Key points of reassembly
The tightening torque necessary for maintenance and lubricating points are indicated by symbols in the
illustration.
NOTE
+ Disassembly and reassembly sequences show general examples and in some operations it may
be possible to change sequences.
WLB003A
Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

j
1 Cover assembly >j
5 Idler gear j9 Relief valve
j
2 Bolt j
6 Spindle j
10 Spring
.>j
3 Idler gear (Pump gear) j
7 Case assembly j
11 Seat
j
4 Nut j
8 Split pin
—2—
c Removal and installation, disassembly and reassembly:
Explanation of removal and installation, disassembly and reassembly is limited to the parts indicated by the
star marks ‘‘.’’ and ‘‘>’’ affixed to the sequence number in the exploded illustration.
NOTE
+ If there are no ‘‘.’’ and ‘‘>’’ marks affixed to the parts, general explanation is given for those
parts.
c The following marks and abbreviations are used in this manual.
Marks :
: Tightening torque
: Should be lubricated with grease. Unless otherwise indicated, use recommended
multi-purpose grease.
: Should be lubricated with oil.
: Sealing point
: Always replace after every disassembly.
Abbreviations
T.D.C. : Top dead center I.D. : Inside diameter
B.T.D.C. : Before top dead center Dia. : Diameter
A.T.D.C. : After top dead center S.T.D. : Standard
B.B.D.C. : Before bottom dead center O.S. : Oversize
A.B.D.C. : After bottom dead center U.S. : Undersize
O.D. : Outside diameter Ass’y : Assembly
c Engine position:
EGE1002F
c Unit:
This manual uses mainly SI units with metric and yard/pound system equivalents in braces.
c Specific terms related to the maintenance standard
+ Maintenance standard
‘‘Maintenance standard’’ indicates the standard clearance when parts are assembled or the standard
performances of assembly parts.
+ Service limit
‘‘Service limit’’ indicates the limit value where adjustment, correction or parts replacement must be done.
c The captions WARNING and CAUTION warn you about procedures that must be followed to prevent
personal injury and/or damage to some parts of the vehicle.
—3—
GENERAL
CONTENTS
SPECIFICATIONS ..................................... GE-1- 1 PRECAUTIONS ON MAINTENANCE ........ GE-3- 1
ENGINE SPECIFICATIONS ........................ GE-1- 1 GENERAL PRECAUTIONS IN
ENGINE NUMBERS ................................... GE-1- 3 DISASSEMBLY ........................................... GE-3- 1
LUBRICATION ............................................ GE-2- 1 CLEANING AND INSPECTION .................. GE-3- 2
GENERAL PRECAUTIONS TIGHTENING TORQUE OF
ON SERVICING .......................................... GE-3- 1 STANDARD BOLTS .................................. GE-4- 1
SPECIFICATIONS
SPECIFICATIONS
ENGINE SPECIFICATIONS
Engine model
RF8TC RF8TD
Item
Max. gross output (JIS) KW {PS}/rpm 316 {430}/2,200 316 {430}/2,000
Type Diesel
Aspiration system Turbocharged with intercooler
Cooling method Water cooled
Number of cylinders and cylinder arrangement 8, V type
Stroke cycle 4
Combustion chamber Direct fuel injection
Valve mechanism Overhead valve, geardriven center camshaft
Cylinder liner Wet
Bore x stroke mm (in) 138.0 x 142.0 (5.43 x 5.59)
Total displacement cm3 (cu in) 16,991 (1,037)
Compression ratio 16.5
Cylinder compression kPa {kgf/cm2, psi}/rpm 2,942 {30, 427}/200±20
Maximum engine speed under no-load conditions rpm 2,600 - 2,700 2,400 - 2,500
Idle speed rpm 460 - 480
Compression ring 2
Number of piston rings
Oil ring 1
Open B.T.D.C. 20°
Intake valve
Closed A.B.D.C. 32°
Valve timing
Open B.B.D.C. 60°
Exhaust valve
Closed A.T.D.C. 14°
Valve clearance Intake valve 0.4 (0.016)
mm (in) Exhaust valve 0.6 (0.024)
Lubricating method Forced lubrication
Type Gear pump
Discharge amount ! (Imp gal)/rpm 220 (48-3/8)/2,200
Oil pump
Safety valve opening pressure
1,079 {11.0, 156} 1,177 {12.0, 171}
kPa {kgf/cm2, psi}
Full-flow Filter paper
Type
Lubricating system
By-pass Filter paper

Oil filter Replacement method Disassembly type
Short valve opening pressure
98 - 137 {1.0 - 1.4, 14 - 20}
kPa {kgf/cm2, psi}
Type Water cooled flat tube type
Oil cooler
Number of cores 12
2
Regulator valve opening pressure kPa {kgf/cm , psi} 4.3 - 4.7
Total capacity 34 (7-1/2)
Oil capacity Oil pan capacity 24 (5-1/4)
! (Imp gal) Filter Full-flow 2.7 (5/8)
capacity By-pass 3.3 (3/4)
GE-1-1
SPECIFICATIONS
Engine model
RF8TC RF8TD
Item
Cooling method Water cooled, forced circulation
Radiator Corrugated fin
Number of fins 8
Cooling fan Fan clutch change over temperature
Cooling system
60 - 70 (140 - 158) [On-off type]

°C (°F)
Type Centrifugal
Water pump Drive V Belt drive
Number of impellers 6
Type Wax pellet
Thermostat
Valve opening temperature °C (°F) x Number 76.5 (169.7) x 1, 82.0 (180) x 1
Cooling water capacity ! (Imp gal) 40 (8-3/4)
Ignition system Compression ignition
Fuel injection timing B.T.D.C. 14° 12.5°
Ignition order 1R-1L-4R-4L-3L-2R-2L-3R
Main Filter paper x 1
Fuel filter Type x Number
Primary Filter paper x 1
Type Bosch
Fuel injection Plunger diameter mm (in) 12.0 (0.472)
Fuel system
pump Governor Centrifugal (Mechanical RFD type)

Timer Centrifugal (Mechanical SDDG type)
Nozzle holder type Flange type
Nozzle type Multi-hole type
Number x Diameter
Nozzle Nozzle holes 5 x 0.36 (0.0142)
mm (in)
Injection pressure 1st valve 17,653 {180, 2,560}
2
kPa {kgf/cm , psi} 2nd valve 22,556 {230, 3,271}
Over flow valve opening pressure Injection pump outlet 157 {1.6, 23}
kPa {kgf/cm2, psi} Fuel filter 108 - 147 {1.1 - 1.5, 16 - 21}
Air intake and exhaust system
Air cleaner Type Paper element (dry)

Model T04E
Turbocharger Max. permissible continuous speed rpm 125,000
Direction of rotation Counterclockwise as viewed from the exhaust turbine side
Type Air to air
Intercooler
Intercooler Corrugated fin
Exhaust Type Cylinder

shutter Operation Air
GE-1-2
SPECIFICATIONS
Engine model
RF8TC RF8TD
Item
Model 0350 702 0610 0350 702 0620
Starting motor Type Shift
Output V-kW 24-7.0
Electrical system
0201 102 2973

Model 0201 172 0220
0201 172 0220
Alternator Type AC, diode-rectified
24-40
Output V-A 24-60
24-60
Type Ribbon
Air heater
Voltage (V) x Current (A) x Number 11.2 x 85 x 2
Auxiliary equipment
Model F9560W12
Theoretical discharge cm3 (cu in) 425 (26)

Air compres-
sor Normal maximum discharge pressure
834 {8.5, 121}
kPa {kgf/cm2, psi}
Cooling method Water-cooled
ENGINE NUMBERS
The engine serial number is stamped on the right of the cylinder
block.
RF8 — 000766 C
C: With turbocharger and intercooler

D: With turbocharger and intercooler
Engine serial number EGE2-003B
Engine model
GE-1-3
LUBRICATION
LUBRICATION
RECOMMENDED FUEL AND LUBRICANTS
Lubricant Specifications Remarks
For further details, refer to the recom-
Engine oil API CD
mended SAE viscosity number.
Grease NLGI No. 2 Lithium soap base
Antifreeze — Ethylene glycol base
2-D Diesel fuel or equivalent blended die-
Above −7°C (20°F)
sel fuel Check with the service establishment to
Fuel
1-D Diesel fuel or equivalent blended die- be sure you get the properly blended fuel.
Below −7°C (20°F)
sel fuel
RECOMMENDED SAE VISCOSITY NUMBER

Use oil having the proper viscosity beforehand which meets
temperatures forecast for areas where you are planning to drive.
EGE1-005
CAPACITIES (APPROXIMATELY)
Unit: liter (Imp gal)
Item Refill capacities
System total capacity
Lubrication oil capacity 36 (7-7/8)
Engine oil (With oil filter)
(gauge H-level)
Oil pan (H-level) 24 (5-1/4)
Cooling system 40 (8-3/4)
Fuel tank 200 (44) + 200 (44)
NOTE
+ Capacities shown are for reference only. When filling, observe the specified level.
GE-2-1
GENERAL PRECAUTIONS ON SERVICING

PRECAUTIONS ON MAINTENANCE
Observe the following when servicing the vehicle.
+ Park the vehicle on a flat surface; otherwise, the correct oil level cannot be checked and the vehicle may
move abruptly.
+ Engage the parking brake and chock the wheels securely.
+ If the engine is hot, wait until it cools off.
+ Set the transmission gear shift lever to ‘‘NEUTRAL’’.
+ Turn the key switch to ‘‘OFF’’. Disconnect the ground cable when servicing the electrical system.
+ Do not touch rotating parts of the engine if servicing requires engine operation. Always operate the engine
in a well-ventilated area.
+ When tilting the cab indoors, make sure that there is a

clearance of at least 4 m (13.1 ft) in H and a clearance of 1 m
(3.3 ft) in F.
DA-141E
GENERAL PRECAUTIONS IN DISASSEMBLY

Checks before disassembly
Before starting to disassemble a system or unit, familiarize yourself with the cause of the problem. For instance,
if the engine is to be disassembled, the problem may be due to an unusual noise, lack of power or oil leakage.
Recognizing the problem in advance will be extremely helpful in locating which part of the engine needs to be
disassembled and which part does not. It will also save time and labor.
Work required during disassembly

Scribe alignment marks on parts where necessary so that they can be easily reinstalled in their original
positions. When repairs involve the electrical system, disconnect the ground cable from the battery.
Checks during disassembly

Whenever each part is disassembled, check for mounting condition, scratches, dirt, damage, etc. Work
efficiency will be degraded after all parts have been disassembled.
Keeping disassembled parts in order

Keep all disassembled parts in order so that they can be readily reinstalled. Separate parts which must be
replaced with new ones and those which should be reinstalled. Replace packings, gaskets, cotter pins, etc.
Do not touch electrical parts, rubber parts, V-belt, etc., with dirty hands. These parts should not be contaminated
with water or oil. Keep them in one place and away from those having engine oil on them.
Cleaning disassembled parts

Clean all disassembled parts in cleaning solvent immediately before reassembly. If they are not cleaned,
scratches, cracks or damage may be overlooked. This may result in entry of dirt or dust, causing problems after
reassembly.
GE-3-1
Reinstallation
Install parts in the specified order and to the specified values (tightening torque, adjustment standards, etc.).
Apply a coat of grease, liquid packing or sealer to designated parts.
Adjustment and operational checks

Use gauges or testers to adjust the parts within specifications if so designated. Also check movable parts for
proper operation.
CLEANING AND INSPECTION

CLEANING
The parts will be coated with dirty oil and sludge. Cleaning is mandatory. Suitable cleaning methods include
steam cleaning, light oil cleaning, acidic or alkaline solution cleaning, neutral agent cleaning, trichloroethylene
steam cleaning, and magnus solution cleaning. The cleaning process may reveal damage. So check closely
while the cleaning is in process.
METAL PARTS
Light oil
Unlike some other solvents, light oil has little penetrating or dissolving power with respect to sludge. Unless the
surface is precision finished, use a wire brush or other tool to dislodge the sludge. Follow this up with two
washings.
Alkaline solution
Do not use an alkaline solution if the parts are made from an alloy. However, an alkaline solution cleans steel
and cast iron parts quite well.
NOTE
+ If an alkaline cleaning solution is to be used, prepare and keep on hand a neutralizing agent (such
as boric acid solution), since the alkaline solution must be immediately washed from the skin or
eyes in the event of contact.
RUBBER PARTS
Do not use mineral oils. Wash in alcohol or merely wipe away dirt with a clean cloth.
OIL PASSAGES
Pass a wire through oil passages, to make sure that they are free. Clean the oil passages with solvent that is
injected under pressure from a nozzle.
PROTECTION AGAINST CORROSION

After removing all traces of old oil and grease from the surfaces of the parts, apply a coat of clean oil to them
to prevent corrosion.
INSPECTION
Parts should be inspected using designated measuring instruments or tools. Whether the parts are suitable for
further use should be determined by consulting the specified Maintenance Standards chart. Faulty parts should
be corrected or replaced as required. If one of the mating parts is found to be worn to such an extent that the
specified clearance is exceeded, replace it and/or its mate as the occasion demands.
Parts which are still within the repair or wear limit should sometimes be replaced before they exceed the limit
from preventive maintenance viewpoint.
All parts should be checked carefully by looking at their appearance or by using the ‘‘red’’ (penetration) method,
whichever is designated. If inspection of the exterior appearance reveals any of the following abnormalities, the
affected part(s) should be repaired or replaced, as required.
All rubber parts, such as O-rings, oil seals, gaskets, etc. should be discarded after they have been removed.
Abnormalities
+ Uneven wear
+ Graded wear
+ Scratches
GE-3-2
+ Cracks
+ Deformity
+ Fatigue or weakness (for springs and rubbers)
+ Bends
+ Loose fit
+ Unusual noise (for bearings)
+ Discoloration or jamming
+ Rust formation
+ Deterioration (for brake linings, etc.)
GE-3-3
TIGHTENING TORQUE OF STANDARD BOLTS

The tightening torque of the bolts and other fasteners that secure the major components parts is specified in the
text. In case there is no mention of tightening torque, these bolts and fasteners should be tightened according
to the following table of bolt standard tightening torque.
NOTE
+ All bolts and nuts are sized using the metric system. Do not use parts other than those designated.
Standard tightening torque (Without lubricant)
Bolt dia. Pitch
Nominal size 4T 7T 9T
mm mm
N·m kgfzm ftzlbf N·m kgfzm ftzlbf N·m kgfzm ftzlbf
M3 3.0 0.5 0.7 0.07 0.5 1.1 0.11 0.8 1.6 0.16 1.2
M4 4.0 0.7 1.5 0.15 1.1 2.5 0.25 1.8 3.5 0.36 2.6
M5 5.0 0.8 2.9 0.3 2.2 5.0 0.51 3.7 7.2 0.73 5.3
M6 6.0 1.0 5.1 0.52 3.8 8.4 0.86 6.2 12 1.2 9
1.25 13 1.3 9 21 2.1 15 29 3.0 22
M8 8.0
1.0 13 1.3 9 22 2.2 16 31 3.2 23
1.5 25 2.5 18 41 4.2 30 59 6.0 43
M10 10.0
1.25 25 2.6 19 43 4.4 32 62 6.3 46
1.75 42 4.3 31 71 7.2 52 98 10.0 72
M12 12.0
1.25 46 4.7 34 77 7.9 57 108 11.0 80
M14 14.0 1.5 74 7.5 54 127 13.0 94 177 18.0 130
M16 16.0 1.5 108 11.0 80 186 19.0 137 275 28.0 203
M18 18.0 1.5 167 17.0 123 275 28.0 203 392 40.0 289
M20 20.0 1.5 226 23.0 166 382 39.0 282 549 56.0 405
M22 22.0 1.5 304 31.0 224 510 52.0 376 736 75.0 542
2.0 275 28 203 461 47 340 667 68 492
M24 24.0
1.5 284 29 210 481 49 354 686 70 506
NOTE
+ Special parts are excluded.
+ This standard is applicable to bolts having the following marks embossed on the bolt head.
Mark
4T ...................... 4 or 40
7T ...................... 7 or 70
9T ...................... 9 or 90
Standard tightening torque of tubing connector

Standard tightening torque
Item
N·m kgfzm ftzlbf
4.75 (0.1870) 13 - 18 1.3 - 1.8 9 - 13
6.35 (0.2500) 16 - 24 1.6 - 2.4 12 - 17
8.0 (0.315) 29 - 39 3.0 - 4.0 22 - 29
Flared nut Tube O.D. mm (in)
10.0 (0.394) 39 - 49 4.0 - 5.0 29 - 36
12.0 (0.472) 59 - 78 6.0 - 8.0 43 - 58
15.0 (0.591) 69 - 93 7.0 - 9.5 51 - 69
Nipple nut 21 - 28 2.1 - 2.9 15 - 21
Eye connector 42 - 57 4.3 - 5.8 31 - 42
GE-4-1
- MEMO -
GE-4-2
MAINTENANCE
CONTENTS
SERVICE DATA .......................................... MA-1- 1 MAINTENANCE PROCEDURE ............ MA-4- 1
SERVICE DATA .......................................... MA-1- 1 BASIC MECHANICAL SYSTEM ................. MA-4- 1
TIGHTENING TORQUE ............................. MA-1- 1 LUBRICATION SYSTEM ............................ MA-4- 5
TOOLS ........................................................... MA-2- 1 COOLING SYSTEM .................................... MA-4- 9
PERIODIC MAINTENANCE FUEL SYSTEM ........................................... MA-4-14
SCHEDULES ............................................... MA-3- 1 INTAKE AND EXHAUST SYSTEM ............. MA-4-21
MAINTENANCE INTERVALS ..................... MA-3- 2 OTHERS ..................................................... MA-4-25
PERIODIC PARTS REPLACEMENT .......... MA-3- 3
SERVICE DATA
SERVICE DATA
SERVICE DATA
Unit: mm (in)
Item Maintenance standard Service limit Remarks
Valve clearance Intake valve 0.4 (0.016) —
(While cold) Exhaust valve 0.6 (0.024) —
Open 20° B.T.D.C. —
Intake valve
Closed 32° A.B.D.C. —
Valve timing
Open 60° B.B.D.C. —
Exhaust valve
Closed 14° A.T.D.C. —
At 180 - 220 rpm
Cylinder compression pressure kPa {kgf/cm2, psi} 2,942 {30, 427} 2,059 {21, 299}
(With engine warm)
Compression pressure difference kPa {kgf/cm2, psi} Less than 392 {4, 57} —
Open water tank cap valve pressure 49 - 69
— Pressure side
kPa {kgf/cm2, psi} {0.5 - 0.7, 7 - 10}
11.0 - 14.0
Water pump pulley - Crank pulley — With a force of about
Deflection of (0.433 - 0.551)
98 N {10 kgf, 22 lbf}
V-belt Cooler compressor pulley - 10.5 - 13.5
— applied to the mid part
Crank pulley (0.413 - 0.531)
Valve opening 76.5°C (170°F) 74.5 - 78.5 (166 - 173) 73.0 - 80.0 (163 - 176)
temperature
°C (°F) 82°C (180°F) 80.0 - 84.0 (176 - 183) 78.5 - 85.5 (173 - 186)
Thermostat More than More than
Valve 76.5°C (170°F)
10/90 (0.394/194) 8.5/90 (0.335/194)
lift/temperature
mm/°C (in/°F) 82°C (180°F) More than More than
10/95 (0.394/203) 8.5/95 (0.335/203)
Fuel injection RF8TC 14°
B.T.D.C. —
timing RF8TD 12.5°
Idle speed rpm 460 - 480 —
TIGHTENING TORQUE
Item Tightening torque Remarks
Valve clearance adjusting screw lock nut 34 - 44 {3.5 - 4.5, 25 - 33}
1st time 147 - 157 {15.0 - 16.0, 108 - 116}
Cylinder head bolt
2nd time 275 - 294 {28.0 - 30.0, 203 - 217}
M8 10 - 13 {1.0 - 1.3, 7 - 9}
Intake manifold nut
M10 19 - 23 {1.9 - 2.3, 14 - 17}
Exhaust manifold nut 54 - 64 {5.5 - 6.5, 40 - 47}
Oil pan drain plug 98 - 127 {10.0 - 13.0, 72 - 94}
Center bolt 59 - 69 {6.0 - 7.0, 43 - 51}
Full-flow and bypass oil filter
Drain plug 16 - 22 {1.6 - 2.2, 12 - 16}
Injection pump coupling mounting Coupling bolt 59 - 64 {6.0 - 6.5, 43 - 47}
bolt Cotter bolt 83 - 93 {8.5 - 9.5, 61 - 69}
Nozzle retaining nut 59 - 78 {6.0 - 8.0, 43 - 58}
Center bolt 59 - 69 {6.0 - 7.0, 43 - 51}
Primary fuel filter
Drain plug 16 - 22 {1.6 - 2.2, 12 - 16}
Turbocharger compressor housing clamp mounting bolt 17 {1.7, 12}
MA-1-1
TOOLS
TOOLS
Feeler gauge For adjusting valve clearance
99541 Z5000 Thickness mm (in)
0.25 (0.0098), 0.3 (0.012), 0.35 (0.0138), 0.4
(0.016), 0.45 (0.0177), 0.5 (0.020)
ET14-049
Feeler gauge For adjusting valve clearance

99541 Z0001 Thickness mm (in)
0.2 (0.008), 0.3 (0.012), 0.4 (0.016)
ET14049A
Timing plate For measuring valve timing

99646 Z0000
ET14-053
Compression gauge For measuring compression pressure

99640 96000
ET14050B
Compression gauge hose Used with the compression gauge (99640 96000)
99644 97000 when the gauge cannot be installed directly due to
interference with the air duct, etc.
ET14-051
Plate For fixing nozzle holder

157944-9520 NOTE
+ Tool number designated by ZEXEL CORPO-
RATION
WMA001A
Pin vice For cleaning nozzle orifice

99727 Z5005
EP14-121
MA-2-1
TOOLS

Nozzle cleaner For removal of carbon from rear of nozzle orifice
99726 Z5000
ET14-072
Filter wrench For removal of fuel filter

99755 00Z01 (Only when replacing cartridge type element)
WMA027A
MA-2-2
PERIODIC MAINTENANCE SCHEDULES

Abbreviations:
I : Inspect. Correct, adjust or replace if necessary.
A : Adjust R : Replace C : Cleaning
RB : Rebuilding T : Tighten to specified torque h : Initial maintenance
NOTE
+ The maintenance or lubrication service shown below are to be performed at the indicated intervals
(km, miles or months, whichever occurs first).
+ Scheduled maintenance services beyond 60,000 km (36,000 miles) or 12 months should be
continued at the same intervals as before except the initial maintenance.
+ Under the following severe operating conditions, more frequent servicing will be required.
— Operation in heavy dust conditions
— Operation at extremely low or high ambient temperature
— Extended high-speed operation with vehicle fully-loaded to its GVW (Gross Vehicle Weight)
— Extended low-speed operation
— Frequent stop-and-go operation
+ Any replacement parts used for required maintenance service or repairs should be genuine Nissan
Diesel parts.
MA-3-1
MAINTENANCE INTERVALS
Maintenance intervals Remarks
Kilometers x 1,000 1 5 10 15 20 25 30 35 40 45 50 55 60
Items
Miles x 1,000 Daily 0.6 3 6 9 12 15 18 21 24 27 30 33 36
Months — 1 2 3 4 5 6 7 8 9 10 11 12
Valve clearance I I
Cylinder head and manifold bolts T T
I : After 200,000 km (125,000 miles)

Crank damper I: Every 100,000 km (60,000 miles)
Cylinder compression pressure I
Oil leakage I I I I I I I I I I I I I I
Oil level and contamination I I I I I I I I I I I I I I
Oil R R: Every 10,000 km (6,000 miles) or 6 months (1)

Engine oil and
filter
Oil filter R: Every 10,000 km (6,000 miles) or 6 months (1)
Coolant leakage I I I I I I
Coolant level I I I I I I I I I I I I I
Coolant (incl. anticorrosive) R R (3)
Coolant (incl. antifreeze) R (4)
Water tank cap I
Fan clutch I
V-belt I I I I I I I I I I I I I
Thermostat I
Injection timing I
Nozzle (injection pressure and pattern) I
Fuel leakage I I I I I I I I I I I I I I
I I I I I I
Fuel filter
Drain Drain Drain Drain Drain Drain (5)
Fuel filter element R
I I I I I I I I I I I I
Primary fuel filter
Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain Drain
Primary fuel filter element R R
Fuel level I
Air cleaner element I/C I/C I/C I/C I/C I/C (2)
Air cleaner element (Dry type) R (2)
Condition of exhaust I I I I I I I I I I I I I
Exhaust tubing and muffler I I I I I
Turbocharger I
Remarks
(1) Replace the engine oil and oil filter whenever the oil filter warning light comes on, even before the scheduled replacement.
(2) If the warning light comes on even before the scheduled replacement, clean or replace element.
(3) Service every 6 months.
(4) Service every 12 months.
(5) Center bolt type
MA-3-2
PERIODIC PARTS REPLACEMENT

Periodic replacement parts are rubber parts such as the fuel hose, etc. which deteriorate with the lapse of time
and require maintenance. It is absolutely necessary to replace those parts periodically to maintain driving safety.
PERIODIC PARTS REPLACEMENT INTERVAL
Items Remarks
Number of years 1 2 3 4 5 6 7 8 9 10
Fuel hose (engine side) R R R R R
Fuel hose (fuel tank side) R R
Air compressor rubber hose R R R R R
MA-3-3
MAINTENANCE PROCEDURE
BASIC MECHANICAL SYSTEM
VALVE CLEARANCE
NOTE
+ Ensure the engine is cool when checking and adjusting the
valve clearance.
1. Align the flywheel housing pointer with the stamp on the
flywheel.
NOTE
+ When turning the flywheel to align the stamp, turn it ZMA123A
counterclockwise when viewed from behind the engine.
2. When the stamps on the injection pump housing and timer are
close to each other, it indicates T.D.C. on the compression
stroke. When they are located opposite to each other, it
indicates T.D.C. on the exhaust stroke.
MM-37
3. Using a feeler gauge, inspect the valves indicated by a circle in

the following chart in sequence.
NOTE
+ The cylinders and valves are numbered as starting from
the side of the fan.
Unit: mm (in)
Item Maintenance standard Service limit
Valve clearance Intake valve 0.4 (0.016) —

(While cold) Exhaust valve 0.6 (0.024) —
EMA2-004
IN: Intake valve EX: Exhaust valve
Right bank Left bank

Cylinder number
1 2 3 4 1 2 3 4
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Valve arrangement
IN EX IN EX IN EX IN EX EX IN EX IN EX IN EX IN
Right bank No. 4 cylinder compression T.D.C. + + + + + + + +
Right bank No. 4 cylinder exhaust T.D.C. + + + + + + + +
4. In the valve clearance is not within the specified range, loosen

the lock nut located at the tip of the rocker arm and adjust the
adjusting screw with a standard screw-driver. After properly
adjusting, tighten the lock nut and re-check the valve clear-
ance.
Lock nut
: 34 - 44 N·m {3.5 - 4.5 kgfzm, 25 - 33 ftzlbf}
EMA2004A
MA-4-1
Valve clearance adjustment

1. If the valve clearance is not correct, loosen the lock nut for the
adjusting screw and adjust the screw until the specified clear-
ance is obtained.
2. After adjusting the valve clearance, hold the adjusting screw
and tighten the lock nut.
: 34 - 44 N·m {3.5 - 4.5 kgfzm, 25 - 33 ftzlbf}
3. Recheck the valve clearance.
4. Rotate the flywheel one complete turn until the mark ‘‘1z6’’ is
aligned with the pointer. Next, check and adjust the remaining EMA2004A
valve clearances.
If the engine operates erratically or vibrates even though the
valve clearances are properly adjusted, problems may be due
to improperly adjusted valve timing which results from incorrect
assembling of the timing gear train, etc. If erratic operation is
noticed, check the valve timing as described below.
Procedure for checking valve timing
1. Remove the V-belt, cooling fan and crank pulley assembly.
2. Turn the flywheel in the normal direction until the No. 1 piston
is at the top dead center on the compression stroke.
NOTE
+ If the flywheel has been rotated excessively, rotate it
backwards beyond the desired position then gradually
rotate it back in the normal direction until it is set in the
proper position.
3. Attach the timing plate (99646 Z5001 or 99646 Z0000) to the

end of the crankshaft. Also attach a needle pointer utilizing the
front cover mounting bolt, and align the needle to ‘‘0’’.
4. Set a dial gauge so that the contact arm is in contact with the
upper valve spring seats of the intake valve and exhaust valve.
EP12-3
MA-4-2
5. If the needle of the dial gauge begins to move, it means that the
valve is beginning to open; the movement of the needle will
stop as the valve closes. Read the needle position on the timing
plate on each occasion.
Item RF8TC Remarks
Intake Open 20° B.T.D.C. j

1
valve Closed 32° A.B.D.C. j

2
Valve
timing Open 60° B.B.D.C. j
3
Exhaust
valve Closed 14° A.T.D.C. j
4
WMA004A
CYLINDER HEAD AND MANIFOLD BOLTS

Cylinder head bolts
Check the cylinder head bolts is specified by the tightening torque.
: 275 - 294 N·m {28 - 30 kgfzm, 203 - 217 ftzlbf}
ZMA124A
Intake and exhaust manifolds

Check the intake and exhaust manifold mounting bolts and nuts for
proper torque. Also check the manifolds for damage or traces of
leakage at the cylinder head connections.
Intake manifold
M8
: 10 - 13 N·m {1.0 - 1.3 kgfzm, 7 - 9 ftzlbf}
M10
: 19 - 23 N·m {1.9 - 2.3 kgfzm, 14 - 17 ftzlbf}
Exhaust manifold
: 54 - 64 N·m {5.5 - 6.5 kgfzm, 40 - 47 ftzlbf}
NOTE
+ Tighten the nuts evenly to the specified torque, starting
from the inside then to the outside.
ZMA106A
MA-4-3
CRANK DAMPER
Check the crank damper for cracks or flaking, and the mounting
bolts for looseness. Replace faulty parts if necessary.
NOTE
+ Be careful not to confuse peeling paint for cracks.
CYLINDER COMPRESSION PRESSURE

1. Warm up the engine.
2. Disconnect all nozzle tubes and remove all nozzle holders.
Refer to the ‘‘DR’’ section for details.
3. Install the compression gauge (99640 96000) to the cylinder

head with a tightening torque of 25 to 29 N·m {2.5 to 3.0 kgfzm,
18 to 22 ftzlbf} with the nozzle holder in place. Press the gauge
bleeder to set the pointer to ‘‘zero’’.
If the gauge interferes with surrounding parts, connect a
specially designed hose (99644 97000) between the gauge
and gauge holder to avoid interference.
NOTE
+ Be careful to prevent foreign matter from getting into the
other nozzle holder holes.
+ Be sure to remove the old nozzle holder gasket. ER12-100
4. Move the engine stop lever completely in the ‘‘FUEL CUT’’

direction and hold it at that position.
5. Crank the engine with the starting motor. Stop cranking the
engine when the gauge pointer stabilizes. Read the cylinder
compression pressure. Measure compression pressure for the
remaining cylinders as described above. If the measured
values or the differences in compression pressure between
cylinders are not within specifications, pistons and/or piston
rings may be worn or the valve mechanism may be faulty.
Overhaul the engine and repair as necessary.
Maintenance
Item Service limit Remarks
standard
Cylinder
At 180 - 220 rpm
compression 2,942 {30, 427} 2,059 {21, 299}
(With engine warm)
pressure
Compression Less than
—
pressure difference 392 {4, 57}
MA-4-4
NOTE
+ Measure the cylinder compression pressure with the en-
gine warm. Measure each cylinder two or three times and
average the measured values. Use the average value as a
reference value. Measurement should be done in all the
cylinders.
LUBRICATION SYSTEM
ENGINE OIL LEAKAGE
Check the cylinder head, front cover, oil pan, oil filters and other
related parts for sign of leakage. If necessary, replace gaskets.
After replacing the gasket, check that point to ensure there is no
leakage.
ENGINE OIL LEVEL AND CONTAMINATION
WARNING
+ To help avoid serious personal injury from hot engine oil,
perform lubrication system checks and maintenance
only after the engine has cooled.
Check the engine oil level and contamination of engine oil before
driving vehicle each day and when you stop for fuel. Check the oil
level and contamination of engine oil with the engine off. When
checking the oil level after stopping the engine, wait at least 6
minutes to allow the oil to return to the oil pan.
To check the engine oil level

1. Park the vehicle on a flat surface.
2. Open the front lid and remove the oil dipstick. Wipe the dipstick
clean with an oil rag and reinsert it. Remove the dipstick and
check the oil level. Maintain the oil level between the high and
low marks on the dipstick.
ZMA107A
MA-4-5
3. If oil level is low, add engine oil of the proper viscosity for the
anticipated temperature range during the service interval
through the oil filler port on the valve cover. After adding oil,
wait at least 6 minutes, then recheck the oil level. Do not add oil
above the high mark on the dipstick.
CAUTION
+ Do not drive the vehicle with the oil level below the low
mark on the oil dipstick. An insufficient quantity of engine
oil can cause engine seizure.
+ Use care to keep dirt and debris from entering the crank-
ZMA108A
case through the oil filler port when adding engine oil.
Avoid spilling oil. Clean up any engine oil that spills
accidentally.
NOTE
+ To check the oil level and to add oil while the cab is being
tilted, there is a sub oil dipstick and oil filler.
To check the engine oil for contamination

Remove the oil dipstick and check the cleanliness of the oil which
is on the dipstick for signs of contamination such as discoloration
and changes in oil texture. See the instructions in this manual
under the caption CHANGING ENGINE OIL.
ENGINE OIL AND OIL FILTER

Engine oil
WARNING
+ To help avoid serious personal injury from hot engine oil,
perform lubrication system checks and maintenance
only after the engine has cooled.
The engine oil and oil filter change interval varies with the type of
engine oil used and vehicle driving conditions. If the vehicle is
driven for extended periods of time at high or low speeds, in dusty
areas, with frequent idling or carrying heavy loads, engine oil will
deteriorate faster and require more frequent changing.
As the temperature rises, the engine oil’s viscosity decreases,
reducing its lubricating effect. To choose an oil with the proper
viscosity for the anticipated ambient temperature range, refer to the
viscosity chart in the ‘‘GE’’ section of this manual.
MA-4-6
To change the engine oil

1. Loosen the oil filler cap.
ZMA109A
2. Undo the four engine undercover catchers (on the left and right
sides of the engine), and remove the undercover assembly. (if
equipped)
3. Place a container under the drain plugs in the bottom of the oil
pan and oil filter. Remove the plugs and drain the oil into the
container.
WMA009A
4. When all the oil has been drained from the oil pan and oil filter,
replace the drain plugs in the drain hole and tighten the drain
plugs.
Oil pan drain plug
: 98 - 127 N·m {10.0 - 13.0 kgfzm, 72 - 94 ftzlbf}
5. Replace the oil filter. See the instructions under the caption OIL
FILTER.
6. Add engine oil through the oil filler port to the specified level.
Refer to the oil capacities in the ‘‘GE’’ section of this manual.
7. After refilling the engine oil, wait for at least 6 minutes, then
DCN-060E
using the dipstick check the oil level. If the oil level is low, add
additional oil. Wait 6 minutes, then recheck the oil level. Repeat
this procedure until the engine oil reading on the dipstick is
between the high and low marks.
8. Install the engine undercover (if equipped).
Oil filter
WARNING
+ Do not handle hot oil filter without hand protection.
Failure to do so may result in burn injury.
NOTE
+ Use genuine filter or equivalent in quality and design.
+ Always replace the oil filter at the same time engine oil is
replaced.
MA-4-7
To replace the filter

1. Undo the four engine undercover catchers (on the left and right
sides of the engine), and remove the undercover assembly (if
equipped).
2. Place a container under the oil filter and remove the drain plug
in the bottom of the oil filter. Drain oil from the filter.
3. Loosen the center bolt, and remove the filter case, element and
other parts.
Full-flow oil filter
j
1 Drain plug j
6 Set spring
j
2 Packing j
7 Element
j
3 Center bolt j
8 Packing
j
4 Packing j
9 Filter body
j
5 Filter case
ZMA110A
Bypass oil filter

j
1 Drain plug j
6 Set spring
j
2 Packing j
7 Element
j
3 Center bolt j
8 Packing
j
4 Packing j
9 Filter body
j
5 Filter case
ZMA111A
MA-4-8
4. Clean all filter parts, except the element, in cleaning fluid.

5. Discard the old element, and insert the new element and
packing.
6. Reassemble each part correctly.
Center bolt
: 59 - 69 N·m {6.0 - 7.0 kgfzm, 43 - 51 ftzlbf}
Drain plug
: 16 - 22 N·m {1.6 - 2.2 kgfzm, 12 - 16 ftzlbf}
7. Pour engine oil into the filter, start the engine and check all
parts of oil filter for signs of oil leakage.
NOTE
+ Do not excessively tighten the center bolt.
8. Install the engine under cover (if equipped).
COOLING SYSTEM
WARNING
To help avoid serious personal injury from hot coolant or
steam release:
+ Do not open the water tank cap while the engine cooling
system is hot. Wait until it cools down.
+ Be extremely careful when opening the water tank cap.
Place a thick cloth on the cap and slowly loosen it to
allow a reduction in pressure in the cooling system.
COOLANT LEAKAGE
Check the cooling system for leakage, especially at tube and hose
connections. Also check piping for fractures, cracks or damage.
Replace parts if faulty.
If water leaks through the small hole in the water pump body, the
water seal may be faulty.
Replace the water pump with a new one.
COOLANT LEVEL
Check the coolant level daily only when the engine is cool.
Check the coolant level in the coolant reservoir tank located in rear
of the cab.
The coolant level should be between the HIGH and LOW lines. If
the coolant level is below the LOW line, add the proper coolant
solution to the HIGH line.
CN-024E
MA-4-9
CAUTION
+ Antifreeze made with methoxy propanol or propylene
glycol is not recommended for use with Nissan Diesel
engines. These types of antifreeze can damage engine
internal seals and coolant hoses and create a potential fire
hazard due to lower flash points than ethylene glycol type
antifreeze.
+ Use only municipally supplied water (tap water) in the
cooling system. River, well or other water produces scale
in the cooling system, which may cause damage to the
engine or cooling system.
+ Do not add water without adding ethylene glycol antifreeze
to the engine cooling system, except in an emergency. If
plain water is added in an emergency, restore the proper
mixture of antifreeze and water as soon as possible.
+ If the coolant should get extremely low and the engine very
hot, let the engine cool before adding coolant; then, with
the engine running, add coolant slowly. Adding cold cool-
ant to a hot engine may crack the cylinder head or
crankcase. Never use water alone.
CHANGE COOLANT AND CLEAN INSIDE

Point of change and flushing
Flush the interior of the cooling system whenever any heavy
contamination in the coolant is noticed. Flushing removes water
scale and fat from the cooling system, and restores its original
cooling efficiency, which greatly reduces the possibility of the
engine overheating.
Flushing procedure
<To clean the cooling system>
The cooling system must be flushed when the coolant temperature
is higher than 80°C (176°F) and the engine is run at high idle. If the
water temperature is too low, the thermostat will remain closed,
and the flushing agent will not circulate in the radiator, so no
flushing effect will occur.
MA-4-10
1. Set the heater control temperature lever to the HOT position.

2. Open the water tank cap.
3. Drain the cooling water from the radiator drain cock completely.
4. Close the drain cock, and pour city water and flushing agent
into the radiator.
5. Run the engine at high idling speed (refer to the flushing agent
manufacturer’s instruction). Cover the front end of the radiator
to prevent the temperature of the fluid in the cooling system
from dropping. Observe the fluid level carefully for five minutes
after starting the engine. If it lowers, add city water.
6. After flushing, stop the engine, and thoroughly drain the fluid ZMA112A
from the radiator drain cock.

7. Close the drain cock, and add fresh city water. Start the engine
and run it at high idle until the water temperature goes above
80°C (176°F). Then stop the engine, and drain the water from
the drain cock once again. Repeat this operation two or more
times, until only clean water is discharged from the drain cock.
Dirty or colored water from the drain cock means that fat or
scale is still in the cooling system.
8. After completing the flushing operation, close the radiator drain
cock securely, and add fresh city water with antifreeze (or
anticorrosive) up to the specified level. Then start the engine,
ZMA116A
and purge the air from the system until the coolant level is
stabilized at the specified position. If the coolant level lowers
during this operation, add fresh city water with antifreeze (or
anticorrosive).
WATER TANK CAP

Attach the water tank cap to a cap tester, and measure the
operating pressure of the water tank cap valve. Replace the water
tank cap if faulty.
49 - 69 {0.5 - 0.7, 7 - 10} — Pressure side
ES8-11
MA-4-11
FAN CLUTCH
Ensure that the engine is off when checking the fan clutch.
1. Check the fan clutch for oil leakage. If leakage is present,
replace the fan clutch assembly.
2. Check the fan clutch for proper operation:
+ Rotate the cooling fan by hand (adjacent parts should be cool)
to ensure it moves smoothly without binding.
+ Then, start the engine and operate it until the pointer of the
water temperature gauge stays within the ‘‘H’’ range. Stop the
engine to ensure that the cooling fan no longer rotates by hand.
NOTE
+ The fan clutch operates in a manner similar to a ‘‘direct
drive’’ when the temperature of parts near the bimetal
located at the front center of the clutch reaches approxi-
mately N°C (N°F). For this reason, it is best to measure the
temperature of those parts to assure proper maintenance
during inspection.
Unit: °C (°F)
Run the engine Operating
Item
continuously temperatures (N)
FD2300 On-off type 2,200 rpm 65±5 (149±9) WMA012A
FAN AND FAN SHROUD

Check the cooling fan and fan shroud for proper installation, cracks
or damage. Replace faulty parts.
CAUTION
+ Do not put your hand near the fan when the engine is
operated.
V-BELT
Be sure the engine is off and the transmission is in ‘‘Neutral’’.
Engage the parking brake securely.
Visually check the V-belt daily for cracks and damage. If the belt is
cracked or damaged excessively, replace it.
Also check that the belt does not come in contact with the bottom
of the pulley groove.
Check the belt tension by applying approximately 98 N {10 kgf, 22
lbf} force to the belt midway between the water pump [or (cooler
compressor)] pulley and the crank pulley.
Unit: mm (in) DE-015E
Water pump pulley - 11.0 - 14.0
—
Crank pulley (0.433 - 0.551)
Cooler compressor pulley - 10.5 - 13.5
—
Crank pulley (0.413 - 0.531)
MA-4-12
To adjust V-belt deflection

1. Loosen the lock bolts and nut.
2. Turn the adjusting bolt so that the belt deflection is the specified
value when pushed midway between the water pump (cooler
compressor) pulley and crank pulley by a force of 98 N {10 kgf,
22 lbf}.
Unit: mm (in)
A Water pump pulley -
j 11.0 - 14.0
—
Crank pulley (0.433 - 0.551) ZMA125A
B Cooler compressor pulley -

j 10.5 - 13.5
—
Crank pulley (0.413 - 0.531)
NOTE
+ Be sure to check for the proper belt tension or the proper
operation of cooler compressor (there should be no noise
while in operation) and also conduct a cooler gas check.
3. Tighten the lock bolts and nut.
ZMA127A
Alternator drive belt

+ Turn the adjusting bolt (B) located on the alternator adjusting
bracket, clockwise until the specified length ‘‘L’’ (shown in the
figure on the right) is obtained.
Length ‘‘L’’: 19.5 mm (0.7677 in), max.
+ Tighten the tensioner spring mounting nut (A) (Shown in the
figure on the right).
: 32 - 38 N·m (3.3 - 3.9 kgfzm, 24 - 28 ftzlbf)
EMA2-027
THERMOSTAT
1. Drain coolant completely. Refer to ‘‘CHANGE COOLANT AND
CLEAN INSIDE’’ for procedures.
2. Disconnect the radiator hose from the water outlet, then
remove the water outlet and rubber ring.
3. Remove the thermostat.
j
1 Thermostat j
3 Thermostat housing
j
2 Rubber ring
ZMA126A
MA-4-13
4. Check the thermostat as described below, and replace if faulty.

+ Ensure that the valve contacts the seat at room temperature.
+ Check the valve opening temperature and the ‘‘lift’’ of the valve.
j
A Bar thermometer j
C Thermostat holder
j
B Stirring rod j
D Heat source

76.5°C 74.5 - 78.5 (166 - 173) 73.0 - 80.0 (163 - 176)
Valve opening (170°F)
temperature
°C (°F) 82°C 80.0 - 84.0 (176 - 183) 78.5 - 85.5 (173 - 186)
(180°F) EP8-9
76.5°C More than More than
Valve lift (170°F) 10/90 (0.394/194) 8.5/90 (0.335/194)
mm/°C (in/°F) 82°C More than More than
(180°F) 10/95 (0.394/203) 8.5/95 (0.335/203)
5. Install the thermostat, the outlet and the gasket. Connect the
upper radiator hose.
6. Add coolant to the radiator. Refer to ‘‘CHANGE COOLANT
AND CLEAN INSIDE’’ for procedures.
FUEL SYSTEM
WARNING
Observe the following when removing parts of the fuel
system:
+ Post a placard that reads: ‘‘CAUTION: FLAMMABLE’’.
+ Prepare a fire extinguisher.
+ Disconnect the ground terminal from the battery.
GOVERNOR SETTING (CHECKING SEALS)

Ensure that the parts shown in the figure below are secured with
sealing caps and wires. If the cap or wire is broken, check and
adjust the injection pump and governor.
CAUTION
+ Any unauthorized adjustments in the injection pump and
governor settings, other than as specified, can cause
serious damage to the engine.
EMA2010E
MA-4-14
INJECTION TIMING
1. Remove the pointer cover. Secure the pointer to the flywheel
housing using bolts.
2. Crank the engine in the standard direction by turning the
flywheel with a lever until the pointer is aligned with the timing
mark.
NOTE
+ If the mark goes past the pointer, move it back past the
pointer and turn again in the standard direction until
alignment is made.
WMA163A
Maintenance
Item Service limit
standard
Fuel injection timing RF8TC 14° —

(B.T.D.C.) RF8TD 12.5° —
3. If the timer marks are not aligned as shown in the figure, adjust
as follows:
EP4-23
Adjustment of fuel injection timing

1. Make sure the pointer points to the specified injection timing
graduation on the outer periphery of the flywheel and loosen
the coupling bolts (2 places).
2. Back the timer off a little in the reverse direction of the normal
timer direction. Turn the timer in the normal direction to adjust
the pointer to the mark.
3. Tighten the coupling bolts and cotter bolt.
Coupling bolt
: 59 - 64 N·m {6.0 - 6.5 kgfzm, 43 - 47 ftzlbf} EMA1002E
Cotter bolt
: 83 - 93 N·m {8.5 - 9.5 kgfzm, 61 - 69 ftzlbf}
MA-4-15
IDLE SPEED
NOTE
+ When checking engine idle speed ensure that the engine
idle control knob inside the cab is set to the low-speed
position.
1. Start the engine and warm it up to the normal operating
temperature.
2. Allow the engine to idle and observe the engine speed on the
tachometer.
3. If idle speed is not within specified range, adjust as follows:
NOTE
+ If equipped with an air conditioner, the air conditioner
switch must be turned off when checking idle speed.
Unit: rpm
Idle speed 460 - 480 —
Idle speed adjustment

1. Loosen the lock nut on the idle adjusting bolt.
2. Turn the idle adjusting bolt to obtain the correct idle speed.
3. Tighten the lock nut on the idle adjusting bolt.
NOTE
+ Accelerate the engine two or three times. Allow the engine
to return to idle speed and observe the tachometer read-
ing. If the idle speed is not within the specified range,
check the accelerator linkage for binding and repeat idle
adjustment.
ACCELERATION AND DECELERATION
1. Start the engine and warm it up to the normal operating
temperature.
2. Depress the accelerator pedal to ensure the engine speed
increases smoothly from idle to the maximum and that it returns
to idle.
NOTE
+ If the engine does not accelerate smoothly, disengage the
accelerator linkage from the injection pump and operate
the fuel control lever of the injection pump to check engine
acceleration. If engine rotates smoothly, the accelerator
linkage may be faulty. Check and repair the linkage. If
engine operation is erratic, the injection pump or governor
may be faulty. Check and repair these parts.
MA-4-16
ACCELERATOR LINKAGE
Check accelerator linkage for bent rods, interference with adjacent
parts or looseness.
NOZZLE (INJECTOR PRESSURE AND PATTERN)

Cleaning nozzle
1. Remove the nozzle holder assembly from the engine. Refer to
the ‘‘ENGINE DISASSEMBLY AND REASSEMBLY’’ section
for details.
2. Clamp the nozzle holder in a vise with a holder plate (157944-
9520).
NOTE
+ 157944-9520 is the assembly number of the nozzle holder
plate which is detailed in the ‘‘EF’’ section.
3. Loosen the retaining nut, and then remove the nozzle from the
nozzle holder. Do not drop the nozzle needle.
EEF1160A
4. Pull the nozzle needle from the nozzle body.

NOTE
+ Do not use the nozzle needle in another nozzle body.
5. Remove carbon from around the openings by using the corner
of a hard piece of wood. Do not use waste or any other material
to push carbon into the openings.
WMA017A
MA-4-17
6. Removing carbon in openings

Use the pin vice (99727 Z5005) and wire to clean the openings.
Unit: mm (in)
Nozzle identifica- Number of injec- Injection nozzle
Wire diameter
tion mark tion nozzle holes hole diameter
H2 5 0.360 (0.0142) 0.35 (0.0138)
+ Allowing too much wire to protrude at the tip of the holder will
permit the wire to bend inside the nozzle, in which case
withdrawal proves difficult. The wire should protrude no more
WMA018A
than 2.0 to 2.5 mm (0.079 to 0.098 in).
+ Carefully push the carbon into the nozzle. Too much force will
bend the wire. Proceed slowly.
+ Remove carbon at the inside end of the openings with the

nozzle cleaner (99726 Z5000).
Exercise care to avoid damaging the surface which the nozzle
needle contacts. The use of compressed air may clog the
openings with foreign particles.
7. Tighten the retaining nut.
: 59 - 78 N·m {6.0 - 8.0 kgfzm, 43 - 58 ftzlbf}
WMA019A
NOZZLE HOLDER (INJECTOR)

Rebuild the nozzle holder at the specified interval. Check and
adjust the nozzle opening pressure and spray pattern. Refer to the
‘‘EF’’ section for rebuilding procedures.
WARNING
+ Fuel from the injection nozzle is injected under extremely
high pressure. If it is directed at your hand, etc., serious
injury may result KEEP YOUR HANDS AWAY FROM THE
NOZZLE DURING TESTS.
FUEL TUBING
Check the fuel rubber hose and clamp of the fuel system for
installation, cracks or damage.
Replace faulty parts if necessary.
Check the fuel tubing for fractures, damage or improper installa-
tion. Replace faulty parts if necessary. Whenever the fuel tubing is
disconnected, be sure to bleed air from the fuel system.
FUEL LEAKAGE
Check the fuel system for leakage at tube or hose connections.
MA-4-18
FUEL FILTER ELEMENT

NOTE
+ Use genuine filter or equivalent in quality and design.
CX-055E
Replacing fuel filter element

1. Place a container under the filter. Remove the filter with a filter
wrench (99755 00Z01). Drain any remaining fuel into the
container.
2. Apply a thin coat of clean engine oil to the gasket of the new
filter.
WARNING
+ Installation of the fuel filter without coating the gasket
with oil may damage the gasket resulting in loss of fuel WMA021A
and fire hazard due to spilled fuel.
3. Install the new fuel filter by hand. After the gasket comes in
contact with the bracket sealing surface, tighten an additional
three-fourths of a turn.
4. After installing the filter, purge air from the fuel system and
check for fuel leaks.
CX-076E
Bleeding air from the fuel system

Refer to ‘‘PURGING AIR FROM FUEL SYSTEM’’.
PRIMARY FUEL FILTER

Draining sediment from primary fuel filter
NOTE
+ It is not necessary to drain all the fuel in the primary fuel
filter case.
Place a container under the filter, then loosen the drain plug to
drain sediment.
Bleed air from the fuel system after draining sediments and
tightening the drain plug.
CX-103E
: 16 - 22 N·m {1.6 - 2.2 kgfzm, 12 - 16 ftzlbf}
MA-4-19
Replacing primary fuel filter element

1. Place a container under the drain plug, and drain the fuel and
sediment.
2. Loosen the center bolt, and remove the filter case, spring and
element.
3. Clean each part in light oil.
4. Replace the element and packings.
5. Reassemble each part correctly, and after reassembly, be sure
to bleed air from the fuel system.
Center bolt
: 59 - 69 N·m {6.0 - 7.0 kgfzm, 43 - 51 ftzlbf}
NOTE
+ Do not excessively tighten bolts and plugs.
j
1 Drain plug j7 Seat
j
2 Packing j8 Element
j
3 Center bolt j9 Packing
j
4 Packing j
10 Filter cover
j
5 Filter case j
11 Filter plug
j
6 Spring j
12 O-ring
WMA022A
PURGING AIR FROM FUEL SYSTEM

Air entrapped in the fuel system will cause poor injection of the fuel,
thus resulting in difficult starting, jerking, or even stoppage of the
engine. After completing any service procedure on fuel system
(replacement of fuel filter element, or reconnection of any fuel
pipe), be sure to bleed air from the fuel system.
Procedure 1
When the fuel pipe is disconnected or precipitates are removed,
bleed air as follows:
1. Twist the knob on the priming pump, which is connected to the
injection pump, and the knob will rise up by itself.
2. Move the priming pump’s knob up and down to send fuel from
fuel tank into the filter.
Continue this procedure until the overflow valve of the fuel filter
no longer gives off a ‘‘hissing’’ sound and movement of the
priming pump is difficult. The air bleeding operation is now CX-104E
complete.
3. After bleeding air, return the pump knob to its original position,
and replace the cover. Start the engine, and make sure that no
fuel is leaking from the fuel system.
Fuel leaks can cause a fire.
CX-154E
MA-4-20
Procedure 2
When the fuel filter element or primary fuel filter element is
replaced, bleed air as follows:
1. When the primary fuel filter element is replaced, refill with fuel
through the filler plug hole.
2. Remove the priming pump cover on the injection pump, and
turn the pump knob counterclockwise to prepare the priming
pump for operation.
3. Slightly loosen the connector bolt on the inlet side of the fuel
filter and move the pump up and down to bleed air from
between the fuel tank and fuel filter. Perform the above CX-104E
operation until no air comes out.
NOTE
+ Place a receiver under the fuel filter. Thoroughly wipe up
any spilled fuel.
4. When bleeding air from between the fuel tank and fuel filter is
completed, retighten the connector bolt and move the priming
pump up and down.
priming pump is difficult.
The air bleeding operation is now complete. CX-154E
5. After bleeding air, return the pump knob to its original position,
and replace the cover. Start the engine, and make sure that no
fuel is leaking from the fuel system as it could cause a fire.
INTAKE AND EXHAUST SYSTEM

AIR CLEANER ELEMENT
Precautions for handling cleaner
1. Be sure to install the element and cover securely. Loose or
improper installation will allow dust to enter, preventing normal
functioning of the air cleaner.
2. Do not touch the filter paper of the element directly with your
hand. Wear gloves. Use special care not to stain the element
with oils.
To inspect the air cleaner element

Start the engine and check if the air cleaner warning light comes
on. If the warning light comes on frequently, clean or replace the
element as follows:
NOTE
+ If the air cleaner element reaches a checking or replacing
period, clean or replace the element regardless of whether
the warning light comes on or not.
AX-370E
MA-4-21
LH
j
1 Cover j
4 Element assembly (Outer)
j
2 Packing j
5 Element assembly (Inner)
j
3 Adapter j
6 Body
ZMA117A
RH
j
1 Cover j
4 Element assembly (Inner)
j
2 Packing j
5 Body
j
3 Element assembly (Outer) j
6 Evacuator valve
ZMA118A
1. Remove the cover assembly.

2. Remove the adapter. (LH only)
3. Remove the outer element.
MA-4-22
4. Check the outer element and packing, and replace if broken or

deformed.
If there is dirt or dust on the outer element, clean it by blowing
compressed air at 196 to 294 kPa {2 to 3 kgf/cm2, 28 to 43 psi}
from inside.
ECJ-035
NOTE
+ After the outer element has been thoroughly dried, shine
light through from the inside of the outer element, and
check it for damage, pin holes, and thinned areas; also
check the packing for damage and/or deformation. Re-
place the elements (outer and inner) if necessary.
ECJ-036
5. Remove the inner element.

NOTE
+ Do not remove the inner element until the specified re-
placement time. In other words, the inner element need not
be checked between replacements.
6. When installing the elements, clean the inside of the case (and
the evacuator valve (LH only)) and assemble each part in the
reverse order of disassembly.
AIR INTAKE SYSTEM (DUCT, HOSE AND CLAMP)

Check the air intake duct connections for loose clamps or cracked
hoses. Check the connection between the air cleaner and air intake
manifold especially. Tighten loose clamps, if any.
MA-4-23
CONDITION OF EXHAUST
Warm up the engine sufficiently, then visually inspect exhaust
smoke during idling, acceleration and deceleration with the vehicle
at a stop.
Color of smoke Judgment standard
Colorless or light blue Normal
Abnormal
Black
Incomplete combustion
Abnormal ECI-037
Engine oil is also burning. However, exhaust
White
gases are often white when either the air or
engine temperature is low.
EXHAUST TUBING AND MUFFLER

Check the various connections of the exhaust tubing for looseness.
Tighten loose parts as necessary. Also check for any sign of gas
leakage from connections or muffler.
TURBOCHARGER
NOTE
+ Before attempting any servicing of the turbocharger, clean
its entire exterior surface.
+ Never use a caustic solution. Caustic solutions attack
aluminum.
To clean the compressor side
1. Remove the turbocharger from the engine.
2. Remove the compressor housing and check the condition of
the impeller (compressor wheel). If it is not excessively dirty,
clean the impeller and the inner surface of the housing with a
brush and a cloth dampened with diesel fuel.
CAUTION
+ Do not use a wire brush or scraper.
3. If the impeller is excessively dirty, overhaul and clean. Refer to
the ENGINE ‘‘IE’’ section for cleaning instructions.
4. When the impeller is wet with cleaning solvent, dry with
compressed air.
MA-4-24
CAUTION
+ Hold the impeller by hand to prevent it from turning while
drying.
5. Install the compressor housing in its original position.
: 17 N·m {1.7 kgfzm, 12 ftzlbf}
OTHERS
STARTING MOTOR
Inspect the moving connector of the magnetic valve. Refer to the
EE section for INSPECTION procedures.
ALTERNATOR
Inspect the charging system.
Refer to the EE section for INSPECTION procedures.
MA-4-25
TROUBLE DIAGNOSIS
CONTENTS
DIAGNOSIS .................................................. TD-1- 1 DECREASED ENGINE POWER ................. TD-1- 5
DIFFICULT ENGINE STARTING ................. TD-1- 2 EXCESSIVE OIL CONSUMPTION ............. TD-1- 6
BLACK EXHAUST SMOKE ......................... TD-1- 3 EXCESSIVE FUEL CONSUMPTION .......... TD-1- 7
WHITE EXHAUST SMOKE ......................... TD-1- 3 NOISY ENGINE ........................................... TD-1- 8
IRREGULAR ENGINE OPERATION ........... TD-1- 4 ENGINE OVERHEATS ................................ TD-1- 9
DIAGNOSIS
DIAGNOSIS
DIAGNOSIS GUIDE
The diagnosis guide is a table which can be used for seeking out the cause of trouble without disassembling
the engine on the basis of the symptoms of the problem complained of by the user and the result of checks
performed in the shop with the engine being mounted in the body.
HOW TO USE THE GUIDE
1. Open the page of the guide corresponding to the trouble symptom complained of by the user.
2. Check all of the points listed in the page.
3. If there is any applicable item in ‘‘Symptoms and checking points’’, the cause of the trouble may be assumed
in the following manner.
+ Each item in the ‘‘Symptoms and checking points’’ section corresponds to one or more items in the ‘‘Cause
of trouble’’ section through the dot mark ‘‘+’’. If there are more than one applicable ‘‘Cause of trouble’’ items,
the item having the largest number of dot marks should be regarded as the central cause of the trouble.
+ The ‘‘cause’’ items having no dot mark can be regarded as not being the cause of the trouble.
NOTE
+ If more than one cause is assumed, repair operation should begin with the simplest operation.
TD-1-1
DIAGNOSIS
Sound of magnetic switch (SW) is heard with starter SW ON

Symptoms and checking points
Poor fuel consumption or oil consumption

Slow starter rotation (less than 100 rpm)
DIFFICULT ENGINE STARTING
Engine cannot be cranked manually

Excessive exhaust smoke
Moderate exhaust smoke
Sufficient starter rotation
Little exhaust smoke

Starter fails to rotate
Engine lacks power

Cause of trouble
Discharged battery + + +
Electrical system
Poor connection of connector and terminal + +

Breaks in electrical wire +
Faulty starter + +
Faulty starter switch and starter relay +
Faulty air heater + + +
Lack of fuel + +
Faulty feed pump + +
Incorrectly installed fuel pipe + +
Faulty injection pump + + + +
Fuel system
Faulty nozzle + + + +
Clogged fuel filter element + + + +
Air in fuel system + +
Incorrect injection timing + + +
Broken or damaged fuel pipe + +
Clogged gauze filter + + +
Damaged ring gear + +
Damaged or seized rotating engine parts + +
Engine proper & others
High engine oil viscosity + +

Incorrect valve clearance + + + +
Inadequate compression pressure + + + +
Incorrect valve timing + +
Clogged air cleaner element + +
Faulty clutch and subsequent power train
+ + +
(Check by connecting and disconnecting the clutch)
TD-1-2
DIAGNOSIS
Poor fuel consumption or oil consumption
Exhaust smoke gradually turns black
Exhaust smoke suddenly turns black

Low compression pressure

High blow-by gas pressure
BLACK EXHAUST SMOKE
Poor engine starting
Low boost pressure

Engine lacks power
Engine knocks
Irregular idling
Cause of trouble
Accumulation of sludge in air heater + + + + +
Intake system
Clogged air cleaner element + + + + +

Turbocharger failure (jamming, etc.) + + +
Oil leakage from compressor side of turbocharger + +
Excessive injection quantity +
Uneven plunger wear + + + + +
Fuel system
Malfunction of delivery valve + + + + + +

Faulty nozzle + + + + + +
Poor fuel quality + + + +
Excessively advanced injection timing + + + +
Faulty boost compensator + +
+ + + + + +
Engine
Wear on piston rings, and cylinder liner

proper
Excessive oil in oil pan + +
WHITE EXHAUST SMOKE

Delayed injection timing + + + +
Engine proper &
Engine temperature too low + + + + + +

+
others
Engine oil leakage down through valve stem

Wear on piston ring, and cylinder liner + + + + + +
Excessive oil in oil pan +
Incorrect valve clearance + + + + + +
TD-1-3
DIAGNOSIS
Specified maximum rpm is not achieved

Specified maximum rpm is exceeded

Engine stabilizes at two speeds

IRREGULAR ENGINE OPERATION
Difficulty in starting engine
Poor fuel consumption

White exhaust smoke
Black exhaust smoke
Engine lacks power
Engine often stalls
Irregular idling
Engine knock
Cause of trouble
Incorrect adjustment of link or rod + + + + +

Fuel leakage from injection pipe + + + + + +
Uneven injection quantity + + + +
Malfunction of governor + + + +
Fuel system
Uneven injection pressure of nozzle + + + + +

Improper fuel spray of nozzle + + + + +
Improper adjustment of idle spring + + + +
Improper adjustment of damper spring + +
Malfunction of delivery valve + + + + +
Air in fuel system + + + + +
Improper placement of valve seat + + + + +
Engine proper
Improper valve clearance + + + + +

Incorrect valve timing + + + + + +
Incorrect compression pressure + + + + + +
Engine temperature too low + + + + +
Deteriorated engine mount rubber + +
Others
Improper adjustment of idling + + +

Rusted control wire + + + + +
TD-1-4
DIAGNOSIS
Specified maximum rpm is not achieved


DECREASED ENGINE POWER
Low specific gravity of fuel

Excessive blow-by gas

White exhaust smoke
Black exhaust smoke
Poor oil consumption

Little exhaust smoke
Low boost pressure

Engine overheats
Irregular idling
Engine knock
Cause of trouble
Improper fuel quality + + + + + +

Improper adjustment of injection quantity + + + + +
Clogged fuel filter element + + +
Water or air in fuel system + + +
Fuel system
Low fuel pressure (overflow valve) + + + +

Improper fuel spray from nozzle + + + + + +
Improper injection timing + + + + + + +
Malfunction of delivery valve + + +
Malfunction of feed pump + + +
Malfunction of injection pump + + + +
Faulty boost compensator +
+ + + + +
Intake and exhaust system
Clogged air cleaner element
Thin or hot intake air + + + + + +
Accumulation of carbon to air heater + + + + +
Clogged or crushed exhaust pipe or muffler + + + +
Half-opened exhaust shutter + + + +
Turbocharger malfunction + + + +
Wear on piston rings and cylinder liner + + + + +

Engine proper
Worn, sticking, or broken piston ring + + + + + +

Seized piston + + + +
Worn or seized valve stem + + + +
Improper seating of valve insert + + + + +
Improper selection of gear while traveling + +
Others
Improper adjustment of control valve + + +

Poor returning of engine stop wire + +
TD-1-5
DIAGNOSIS
Continuous emission of white smoke at high-speed running

Oil attaching to exhaust pipe and manifold
Engine oil measuring method incorrect

Engine emits white smoke after idling
EXCESSIVE OIL CONSUMPTION
Engine overheated previously


Engine lacks power
Engine knock
Cause of trouble
Worn piston rings and cylinder liner + + + + + +
Aligned piston ring end gaps + + +
Insufficient piston ring tension + +
+ +
Engine proper
Improper break-in of piston ring

Inversely fitted piston rings +
Broken or seized piston rings + + + + + +
Worn piston ring + + + + +
Scuffing of cylinder liner + +
Worn valve stem or guide + + +
Worn valve stem seal + +
Worn or broken seal ring + +
charger
Turbo-
Oil return hole obstructed by carbon + +

Improper installation of seal ring + +
Leakage of engine oil +
Others
Excess of engine oil + +

Improper quality of engine oil
Clogged air cleaner element + +
TD-1-6
DIAGNOSIS

EXCESSIVE FUEL CONSUMPTION
White exhaust smoke

Black exhaust smoke
Poor oil consumption
Low boost pressure

Engine lacks power
Engine overheats
Irregular idling
Engine knock
Cause of trouble
Maladjusted nozzle injection pressure + +
Improper fuel spray from nozzle + + + +
Fuel system
Maladjusted injection quantity + + +

Improper seating of delivery valve seat + + +
Improper injection timing + + + +
Faulty boost compensator +
Worn or seized piston, and piston ring + + + + + + +
Engine proper
Worn cylinder liner + + + + +

Improper seating between valve seat and insert + + + +
Maladjusted valve clearance + + + +
Clogged air cleaner element + + + +
Others
Half-opened exhaust shutter +

Clogged or crushed exhaust pipe or muffler +
Engine temperature too high + + + +
Dragged brake
Chassis
Clutch slip
Seizure in drive line
Insufficient tire inflation pressure
Driving habits
Unnecessary acceleration and deceleration
Improper gear shifting +
Prolonged idling
TD-1-7
DIAGNOSIS

NOISY ENGINE

White exhaust smoke
Black exhaust smoke
Low boost pressure

Engine lacks power
Engine overheats
Cause of trouble
Improper timer advance angle + + +
Uneven injection quantity + + +
Excessively advanced injection timing + + +
Fuel system
Delayed injection timing + + +

Uneven nozzle injection pressure + + +
Improper fuel spray from nozzle + + + +
Malfunction of delivery valve + + + +
Poor fuel quality +
Wear or seizure on rotating and sliding portions + + + + +
Insufficient intake air quantity + + +
Improper valve clearance, or seizure of valve + +
Others
Low intake air temperature +

Engine too cold, or overheated +
Insufficient compression pressure and compression air
+ + +
temperature
Excessive oil coming up into cylinder + + + +
TD-1-8
DIAGNOSIS
Air bubbles appear in water tank only when water temperature is high
Water temperature difference between water inlet and outlet is small
Water temperature difference between water inlet and outlet is great

Cooling water reduces in quantity only after high-speed operation
Air bubbles appear in water tank only after engine racing

Radiator remains cold even after engine warm up

ENGINE OVERHEATS
Excessive reduction of cooling water

Engine noisy in operation
Cooling water acidified

Air bubbles in radiator
Engine lacks power
Cause of trouble
Improper fan belt tension + +
Water pump
Worn or seized bearing + +

Air drawn from suction side + +
Improper water seal +
Damaged impeller + +
Coolant passage
Malfunction of thermostat + +
Water leakage from cooling water passage +
Overflow of cooling water due to blow-out of gas + + +
Accumulation of water scale in cylinder block + +

Clogging by oxide of iron + + + + +
Clogging by water seal + + +
Radiator
Water leakage +
Malfunction of water tank cap +
Clogged core due to accumulation of mud and insects + +
Improper fuel spray from nozzle +
State of combustion
Improper injection timing +

Half-opened exhaust shutter + +
Clogged or crushed exhaust pipe or muffler + +
Gas leakage from cylinder head nozzle tube + + + +
Gas leakage from head gasket + + + +
Continuous operation under heavy load, or other improper
Others
operation
Improper selection of gears while traveling
Incorrect indication of thermometer
TD-1-9
LUBRICATION SYSTEM
CONTENTS
SERVICE DATA ............................................. LB-1-1 INSPECTION ................................................. LB-4-2
SPECIFICATIONS ......................................... LB-1-1 REASSEMBLY ............................................... LB-4-3
SERVICE DATA ............................................. LB-1-1 INSTALLATION .............................................. LB-4-3
TIGHTENING TORQUE ................................ LB-1-2 OIL FILTER ..................................................... LB-5-1
LUBRICATING SYSTEM ............................... LB-1-2 CONSTRUCTION .......................................... LB-5-1
TOOLS .............................................................. LB-2-1 REMOVAL ...................................................... LB-5-1
OIL PUMP ........................................................ LB-3-1 DISASSEMBLY .............................................. LB-5-2
CONSTRUCTION .......................................... LB-3-1 INSPECTION ................................................. LB-5-3
REMOVAL ...................................................... LB-3-2 REASSEMBLY ............................................... LB-5-4
DISASSEMBLY .............................................. LB-3-2 INSTALLATION .............................................. LB-5-4
INSPECTION ................................................. LB-3-3 OIL JET ............................................................ LB-6-1
INSTALLATION .............................................. LB-3-4 CONSTRUCTION .......................................... LB-6-1
OIL COOLER ................................................. LB-4-1 REMOVAL ...................................................... LB-6-1
CONSTRUCTION .......................................... LB-4-1 INSPECTION ................................................. LB-6-1
REMOVAL ...................................................... LB-4-2 INSTALLATION .............................................. LB-6-1
DISASSEMBLY .............................................. LB-4-2
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
Engine model
RF8TC RF8TD
Item
Oil pump Type Gear type
Full flow Paper element type
Oil filter
Bypass Paper element type
Oil cooler Type Built-in, water cooled
Full capacity 34
Lubrication oil
H 24 (5-1/4)
capacities ! (Imp gal) Oil pan capacity
L 16 (3-1/2)
SERVICE DATA
Unit: mm (in)
Posi- Maintenance Service
Item Remarks
tion standard limit
0.05 - 0.11 One side: 0 mm
Side clearance 0.15 (0.0059)
(0.0020 - 0.0043) (0 in)
0.08 - 0.21
Backlash between crank gear and idler gear 0.50 (0.0197)
(0.0031 - 0.0083)
0.08 - 0.21
Backlash between idler gear and head gear 0.50 (0.0197)
(0.0031 - 0.0083)
0.10 - 0.27
Idler gear end play 0.50 (0.0197)
Oil pump
(0.0039 - 0.0106)
0.08 - 0.15
Spindle-to-idler gear bushing clearance 0.12 (0.0047)
(0.0031 - 0.0059)
Drive-to-driven gear bushing clearance — 0.15 (0.0059)
Valve opening pressure RF8TC 1,079 {11, 156}
—
kPa {kgf/cm2, psi}
Relief valve
RF8TD 1,177 {12, 171}

Spring free length 50.2 (1.976) —
353 - 412 When compressed to
Spring tension N {kgf, lbf} 235 {24, 53}
{36 - 42, 79 - 93} 66.6 mm (2.622 in)
275 - 314
Oil cooler
Short valve opening pressure kPa {kgf/cm2, psi} —

{2.8 - 3.2, 40 - 46}
Cooler core hydraulic test pressure
490 {5, 71} —
kPa {kgf/cm2, psi}
98 - 137
kPa {kgf/cm2, psi}
Short valve
Valve opening pressure —

{1.0 - 1.4, 14 - 20}
Spring free length 62.7 (2.468) —
39.2 - 43.2 When compressed to
Spring tension N {kgf, lbf} —
Oil filter
{4.0 - 4.4, 8.8 - 9.7} 47 mm (1.85 in)

Regulator valve
Valve opening pressure 422 - 461

‘‘Tsuchiya’’ make —
kPa {kgf/cm2, psi} {4.3 - 4.7, 61 - 67}
Spring free length ‘‘Tsuchiya’’ make 49.5 (1.949) —
Spring tension 159.9 - 177.5 When compressed to
‘‘Tsuchiya’’ make —
N {kgf, lbf} {16.3 - 18.1, 35.9 - 39.9} 36.2 mm (1.425 in)
Piston cooling oil jet valve opening pressure 226 - 265
—
kPa {kgf/cm2, psi} {2.3 - 2.7, 33 - 38}
LB-1-1
SERVICE DATA
TIGHTENING TORQUE
Part Tightening torque
Oil pump cover mounting bolt 25 - 39 {2.6 - 4.0, 19 - 29}
Oil pump assembly mounting bolt 34 - 49 {3.5 - 5.0, 25 - 36}
At flange 34 - 49 {3.5 - 5.0, 25 - 36}
Oil screen mounting bolt
At support 17 - 23 {1.7 - 2.3, 12 - 17}
Oil outlet pipe 34 {3.5, 25}
Center bolt (for full-flow and bypass oil filters) 59 - 69 {6.0 - 7.0, 43 - 51}
Drain plug (for full-flow and bypass oil filters) 16 - 22 {1.6 - 2.2, 12 - 16}
Oil jet connector bolt 49 - 59 {5.0 - 6.0, 36 - 43}
Oil cooler housing mounting bolt 16 - 19 {1.6 - 1.9, 12 - 14}
Oil cooler drain cock 10 - 15 {1.0 - 1.5, 7 - 11}
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
ZLB042A
LB-1-2
SERVICE DATA
LUBRICATION CIRCUIT
ZLB043A
LB-1-3
TOOLS
TOOLS
Hydraulic pump For testing water pressure of oil cooler element
99570 Z5000
EP14-119
Oil cooler attachment For water pressure test of oil cooler element
99578 97001
EP14-118
LB-2-1
OIL PUMP
OIL PUMP
CONSTRUCTION
ZLB044A
LB-3-1
OIL PUMP
REMOVAL
1. Remove the drain plug from the oil pan and drain the engine oil
into an oil tray.
2. Remove the oil level gauge and guide.
3. Remove the oil pan and gasket.
4. Remove the oil screen and oil pipe.
5. Remove the oil pump assembly.
DISASSEMBLY
ZLB049A
Disassembly sequence (Reassembly sequence is the reverse of disassembly.)

j
1 Bolt j
6 Spring j
10 Idler gear assembly
j
2 Bolt j
7 Relief valve j
11 Pump gear assembly
j
3 Cover assembly j
8 Driven gear assembly (Drive gear)
j
4 Split pin j
9 Spindle j
12 Head gear
j
5 Spring seat
LB-3-2
OIL PUMP
INSPECTION
Clean the oil pump assembly thoroughly with cleaning fluid. After
cleaning, inspect for cracks or any other damage carefully. If faulty,
replace with a new one.
Idler gear and head gear backlash

Unit: mm (in)
0.08 - 0.21 (0.031 - 0.0083) 0.50 (0.0197)
ELB2-004
Backlash between crank gear and idler gear

Unit: mm (in)
0.08 - 0.21 (0.031 - 0.0083) 0.50 (0.0197)
Spindle-to-idler gear bushing clearance

Unit: mm (in)
0.08 - 0.15 (0.031 - 0.0059) —
Idler gear end play

Unit: mm (in)
0.10 - 0.27 (0.0039 - 0.0106) 0.50 (0.0197)
ELB2-005
Gear shaft and bushing clearance

Unit: mm (in)
Drive-to-driven gear
— 0.15 (0.0059)
bushing clearance
ELB2-021
LB-3-3
OIL PUMP
Side clearance
Unit: mm (in)
0.05 - 0.11 (0.0020 - 0.0043) 0.15 (0.0059) One side: 0 mm (0 in)
ELB1-004
Relief valve spring tension and free length

Maintenance
standard
Opening pressure RF8TC 1,079 {11, 156}

—
kPa {kgf/cm2, psi} RF8TD 1,177 {12, 171}
353 - 412
Spring tension When compressed
{36 - 42, 235 {24, 53}
N {kgf, lbf} to 44 mm (1.73 in)
79 - 93}
Spring free length
50.2 (1.976) —
mm (in)
INSTALLATION
1. Install the oil pump assembly.
: 34 - 49 N·m {3.5 - 5.0 kgfzm, 25 - 36 ftzlbf}
2. Install the oil pipe and oil screen.
N·m {kgfzm, ftzlbf}
Oil outlet pipe 34 {3.5, 25}
Flange section 34 - 49 {3.5 - 5.0, 25 - 36}
Oil screen
Support section 17 - 23 {1.7 - 2.3, 12 - 17}
3. Install the oil pan with the gasket in place.

4. Install the drain plug of the oil pan with the gasket in place.
: 98 - 127 N·m {10 - 13 kgfzm, 72 - 94 ftzlbf}
5. Install the oil level gauge and guide.
6. Add the specified amount of engine oil.
LB-3-4
OIL COOLER
OIL COOLER
CONSTRUCTION
ZLB045A
j
1 Bolt j7 Rubber ring j
13 Short valve assembly
j
2 Stay j8 Gasket j
14 Gasket
j
3 Equalizer j9 Rubber ring j
15 Hose
j
4 Bolt j
10 Rubber ring j
16 Drain cock
j
5 Oil cooler element j
11 Oil cooler housing j
17 Spindle
j
6 Rubber ring j
12 Bolt
LB-4-1
OIL COOLER
REMOVAL
into an oil tray.
2. Drain the cooling water by loosening the water drain cock.
3. Remove the water tube and gasket.
4. Remove the equalizer and stay.
5. Loosen the oil cooler housing mounting bolt and remove the
housing and oil cooler element.
ELB2-008
DISASSEMBLY
Short valve assembly
1. Remove the short valve assembly and gasket from the cylinder
block.
2. Remove the plug of the short valve and separate the packing,
spring and valve.
ELB2-009
INSPECTION
While cleaning, inspect for cracks or any other damage carefully. If
In addition, when water scale is attached to the oil cooler element,
clean with caustic soda solvent or the like, and then wash
thoroughly with water.
Short valve
Examine the condition of short valve and valve seat contacting
surface for damage or uneven wear, and the valve spring for
breaks or aging. If any abnormality is noted, replace the short valve
assembly.
Short valve opening 275 - 314
—
pressure {2.8 - 3.2, 40 - 46}
LB-4-2
OIL COOLER
Leakage in cooler element

Using the oil cooler attachment (99578 97001) and hydraulic pump
(99570 Z5000), perform a water pressure test on the oil cooler
element. If any abnormality is noted, replace the element.
No leakage should exist at a water pres-
—
sure of 490 kPa {5 kgf/cm2, 71 psi}.
EP7-7
REASSEMBLY
When reassembling, apply a coat of engine oil to the sliding
surfaces.
Short valve
1. Install the short valve and spring, then install the cap with the
packing in place.
2. Install the short valve assembly for the oil cooler with the gasket
in place.
INSTALLATION
1. Install the element into the oil cooler housing with the gasket in
place.
2. Install the oil cooler assembly to the cylinder block with rubber
rings placed in the inlets and outlets for oil and water.
: 16 - 19 N·m {1.6 - 1.9 kgfzm, 12 - 14 ftzlbf}
3. Install the equalizer.
4. Install the water tube with the gasket in place.
5. Close the water drain cock and refill the specified amount of
cooling water.
6. Add the specified amount of engine oil from the oil filler.
7. Start up the engine and check to make sure that there is no
leakage of air and engine oil.
8. Stop the engine, then check the level of engine oil using a level
gauge.
LB-4-3
OIL FILTER
OIL FILTER
CONSTRUCTION
ZLB046A
REMOVAL
into the oil tray.
2. Remove the drain plug from the oil filter and drain the engine oil
left in the filter to the oil tray.
DCN-060E
3. Loosen the center bolts, then remove the cases, element

assemblies, set springs and packings.
4. Remove the oil filter cover assembly (oil filter bracket assem-
bly).
EMA2008F
LB-5-1
OIL FILTER
DISASSEMBLY
ZLB047A

j
1 Drain plug j
10 Packing j
18 Washer
j
2 Packing j
11 Center bolt j
19 Packing
j
3 Center bolt j
12 Packing j
20 Spring
j
4 Packing j
13 Element assembly j
j
5 Element assembly j
14 Spring seat j
22 Snap ring
j
6 Set spring j
15 Spring j
23 Washer
j
7 Packing j
16 Cover assembly
j
24 Valve spring
j
8 Body j j
25 Regulator valve
17 Switch assembly
j
9 Drain plug
LB-5-2
OIL FILTER
OIL FILTER SHORT VALVE

Remove the clogging alarm switch assembly first, then remove the
retainer, packing, valve spring and short valve assembly.
ELB2024C
REGULATOR VALVE
Remove the snap ring first, then remove the washer, valve spring
and regulator valve.
ELB2-025
INSPECTION
Spring free length

Unit: mm (in)
Oil filter short valve 62.7 (2.468) —
Regulator valve 49.5 (1.949) —
ES-87
Spring tension
Unit: N {kgf, lbf}
Service
Item Maintenance standard Remarks (H)
limit
Oil filter short 39.2 - 43.2 When compressed to
—
valve {4.0 - 4.4, 8.8 - 9.7} 47 mm (1.85 in)
Regulator 159.9 - 177.5 When compressed to
—
valve {16.3 - 18.1, 35.9 - 39.9} 36.2 mm (1.425 in)
EHV3-011
LB-5-3
OIL FILTER
REASSEMBLY
Oil filter short valve
Install the short valve assembly, valve spring and retainer onto the
cover, then install the clogging alarm switch assembly with the
packing in place.
Regulator valve
Install the regulator valve, valve spring and washer, then fix with
the snap ring.
INSTALLATION
1. Install the oil filter cover assembly (oil filter bracket assembly)
onto the cylinder block.
2. Install the packings, element assemblies, set springs and
cases, then tighten the center bolts with the packings in place.
: 59 - 69 N·m {6.0 - 7.0 kgfzm, 43 - 51 ftzlbf}
3. Install the plug with the packing in place.
: 16 - 22 N·m {1.6 - 2.2 kgfzm, 12 - 16 ftzlbf}
4. Open the cap of the oil filler and refill the specified amount of
engine oil.
leakage of engine oil.
6. Check the level of engine oil using a level gauge.
LB-5-4
OIL JET
OIL JET
CONSTRUCTION
j
1 Oil jet j
4 Valve spring
j
2 Oil jet bolt j
5 Valve spring plate
j
3 Valve
ZLB048A
REMOVAL
1. Loosen the oil jet bolt and remove it together with the oil jet.
INSPECTION
226 - 265 {2.3 - 2.7, 33 - 38} —
INSTALLATION
1. Align the location plate of the oil jet to the hole, then fix the oil
jet with the oil jet bolt.
: 49 - 59 N·m {5.0 - 6.0 kgfzm, 36 - 43 ftzlbf}
ER3-154
2. When installing, attach the oil jet to applied engines.

Discrimination paint
Yellow
LB-6-1
AUXILIARY EQUIPMENT
CONTENTS
SERVICE DATA ........................................... EA-1- 1 AIR COMPRESSOR (F9560W12) ......... EA-3- 1
SPECIFICATIONS ....................................... EA-1- 1 CONSTRUCTION ........................................ EA-3- 1
SERVICE DATA ........................................... EA-1- 1 DISASSEMBLY ............................................ EA-3- 1
TIGHTENING TORQUE .............................. EA-1- 2 INSPECTION ............................................... EA-3- 4
TOOLS ........................................................... EA-2- 1 REASSEMBLY ............................................. EA-3- 6
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
Model F9560W12
Type Reciprocating type
Bore x stroke − No. of cylinders mm (in) 95 x 60 − 1 (3.74 x 2.36 − 1)
3
Theoretical discharge cm (cu in)/rev 425 (25.93)
Normal maximum speed rpm 2,400
2
Normal maximum pressure kPa {kg/cm , psi} 834 {8.5, 121}
Cooling method Water cooled
SERVICE DATA
Unit: mm (in)
400 Tank capacity:
Less than 124 sec. —
Air charging per- Engine rpm 30! (6-5/8 Imp gal)
formance speed 2,000 0 → 785 kPa {0 → 8 kg/cm2,
Less than 32 sec. —
rpm 0 → 114 psi}
0.18 - 0.25
Clearance be- Piston top 0.28 (0.0110)
(0.0071 - 0.0098)
tween piston and
0.08 - 0.15
cylinder Piston skirt 0.18 (0.0071)
(0.0031 - 0.0059)
Compression 0.15 - 0.30
1.00 (0.0394)
Piston ring end ring (0.0059 - 0.0118)
gap 0.20 - 0.70
Oil ring 1.00 (0.0394)
(0.0079 - 0.0276)
Clearance between piston ring and 0.010 - 0.045
0.08 (0.0031) Compression ring only
ring groove (0.0004 - 0.0018)
Clearance between piston pin hole 0.01 T - 0.02 L T: Tight
0.08 L (0.0031 L)
and piston pin (0.0004 T - 0.0008 L) L: Loose
Clearance between connecting rod 0.02 - 0.04
0.07 (0.0028)
small end and piston pin (0.0008 - 0.0016)
0.10 (0.0039)
large end bushing and crank pin (0.0008 - 0.0035)
0.1 - 0.7
Crankshaft end play 1.0 (0.0039)
(0.004 - 0.028)
Suction valve
11.5 (0.453) —
Free length of spring
valve spring Delivery valve
13.4 (0.528) —
spring
12.26 8.53 When compressed to
Tension of valve Suction valve
{1.25, 2.76} {0.87, 1.92} 7.5 mm (0.295 in)
spring
Delivery valve 10.79 7.85 When compressed to
N {kgf, lbf}
spring {1.10, 2.43} {0.80, 1.76} 10.0 mm (0.394 in)
EA-1-1
SERVICE DATA
TIGHTENING TORQUE
Item Tightening torque
Suction valve holder 137 - 157 {14.0 - 16.0, 101 - 116}
Delivery valve holder 137 - 157 {14.0 - 16.0, 101 - 116}
Unloader valve connector 98 - 118 {10.0 - 12.0, 72 - 87}
Cylinder head mounting bolts and nut 25 - 29 {2.5 - 3.0, 18 - 22}
Bearing holder securing screws 2.5 - 4 {0.25 - 0.40, 1.8 - 2.9}
Cylinder liner mounting bolts 25 - 29 {2.5 - 3.0, 18 - 22}
Connecting rod cap mounting nuts 23 - 25 {2.3 - 2.6, 17 - 19}
Air compressor drive gear mounting nut (Left-hand screw) 186 - 206 {19.0 - 21.0, 137 - 152}
Air compressor mounting bolts 30 - 41 {3.1 - 4.2, 22 - 30}
EA-1-2
TOOLS
TOOLS
AIR COMPRESSOR

Valve holder tool For removal and installation of suction valve holder
99744 97003
EP14-164
Piston insert tool kit For installation of air compressor piston

99750 97001 j1 Piston insert tool
j1 99754 97002 j2 Crankshaft holder
j2 99756 97001
WEA001A
EA-2-1
AIR COMPRESSOR F9560
AIR COMPRESSOR
CONSTRUCTION
WEA002A
DISASSEMBLY
REMOVAL
Key point of removal
Remove the three bolts and one nut, then pull out the air compres-
sor to the back side along the stud being careful not to drop the
O-ring.
WEA003A
EA-3-1
DISASSEMBLY
WEA004A

j1 O-ring j
14 Bearing case j
27 Delivery valve
j2 Nut j
15 O-ring j
28 Delivery valve seat
j3 Plain washer >j
16 Crankshaft j
29 Connector
.j4 Drive gear >j
17 Connecting rod cap j
30 Packing
j5 Cylinder head j
18 Connecting rod metal j
31 O-ring
>j6 Cylinder liner j
19 Connecting rod >j
32 Unloader valve
j7 O-ring .>j
20 Ball bearing j
33 Unloader valve spring
j8 O-ring .>j
21 Ball bearing .>j
34 Suction valve holder
j9 Clip >j
22 Delivery valve holder j
35 Suction valve spring
j
10 Piston pin j
23 O-ring j
36 Suction valve
j
11 Piston j
24 O-ring j
37 Suction valve seat
>j
12 Compression ring j
25 Spring holder j
38 Suction valve packing
>j
13 Oil ring j
26 Delivery valve spring j
39 Crankcase
EA-3-2

j
4 Drive gear
Using a puller, remove the drive gear from the air compressor.
WEA005A
+ Before disassembling the air compressor, measure the end

play of the crankshaft.
EEA2003B
j
20 , j
21 Ball bearing
Using a puller, remove the ball bearing from the crankshaft.
EEA2-010
j34 Suction valve holder

Remove the suction valve holder, using the valve holder tool
(99744 97003). Then remove the suction valve spring, suction
valve, suction valve seat and suction valve packing from the
cylinder head.
WEA006A
EA-3-3
INSPECTION
Clearance between piston and cylinder

Unit: mm (in)
Piston top 0.18 - 0.25 (0.0071 - 0.0098) 0.28 (0.0110)
Piston skirt 0.08 - 0.15 (0.0031 - 0.0059) 0.18 (0.0071)
WEA017A
Piston ring end gap

Unit: mm (in)
Compression ring 0.15 - 0.30 (0.0059 - 0.0118) 1.00 (0.0394)
Oil ring 0.20 - 0.70 (0.0079 - 0.0276) 1.00 (0.0394)
EP11-14
Clearance between piston ring and ring groove

Unit: mm (in)
0.010 - 0.045
0.08 (0.0031) Compression ring only
(0.0004 - 0.0018)
EP11-13
EA-3-4
Clearance between piston pin hole and piston pin

Unit: mm (in)
0.01 T - 0.02 L T: Tight
0.08 L (0.0031 L)
(0.0004 T - 0.0008 L) L: Loose
WEA018A
Clearance between connecting rod small end and pis-

ton pin
Unit: mm (in)
0.02 - 0.04 (0.0008 - 0.0016) 0.07 (0.0028)
WEA019A
Clearance between connecting rod large end bushing

and crank pin
NOTE
+ Before measuring the clearance between the connecting
rod large end bushing and crank pin, tighten the nut to the
specified torque.
: 23 - 25 N·m {2.3 - 2.6 kgfzm, 17 - 19 ftzlbf}
Unit: mm (in)
0.02 - 0.09 (0.0008 - 0.0035) 0.10 (0.0039)
WEA020A
Crankshaft end play

NOTE
+ Check the end play of the crankshaft measured while
disassembling.
Unit: mm (in)
0.1 - 0.7 (0.004 - 0.028) 1.0 (0.039)
EEA2003B
EA-3-5
Free length of valve spring

Unit: mm (in)
Suction valve spring 11.5 (0.453) —
Delivery valve spring 13.4 (0.528) —
ES-87
Tension of valve spring

Unit: N {kgf, lbf}
Maintenance
standard
Suction valve 12.26 When compressed to
8.53 {0.87, 1.92}
spring {1.25, 2.76} 7.5 mm (0.295 in)
Delivery valve 10.79 When compressed to
7.85 {0.80, 1.76}
spring {1.10, 2.43} 10.0 mm (0.394 in)
WEA007A
REASSEMBLY
j
34 Suction valve holder
1. Install the suction valve packing, suction valve seat, suction
valve and suction valve spring, then, using a valve holder tool
(99744 97003), tighten the suction valve holder into the cylinder
head.
: 137 - 157 N·m {14.0 - 16.0 kgfzm, 101 - 116 ftzlbf}
WEA006A
2. After tightening the valve holder, push the suction valve with
your fingers or a rod from the unloader valve side. When doing
so, make sure the suction valve and suction valve spring
operate smoothly.
WEA008A
EA-3-6
3. Using a punch, stake the periphery of the suction valve holder

in three locations so that the suction valve does not rotate.
NOTE
+ Do not stake the same portion that has previously staked.
WEA022A
j
32 Unloader valve
1. Install the O-ring and unloader valve spring to the unloader
valve. After inserting them into the cylinder head, tighten the
connector with the packing in place.
: 98 - 118 N·m {10.0 - 12.0 kgfzm, 72 - 87 ftzlbf}
NOTE
+ Before installing, be sure to coat the O-ring and O-ring
groove in the valve with grease.
WEA009A
2. After tightening the connector, push the unloader valve with

your fingers or a rod. When doing so, make sure the unloader
valve and unloader valve spring operate smoothly.
WEA010A
j
22 Delivery valve holder
1. Install the O-ring to the delivery valve holder.
2. Insert the delivery valve seat, delivery valve, delivery valve
spring and spring holder into the cylinder head.
3. Tighten the delivery valve holder with the O-ring in place.
: 137 - 157 N·m {14.0 - 16.0 kgfzm, 101 - 116 ftzlbf}
NOTE
+ Apply a coat of 0.2 to 0.3 m! (0.007 to 0.11 Imp fl oz)
LOCTITE No. 271 to three threads of the delivery valve
WEA011A
holder.
EA-3-7
4. After tightening the delivery valve holder, push the spring

holder with your fingers or a rod. When doing so, make sure the
spring holder and delivery valve spring operate smoothly.
WEA012A
j20 , j
21 Ball bearing
Install the ball bearings on the crankshaft by press-fitting.
EP11-19
j
17 Connecting rod cap
Fit the metals in the connecting rod and bearing cap, and install the
connecting rod to the crankshaft through the lock washer.
: 23 - 25 N·m {2.3 - 2.6 kgfzm, 17 - 19 ftzlbf}
NOTE
+ Assemble with the matching marks of the connecting rod
and bearing cap on the same side.
WEA021A
j
16 Crankshaft
Press-fit the crankshaft assembly to the crankcase.
WEA015A
EA-3-8
j13 Oil ring

j12 Compression ring
Install the piston rings in the ring grooves, and attach the connect-
ing rod to the piston.
NOTE
+ Install the piston rings so that their joints are neither
parallel nor normal to the piston pin and the
manufacturer’s mark faces up.
WEA023A
j6 Cylinder liner
Install the O-ring onto the cylinder liner, then, using a piston insert
tool kit (99750 97001), install them into the crankcase with the
O-ring in place.
: 25 - 29 N·m {2.5 - 3.0 kgfzm, 18 - 22 ftzlbf}
99750 97001 (Piston insert tool kit)
j1 99754 97002 (Piston insert tool)
j2 99756 97001 (Crankshaft holder)
WEA016A
+ Make sure that the end play of the crankshaft is within the
service limit.
Unit: mm (in)
0.1 - 0.7 (0.004 - 0.028) 1.00 (0.0394)
EEA2003B
EA-3-9
FUEL SYSTEM
CONTENTS
SERVICE DATA ........................................... EF-1- 1 NOZZLE AND NOZZLE HOLDER ........ EF-4- 1
SPECIFICATIONS ....................................... EF-1- 1 CONSTRUCTION ........................................ EF-4- 1
SERVICE DATA ........................................... EF-1- 2 REMOVAL .................................................... EF-4- 1
TIGHTENING TORQUE .............................. EF-1- 2 DISASSEMBLY ............................................ EF-4- 2
FUEL SYSTEM ............................................ EF-1- 4 INSPECTION ............................................... EF-4- 3
TOOLS ........................................................... EF-2- 1 REASSEMBLY ............................................. EF-4- 4
INJECTION PUMP ASSEMBLY ............. EF-3- 1 ADJUSTMENT ............................................. EF-4- 5
INJECTION PUMP PROPER ...................... EF-3- 1 INSTALLATION ............................................ EF-4-11
FEED PUMP ................................................ EF-3- 4 FUEL FILTER ............................................... EF-5- 1
TIMER .......................................................... EF-3- 5 REPLACEMENT .......................................... EF-5- 1
GOVERNOR ................................................ EF-3- 8 ENGINE CONTROL SYSTEM ................ EF-6- 1
ADJUSTMENT ............................................. EF-3-13 CONSTRUCTION ........................................ EF-6- 1
INJECTION PUMP CALIBRATION DATA ... EF-3-24 ADJUSTMENT ............................................. EF-6- 1
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
Engine model
RF8TC RF8TD
Item
Ignition system Compression ignition
Fuel injection timing B.T.D.C. 14° 12.5°
Ignition order 1R-1L-4R-4L-3L-2R-2L-3R
Main Cartridge type
Fuel filter Type x Number
Primary Filter paper x 1
Type Bosch
Plunger diameter mm (in) 12.0 (0.472)
Fuel injection pump
Governor Centrifugal [Mechanical RFD type]
Timer Centrifugal [Mechanical SDD-G type]
Nozzle holder Flange type
Nozzle Multi-hole type
Nozzle Number of nozzle holes 5
Injection pressure 1st valve 17,653 {180, 2,560}

2
kPa {kgf/cm , psi} 2nd valve 22,556 {230, 3,271}
Overflow valve opening pressure Injection pump outlet 157 {1.6, 23}
2
kPa {kgf/cm , psi} Fuel filter 108 - 147 {1.1 - 1.5, 16 - 21}
EF-1-1
SERVICE DATA
SERVICE DATA
Valve opening pressure No. 1 valve 17,653 {180, 2,560} —

kPa {kgf/cm2, psi} No. 2 valve 22,556 {230, 3,271} —
18,143 - 18,928
No. 1 valve —
Fuel injection pressure {185 - 193, 2,631 - 2,744}
Nozzle
kPa {kgf/cm2, psi} 23,537 - 24,518
No. 2 valve —
{240 - 250, 3,413 - 3,555}
Valve full lift mm (in) 0.40 (0.0157) —
Valve pre-lift mm (in) 0.05 - 0.09 (0.0020 - 0.0035) —
Accelerator Clearance between the pedal
1 - 2 (0.04 - 0.08) —
pedal and stopper bolt mm (in)
TIGHTENING TORQUE
INJECTION PUMP PROPER
Bearing cover setting screw 7 - 9 {0.7 - 0.9, 5.1 - 6.5}
Screw bushing 39 - 59 {4.0 - 6.0, 29 - 43}
Eye bolt 25 - 41 {2.5 - 4.2, 18 - 30}
Overflow valve 25 - 41 {2.5 - 4.2, 18 - 30}
Eye bolt 10 - 18 {1.0 - 1.8, 7 - 13}
Delivery valve holder 108 - 118 {11.0 - 12.0, 80 - 87}
Delivery valve holder lock nut 29 - 49 {3.0 - 5.0, 22 - 36}
FEED PUMP
Eye bolt 25 - 41 {2.5 - 4.2, 18 - 30}
TIMER
Timer special nut 83 - 93 {8.5 - 9.5, 61 - 69}
EF-1-2
SERVICE DATA
GOVERNOR
Govenor housing setting screw 5 - 6 {0.5 - 0.6, 3.6 - 4.3}
Flyweight round nut 59 - 69 {6.0 - 7.0, 43 - 51}
Govenor cover setting screw 5 - 7 {0.5 - 0.7, 3.6 - 5.1}
Minimum-speed stopper bolt lock nut 10 - 15 {1.0 - 1.5, 7.2 - 10.8}
Eye bolt 15 - 34 {1.5 - 3.5, 10.8 - 25.3}
Idle adjusting screw lock nut 4.9 - 7.0 {0.5 - 0.7, 3.6 - 5.1}
Full load stopper bolt lock nut 12 - 14 {1.2 - 1.4, 8.7 - 10.1}
NOZZLE AND NOZZLE HOLDER

Nozzle holder assembly mounting bolt 25 - 34 {2.5 - 3.5, 18 - 25}
Nozzle retaining nut 59 - 78 {6 - 8, 43 - 58}
FUEL FILTER
Connector bolt 25 - 41 {2.5 - 4.2, 18 - 30}
Center bolt 59 - 69 {6.0 - 7.0, 43 - 51}
PRIMARY FUEL FILTER

Center bolt 59 - 69 {6 - 7, 43 - 51}
Drain plug 16 - 22 {1.6 - 2.2, 12 - 16}
EF-1-3
SERVICE DATA
FUEL SYSTEM
EEF2-001D
EEF2-001E
EF-1-4
TOOLS
TOOLS
Pin vice For cleaning nozzle orifice
99727 Z5005
EP14-121
Nozzle cleaner For removal of carbon from rear of nozzle orifice

99726 Z5000
EP14-122
Filter wrench For removal of fuel filter

99756 00Z01 (Only when replacing cartridge type element)
WMA027A
+ Tool numbers are designated by Zexel Co.

Special wrench For removal and installation of screw bushing
157915-6500
EP14-124
Special wrench For adjusting idling

157916-2620
ETL3-003
Special wrench For supporting SD-D flange

157916-8320
ER14-122
Plunger inserter For inserting plunger

157921-5620
ER14-181
Mounting device For removal and installation of tappet

157921-89000
EP14-126
EF-2-1
TOOLS

Base For disassembling and reassembling the timer
157924-2520
ER14-145
Tappet holder For support of tappet

157931-4800
WEF036A
Plate For fixing nozzle holder

157944-9520
j1 157944-9500
j2 157944-9620
j3 157944-9800
j4 157944-9900
ETL1008A
Socket wrench For dismounting and mounting delivery valve holder

157914-0500
ZEF491A
Measuring device For plunger pre-stroke

105782-4270
WEF055A
EF-2-2
TOOLS
Tool name and number Descripition Shape

Adjusting device Used to adjust opening pressure of 2-stage valve-open type
j1 157892-5300 Pin nozzle.
j2 157954-3800 Dial gauge
j3 157892-1500 Gasket
j4 157892-4000 Retaining
nut
j5 026508-1140 Gasket
j6 157892-1600 Plug
j7 157892-1000 Nut
j8 157892-4120 Holder
ETL2008A
NOTE
+ Dial gauge and nozzle tester (49,035 kPa {500 kgf/cm2, 7,110 psi}) are commercially available.
EF-2-3
TOOLS
- MEMO -
EF-2-4
INJECTION PUMP ASSEMBLY

INJECTION PUMP PROPER
DISASSEMBLY & REASSEMBLY
ZEF480A
EF-3-1
Disassembly sequence (Reassembly sequence is in the reverse of disassembly.)
j1 Cover j
17 Plunger j
33 Gasket
j2 Gasket j
18 Plunger spring j
34 O-ring
j3 Plug >.j
19 Spring seat j
35 Retaining ring
j4 Key >.j
20 Control sleeve j
36 Deflector
j5 Cover >.j
21 Screw bushing j
37 Washer
j6 Shim j
22 Pin j
38 O-ring
j7 O-ring j
23 Control rack j
39 Ring
>.j8 Center bearing j
24 Bushing
j
40 Plunger barrel
>.j9 Camshaft j
25 Bushing
j
41 Flange sleeve
j
10 Oil seal j
26 Washer
j
42 Eye bolt
j
11 Bearing j
27 Shim
j
43 Overflow valve
j
12 Bearing j
28 Delivery valve holder
j
44 Eye bolt
j
13 Ring j
29 O-ring
j
45 Plug
j
14 Shim j
30 Stopper
j
46 Gasket
>.j
15 Tappet assembly j
31 Spring
j
16 Lower spring seat j
32 Delivery valve
j
47 Gasket
NOTE
+ This illustration is for the 6-cylinder engine. As for 8 cylinder engines, the fundamental construction
of the injection pump proper is the same as that of the 6-cylinder engine.
EF-3-2
Key points of disassembly & reassembly

j8 Center bearing j 9 Camshaft
Operate the spanner to position the tappets in the top lead center
position. Then, insert the tappet holders into each cylinder’s plug
hole to separate the tappets from the camshaft.
Tool Name Tool Number Remarks
10 mm (0.39 in);
Tappet holder 157931-4800 Cam lift:
{ 11 mm (0.43 in);
12 mm (0.47 in)
EEF008A
j
15 Tappet assembly
1. Attach the tappet inserter to both end-faces of the pump
housing.
Tool Name Tool Number Remarks
Tappet insert shaft 157921-89000 —
EEF1154A
2. Operate the tappet inserter lever to raise the tappet, and then
remove the tappet holder.
NOTE
+ Return the lever slowly after removing the tappet holder,
as the plunger spring force may cause the tappet assem-
bly to spring out.
EEF009A
j19 Spring seat j

20 Control sleeve
Using the plunger inserter (157921-5620), remove the control
sleeve and the upper spring seat together.
NOTE
+ If the ball attached to the sleeve and the pump housing’s
tappet guide groove are not aligned during control sleeve
removal, the control sleeve and upper spring seat cannot
be removed.
EEF1154C
j
21 Screw bushing
Using the special wrench (157915-6500), remove the governor
side screw bushing.
EEF1154D
EF-3-3
FEED PUMP
DISASSEMBLY
ZEF426A
j
1 Eye bolt j7 Plug j
13 Spring
j
2 Eye bolt j8 Gasket j
14 Piston
j
3 Priming pump j9 Spring j
15 Rod
j
4 Gasket j
10 Valve j
16 Snap ring
j
5 Spring j
11 Plug j
17 Tappet
j
6 Valve j
12 Gasket j
18 Housing
EF-3-4
TIMER
WEF006A
j
1 Cap j7 Cover j
13 Spring
j
2 Nut j8 O-ring j
14 Spring seat
j
3 O-ring j9 Washer j
15 Flange
j
4 Spring washer .>j
10 Roller j
16 Flyweight
j
5 Bolt .>j
11 Bushing j
17 Oil seal
j
6 Gasket j
12 Retainer
EF-3-5
Key points of disassembly & reassembly

+ Clamp the base (157924-2520) in a vise, then install the timer
on the base.
ER9-184
j10 Roller j
11 Bushing
Turn the wrench (157916-8320) to compress the timing device
spring and remove the washer, roller and bushing from the
flyweight pin.
EEF1-155
EF-3-6
- MEMO -
EF-3-7
GOVERNOR
Whole view
EEF1-014R
EF-3-8
Governor cover
WEF007A
EF-3-9
j1 Eye bolt j
13 Control rod j
25 Collar
j2 Bracket j
14 Start spring j
26 Shim
j3 Cover j
15 Plug j
27 Retaining ring
j4 O-ring j
16 Shaft j
28 Bushing
j5 Spring capsule j
17 Guide lever assembly j
29 Oil seal
j6 Spring capsule j
18 Collar j
30 Governor spring
j7 Nut j
19 Stroke adjusting bolt j
31 Speed setting lever
j8 Cap nut j
20 Pin j
32 Control lever
j9 Spring capsule j
21 Tension lever j
33 Control lever
j
10 Bolt j
22 Speed control lever j
34 Shaft
j
11 Governor cover j
23 Key j
35 Supporting lever
j
12 Gasket j
24 Washer j
36 Lever
EF-3-10
Governor housing
WEF008A
j
1 Round nut j
5 Return spring j9 Plate
j
2 Flyweight assembly j
6 Collar j
10 Governor housing
j
3 Key j
7 Shaft j
11 Gasket
j
4 Stop lever j
8 Lever
EF-3-11
Boost compensator
WEF009A
j
1 Cap nut j
5 Lever j9 Spring
j
2 Spring capsule j
6 Cap nut j
10 Collar
j
3 Boost compensator assembly j
7 Cover j
11 Boost compensator housing
j
4 Pin j
8 Diaphragm j
12 Governor housing
EF-3-12
ADJUSTMENT
When the injection pump has been disassembled, plungers or
plunger springs have been replaced, or other reasons exist, use a
pump tester and adjust the injection pump.
INJECTION PUMP PREPARATIONS
Remove the cap of the control rack and install the measuring
device (105782-6280).
INITIAL INJECTION TIMING ADJUSTMENT
The start of injection is considered as the time at which the top of
the plunger covers the fuel intake hole of the barrel. The pump
tester must be capable of developing a pressure in the range of
3,138 to 4,707 kPa {32 to 48 kgf/cm2, 455 to 683 psi} in order to
overcome tension of the delivery valve spring (to force the delivery
valve open).
Installing injection pump
1. Attach the injection pump to the tester and connect the fuel
system lines. Arrange so that the camshaft angle can be read
on the tester angle scale plate.
2. Secure the control lever at the full injection position.
Adjusting the injection timing of the standard cylinder

1. Removing the 1st cylinder delivery valve holder. To do this, use
the Socket wrench (157914-0500). The delivery valve spring,
delivery valve and gasket can then be taken out.
EP9-162
2. Install the special tool ‘‘Plunger stroke measuring tool (105782-

4270)’’ to the flange sleeve by turning it as for as it will go.
EP9-163
3. Rotate the camshaft to bring the tappet for No. 1 cylinder in the
bottom dead center position, zero the dial indicator.
4. Proper position is indicated by the stop of fuel flowing out of the
end of the nozzle pipe when turning the camshaft to raise the
plunger, if the tappet lift reads 3.90±0.05 mm (0.1535±0.020
in), the pump is set for the start of injection of No. 1 cylinder.
The engine is then set to the proper position for injection on that
cylinder.
EF-3-13
5. When fuel injection does not stop even when the tappet has
risen more than 3.90±0.05 mm (0.1535±0.0020 in), pull out the
plunger block assembly, and remove adjusting shims until the
fuel flow stops at a lift of 3.90±0.05 mm (0.1535±0.0020 in).
6. When the fuel flow stops before the tappet is raised 3.90±0.05
mm (0.1535±0.0020 in), pull out the plunger block assembly
and add adjusting shims until the fuel flow stops at a lift of
3.65±0.05 mm (0.1437±0.0020 in) 3.90±0.05 mm
(0.1535±0.0020 in).
EP9-164
Checking timer mark

Under conditions described in ‘‘Installing injection pump’’ and
‘‘Adjusting the injection timing of the standard cylinder’’ above, the
position of initial injection of the reference plunger must appear
when the mark of the flyweight holder and that of the bearing cover
(pump body) coincide. If these marks do not coincide at this time,
the timer flyweight holder mark must be shifted. When the timer
has been replaced, alignment must also be made to the bearing
cover mark after adjusting initial injection timing for the reference
cylinder.
EP9-165
Adjusting injection interval
1. After completing adjustment of initial injection timing of the
reference No. 1 cylinder (timer side), turn the camshaft to the
right (as viewed from the drive end) and set the injection
interval for the remaining cylinders by adjusting shims.
See the table below.
2. Adjust the cylinder injection intervals within ±30′.
Injection
1 — 8 — 7 — 5 — 4 — 3 — 6 — 2 — 1
order
Injection
45° 45° 45° 45° 45° 45° 45° 45°
interval
Scale plate
0° — 45° — 90° — 135° — 180° — 225° — 270° — 315° — 360°
indication
EF-3-14
Setting the control rod’s zero position

1. Remove the rack limiter (or rack cap) mounted on the pump’s
drive side and then mount the measuring device used for
setting the control rod position.
NOTE
+ If a boost compensator is installed on the pump’s drive
side, remove it and then mount the measuring device.
EEF1-241
2. Fix the load control lever in the idling position.

3. Drive the pump at 500 rpm to 600 rpm and temporarily fix the
speed control lever so that governor control starts within this
speed range.
EEF1114C
4. Increase pump speed so that the control rod travels to the

non-injection position.
Push the end of the measuring device mounted on the end of
the control rod fully to the governor side and set the measuring
device at ‘‘0’’.
NOTE
+ Do not set the control rack’s ‘‘0’’ position by operating the
control lever when the pump is not being driven. This can
damage the link connection.
EEF1140B
Flyweight lift and full load position

Total flyweight lift includes the lift necessary for high-speed control
and the lift necessary for idling.
1. Temporarily fix the load control lever in the full load position
(control rod position ‘‘Rb’’).
2. Temporarily set the speed control lever so that governor control
starts at a pump speed of approximately 700 rpm to 800 rpm.
WEF010A
EF-3-15
3. Increase the pump speed to ‘‘Na rpm’’ and adjust using the full
load stopper bolt so that the control rod position is ‘‘Ra’’.
EEF1241B
4. Next, lower the pump speed to ‘‘Nb rpm’’ and adjust the
high-speed lift to ‘‘L’’ using the stroke adjusting screw.
WEF011A
Maximum-speed control and speed droop

1. Set the load control lever to the full position. Temporarily fix the
speed control lever in the maximum speed position.
2. Slowly increase the pump speed, adjust the minimum speed
stopper bolt so that the control rod starts moving in the
fuel-decrease direction at ‘‘Nk rpm’’ and then fix the lock nut.
3. Further increase the pump speed and check that the pump
speed is ‘‘N! rpm’’ or less when the control rod is at the ‘‘Ri’’
position.
Also increase the pump speed and confirm the flyweight lift (L)
for high speed control. EEF1241D
NOTE
+ When the high-speed droop confirmation point is at the
point where the damper spring is operating, adjust the
idling and damper springs and then make the above
adjustments and confirmations.
+ Replace the governor spring if the specified values cannot
be obtained.
4. Further increase the pump speed and confirm that the control
rod is in the non-injection zone [or 3 m! (0.11 Imp
fl oz)/1,000 st or less] at ‘‘Nm rpm’’.
WEF012A
EEF1241F
EF-3-16
Idling
1. Drive the pump at ‘‘Nc rpm’’ (Nd + 100 rpm).
2. Adjust the control rod position to ‘‘Rc’’ using the idle adjusting
screw.
WEF013A
EEF1241H
3. Decrease the pump speed to ‘‘Ne rpm’’ and adjust the idling
spring capsule using the wrench (157916-2620) so that the
control rod position is ‘‘Rd’’.
4. Confirm that the control rod position is ‘‘Re’’ or more when the
pump speed is 0 rpm and that the control rod position is ‘‘Rc’’
when the pump speed is increased to ‘‘Nd rpm’’.
EEF1241J
Load control lever angle measurement

Confirm that the lever angles are as specified when the load control
lever is at the idling position and the full load position. If not as
specified, replace the shim located between the shifter and sleeve.
NOTE
+ When the shim is replaced, the maximum speed control
and idling adjustments must be repeated.
WEF037A
WEF038A
EF-3-17
Damper spring
1. Hold the load control lever at the idling position.
2. Slowly increase the pump speed from idling speed ‘‘Ne rpm’’,
and maintain the pump speed of ‘‘Nc rpm’’ where the control
rod position is ‘‘Rf − 0.2 mm (0.008 in)’’.
WEF014A
3. Screw in the damper spring so that the rod position is

‘‘Rf − 0.1 mm (0.004 in)’’ and fix it with the lock nut.
WEF015A
EEF1241M
Stopper bolt
If idling performance is included in calibration data, as represented
by the dotted line in the illustration at right, adjust the setting of the
idle adjusting screw.
1. After adjusting the damper spring, the control rod position
should be ‘‘Re’’ when the pump is stopped.
WEF039A
2. Under the above conditions, loosen the idle adjusting screw

and adjust it so that the control rod position is ‘‘Rg’’.
WEF040A
EF-3-18
Positive torque control (When installed)

1. Drive the pump at ‘‘Nc rpm’’ and hold the load control lever in
the full load position.
2. Next, adjust the torque control spring capsule using the wrench
(157916-2620) so that the torque control stroke is the specified
value. After adjustment, fix it securely with a lock nut.
WEF016A
EEF1241P
3. Slowly increase the pump speed from ‘‘Nc rpm’’ and adjust the
screw so that the torque control spring starts to take effect at
‘‘Nf rpm’’.
NOTE
+ When shims are used, adjust by varying the shim thick-
ness.
4. Increase the pump speed and confirm that the torque control
spring stops taking effect at ‘‘Nh rpm’’.
5. Increase and decrease the pump speed between ‘‘Nc rpm’’ and
‘‘Nb rpm’’ and confirm that the torque control stroke is the
WEF017A
specified value.
NOTE
+ If the torque control stroke is not the specified value,
readjust using the spring capsule screw.
+ If the torque control spring does not stop taking effect at
the specified speed, replace the spring capsule.
EEF1241R
Minimum-speed stopper bolt

+ Minimum-maximum speed governor
1. Move the speed control lever until it contacts the maximum
speed stopper bolt, and then screw the minimum speed
stopper bolt in until it contacts the speed control lever.
EEF1227A
EF-3-19
+ Variable-speed governor
1. Fix the load control lever in the full load position.
2. Return the speed control lever in the fuel-decrease direction
and drive the pump at ‘‘Ny rpm’’, slightly faster than idling
speed.
WEF041A
3. Next, adjust the minimum-speed stopper bolt so that the control

lever is at the ‘‘Rb/Ny’’ position and then fix it with the lock nut.
WEF042A
Speed control lever angle confirmation

1. Confirm that the angle of the speed control lever is the specified
value at the maximum-speed position.
2. Confirm that the angle of the speed control lever is the specified
value at the minimum-speed position.
3. If the angle is not as specified, replace the governor spring.
WEF043A
Torque spring (when installed)

1. Hold the load control lever in the full load position. Also hold the
speed control lever in the maximum speed position.
2. Confirm that governor control starts at a speed of ‘‘Nk rpm’’.
3. Slowly decrease the pump speed from ‘‘Nv rpm’’ and adjust the
torque spring capsule so that the control rod is at position ‘‘Rc’’
at a speed of ‘‘Nq rpm’’.
4. Confirm that the control rod is at position ‘‘Rd’’ at a pump speed
of ‘‘Nr rpm’’, and at position ‘‘Rp’’ at a pump speed of ‘‘Np rpm’’.
5. Also confirm the injection quantity at point B.
WEF044A
NOTE
+ The plug on the side of the governor cover is used to hold
the torque lever. Thus, this plug has no relationship to
torque spring adjustment and should not be touched.
The plug is coated with paint to draw attention to it at
repair shops. If this paint seal should be broken, disas-
semble the governor, check the torque lever position and
then repaint it.
WEF045A
EF-3-20
Full load injection quantity confirmation

1. Hold the load control lever in the full load position.
2. Next, confirm that the fuel injection quantity (point A) under a
full load is as specified.
WEF046A
3. If not as specified, adjust using the full load stopper bolt.
WEF047A
Smoke limiter
1. Hold the load control lever in the full load position.
2. Maintain the pump speed at ‘‘Nn rpm’’.
3. Screw in the spring capsule or screw and lock it at point E,
where the specified fuel injection quantity may be obtained.
NOTE
+ There is no rack limiter when a boost compensator is
mounted on the drive side.
WEF018A
WEF019A
WEF020A
EF-3-21
Stop lever position

1. Drive the pump at 800 rpm.
2. Move the stopper lever to the stop side and confirm that the
control rod enters the non-injection zone.
3. If the control rod does not enter the non-injection zone, check
the linkage inside the governor.
EEF1113D
Boost compensator
1. Mount the boost compensator assembly on the top of the
governor. Set the screw to the position measured at the time of
disassembly.
2. Attach a tube to the eye of the boost pressure intake port and
install the air tube.
WEF048A
3. Hold the load control lever in the full load position and drive the
pump at a speed of ‘‘Nu rpm’’ (500 rpm unless otherwise
specified).
WEF049A
4. With no boost pressure applied, adjust the boost compensator

stroke to the specified value using the screw for rack position
adjustment.
WEF050A
WEF051A
EF-3-22
5. Adjust using the adjusting screw (250/62) so that, when the

pressure is P1, the control rod begins to move in the fuel-
increase direction.
Then lock it with the nut.
WEF052A
6. Increase the boost pressure and confirm that the control rod is
in position R1 at P1. Also confirm that the control rod is at the R2
position at P2.
7. If not as specified, replace the boost compensator spring.
WEF053A
WEF054A
EF-3-23
INJECTION PUMP CALIBRATION DATA

Testing conditions
Failure of pump to deliver fuel evenly throws the engine out of balance so that roughness and loss of power is
evident. In calibrating a pump, observe the following:
+ ZEXEL No. 106871-5480
Item Test condition
Nozzle and Nozzle holder assembly 105780-8140 (BOSCH Type No. EF8511/9A)
Nozzle 105780-0000 (BOSCH Type No. DN12SD12T)
Nozzle holder 105780-2080 (BOSCH Type No. EF8511/9)
2
Nozzle opening pressure kPa {kgf/cm , psi} 17,162 {175, 2,489}
Feed pump oil pressure kPa {kgf/cm2, psi} 157 {1.6, 23}
Injection pipe (OD x ID − L) mm (in) 8 x 3 − 600 (0.31 x 0.12 − 23.62)
Test oil IS04113 or SAE standard test oil (SAE J967d)
Test oil temperature °C (°F) 40 - 45 {104 - 113}
2
Overflow valve opening pressure kPa {kgf/cm , psi} 157 {1.6, 23}
+ ZEXEL No. 106871-5670

Item Test condition
Nozzle and Nozzle holder assembly 105110-7070
Nozzle 105015-9250
Nozzle holder 105041-4020
2
Nozzle opening pressure kPa {kgf/cm , psi} 17,653 {180, 2,560}
Feed pump oil pressure kPa {kgf/cm2, psi} 157 {1.6, 23}
Injection pipe (OD x ID − L) mm (in) 6 x 2.2 − 760 (0.236 x 0.087 − 29.921)
Test oil IS04113 or SAE standard test oil (SAE J967d)
Test oil temperature °C (°F) 40 - 45 {104 - 113}
2
Overflow valve opening pressure kPa {kgf/cm , psi} 157 {1.6, 23}
Injection quantity standards (‘‘ZEXEL No.’’ is Inj. Pump assembly No.)

+ ZEXEL No. 106871-5480
Adjusting Rack Pump Injection q’ty Max. var.
Point Position Speed m! (Imp fl oz)/ bet. cyl. Fixed Remarks
mm (in) rpm 1,000 strokes (%)
Boost press. kPa
A 10.6 (0.417) 600 179±1 (6.30±0.04) ±4 Lever Basic {mmHg, inHg}
Above 32.0 {240, 9.45}
C Approx. 235 12±2 (0.42±0.07) ±10 Rack Boost press. 0

4.8 (0.189)
+ ZEXEL No. 106871-5670

Adjusting Rack Pump Injection q’ty Max. var.
Point Position Speed m! (Imp fl oz)/ bet. cyl. Fixed Remarks
mm (in) rpm 1,000 strokes (%)
Boost press. kPa
A 11.6 (0.457) 600 226±2 (7.96±0.07) ±4 Lever Basic {mmHg, inHg}
Above 33.3 {250, 9.84}
C Approx. 235 15±2 (0.53±0.07) ±10 Rack Boost press. 0

5.3 (0.209)
NOTE
+ The injection quantity and the governor must be adjusted at an ambient temperature of at least 15°C
(59°F) (as the boost compensator start spring is a shape—memory alloy).
EF-3-24
Governor adjustment diagram (‘‘ZEXEL No.’’ is Inj. pump assembly No.)

ZEXEL NO. 106871-5480
ZEF479A
EF-3-25
ZEXEL NO. 106871-5670
EEF080A
EF-3-26
TESTING TIMER
In general, measurement of the timer advance angle is performed
on the pump tester after completing an adjustment of the injection
timing, injection quantity and governor.
Timing Advance Specification
+ ZEXEL No. 106871-5480

Pump speed (rpm) Below 800 750 900 1,080
(Measure) Finish
Advance angle (°) Start Below 0.3
±0.5 3.75±0.3
+ ZEXEL No. 106871-5670

Pump speed (rpm) Below 770 720 930
Finish
Advance angle (°) Start Below 0.3
3.0±0.3
EF-3-27

CONSTRUCTION
ZEF427A
REMOVAL
1. Chock the wheels and tilt the cab.
2. Turn the key switch off and disconnect the cable from the
negative terminal of the battery.
3. Disconnect the injection nozzle tube and spill tube, remove the
nozzle holder assembly from the cylinder head.
EF-4-1
DISASSEMBLY
ZEF428A
j
1 Nozzle holder j6 Push rod j
11 Lift piece
j
2 No. 1 shim (for valve opening j7 No. 2 spring j
12 Spacer
pressure adjustment) j8 No. 2 shim (for valve opening j
13 Pin
j
3 No. 1 spring pressure adjustment) j
14 Nozzle
j
4 No. 1 spring seat j9 No. 2 spring seat j
15 Retaining nut
j
5 Collar j
10 Pin
EF-4-2
1. With the injection orifice downward, clamp the nozzle holder in

a vise.
2. Loosen the retaining nut and remove the nozzle assembly and
pin.
3. Remove the spacer, lift piece, pin, No. 2 spring seat, No. 2
spring shim, No. 2 spring, push rod, collar, No. 1 spring seat,
No. 1 spring and No. 1 spring shim.
4. Remove the nozzle needle from the nozzle body.
NOTE
+ Do not use the nozzle needle in another nozzle body.
ZEF481A
INSPECTION
NOTE
+ Remove carbon from around nozzle jets using a wire
brush.
Clearance between nozzle body and nozzle

1. Remove carbon from around nozzle jets using the pin vise
(99727 Z5005).
Unit: mm (in)
Nozzle identifica- Number of injec- Injection nozzle
Wire diameter
tion mark tion nozzle holes hole diameter
E7 5 0.34 (0.0134) 0.29 (0.0114)
NOTE
+ Do not extend tip of the holder more than 2 to 2.5 mm ZEF007A
(0.079 to 0.098 in). Otherwise, it may bend inside the nozzle

body and it cannot be removed.
+ Carefully push the holder into the inside of the nozzle to
remove carbon.
+ Use an oil stone to grind the wire tip of the holder until it is
shaped as shown in the figure.
EF-4-3
2. Clean remaining carbon off the back of the nozzle jet using the
nozzle cleaner (99726 Z5000).
NOTE
+ Be careful not to scratch the seating surface of the nozzle
jet and the nozzle needle.
Do not use compressed air to remove carbon because this
may introduce foreign matter into the jet.
3. Install the needle on the nozzle body while immersing both in
clean diesel fuel.
EP9-156
4. Visually check the needle valve seat, guide shaft and injection
shaft for damage or carbon accumulation.
5. Position the nozzle body vertically. Pull out the needle so that it
protrudes approximately 1/3 its total length beyond the top of
the nozzle body. Then release it to ensure that it drops to the
valve seat under its own weight.
REASSEMBLY
To reassemble, reverse the order of the above removal proce-
dures. Observe the following:
NOTE
+ Clean the mating surfaces of the nozzle and nozzle holder
and the retaining nut in clean diesel fuel before installa-
tion.
+ Use new gaskets.
For reassembly, refer to ‘‘Adjustment’’.
Retaining nut 59 - 78 {6 - 8, 43 - 58}
EF-4-4
ADJUSTMENT
1. With the nozzle side facing up, place the nozzle holder in a vise
using plates (157992-2820).
2. Install the No. 1 pressure adjustment shim, No. 1 spring and

No. 1 spring seat, in that order, on the nozzle holder body.
EEF2012A
3. Install the collar, No. 2 spring, No. 2 pressure adjustment shim,

No. 2 spring seat and push rod.
EEF2015A
4. Install the pin, lift piece and spacer on the nozzle holder.
EEF2-061
5. Install the nozzle and pin on the spacer.
EEF2-062
EF-4-5
6. After installing gasket (157892-1500) on the nozzle, secure the

nozzle to the nozzle holder using retaining nut (157892-4000)
furnished.
: 59 - 78 N·m {6 - 8 kgfzm, 43 - 58 ftzlbf}
EEF2019A
No. 1 valve opening pressure adjustment

1. Using a nozzle tester (equipped with a 49,035 kPa {500
kgf/cm2, 7,110 psi} gauge), measure No. 1 valve opening
pressure.
Item Maintenance standard
18,143 - 18,928
Valve opening pressure
{185 - 193, 2,631 - 2,744}
2. If the No. 1 valve opening pressure is outside specifications, EEF2-013

replace the adjustment shim with a suitable one until the
specified opening pressure is obtained.
NOTE
+ When using a shim, always measure the thickness of the
shim with a micrometer before assembling.
+ Adding a 0.01 mm thick shim corresponds to a change of
approximately 1.2 kg/cm2 in valve opening pressure.
Unit: mm (in)
Pre-lift (valve opening pressure) adjusting shim thickness
0.40, 0.50, 0.52, 0.54, 0.56, 0.58, 0.60, 0.70
(0.0157, 0.0197, 0.0205, 0.0213, 0.0220, 0.0236, 0.0276)
Install the special service tool and air purged.

Before checking the needle valve full lift and pre-lift, or
checking or adjusting the No. 2 valve opening pres-
sure, install the special service tool.
1. Install plug (157892-1600) on retaining nut (157892-4000)

using gasket (026508-1140).
EEF2019B
EF-4-6
2. Place the nozzle holder body in a vise with the nozzle facing up,
then install holder (157892-4100) in the nozzle holder.
3. Install nut (157892-1000) on the holder.
EEF2-063
4. Install pin (157892-5300) on dial gauge (157954-3800).

!: 60 mm
EEF2016B
5. Install the dial gauge on the nozzle holder assembly so that pin
(157892-5300) is in contact with the upper surface of the No. 1
spring seat; then snugly tighten the dial gauge using a nut.
NOTE
+ Do not overtighten the nut as this may jam the gauge shaft
resulting in malfunctioning.
EEF2016C
6. Install the nozzle holder assembly on the nozzle tester and

reset the dial gauge to ‘‘0’’.
7. Loosen plug (157892-1600) on the end of the retaining nut
(furnished as a special service tool), activate the nozzle tester
to purge air from the plug opening, then tighten the plug
(157892-1600).
NOTE
+ Air can be purged at a pressure of 9,807 kPa {100 kgf/cm2,
1,422 psi}.
EEF2014B
EF-4-7
Checking needle valve full lift

<Nozzle cover method>
1. Activate the nozzle tester. When the line pressure is in the
34,325 - 44,132 kPa {350 - 450 kgf/cm2, 4,977 - 6,399 psi}
range, the needle valve is completely lifted. Record the full-lift
length ‘‘L’’.
NOTE
+ Read the dial gauge in units of 1/100 mm.
+ Checking the full-lift length of the needle valve is required
to determine whether or not the nozzle seat is worn or the
ZEF483A
nozzle assembly is of a specified type.
Unit: mm (in)
Full-lift: ! 0.40 (0.0157)
Checking needle valve pre-lift

1. When the nozzle tester handle is left unattended with the
needle valve fully lifted, both the line pressure and the dial
gauge indication (needle valve lift) decrease.
EEF2014C
2. When No. 2 spring action ceases and the needle valve no

longer goes down, read the dial gauge indication (valve
lift: !) to ensure it is within specifications. Refer to the figure at
right and the figure corresponding to step 3) below.
EEF2018D
3. When the needle valve reaches the pre-lift measuring point

(No. 1 valve opening pressure plus approximately 981 kPa {10
kgf/cm2, 142 psi}), read the dial gauge indication.
NOTE
+ Determine the point (corresponding to the No. 1 valve
opening pressure plus approximately 981 kPa {10 kgf/cm2,
142 psi}) while decreasing line pressure.
Unit: mm (in)
Pre-lift: ! 0.05 - 0.09 (0.0020 - 0.0035) ZEF484A
EF-4-8
4. If the pre-lift length is outside specifications, replace the pin, lift

piece, spacer and nozzle with a service kit.
Service kit part No.
Engine Zexel part No.
RF8TC 105019-0240
EEF2-064
Checking the No. 2 valve opening pressure

1. After checking the needle valve pre-lift, activate the nozzle
tester and increase the line pressure in the 34,325 - 44,132 kPa
{350 - 450 kgf/cm2, 4,977 - 6,399 psi} range until the needle
valve is fully lifted.
2. When the nozzle tester handle is left unattended with the
needle valve fully lifted, both the line pressure and the dial
gauge indication (valve lift) decrease.
ZEF485A
3. Read the pressure gauge indication the instant the dial gauge
registers the specified needle valve lift [pre-lift ‘‘!’’ plus 0.05 mm
(0.0020 in)].
ZEF486A
ZEF487A
EEF2018F
EF-4-9
Adjusting the No. 2 valve opening pressure

NOTE
+ After properly adjusting the No. 1 valve opening pressure,
adjust the No. 2 valve opening pressure.
If shim(s) need to be replaced during pressure adjustment,
replace only No. 2 shim(s).
1. Using a nozzle tester (provided with a 49,035 kPa {500
kgf/cm2, 7,110 psi} gauge), measure the No. 2 valve opening
pressure.
Unit: kPa {kgf/cm2, psi} ZEF488A

23,537 - 24,518
Valve opening pressure
{240 - 250, 3,413 - 3,555}
2. If the No. 2 valve opening pressure is outside specifications,

disassemble the nozzle section of the nozzle holder and
replace the No. 2 spring shim.
NOTE
+ Before installing a shim, measure its thickness using a
micrometer.
+ Adding a 0.01 mm (0.0004 in) thick shim corresponds to a
change of approximately 118 kPa {1.2 kg/cm2, 17 psi} in
valve opening pressure.
Unit: mm (in)
ZEF489A
Thickness of pre-lift (valve opening pressure) adjustment shim
0.40, 0.50, 0.52, 0.54, 0.56, 0.58, 0.60, 0.70
(0.0157, 0.0197, 0.0205, 0.0213, 0.0220, 0.0236, 0.0276)
Retaining nut replacement

1. Remove the dial gauge, nut, holder and gasket.
2. Remove the retaining nut (furnished as a service tool) and
gasket, then install the specified retaining nut in its place.
: 59 - 78 N·m {6 - 8 kgfzm, 43 - 58 ftzlbf}
3. Attach the nozzle to the nozzle tester and confirm the initial
injection pressure.
Injection beginning pressure
17,653 {180, 2,560}
(1st stage)
ER9-198
EF-4-10
NOTE
+ The spray ejected from the nozzle can cause structural
collapse of living tissues by penetrating deeply, and can
cause blood poisoning if it gets into the blood. Exert
utmost caution to avoid getting the spray on your hands.
4. Inspect the spray pattern and inspect for leakage and plugged
spray holes. If there is wear or damage due to fuel impurities or
carbon on the nozzle needle or nozzle body sheet surface,
correct minor wear or damage by lapping with compound.
In addition, the nozzle needle and the body must be replaced
as a set.
j1 Uniform and symmetrical
j2 Not symmetrical
j3 Branching
j4 Thin spray
j5 Stepped injection EEF3-010
j6 Must be evenly injected from the five orifices
INSTALLATION
1. Install the nozzle holder assembly onto the cylinder head.
: 25 - 34 N·m {2.5 - 3.5 kgfzm, 18 - 25 ftzlbf}
2. Install the spill tube and injection nozzle tube.
3. Remove the air in the fuel system.
4. Connect the battery cable to the negative terminal of the
battery.
EF-4-11
FUEL FILTER
FUEL FILTER
REPLACEMENT
REPLACE FUEL FILTER ELEMENT
Method of replacement
Cartridge type
1. Place a container under the filter. Remove the filter with a filter
wrench. Drain any remaining fuel into the container.
WEF034A
2. Apply a thin coat of clean engine oil to the gasket of the new
filter.
CAUTION
+ Installation of the fuel filter without coating the gasket with
oil may damage the gasket resulting in leakage of fuel and
fire hazard due to spilled fuel.
3. Install the new fuel filter. After the gasket comes in contact with
the bracket sealing surface, tighten an additional three-fourths
of a turn.
CX-076E
NOTE
+ When installing the fuel filter, securely tighten it three-
fourths of a turn using the exclusive filter wrench provided
in the vehicle.
DRAIN SEDIMENT FROM PRIMARY FUEL FILTER

Draining procedure
NOTE
+ It is not necessary to drain all the fuel in the primary fuel
filter case.
Place a receiver under the filter, then loosen the drain plug to drain
sediment.
Put the drained precipitates in a glass container such as a test
tube. If there is fuel on top of the water, dust and precipitates, it
indicates that the precipitates have been removed. EMA1-046
Bleed air from the fuel system after draining sediments.
EF-5-1
FUEL FILTER
REPLACE PRIMARY FUEL FILTER ELEMENT

Method of replacement
1. Place a suitable oil can under the drain cock, and drain the fuel
and sediment.
2. Loosen the center bolt, and remove the filter case, spring and
element.
3. Clean each part in light oil.
4. Replace the element and packings.
5. Reassemble each part correctly, and after reassembly, be sure
to bleed air from the fuel system.
Fuel filter center bolt
: 59 - 69 N·m {6.0 - 7.0 kgfzm, 43 - 51 ftzlbf}
NOTE
+ Do not excessively tighten bolts and plugs.
Disassembly sequence (Reassembly sequence is in the re-
verse order of disassembly.)
j
1 Drain plug j7 Seat
j
2 Packing j8 Element
j
3 Center bolt j9 Packing
j
4 Packing j
10 Filter cover
j j WEF035A
5 Filter case 11 O-ring
j
6 Spring j
12 Plug assembly
Bleeding air from the fuel system

Refer to ‘‘PURGING AIR FROM FUEL SYSTEM’’.
PURGING AIR FROM FUEL SYSTEM

Air entrapped in the fuel system will cause poor injection of the fuel,
thus resulting in difficult starting, jerking, or even stall of the engine.
After completing any service procedure on the fuel system (inspec-
tion, replacement of fuel filter element, or reconnection of any fuel
pipe), be sure to bleed air from the fuel system.
1. Twist the knob on the priming pump, which is connected to the

injection pump, and the knob will rise up by itself.
2. Move the priming pump’s knob up and down to send fuel from
fuel tank into the filter.
priming pump is difficult. The air bleeding operation is now
complete.
3. After bleeding air, return the pump knob to its original position.
Start the engine, and make sure that no fuel is leaking from the
fuel system. Fuel leaks can cause a fire. If a leak is found,
immediately repair the affected part.
EF-5-2
ENGINE CONTROL SYSTEM

CONSTRUCTION
Schematic diagram
ZEF432A
ADJUSTMENT
ENGINE CONTROL WIRE
1. Turn the engine control knob counterclockwise all the way.
Under this condition, install the engine control wire to lever B.
2. Install the engine control wire clamp to the accelerator linkage
assembly.
3. With the accelerator pedal contacting lever B, make sure the
accelerator pedal angle is 50° to the floor.
WEF057A
ACCELERATOR WIRE
1. Connect one end of the accelerator wire to lever. Securely fit
the clip on the wire in the panel.
NOTE
+ Be careful not to break the boot.
EEF1154G
EF-6-1
2. Connect the accelerator wire to the engine side. When the load
control lever of the injection pump touches the full load position
of the set bolt, ensure that there is clearance ‘‘H’’ between the
pedal and stopper bolt. Then, secure the stopper bolt.
Unit: mm (in)
Clearance (H) 1 - 2 (0.04 - 0.08) —
WEF058A
ENGINE STOP LINKAGE

1. Temporarily install the engine stop wire to the bracket and
connect the clevis to the engine stop lever.
2. Turn the wire lock nut until the stop lever comes into contact
with the set bolt on the stop side. Then, tighten the lock nut.
ZEF435A
EF-6-2
AIR INTAKE AND EXHAUST SYSTEM
CONTENTS
SERVICE DATA ........................................ IE- 1- 1 INTERCOOLER ........................................ IE- 4- 1
SPECIFICATIONS .................................... IE- 1- 1 CONSTRUCTION ..................................... IE- 4- 1
SERVICE DATA ........................................ IE- 1- 2 INSPECTION ............................................ IE- 4- 1
TIGHTENING TORQUE ........................... IE- 1- 3 AIR CLEANER .......................................... IE- 5- 1
INTAKE AND EXHAUST SYSTEM ........... IE- 1- 4 DISASSEMBLY ......................................... IE- 5- 1
TOOLS ......................................................... IE- 2- 1 ELEMENT REPLACEMENT ..................... IE- 5- 1
TURBOCHARGER .................................. IE- 3- 1 EXHAUST BRAKE .................................. IE- 6- 1
CONSTRUCTION ..................................... IE- 3- 1 CONSTRUCTION ..................................... IE- 6- 1
REMOVAL ................................................. IE- 3- 1 DISASSEMBLY ......................................... IE- 6- 2
DISASSEMBLY ......................................... IE- 3- 2 INSPECTION ............................................ IE- 6- 4
INSPECTION ............................................ IE- 3- 5
REASSEMBLY .......................................... IE- 6- 4
REASSEMBLY .......................................... IE- 3- 9
INSTALLATION ......................................... IE- 6- 6
INSTALLATION ......................................... IE- 3-13
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
AIR CLEANER
Type Cyclone
Element Paper element (Dry)
TURBOCHARGER
Model and (Type) T04E
External dimensions
230 x 195 x 265 (9.06 x 7.68 x 10.43)
(Length x Width x Height) mm (in)
Max. permissible continuous speed rpm 125,000
Direction of rotation Counterclockwise as viewed from the exhaust turbine side
Air volume kg/min (lb/min) 20.0 (44.1)
Compression ratio 3.0
INTERCOOLER
Type Air to air
Intercooler Corrugated fin
EXHAUST BRAKE
Type Cylinder type
Operating method Air type
IE-1-1
SERVICE DATA
SERVICE DATA
TURBOCHARGER
Unit: mm (in)
0.03 - 0.08
Axial play
(0.0012 - 0.0031)
Play in shaft axial direction —
0.08 - 0.15
Radial play
(0.0031 - 0.0059)
Inside diameter of center Bearing part — 15.81 (0.6224)

housing Piston ring part — 18.06 (0.7110)
Outside diameter of turbine Journal part — 10.15 (0.3996)

wheel shaft Piston ring part — 14.40 (0.5669)
Outside diameter of turbine wheel shaft hub — 17.25 (0.6791)
Piston ring groove width of shaft — 1.74 (0.0685)
Runout of shaft 0.01 (0.0004) —
Seal land height of back plate — 11.68 (0.4598)
Inside diameter of back plate — 12.71 (0.5004)
Flatness of back plate compressor housing to mat-
— 0.025 (0.0010)
ing surface
Groove width of thrust collar piston ring — 1.66 (0.0654)
Groove diameter of thrust collar piston ring — 10.29 (0.4051)
Thrust collar groove width — 4.44 (0.1748)
Inside diameter of thrust collar — 6.36 (0.2504)
INTERCOOLER
Intercooler check pressure (air) 196 {2.0, 28} —
EXHAUST BRAKE
Unit: mm (in)
When compressed to
Air cylinder Spring tension N {kgf, lbf} 77.5 {7.9, 17.4} —
113.2 mm (4.46 in)
Valve movement in the axial direction More than
—
when closing the valve 0.7 (0.028)
0.6 - 0.8
Exhaust shutter One side —
Clearance between (0.024 - 0.031)
valve and body 1.2 - 1.4
Both sides —
(0.047 - 0.055)
More than
Clearance between air cylinder shaft and clevis —
1.0 (0.04)
IE-1-2
SERVICE DATA
TIGHTENING TORQUE
TURBOCHARGER
Oil inlet adapter mounting bolt 21 - 26 {2.1 - 2.7, 15 - 20}
Oil drain pipe mounting bolt 30 - 34 {3.1 - 3.5, 22 - 25}
Back plate and center housing mounting bolt 13.2 {1.35, 9.8}
Compressor wheel mounting nut 2.3 {0.23, 1.7} → Tighten (120°)
Turbine housing mounting bolt 22 {2.2, 16}
Compressor housing mounting bolt 17 {1.7, 12}
Exhaust connector mounting bolt 39 - 49 {4.0 - 5.0, 29 - 36}
Turbocharger assembly mounting bolt 34 - 44 {3.5 - 4.5, 25 - 33}
EXHAUST BRAKE
Air cylinder mounting bolt and nut 21 - 25 {2.1 - 2.6, 15 - 19}
Air cylinder cover mounting bolt 10 - 16 {1.0 - 1.6, 7 - 12}
Air cylinder shaft nut 10 - 16 {1.0 - 1.6, 7 - 12}
Exhaust shutter shaft nut 10 - 16 {1.0 - 1.6, 7 - 12}
Exhaust shutter shaft cover mounting nut 21 - 25 {2.1 - 2.6, 15 - 19}
Lever mounting nut (Exhaust shutter only) 10 - 16 {1.0 - 1.6, 7 - 12}
Stopper bolt lock nut (Exhaust shutter only) 10 - 16 {1.0 - 1.6, 7 - 12}
Exhaust shutter mounting bolt 21 - 25 {2.1 - 2.6, 15 - 19}
Turbine housing mounting bolt 22 {2.2, 16}
Compressor housing mounting bolt 17 {1.7, 12}
Exhaust connector mounting bolt 39 - 49 {4.0 - 5.0, 29 - 36}
IE-1-3
SERVICE DATA
INTAKE AND EXHAUST SYSTEM

INTAKE SYSTEM
ZIE118A
IE-1-4
SERVICE DATA
EXHAUST SYSTEM
ZIE119A
IE-1-5
TOOLS
TOOLS
Holding fixture Used to hold the shaft wheel when removing the impeller.
99768 Z5500
ETL2036
Radial play measuring tool Used when measuring the radial play of parts.
99764 96000
ETL2038
Radial play measuring ele- Used when measuring the radial play of parts.
ment
99765 96000
ETL1053
End play measuring element Used when measuring the end play of parts.
99765 96001
ETL2037
Flexible tube setting tool Used to install flexible tube.

99780 96502
ETL3-021
IE-2-1
TURBOCHARGER
TURBOCHARGER
CONSTRUCTION
ZIE122A
REMOVAL
WARNING
+ To avoid being burned, do not touch the exhaust pipe,
turbocharger and muffler while the engine is running or
immediately thereafter. Check that the engine has cooled
before starting work.
1. Remove the air intake duct and shield plate.

2. Remove the exhaust brake assembly and exhaust connector.
3. Remove the oil inlet tube and oil inlet adapter.
4. Remove the oil outlet pipe.
5. Remove the air intake hose and intake housing.
6. Remove the turbocharger assembly.
IE-3-1
TURBOCHARGER
DISASSEMBLY
ZIE123A
j
1 Clip >.j
10 Compressor wheel >j
19 Thrust bearing
j
2 Bolt >j
11 Turbine wheel j
20 Piston ring
j
3 Clamp >j
12 Piston ring >j
21 Retaining ring
>.j
4 Turbine housing j
13 Shroud wheel >j
22 Journal bearing
j
5 Bolt j
14 Bolt >j
23 Retaining ring
j
6 Clamp >j
15 Back plate assembly >j
24 Retaining ring
j
7 Compressor housing j
16 O-ring >j
25 Journal bearing
>j
8 Actuator assembly j
17 Seal ring >j
26 Retaining ring
j
9 Lock nut >j
18 Thrust collar j
27 Center housing
IE-3-2
TURBOCHARGER
INSPECTION BEFORE DISASSEMBLY

Place the turbocharger on a level surface, and turn the compressor
wheel with finger tip to determine whether it operates smoothly.
Then use the following procedure to measure both axial play.
Prior to starting disassembly, spread a piece of clean oil paper or
cardboard on the work bench and make matching marks at the
connection sections of the turbine housing, center housing, and
compressor housing so that there will be no mistakes during
reassembly.
Since the turbocharger is a precision device, disassemble it with
the utmost care.
j4 Turbine housing
1. Remove the clip and actuator rod from the waste gate crank.
NOTE
+ Be careful not to lose the clip during removal.
ZIE124A
2. Carefully remove the turbine housing, taking care not to

damage the turbine.
NOTE
+ Do not disassemble the waste gate: it is not designed to be
disassembled.
ZIE125A
j
10 Compressor wheel
1. Place the holding fixture (99768 Z5500) in a vise. Place the
shaft wheel onto the fixture.
ZIE126A
IE-3-3
TURBOCHARGER
2. Remove the lock nut using a T-handle. Lift the compressor

straight off the center housing. Do not rotate the compressor
wheel during removal.
NOTE
+ Always use both hands to lift the compressor wheel,
taking care not to apply a bending force to the shaft.
ZIE127A
IE-3-4
TURBOCHARGER
INSPECTION
INSPECTION BEFORE CLEANING
Turbocharger failure may sometimes be due to faulty engine parts.
It is, therefore advisable to closely inspect parts for accumulation of
carbon, presence of dirt or dust, obstruction of oil passages, etc.
prior to cleaning, so that the cause of problems may be located
easily.
CLEANING
After soaking all the parts in clean detergent for about 20 to 30
minutes, remove dirt and grime with a rough brush and then blow
dry with compressed air.
NOTE
+ Be extremely careful not to damage parts. Avoid filing any
rotating parts. Also be sure to clean parts completely.
Failure to observe these points may cause the parts to
become imbalanced.
Contents of inspection Inspection point
Carbon accumulation (check whether parts are jammed) + Turbine wheel journal parts.
+ Outside periphery of center housing.
+ Inside periphery of heat shroud.
+ Inside wall of center housing.
+ Surface of blades of turbine wheel.
Lubrication (wear, burning, discoloration etc.) + Turbine wheel journal parts.
+ Journal bearing.
+ Center housing bore part.
+ Thrust collar.
+ Thrust bearing.
Oil leakage + Inside and outside periphery of turbine housing.
+ Inside periphery of heat shroud.
+ Inside of compressor housing.
+ Surface of back plate.
+ Surface of blades of turbine wheel.
+ Rear surface of compressor wheel.
Foreign matter (Also check for obstruction while cleaning parts.) + Inside of center housing.
+ Inside of turbine case.
+ Inside of compressor case.
Clogging + Center housing of oil hole.
+ Oil inlet adapter.
+ Oil outlet adapter.
+ Thrust bearing of oil hole.
IE-3-5
TURBOCHARGER
INSPECTION
The turbine wheel and compressor wheel are power-balanced to a high degree of accuracy since they rotate
at very high speeds. If their wheel shafts are scratched or bent, the entire wheel assembly will become
unsuitable for further use. For this reason, extreme care should be taken when handling these assemblies.
The wheel component parts must be cleaned in new kerosene or new light oil. Never use a wire brush to clean
these parts.
+ There should be no interference with the compressor wheel.
+ Check the mating surface of the back plate for abnormalities such as deformity, damage, etc.
Compressor housing
+ Check the intake and exhaust port connections for deformity or other damage.
+ Check bolt hole threads for damage.
+ There should be no trace of interference with the turbine wheel.
+ Check the turbine housing for cracks or other damage.
+ Check the housing interior for any indication of corrosion or oxidation.
Turbine housing + Check the divider for cracks. There should be no more than 5 cracks over the entire perimeter of
the turbine housing and no two cracks closer than 25 mm (0.98 in).
+ Check for deformity on the flange surface.
+ Check the bolt hole for damage.
+ Check the blade for bending, cracks or other damage.
+ Check the blade for any indication of interference with the compressor housing.
+ Check the blade for any indication of interference with the back plate.
Compressor wheel
+ Check for interference with the contact surface of the lock nut.
+ Check the shaft bore for damage.
+ Check for interference with the contact surface of the thrust collar.
+ Check the actuator body and cover for dents or other damage.
Actuator assembly + Check for bent rods.
+ Check for cracked hoses.
+ Check for scratches on the contact surface of the bearing.
+ Check for scratches or damage to the contact surface of the piston ring.
+ Check for damage to the retaining ring groove.
Center housing + Check for obstacles in the oil hole.
+ There should be no internal caulking.
+ Check for damage to the flange surfaces (IN and OUT).
+ Check for thermal deformity or excessive thermal discoloration.
+ Check the blade for bending or deformity.
+ Check the blade for any indication of interference with the turbine housing.
+ Check the shaft journal for any trace of excessive thermal discoloration, scratches or overheating.
+ Check the thread of the shaft end for damage.
+ Check the back of the wheel for any indication of interference with the shroud.
+ Check the F area (shown in the figure below) for traces of carbon accumulation, wear or interfer-
ence damage.
+ Check the G area (shown in the figure below) for traces of compressor wheel rotation.
Turbine wheel
ZIE151A
IE-3-6
TURBOCHARGER

+ Check the seal land area for any indication of thermal discoloration.
+ Check the bolt hole for damage.
+ Check the thrust spring for cracks, deformity or other damage.
Compressor housing
+ Check the compressor housing for cracks.
+ Check the contact surface of the compressor housing and mating part for misalignment.
+ Check the seal bore for any indication of scratches caused by the piston ring or wear.
+ Check the E area (shown in the figure below) for any indication of circumferential scratches, over-
heating, bluish fading, etc. land.
+ Check the thrust bearing groove for scratches or discoloration.
+ Check the bore diameter for any indication of scratches or wear.
Thrust collar
ZIE152A
IE-3-7
TURBOCHARGER
NOTE
+ If the measured value exceeds the maintenance standard,
replace the part.
Inside diameter of center housing
Unit: mm (in)
Bearing part (A) — 15.81 (0.6224)
Piston ring part (B) — 18.06 (0.7110)
EIE2040
Turbine wheel
Unit: mm (in)
Maintenance
Item Service limit
standard
Journal part (A) — 10.15 (0.3996)
Outside
Piston ring part (B) — 14.40 (0.5669)
diameter
Turbine wheel shaft hub (D) — 17.25 (0.6791)
Piston ring groove width (C) — 1.74 (0.0685)
ZIE130A
EP15-034
Runout of shaft
Unit: mm (in)
0.01 (0.0004) —
EP15-035
Back plate
Unit: mm (in)
Seal land height (A) — 11.68 (0.4598)
Back plate seal bore diameter
— 12.71 (0.5004)
(B)
Compressor housing-to-mating
— 0.025 (0.0010)
surface flatness (C)
EIE2042
IE-3-8
TURBOCHARGER
Thrust collar
Unit: mm (in)
Piston ring groove width (A) — 1.66 (0.0654)
Piston ring groove diameter (B) — 10.29 (0.4051)
Thrust bearing groove width (C) — 4.44 (0.1748)
Bore diameter (D) — 6.36 (0.2504)
ZIE133A
REASSEMBLY
Preparations before reassembly
Repair light damage by polishing. Aluminum parts must be pol-
ished with a polishing cloth using silicon carbide.
Moreover, steel parts must be polished with a polishing cloth using
polishing powder. Always replace the following parts.
Part name Quantity
Clip 1
Bolt (Compressor housing) 3
Bolt (Turbine housing) 3
Piston ring (Turbine wheel) 1
Bolt (Center housing) 1
Seal ring 1
Clamp (Turbine housing) 1
Clamp (Compressor housing) 1
Journal bearing 2
Retaining ring 4

j26 j
24 j 23 j
21 Retaining ring, j
25 j
22 Journal bearing
Install the retaining ring and journal bearing to the bore in the
center housing. The journal bearing must be installed immediately
after it has been dipped in clean engine oil.
ZIE134A
j
19 Thrust bearing, j 18 Thrust collar
1. Install the piston ring to the thrust collar.
NOTE
+ Be careful: the piston ring can easily breaks when bent.
ZIE135A
IE-3-9
TURBOCHARGER
2. Dip the thrust bearing into clean engine oil. Remove the thrust
ring from engine oil and install to the pin groove on the center
housing.
3. Dip the seal ring into clean engine oil. Remove the seal ring and
install to the ring groove on the center housing.
ZIE136A
j15 Back plate assembly

Install the back plate on the center housing and tighten with bolts.
: 13.2 N·m {1.35 kgfzm, 9.8 ftzlbf}
EIE2034
j12 Piston ring

Install the piston ring to the piston ring groove on the turbine wheel.
ZIE138A
ZIE139A
j11 Turbine wheel

The piston ring bore in the center housing is tapered. Position the
turbine wheel in the center housing using the shroud wheel as a
guide.
NOTE
+ Make sure the piston ring in the groove is not caught by
the turbine wheel during installation.
EIE2036
IE-3-10
TURBOCHARGER
j
10 Compressor wheel
1. Install the compressor wheel and temporarily tighten the lock
nut.
NOTE
+ Make sure the contact surfaces of the back surface of the
compressor wheel and thrust collar or spacer are clean
and free from scratches or foreign particles. Also check to
make sure the contact surface of the lock nut is clean.
+ Apply a thin coat of oil to the threaded portion of the shaft
before installation.
2. Set the assembled unit on the holding fixture (99768 Z5500) in

a vise.
ZIE126A
3. Attach the T-handle to the lock nut. Loosen the lock nut by
turning the T-handle counterclockwise, then tighten the lock nut
again by turning the handle clockwise. The lock nut must be
tightened in two steps.
1st step ... : 2.3 N·m {0.23 kgfzm, 1.7 ftzlbf}
2nd step ... 120° tightening angle
ZIE127A
4. Check for smooth rotation of the center housing.

NOTE
+ The center housing rotates clockwise as viewed from the
compressor wheel side.
If the center housing does not rotate smoothly, it may be
due to incorrect assembly. Disassemble and check for the
cause of the problem.
5. Install the compressor housing and actuator at the same time.
NOTE
+ Be careful not to scratch or bend the compressor wheel
during installation.
IE-3-11
TURBOCHARGER
j8 Actuator assembly
1. Connect an air hose to the actuator hose connection.
2. Following hose installation, apply air pressure through the air
hose until the rod moves to its stroke end. With the rod held in
that position, install the rod end to the waste gate.
3. Reduce air pressure to zero (0).
4. Attach a dial gauge so that it is coaxial with the rod end. Reset
the dial gauge to zero (0).
5. Gradually increase air pressure to move the rod until the dial
gauge registers 0.38 mm (0.0150 in). During air pressure
ZIE146A
application, apply light hammer blows to the turbine housing.
Use of a plastic hammer is preferred.
Pressure setting 130.0 - 136.6
kPa {mmHg, inHg} {975 - 1,025, 38.39 - 40.35}
Rod stroke length mm (in) 0.38 (0.0150)
NOTE
+ Do not increase air pressure abruptly. If the rod stroke
length exceeds 0.38 mm (0.0150 in) during air-pressure
application, reduce air pressure to zero (0) and gradually
increase air pressure again.
When the air pressure gauge reading is outside specifications
at a dial gauge indication of 0.38 mm (0.0150 in), proceed as
follows:
Air pressure reading greater than specifications:
Remove the rod end from the waste gate crank and loosen the
adjustable rod end to lengthen the rod.
Air pressure reading less than specifications:
Remove the rod end from the waste gate crank and tighten the
adjustable rod end to shorten the rod.
6. Following rod length adjustments, confirm that the air pressure
gauge reading is within specifications at a dial gauge indication
of 0.38 mm (0.0150 in). If adjustments are correct reduce air
pressure to zero.
NOTE
+ Be sure to reset the dial gauge to zero after adjustments.
+ The waste gage cannot be disassembled.
j4 Turbine housing
1. Temporarily tighten the turbine housing.
NOTE
+ To prevent turbine seizure, pour a seizure-preventative
agent (molybdenum disulfide) into the turbine bolt hole.
+ Be careful not to scratch, bend or otherwise damage the
turbine wheel during installation.
EIE2037
IE-3-12
TURBOCHARGER
2. The α angle and β angle of the turbine housing must be

maintained within a tolerance of ±1°.
α angle β angle
RH 42° 0°
LH 289° 40°
ZIE143A
3. Tighten the turbine housing to the specified torque setting.

Compressor housing 17 {1.7, 12}
Turbine housing 22 {2.2, 16}
4. Measure the axial play and radial play of the turbine housing
using the specific tools indicated in the Table below.
Item Tool number
Axial play measuring tool 99765 96001
99764 96000
Radial play measuring tool
99765 96000
ZIE144A
Unit: mm (in)
0.03 - 0.80
Axial play —
(0.0012 - 0.0315)
0.08 - 0.15
Radial play —
(0.0031 - 0.0059)
EIE2044A
INSTALLATION
1. Install the turbocharger assembly on the exhaust manifold
using a gasket.
: 34 - 44 N·m {3.5 - 4.5 kgfzm, 25 - 33 ftzlbf}
NOTE
+ Mounting nuts are heat-resistant types. Do not confuse
them with conventional nuts.
IE-3-13
TURBOCHARGER
2. Install the exhaust connector using a gasket and spacer to the

turbocharger assembly.
: 39 - 49 N·m {4.0 - 5.0 kgfzm, 29 - 36 ftzlbf}
NOTE
+ Mounting nuts are heat-resistant types. Do not confuse
them with conventional nuts.
3. Install the oil pipe.
: 21 - 26 N·m {2.1 - 2.7 kgfzm, 15 - 20 ftzlbf}
4. Connect the oil drain pipe to the turbocharger.
: 30 - 34 N·m {3.1 - 3.5 kgfzm, 22 - 25 ftzlbf}
5. Install the turbocharger shield plate, shield bracket and exhaust
connector shield plate.
6. Connect the air intake duct and exhaust pipe using a gasket.
7. After installing the turbocharger assembly, crank the engine
using the sub-starter switch. Crank for approximately 10 to 20
seconds while pulling the engine stop lever. Crank the engine
until the oil pressure gauge activates, since oil is not distributed
to the oil line.
IE-3-14
INTERCOOLER
INTERCOOLER
CONSTRUCTION
ZIE147A
INSPECTION
Remove the intercooler. If mud, insects, etc. are attached to the front surface of the intercooler core, remove
them using a copper wire or the like exercising care not to damage the tube.
Water pressure test
Seal one of the air intakes on the intercooler with a lid and connect a hose to the other intake. Then submerge
the intercooler under water in a tank and blow compressed air through the hose to the specified pressure to
check for air leakage.
Intercooler check pressure (air): 196 kPa {2.0 kgf/cm2, 28 psi}
IE-4-1
AIR CLEANER
AIR CLEANER
DISASSEMBLY
ZIE148A
j
1 Cover j
4 Element assembly (Outer) j
6 Body
j
2 Packing j
5 Element assembly (Inner) j
7 Evacuator valve
j
3 Adapter (LH only)
ELEMENT REPLACEMENT
For inspection and maintenance procedures, refer to the ‘‘MA’’ section.
IE-5-1
EXHAUST BRAKE
EXHAUST BRAKE
CONSTRUCTION
EXHAUST SHUTTER
ZIE149A
IE-6-1
EXHAUST BRAKE
DISASSEMBLY
WARNING
+ Before disassembling the exhaust system, ensure that
the engine is cool. If it is hot, wait until it cools off to
prevent scalding yourself.
EXHAUST SHUTTER
ZIE150A
j
1 Snap >j7 Lever j
12 Seal ring
j
2 Pin >j8 Stopper bolt j
13 Seal ring
j
3 Clevis j9 Plate j
14 Cover
j
4 Collar (Type II only) j
10 Seal ring j
15 Gasket
j
5 Air cylinder assembly j
11 Seal ring >j
16 Exhaust shutter assembly
j
6 Shield plate
Mark ‘‘>’’ indicates that the key points of operation are explained in the text.
IE-6-2
EXHAUST BRAKE
AIR CYLINDER
WIE013A
j
1 Snap j7 O-ring j
13 Guide
j
2 Pin j8 Retainer j
14 Washer (Exhaust shutter side only)
j
3 Clevis j9 Packing j
15 Protector
j
4 Dust seal j
10 Wear ring >j
16 Shaft
j
5 Cover j
11 Plate j
17 Cylinder body
.>j
6 Cover j
12 Spring
AIR CYLINDER
j6 Cover
Remove the cover and O-ring.
NOTE
+ Be careful when removing the cover - the shaft assembly
may jump out due to spring tension.
IE-6-3
EXHAUST BRAKE
INSPECTION
AIR CYLINDER
Spring tension
Unit: N {kgf, lbf}
When compressed to
77.5 {7.9, 17.4} —
113.2 mm (4.46 in)
EXHAUST SHUTTER
Valve movement in the axial direction when closing the
valve
Unit: mm (in)
More than 0.7 (0.028) —
Clearance between valve and body

Unit: mm (in)
One side 0.6 - 0.8 (0.024 - 0.031) —
Both sides 1.2 - 1.4 (0.047 - 0.055) —
REASSEMBLY
Discard old packings and O-rings; replace with new ones. Apply a
coat of specified grease to the rotating and sliding parts if so
designated. Unless otherwise specified, the frictional surfaces
must be coated with engine oil.
EXHAUST SHUTTER
j16 Exhaust shutter assembly
Install the shutter assembly to the plate.
: 10 - 16 N·m {1.0 - 1.6 kgfzm, 7 - 12 ftzlbf}
IE-6-4
EXHAUST BRAKE
j8 Stopper bolt
Turn the lever open all the way until it hits the stopper bolt. Adjust
the stopper bolt with the lever in this position, so that the valve and
the body flange surface make a 90 degree angle.
Then, turn the lever shut all the way until it hits the stopper bolt
again. Adjust the stopper bolt with the lever in this position, so that
the valve-to-body clearance is 0.6 to 0.8 mm (0.024 to 0.031 in) for
one side, and 1.2 to 1.4 mm (0.047 to 0.055 in) when both sides are
added.
EP15-4
j7 Lever
Install the lever to the spindle.
: 10 - 16 N·m {1.0 - 1.6 kgfzm, 7 - 12 ftzlbf}
After adjustment, fasten the stopper bolt with the lock nut.
Unit: mm (in)
Clearance 0.6 - 0.8

One side —
between (0.024 - 0.031)
valve and 1.2 - 1.4
body Both sides —
(0.047 - 0.055)
ZIE141A
AIR CYLINDER
Apply a coat of grease G420 (Shin-e-tsu Chemical-make) to the
cylinder interior, shaft surface and packing before assembly.
j16 Shaft
Install the protector, spring, ring, plate, packing and retainer to the
shaft, then tighten with nut and a washer in place.
: 10 - 16 N·m {1.0 - 1.6 kgfzm, 7 - 12 ftzlbf}
j6 Cover
Install the cover with an O-ring in place.
: 10 - 16 N·m {1.0 - 1.6 kgfzm, 7 - 12 ftzlbf}
IE-6-5
EXHAUST BRAKE
INSTALLING EXHAUST SHUTTER AND AIR CYLINDER

1. Install the air cylinder onto the plate.
2. Connect the shaft of the air cylinder with the clevis using a pin.
When connecting, turn the lever open all the way until it hits the
stopper bolt and pull out the shaft by the specified length (L)
with the lever in this position. In this state, fasten the air
cylinder.
Unit: mm (in)
Maintenance
Item Service limit
standard
WIE016A
Clearance between air
More than 1.0 (0.04) —
cylinder shaft and clevis
: 21 - 25 N·m {2.1 - 2.6 kgfzm, 15 - 19 ftzlbf}
INSTALLATION
Prior to installation, connect the exhaust valve and air cylinder in
advance.
Install the air cylinder to the plate first. Then connect the shaft of
the air cylinder assembly and the clevis with a pin.
Installing exhaust break
1. Fit the gasket onto the exhaust break assembly and temporarily
tighten the exhaust shutter mounting bolt.
2. Align the jig (99780 96502) for installing flexible tube.
3. Tighten the exhaust shutter mounting bolt securely. EIE2-024
4. Tighten the exhaust tube clamp securely.
5. Remove the jig for installing the flexible tube.
6. Connect the air hose with the air cylinder.
7. Install the exhaust break cover, engine room cover and other
covers.
IE-6-6
ENGINE DISASSEMBLY
AND REASSEMBLY
CONTENTS
SERVICE DATA .......................................... DR-1- 1 DISASSEMBLY AND
TIGHTENING TORQUE .............................. DR-1- 1 REASSEMBLY ............................................ DR-5- 1
TOOLS ........................................................... DR-2- 1 OUTSIDE OF ENGINE ............................... DR-5- 1
CONSTRUCTION ....................................... DR-3- 1 CYLINDER HEAD ....................................... DR-5- 8
ENGINE ....................................................... DR-3- 1 ENGINE PROPER ...................................... DR-5-11
GEAR TRAIN .............................................. DR-3- 3 ENGINE INSTALLATION ........................ DR-6- 1
ENGINE REMOVAL .................................. DR-4- 1
SERVICE DATA
SERVICE DATA
TIGHTENING TORQUE
Nozzle holder assembly mounting bolt 25 - 34 {2.5 - 3.5, 18 - 25}
Spill tube mounting bolt 29 {3.0, 22}
Pump side 29 - 39 {3.0 - 4.0, 22 - 29}
Injection tube
Nozzle side 25 - 34 {2.5 - 3.5, 18 - 25}
Fuel tube & fuel return tube 25 - 29 {2.5 - 3.0, 18 - 22}
Crank pulley bolt 177 - 196 {18.0 - 20.0, 130 - 145}
Cooling fan mounting nut 16 - 19 {1.6 - 1.9, 12 - 14}
Hydraulic pump drive gear mounting nut 54 - 64 {5.5 - 6.5, 40 - 47}
Alternator mounting bolt 59 - 78 {6 - 8, 43 - 58}
Exhaust manifold mounting nut 54 - 64 {5.5 - 6.5, 40 - 47}
Oil outlet pipe mounting bolt 30 - 34 {3.1 - 3.5, 22 - 25}
Oil cooler housing mounting bolt 16 - 19 {1.6 - 1.9, 12 - 14}
Turbocharger mounting bolt 34 - 44 {3.5 - 4.5, 25 - 33}
M8 10 - 13 {1.0 - 1.3, 7 - 9}
Air intake manifold mounting nut
M10 19 - 23 {1.9 - 2.3, 14 - 17}
Air compressor mounting bolt 30 - 36 {3.1 - 3.7, 22 - 27}
Starting motor mounting bolt 93 - 108 {9.5 - 11, 69 - 80}
Injection pump bracket mounting bolt 49 - 59 {5.0 - 6.0, 36 - 43}
Injection pump mounting bolt 34 - 39 {3.5 - 4.0, 25 - 29}
Injection pump coupling mount- Coupling bolt 59 - 64 {6.0 - 6.5, 43 - 47}

ing bolt Cotter bolt 83 - 93 {8.5 - 9.5, 61 - 69}
Feed side 10 - 18 {1.0 - 1.8, 7.2 - 13.0}
Injection pump oil tube connec-
Return Pump side 15 - 34 {1.5 - 3.5, 11 - 25}
tor
side Block side 25 - 41 {2.5 - 4.2, 18 - 30}
Engine mounting bracket mounting bolt 98 - 118 {10.0 - 12.0, 72 - 87}
Engine lifter mounting bolt 78 - 98 {8.0 - 10.0, 58 - 72}
1st 98 - 118 {10.0 - 12.0, 72 - 87}
Water pump tension pulley mounting bolt 2nd Loosen
3rd 98 - 118 {10.0 - 12.0, 72 - 87}
1st 147 - 157 {15.0 - 16.0, 108 - 116}
Cylinder head bolt
2nd 275 - 294 {28.0 - 30.0, 203 - 217}
Rocker shaft bracket mounting bolt 39 - 49 {4.0 - 5.0, 29 - 36}
Push rod cover mounting bolt 15 - 23 {1.5 - 2.3, 11 - 17}
DR-1-1
SERVICE DATA

Oil jet connector bolt 49 - 59 {5.0 - 6.0, 36 - 43}
Main bearing cap bolt 412 - 441 {42.0 - 45.0, 304 - 325}
Connecting rod cap nut 226 - 245 {23.0 - 25.0, 166 - 181}
Front cover mounting bolt 16 - 21 {1.6 - 2.1, 12 - 15}
Injection pump drive gear mounting nut 392 - 441 {40 - 45, 289 - 325}
Camshaft gear mounting nut 490 - 588 {50.0 - 60.0, 362 - 434}
Camshaft locating plate mounting bolt 20 {2.0, 14}
Idler gear shaft bolt 127 - 157 {13.0 - 16.0, 94 - 116}
Air compressor drive gear mounting nut 186 - 206 {19 - 21, 137 - 152}
Oil pump mounting bolt 34 - 49 {3.5 - 5.0, 25 - 36}
Oil screen & oil outlet pipe mounting bolt 30 - 34 {3.1 - 3.5, 22 - 25}
M10 54 - 59 {5.5 - 6.0, 40 - 43}
Flywheel housing mounting bolt
M12 88 {9.0, 65}
Housing side 147 {15.0, 108}
Stiffener mounting bolt
Block side 118 {12.0, 87}
Oil pan mounting bolt and nut 16 - 19 {1.6 - 1.9, 12 - 14}
Flywheel mounting bolt 275 - 304 {28 - 31, 203 - 224}
Crank damper mounting bolt 98 - 108 {10 - 11, 72 - 80}
Speed sensor lock nut 44 - 54 {4.5 - 5.5, 33 - 40}
DR-1-2
TOOLS
TOOLS
Guide bolt Used to remove/install flywheel.
99687 97001 M16 x 1.5
ER14-151
Engine stand Used to disassemble/reassemble engine.

99550 96001
ET14-001
Engine stand attachment Used to install engine on engine stand.

99554 97001
EP14-100
Piston insert tool Used as a guide when inserting piston into cylinder liner.
99631 97002
ET14045C
E-type socket Used to remove/install injection pump bracket.

99739 97000
ER14-100
DR-2-1
TOOLS

Main bearing cap puller Used to remove main bearing cap.
99601 97000
ER14-103
Guide bolt Used as a guide when installing main bearing cap.

99687 97004 M18 x 2.0
ER14-107
Hex wrench Used to remove/install main bearing cap side bolt.

99545 97000 Width across flats: 10 mm (0.39 in)
ER14-102
Bracket setting tool assembly Used as a centering tool when installing injection pump
99720 96000 bracket on cylinder block.
ETL2-003
Engine hanger Used when dismounting or mounting the engine.

99785 97000
ETL2-040
DR-2-2
CONSTRUCTION
CONSTRUCTION
ENGINE
ZDR097A
DR-3-1
CONSTRUCTION
ZDR098A
DR-3-2
CONSTRUCTION
GEAR TRAIN
ZDR099A
DR-3-3
ENGINE REMOVAL
ENGINE REMOVAL
PREPARATORY OPERATIONS
1. Turn the key switch off and disconnect the grounding cable from the negative terminal of the battery.
2. Tilt the cab.
NOTE
+ Visually check to make sure that the tilt stopper is being locked.
3. Drain the engine oil, power steering oil and cooling water, and remove the air in the air reservoir.
REMOVING PARTS AROUND THE ENGINE
1. Remove the noise cover from around the engine.
2. Remove the transmission noise cover.
3. Remove the air cleaner assembly and related parts.
4. Remove the car cooler compressor and related parts when equipped with an air conditioner.
5. Disconnect all wiring, pipes and linkages.
6. Disconnect the propeller shaft from the transmission.
7. Disconnect the control linkage, then remove the transmission assembly using a transmission jack.
8. Disconnect the water hose, then remove the radiator assembly.
9. Disconnect the exhaust manifold from the exhaust tube.
10. Remove the cab blower noise cover.
DISMOUNTING ENGINE
1. Remove the engine mount bracket on the engine side and the cushion rubber.
2. Attach the chain to the engine lifter, then dismount the engine assembly from the vehicle body by
suspending it using a crane.
NOTE
+ Before lifting the engine using a chain of less than 2.5 m (8.2 ft) in length, remove the intake duct,
tubes, etc., which may interfere with it. Or use the specified lifting device (99785 97000) to lift the
engine.
DR-4-1
DISASSEMBLY AND REASSEMBLY

OUTSIDE OF ENGINE
UPPER SIDE OF ENGINE
ZDR100A
DR-5-1
j
1 Air intake duct (A) j7 Fuel spill tube j
13 Fan shroud support
j
2 Air intake duct (B) j8 Fuel injection tube j
14 Fan shroud
j
3 Air pipe (Left) j9 Fuel tube (Outlet) j
15 Water tube
j
4 Air pipe (Right) j
10 Fuel tube (Inlet) j
16 Water tube
j
5 Fuel tube j
11 Air hose j
17 Oil tube
j
6 Fuel filter assembly .>j
12 Injection pump assembly

j
1. Removing the injection pump bracket:
Do not remove it unless it is damaged. When removing the
injection pump bracket, always use E type socket (99739
97000).
EDR2-029
2. Removing the injection pump support assembly:

Screw two guide bolts (M8 X 1.25) into the bolt holes in the
meter driver mounting and fix the injection pump drive gear to
the flywheel housing. Then remove the mounting nut.
EDR2027A

j
1. Installing the injection pump bracket:
Do not remove it unless it is damaged. When installing the
injection pump bracket, always use E type socket (99739
97000).
EDR2-029
DR-5-2
2. Centering the injection pump bracket:

Set a bracket setting tool (99720 96000) in place. then slide the
shaft and adjust by changing the thickness of the injection
pump bracket shims so the axis of the injection pump support
enters the hole on the end of the shaft smoothly.
Shim thickness [mm (in)]: 0.05, 0.10, 0.20, 0.30
(0.0020, 0.0039, 0.0079, 0.0118)
EDR2106A
3. Installing the injection pump support assembly:

Install the nuts and remove the two guide bolts which secure
the injection pump drive gear to the flywheel housing from the
holes at the meter driver.
EDR2027A
4. Installing the injection pump assembly:

+ Turn the flywheel in the standard direction of rotation to align
the scribed injection timing line at the No.4R cylinder compres-
sion stroke with the pointer. If not aligned properly, rotate the
flywheel in the reverse direction sufficiently, and reexecute the
alignment operation.
NOTE
+ Fuel injection timing
RF8TC: 14° B.T.D.C.
RF8TD: 12.5° B.T.D.C.
WMA163A
+ Align the mark on the injection pump with the scribed line on the
timer, then connect the coupling.
EDR2022A
DR-5-3
FRONT SIDE OF ENGINE
ZDR111A
>j
1 Cooling fan j6 Air compressor j
11 Thermostat housing
>j
2 Water pump drive belt j7 Water pump j
12 Water duct
>j
3 Alternator drive belt j8 Idler pulley j
13 Breather pipe
j
4 Crank pulley j9 Auto tensioner pulley j
14 Water pump drive belt
j
5 Alternator j
10 Adjusting bracket j
15 Tension pulley
DR-5-4
Key points of reassembly

j3 Alternator drive belt
+ Turn the adjusting bolt (B), located on the alternator adjusting
bracket, clockwise until the specified length ‘‘L’’ (shown in the
figure on the right) is obtained.
Length ‘‘L’’: 19.5 mm (0.768 in), max.
+ Tighten the tensioner spring mounting nut (A) (shown in the
figure on the right).
: 32 - 38 N·m {3.3 - 3.9 kgfzm, 24 - 28 ftzlbf} EMA2-027
j2 Water pump drive belt

Attach the tension pulley. Then place the belt on the unit and
stretch it with the tension pulley adjustment bolt.
+ ‘‘L’’ dimensions: 11 - 14 mm (0.43 - 0.55 in) (when the
center of the belt between the water pump and the tension
pulley is pressed with 98 N {10 kgf, 22 lbf} of force)
: 1st time: 98 - 118 N·m {10.0 - 12.0 kgfzm, 72 - 87 ftzlbf}
: 2nd time: Loosen
: 3rd time: 98 - 118 N·m {10.0 - 12.0 kgfzm, 72 - 87 ftzlbf}
EDR2038D
j1 Cooling fan
Install the fan shroud support and fan shroud.
+ Make sure that the clearance between the fan and fan shroud
is 5.0 mm (0.197 in).
NOTE
+ Refer to the figure at right for the belt layout.
+ Measuring points are shown in the figure at right.
+ Deflection A: 10.5 - 13.5 mm (0.413 - 0.531 in)
B: 11.0 - 14.0 mm (0.433 - 0.551 in)
Deflection weight 98 N {10 kgf, 22 lbf} constant
EDR2038F
DR-5-5
RIGHT SIDE OF ENGINE
ZDR102A
j
1 Exhaust manifold shield j
4 Oil cooler j
7 Shield plate
j
2 Exhaust manifold j
5 Drain cock j
8 Stiffener
j
3 Oil filter >j

j6 Short valve assembly
Install the oil cooler short valve assembly.
+ Install the short valve so that mark ‘‘→ F’’ faces the front of the
engine.
EDR2050A
DR-5-6
LEFT SIDE OF ENGINE
ZDR103A
j
1 Exhaust manifold shield j
4 Stiffener j
6 Oil level gauge
j
2 Exhaust manifold j
5 Oil pressure switch j
7 Cylinder block shield
j
3 Starting motor
DR-5-7
CYLINDER HEAD
EDR2114B
>j
1 Cylinder head cover assembly .>j
3 Cylinder head bolt j
5 Cylinder head gasket
.>j
2 Valve rocker assembly j
4 Cylinder head assembly
DR-5-8

j2 Valve rocker assembly
Be sure to loosen the mounting bolts proceeding from the outside
in.
j3 Cylinder head bolt
Be sure to loosen the bolts diagonally proceeding from the outside
in.

j3 Cylinder head bolt
Insert cylinder head bolts and tighten them evenly in 2 steps and in
the sequence shown in the figure.
: 1st: 147 - 157 N·m {15.0 - 16.0 kgfzm, 108 - 116 ftzlbf}
2nd: 275 - 294 N·m {28.0 - 30.0 kgfzm, 203 - 217 ftzlbf}
j2 Valve rocker assembly
Be sure to tighten the mounting bolts starting with inner ones and
proceeding to the outer ones. ZDR104A
: 39 - 49 N·m {4.0 - 5.0 kgfzm, 29 - 36 ftzlbf}
j1 Head cover assembly

Attaching the cylinder head cover:
+ When attaching the cylinder head cover, be especially careful
of the type of collars, cushions, and washers which are used.
EDR2056A
+ Install the rocker cover with attached oil filler at the third
cylinder from the front of the left bank.
ZDR105A
DR-5-9
- MEMO -
DR-5-10
ENGINE PROPER
ZDR106A
DR-5-11

j1 Water drain hose j
36 1st ring j
70 Plate
j2 Water drain cock assembly j
37 2nd ring j
71 Cover
j3 Oil pressure switch j
38 Oil ring j
72 Gasket
j4 Connector j
39 Snap ring .>j
73 Main bearing side bolt
j5 Connector bolt j
40 Piston pin j
74 Seal washer
j6 Bolt >j
41 Piston j
75 Main bearing cap bolt
j7 Spring washer j
42 Bushing .>j
76 Main bearing cap
j8 Plain washer j j
77 Main shell metal
43 Cylinder liner
j9 Cushion rubber j
78 Thrust washer
j
44 Water seal rubber ring
j
10 Cylinder block shield j
79 Thrust washer
j
j
11 Spacer .>j
80 Crankshaft assembly
j
j
12 Oil level gauge j
81 Front oil seal sleeve
j
47 Bolt
>j
13 Oil level guide j
82 O-ring
.>j
48 Crank pulley
>j
14 Oil pan j
83 Straight pin
j
49 Lock plate
j
15 Oil pan gasket j
84 Balancer weight bolt
j j
50 Crank damper j
16 Oil filler connector 85 Camshaft nut
j
17 Gasket
j
51 Crank weight j
86 Lock washer
j
18 O-ring j
52 Front cover .>j
87 Camshaft gear
j
19 Oil drain plug j
53 Gasket j
88 Camshaft collar
j
20 Gasket j
54 Front oil seal j
89 Locating washer
j
21 Oil screen assembly j
55 Flywheel bolt j
90 Key
j
22 Gasket .>j
56 Flywheel assembly j
91 Camshaft assembly
j
23 Spacer j
57 Lock plate >j
92 Push rod cover
j
24 Outlet pipe assembly j
58 Balancer weight j
93 Spacer
j
25 Gasket j
59 Ball bearing j
94 1st camshaft bushing
j
26 O-ring j
60 Rear oil seal j
95 2nd camshaft bushing
j
27 Oil pump assembly >j
61 Flywheel housing j
96 3rd camshaft bushing
j
28 Piston oil jet bolt j
62 Gasket j
97 4th camshaft bushing
j
29 Piston oil jet nut j
63 Rear end plate j
98 Rear camshaft bushing
j
30 Nut j
64 Gasket j
99 Idler shaft bolt
>j
31 Connecting rod bearing cap >j
65 Speed sensor 100 Idler plate
j
j
32 Lower shell metal j
66 Lock nut 101 Idler cluster gear
.>j
j
33 Cap bolt j
67 Pointer cover 102 Idler bushing
j
j
34 Upper shell metal j
68 Gasket 103 Idler gear shaft
j
.>j
35 Connecting rod j
69 Pointer 104 Cylinder block
j
Key points of disassembly

Engine stand attachment
Attach the engine stand attachment (99554 97001).
+ Be sure to insert a mounting bolt in the upper left corner of the
engine stand before attaching to the engine.
+ Using the special hex wrench (99545 97000), remove the No.
3 and No. 4 main bearing side bolts on the left side of the
cylinder block in advance.
EDR2076A
DR-5-12
EDR2-065
Engine stand
Raise the engine using a hoist, and mount it on the engine stand
(99550 96001).
EDR2-067
Gear train
Measure and record the backlash of the gear train.
ZDR107A
j35 Connecting rod

Before removing the piston assembly and connecting rod assem-
bly, measure and record the side clearance at the large end of the
connecting rod for each cylinder.
ER3-140
j48 Crank pulley

Straighten the lock washers, then remove the crank pulley mount-
ing bolts. The crank pulley, crank damper and balancer weight can
then be removed as a unit.
EDR2062B
DR-5-13
j
56 Flywheel assembly
1. Before removing the flywheel, measure and record the lateral
runout of the clutch disc surface of the flywheel.
CCL1030C
2. Remove the flywheel utilizing the guide bolts (99687 97001).
EDR2-063
j73 Main bearing side bolt

Remove the main bearing cap side bolt using a hexagonal wrench
(99545 97000).
EDR2-076
j
76 Main bearing cap
Remove the main bearing cap using a special puller (99601
97000).
EDR2-079
j
Measure and record the crankshaft end play.
ER3-143
DR-5-14
j87 Camshaft gear

Measure and record the camshaft end play before removing the
camshaft gear.
ER3-208
101 Idler cluster gear

j
Measure and record the idler gear (cluster gear) end play.
ER3-150

101 Idler cluster gear
j
1. Installing the idler gear (cluster gear) assembly.
+ Align the marks on the crank gear and idler gear, and install the
cluster gear assembly onto the idler shaft. Then tighten the idler
shaft bolt with the idler shaft plate in place.
ER4-106
NOTE
+ Install the idler shaft plate with the grooved side (on the
flat surface) facing the idler shaft bolt seat (that is, the rear
side of the engine).
: 127 - 157 N·m {13 - 16 kgfzm, 94 - 116 ftzlbf}
EDR2094A
2. Align the marks on the idler gear and injection pump drive gear,
then install them.
EDR2003C
DR-5-15
3. Install the oil jets used to lubricate the gear train with the oil
holes [1.0 mm (0.039 in) diameter] facing the center of the
crankshaft.
EDR2-129
4. Measure and record the idler gear (cluster gear) end play.
ER3-150
j92 Push rod cover

When the push rod cover which has been removed is used again,
apply an appropriate amount of liquid gasket (Three Bond No.1207
or equivalent) to the contacting surface of the block and cover.
Then install the push rod cover according to the tightening order
with the gasket in place.
Install the main bearing shell in its original position.
The thrust washer has an oil groove which should face the
crankshaft when installed. Install upper and lower washers of the
same thickness with the grooves facing the same direction.
EDR2-112
NOTE
+ Before applying liquid gasket, remove any dust, oil and
water from the flanged surface of all parts.
+ Apply an equal amount of liquid gasket to the flanged
surface without breaks. Be sure to overlap the gasket
ends.
+ Install the parts within 10 minutes after liquid gasket
application.
+ After installing the parts, ensure all parts are properly set
in their positions.
+ If any of the parts are removed for some reason after
installation, completely remove all traces of liquid gasket ZDR108A
from the mating surfaces of the parts before applying new
liquid gasket again.
DR-5-16
j87 Camshaft gear

Measure and record the camshaft end play after installing the
camshaft gear.
ER3-208
j
Measure and record the crankshaft end play.
ER3-143
j
76 Main bearing cap
1. Attach the main bearing cap using a special guide bolt (99687
97004).
EDR2-091
2. Attaching direction of the main bearing cap.

Tighten the main bearing cap bolts.
: 412 - 441 N·m {42 - 45 kgfzm, 304 - 325 ftzlbf}
EDR2-092
j73 Main bearing side bolt

Install the main bearing cap side bolt using a hexagonal wrench
(99545 97000).
EDR2-076
DR-5-17
j65 Speed sensor

Install the speed sensor (pickup) on top of the flywheel housing and
adjust the clearance between the tip of the sensor and the outer
perimeter of the flywheel pulse gear. For details, refer to the
adjustment procedure described below.
ZDR113A
<Adjustment procedure>
+ Tighten the speed sensor until the tip end is in contact with
the outer perimeter of the pulse gear, then back off one
rotation.
+ Using a feeler gauge, measure the clearance between the
tip of the speed sensor and the outer perimeter of the
pulse gear. The clearance must be 3 mm (0.12 in).
+ Tighten the lock nut.
Gear train
Measure and record the backlash of the gear train.
ZDR107A
j
61 Flywheel housing
Measure the misalignment of the flywheel housing.
ER3-136
j
56 Flywheel assembly
1. Install the flywheel utilizing the guide bolt (99687 97001).
EDR2-063
DR-5-18
2. Measure the runout of the clutch disc contacting surface on the

flywheel after installing the flywheel.
CCL1030C
j
48 Crank pulley
1. Install the crank pulley assembly.
Tighten the crank pulley bolts in a criss-cross fashion to the
specified torque. After tightening all bolts, recheck all bolts for
the specified torque setting.
: 177 - 196 N·m {18.0 - 20.0 kgfzm, 130 - 145 ftzlbf}
EDR2061A
2. Place each piston at its top dead center on the compression

stroke, and measure the piston top clearance at this position.
EDR2-100
j
41 Piston
1. Install the piston assembly with a connecting rod using a piston
insert tool (99631 97002).
ET14046A
2. Position and direction of the piston:
EDR016A
DR-5-19
3. Do not install the piston ring in such a way that its gap faces the
direction of the piston pin and is in a vertical direction.
ZDR112A
j
35 Connecting rod
After installing the piston assembly and connecting rod assembly,
measure and record the side clearance at the large end of the
connecting rod for each cylinder.
ER3-140
j
31 Connecting rod bearing cap
Align the marks stamped on the end faces of the connecting rod
and cap. Tighten the cap nuts.
NOTE
+ Apply a coat of engine oil to the cap nut seating surfaces
and bolt threads before installation.
: 226 - 245 N·m {23.0 - 25.0 kgfzm, 166 - 181 ftzlbf}
ER4-114
j14 Oil pan

Before installing the oil pan, apply a coat of liquid gasket (Three
Bond 1207D or equivalent) sparingly to the mating surfaces of the
front cover, end plate located at the flywheel, and the gasketed
joint.
NOTES
+ Before applying liquid gasket, remove any dust, oil and
water from the flanged surfaces of the parts.
+ Install the parts within 10 minutes after liquid gasket
application.
+ Ensure the oil pan is correctly installed.
+ If any of the parts are removed for some reason, com-
pletely remove all traces of liquid gasket from the parts
before applying new liquid gasket again.
ZDR110A
DR-5-20
j13 Oil level guide

Install the oil level guide on the oil pan. Use a wrench to prevent the
connector from turning and tighten the flare nut.
EDR2007G
DR-5-21
ENGINE INSTALLATION
ENGINE INSTALLATION
MOUNTING ENGINE
1. Raise the engine assembly using a crane and move it to the mounting position of the vehicle body.
2. Gently lower the engine, then align the front and rear engine mounting positions and tighten the bolts.
INSTALLING PARTS AROUND ENGINE
1. Install the rear cab mount bracket.
2. Connect the exhaust tube with the exhaust manifold.
3. Install the radiator assembly and connect the water hose.
4. Mount the transmission assembly using a transmission jack. Then connect the control linkage, cables and
wires.
5. Connect the transmission with the propeller shaft. Connect all wiring, pipes and linkages.
6. Install the car cooler compressor and accessories when equipped with an air conditioner.
7. Install the air cleaner assembly and related parts and connect the air hose.
PREPARATORY OPERATIONS PRIOR TO STARTING ENGINE
1. Fill the engine oil, power steering oil and engine cooling water.
2. Remove the air in the fuel system.
3. Adjust the valve clearance.
4. Install the V-belt and adjust the tension.
5. Connect the cable to the negative terminal of the battery.
6. Start up the engine, then remove the air in the power steering system.
7. Check to make sure that there is no leakage of air, cooling water, fuel or oil from any connecting points.
8. Install the transmission under cover, engine room side cover, under cover and other covers.
DR-6-1
ENGINE PROPER
CONTENTS
SERVICE DATA ........................................... EP-1- 1 V-BELT ......................................................... EP-3-13
TOOLS ........................................................... EP-2- 1 REPAIR AND REPLACEMENT ............. EP-4- 1
INSPECTION ............................................... EP-3- 1 CYLINDER LINER REPLACEMENT ........... EP-4- 1
CYLINDER BLOCK ..................................... EP-3- 1 CAMSHAFT CORRECTION ........................ EP-4- 1
CRANKSHAFT ............................................ EP-3- 2 CAMSHAFT BUSHING REPLACEMENT ... EP-4- 2
MAIN BEARING SHELL .............................. EP-3- 5 CRANKSHAFT CORRECTION ................... EP-4- 3
CYLINDER LINER ....................................... EP-3- 5 CRANKSHAFT ACCESSORIES
PISTON AND CONNECTING ROD ............ EP-3- 6 REPLACEMENT .......................................... EP-4- 4
CAMSHAFT ................................................. EP-3-10 CONNECTING ROD REPLACEMENT ....... EP-4- 7
GEAR TRAIN ............................................... EP-3-11 REPLACING CONNECTING ROD SMALL
FLYWHEEL .................................................. EP-3-12 END BUSHING ............................................ EP-4- 7
FLYWHEEL HOUSING, REAR END PLATE IDLER GEAR (A) BUSHING
AND FRONT COVER .................................. EP-3-12 REPLACEMENT .......................................... EP-4- 9
CRANK PULLEY AND DAMPER ................ EP-3-12 FLYWHEEL CORRECTION ........................ EP-4- 9
SERVICE DATA
SERVICE DATA
Unit: mm (in)
Item Remarks
tion standard limit
Longitudinal Less than
—
Flatness of the top direction 0.01 (0.0004)
surface Transverse Less than
—
direction 0.02 (0.0008)
Less than
Roundness —
0.025 (0.0010)
Cylinder block
Roundness of the
0.014T - 0.031L
liner engaging inner Upper —
Fitting (0.0006T - 0.0012L) L: Loose
wall
length 0.010T - 0.035L T: Tight
Lower —
(0.0004T - 0.0014L)
0.05T - 0.02L
Clearance between Fit-in section —
(0.0020T - 0.0008L) L: Loose
main bearing cap and
Side bolt 0 - 0.07L T: Tight
cylinder block —
section (0 - 0.0028L)
Water pressure test kPa {kgf/cm2, psi} 392 {4.0, 57} —
109.87 - 109.89
Outside diameter of journal 109.00 (4.2913)
(4.3256 - 4.3264)
89.89 - 89.91
Outside diameter of crankshaft pin 88.89 (3.4996)
(3.5390 - 3.5398)
Less than
Out-of-roundness of journal and crank pin 0.06 (0.0024)
0.005 (0.0002)
Less than
Taper of journal and crank pin —
0.01 (0.0004)
109.62 - 109.64
Crankshaft
0.25 U.S. —
(4.3157 - 4.3165)
Journal grinding 109.37 - 109.39
0.50 U.S. —
dimensions (4.3059 - 4.3067)
109.12 - 109.14
0.75 U.S. —
(4.2961 - 4.2968)
U.S.: Undersize
89.64 - 89.66
0.25 U.S. —
(3.5291 - 3.5299)
Crank pin grinding 89.39 - 89.41
0.50 U.S. —
dimensions (3.5193 - 3.5201)
89.14 - 89.16
0.75 U.S. —
(3.5094 - 3.5102)
EP-1-1
SERVICE DATA
Unit: mm (in)
Item Remarks
tion standard limit
Journal Less than
0.40 (0.0157)
location (A) 0.03 (0.0012)
Oil seal Less than Support the No. 2 and No. 4
Runout —
location (B) 0.01 (0.0004) journals
Flywheel Less than
—
location (C) 0.02 (0.0008)
0.05 - 0.14
End play 0.50 (0.0197)
(0.0020 - 0.0055)
3.995 - 4.025
A —
Crankshaft
(0.1573 - 0.1585)
3.970 - 4.000
B — Standard
(0.1563 - 0.1575)
3.945 - 3.975
Thrust washer types C —
(0.1553 - 0.1565)
4.145 - 4.175
0.15 O.S. —
(0.1632 - 0.1644)
O.S.: Oversize
4.295 - 4.325
0.30 O.S. —
(0.1691 - 0.1703)
Clearance between main bearing shell and 0.04 - 0.12
0.20 (0.0079)
crankshaft journal (0.0016 - 0.0047)
Oil seal sleeve press-fit length ‘‘L’’ 12 (0.47) —
EP-1-2
SERVICE DATA
Unit: mm (in)
Maintenance Service
Position Item Remarks
standard limit
Measure at 40, 90, 120, 170
Inside diameter and 200 mm (1.57, 3.54, 4.72,
138.00 - 138.03
(without dismounting it from the cyl- 138.25 (5.4429) 6.69 and 7.87 in) positions
(5.4331 - 5.4342)
Cylinder liner
inder block) from the top surface of the

block
Out-of-roundness Less than 0.03 (0.0012) —
Taper Less than 0.03 (0.0012) —
Protrusion of cylinder liner flange 0.01 - 0.07
—
above cylinder block (0.0004 - 0.0028)
Gap between adjoining cylinders Less than 0.05 (0.0020) —
Measure at 25.0 mm (0.984 in)
137.900 - 137.930
Outside diameter — position from bottom surface,
(5.4291 - 5.4303)
perpendicular to piston pin
Clearance between piston and cyl- 0.09 - 0.11
Piston
—
inder liner (0.0035 - 0.0043)
50.00 - 50.02
Inside diameter of piston pin 50.10 (1.9724)
(1.9685 - 1.9693)
0.30 - 0.84 Upper surfaces of piston and
Top clearance —
(0.0118 - 0.0331) cylinder block
Clearance be- 0.04 - 0.06
2nd ring 0.40 (0.0157)
tween the piston (0.0016 - 0.0024)
ring and ring 0.02 - 0.06
Oil ring 0.20 (0.0079)
groove (0.0008 - 0.0024)
Piston ring
Piston and connecting rod
0.33 - 0.48
1st ring 2.00 (0.0787)
(0.0130 - 0.0189)
End gap of each 0.45 - 0.60
2nd ring —
piston ring (0.0177 - 0.0236)
0.25 - 0.45
Oil ring 2.00 (0.0787)
(0.0098 - 0.0177)
49.99 - 50.00
Outside diameter 49.90 (1.9646)
(1.9681 - 1.9685)
Piston pin
Clearance between piston pin and 0 - 0.03

0.10 (0.0039)
piston pin bore (0 - 0.0012)
0.10 (0.0039)
small end bushing and piston pin (0.0012 - 0.0020)
Inside diameter of small end bush- 50.03 - 50.04
—
ing (1.9697 - 1.9701)
Connecting rod
Clearance between large end bear- 0.046 - 0.112

0.20 (0.0079)
ing and crank pin (0.0018 - 0.0044)
Bend Less than 0.05 (0.0020) — When the distance between
Twist Less than 0.06 (0.0024) — pins is 250 mm (9.84 in)
Side clearance between 0.20 - 0.45 Measure with one side set to
—
connecting rod and crank pin (0.0079 - 0.0177) zero
EP-1-3
SERVICE DATA
Unit: mm (in)
Item Remarks
tion standard limit
0.07 - 0.23
End play 0.50 (0.0197)
(0.0028 - 0.0091)
65.69 - 65.78
No. 1 65.43 (2.5760)
(2.5862 - 2.5898)
65.89 - 65.98
No. 2 65.63 (2.5839)
(2.5941 - 2.5976)
Outside diameter of 66.09 - 66.18
No. 3 65.83 (2.5917)
journal (2.6020 - 2.6055)
66.29 - 66.38
Camshaft
No. 4 66.03 (2.5996)

(2.6098 - 2.6134)
66.49 - 66.58
No. 5 66.23 (2.6075)
(2.6177 - 2.6213)
Clearance between journal and 0.02 - 0.11
0.20 (0.0079)
bushing (0.0008 - 0.0043)
56.76 - 56.80
Intake —
(2.2346 - 2.2362)
Height of
55.67 - 55.71
cam Exhaust —
(2.1917 - 2.1933)
profile
Less than 0.03 Support the No. 2 and No. 4
Runout 0.06 (0.0024)
(0.0012) journals
A, B, 0.07 - 0.14
—
C, D, E (0.0028 - 0.0055)
Gear train backlash
0.09 - 0.22
F, G —
(0.0035 - 0.0087)
Gear train
0.05 - 0.20
Idler gear end play 0.30 (0.0118)
(0.0020 - 0.0079)
Clearance between idler gear 0.03 - 0.06
0.20 (0.0079)
bushing and shaft (0.0012 - 0.0024)
50.00 - 50.02
Inside diameter of bushing A — ZDR107A
(1.9685 - 1.9693)
Lateral runout of clutch disc Less than 0.10

0.15 (0.0059)
surface (0.0039)
Flywheel
Standard depth from flange 5.9 - 6.1

8.0 (0.315)
end face (A) (0.232 - 0.240) ZEP048A
11 - 14
A —
(0.43 - 0.55)
Deflection of V-belt
V-belt
[when applied with

98 N {10 kgf, 22 lbf}
force at midpoint]
10.5 - 13.5
B —
(0.413 - 0.531)
ZEP049A
EP-1-4
TOOLS
TOOLS
Straight edge For measuring flatness of cylinder block and cylinder head
99645 Z5001 gasketed surfaces
ES14-8
Hydraulic pump Used to conduct hydraulic tests on cylinder block, cylinder

99570 Z5000 head and oil cooler element.
EP14-119
Cylinder block & cylinder

head attachment assembly
99561 97000
ER14-104
Piston ring tool For removal and installation of piston ring

99630 Z0001
EP14-111
Cylinder liner tool For removal and installation of cylinder liner

99600 97001
ER14-105
EP-2-1
TOOLS

Cam bush tool assembly For removal of cam bushing
99590 97002
ET14010A
Cam bush tool assembly For installation of cam bushing

99590 97003 Cam bush replacer
j1 For No. 1
j2 For No. 5
j3 For No. 2
j4 For No. 3
j5 For No. 4
Replace bar
j6 For No. 2 - 4
ET14012E
Front oil seal replacer For pressing front oil seal sleeve
99691 97004
ETL2006D
Rear oil seal sleeve For removing oil seal sleeve and oil seal as a unit
remover
99692 97000
ETL2-039
Rear oil seal sleeve Used to install oil seal sleeve and oil seal as a unit.
replacer
99691 97005
ETL2006E
EP-2-2
TOOLS

Connecting rod bush Used to install connecting rod small end bushing.
replacer tool assembly
99740 97004
ETL2027A
Connecting rod bush Used to remove connecting rod small end bushing.
remover tool
99740 97002
ETL2-026
EP-2-3
INSPECTION
INSPECTION
+ Clean all the disassembled parts thoroughly with cleaning fluid.
While cleaning, inspect the parts for cracks and other damage
carefully. If faulty, replace with a new one.
+ If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.
CYLINDER BLOCK
Flatness of the top surface
Using a straight edge (99645 Z5001), measure the flatness of the
top surface.
Unit: mm (in)
Longitudinal direction Less than 0.01 (0.0004) —
Transverse direction Less than 0.02 (0.0008) —
ER4-142
Roundness of the liner engaging inner wall and fitting

length
Unit: mm (in)
Roundness Less than 0.025 (0.0010) —
0.014T - 0.031L
Upper —
Fitting (0.0006T - 0.0012L) L: Loose
length 0.010T - 0.035L T: Tight
Lower —
(0.0004T - 0.0014L)
EEP2-005
Inside diameter of the camshaft bushing

Measure and record the inside diameter of the camshaft bushing.
ER5-103
Clearance between main bearing cap and cylinder

block
Unit: mm (in)
Item Maintenance standard Remarks
0.05T - 0.02L
Fit-in section L: Loose
(0.0020T - 0.0008L)
T: Tight
Side bolt section 0 - 0.07L (0 - 0.0028L)
EEP2-004
EP-3-1
INSPECTION
WATER PRESSURE TEST

Using a hydraulic pump (99570 Z5000) and a cylinder block
attachment (99561 97000), perform a water pressure test.
Maintenance standard
Water pressure 392 {4.0, 57}
ER5-104
CRANKSHAFT
Outside diameter of the journal
Measure and record the outside diameter of the journal. If the
measured value has reached the service limit, grind the journal to
the undersize, and install the undersize main bearing shell.
Unit: mm (in)
Maintenance
standard
109.87 - 109.89
S.T.D. 109.00 (4.2913) ER5-108
(4.3256 - 4.3264)
109.62 - 109.64
0.25 U.S. —
(4.3157 - 4.3165)
U.S.: Undersize
109.37 - 109.39
0.50 U.S. —
(4.3059 - 4.3067)
109.12 - 109.14
0.75 U.S. —
(4.2961 - 4.2968)
Out-of-roundness of the journal

If the out-of-roundness has exceeded the maintenance standard,
grind the journal to the undersize, and install the undersize main
bearing shell.
Unit: mm (in)
Less than 0.005 (0.0002) 0.06 (0.0024)
Taper of the journal

If the taper has exceeded the maintenance standard, grind the
journal to the undersize, and install the undersize main bearing
shell.
Unit: mm (in)
Less than 0.01 (0.0004) —
EP-3-2
INSPECTION
Outside diameter of the crankshaft pin

Measure and record the outside diameter of the crankshaft pin. If
the measured value has reached the service limit, grind the pin to
the undersize, and install the undersize bearing shell.
Unit: mm (in)
89.89 - 89.91
S.T.D. 88.89 (3.4996)
(3.5390 - 3.5398)
89.64 - 89.66
0.25 U.S. — ER5-109
(3.5291 - 3.5299)
89.39 - 89.41
0.50 U.S. —
(3.5193 - 3.5201)
89.14 - 89.16
0.75 U.S. —
(3.5094 - 3.5102)
U.S.: Undersize
Out-of-roundness of the crankshaft pin

If the out-of-roundness has exceeded the maintenance standard,
grind the pin to the undersize, and install the undersize bearing
shell.
Unit: mm (in)
Less than 0.005 (0.0002) 0.06 (0.0024)
Crankshaft pin taper

If the taper has exceeded the maintenance standard, grind the pin
to the undersize, and install the undersize bearing shell.
Unit: mm (in)
Less than 0.01 (0.0004) —
EP-3-3
INSPECTION
Runout
Support the No. 2 and No. 4 journals and measure the runout of
each part.
Unit: mm (in)
At journal Less than 0.03 (0.0012) 0.40 (0.0157)
Front oil seal contacting
Less than 0.01 (0.0004) —
surface
Rear flywheel mounting ER5-149
Less than 0.02 (0.0008) —
surface
End play
If the end play measured during disassembly has reached the
specified service limit, replace the upper and lower thrust washers
as a unit with a suitable set of thrust washers so that the end play
is within the maintenance standard.
Unit: mm (in)
0.05 - 0.14 (0.0020 - 0.0055) 0.50 (0.0197)
Unit: mm (in)
Size identification mark Thickness Remarks
3.995 - 4.025
A
(0.1573 - 0.1585)
3.970 - 4.000
B Standard
(0.1563 - 0.1575)
Thrust washer 3.945 - 3.975
C
type (0.1553 - 0.1565)
4.145 - 4.175
0.15 O.S.
(0.1632 - 0.1644)
O.S.: Oversize
4.295 - 4.325
0.30 O.S.
(0.1691 - 0.1703)
EP-3-4
INSPECTION
MAIN BEARING SHELL

Clearance between main bearing shell and crankshaft
journal
With the main bearing shell assembled to the cylinder block,
tighten the main bearing cap to the specified torque and measure
the inside diameter of the main bearing shell.
Calculate the clearance between the journal O.D. and main
bearing shell I.D. from the measured values.
: 412 - 441 N·m {42 - 45 kgfzm, 304 - 325 ftzlbf}
ER5-107
Unit: mm (in)
0.04 - 0.12 (0.0016 - 0.0047) 0.20 (0.0079)
CYLINDER LINER
Measure the cylinder liner without dismounting it from the cylinder
block.
Inside diameter
Unit: mm (in)
138.00 - 138.03 (5.4331 - 5.4342) 138.25 (5.4429)
ZEP050A
Out of roundness
Unit: mm (in)
Less than 0.03 (0.0012) —
Taper
Unit: mm (in)
Less than 0.03 (0.0012) —
Protrusion of cylinder liner flange above cylinder block

and gap between adjoining cylinder
Unit: mm (in)
0.01 - 0.07
Protrusion —
(0.0004 - 0.0028)
Gap Less than 0.05 (0.0020) —
ER4-147
EP-3-5
INSPECTION
PISTON AND CONNECTING ROD

It is necessary to examine the piston and connecting rod.
When they are disassembled, keep the component parts
grouped by cylinder numbers.
NOTE
+ The piston rings for all cylinders should be replaced as an
assembly during overhaul.
j
1 1st ring j8 Bolt
j
2 2nd ring j9 Connecting rod
j
3 Oil ring j
10 Bearing shell (upper)
j
4 Piston j
11 Bearing shell (lower)
j
5 Retaining ring j
12 Connecting rod cap
j
6 Piston pin j
13 Nut
j
7 Bushing
EP5-11A
Disassembling the piston and connecting rod

+ Remove the retaining ring and piston pin.
EEP1-006
+ Remove the piston rings using a piston ring tool (99630 Z0001).
EEP3-005
PISTON
Outside diameter
Measurement should be made at 25.0 mm (0.984 in) ‘‘L’’ position
from the bottom side of the piston at a right angle to the piston pin
axis.
Unit: mm (in)
137.900 - 137.930 (5.4291 - 5.4303) —
ZEP051A
EP-3-6
INSPECTION
Clearance between piston and cylinder liner

Calculate the clearance between the cylinder liner I.D. and piston
O.D. from the measured values.
Unit: mm (in)
0.09 - 0.11 (0.0035 - 0.0043) —
Inside diameter of the piston pin

Unit: mm (in)
50.00 - 50.02 (1.9685 - 1.9693) 50.10 (1.9724)
ER5-114
PISTON RINGS
Clearance between the piston ring and ring groove
Unit: mm (in)
2nd ring 0.04 - 0.06 (0.0016 - 0.0024) 0.40 (0.0157)
Oil ring 0.02 - 0.06 (0.0008 - 0.0024) 0.20 (0.0079)
NOTE
+ The first ring is a keystone ring and cannot be measured. ER5-169
End gap of each piston ring

Unit: mm (in)
0.33 - 0.48
1st 2.00 (0.0787)
(0.0130 - 0.0189)
0.45 - 0.60
2nd —
(0.0177 - 0.0236)
0.25 - 0.45
Oil 2.00 (0.0787)
(0.0098 - 0.0177)
ER5-150
PISTON PIN
Outside diameter
Unit: mm (in)
49.99 - 50.00 (1.9681 - 1.9685) 49.90 (1.9646)
EEP1-011
EP-3-7
INSPECTION
Clearance between piston pin and piston pin bore

Calculate the clearance between the piston pin O.D. and piston pin
bore I.D. from the measured values.
Unit: mm (in)
0 - 0.03 (0 - 0.0012) 0.10 (0.0039)
CONNECTING ROD
Inside diameter of small end bushing
Unit: mm (in)
50.03 - 50.04 (1.9697 - 1.9701) —
ER4-145
Clearance between small end bushing and piston pin

Calculate the clearance between the piston pin O.D. and small end
bushing I.D. from the measured values.
Unit: mm (in)
0.03 - 0.05 (0.0012 - 0.0020) 0.10 (0.0039)
Clearance between large end bearing and crank pin

Fit each bearing shell to the connecting rod having the same
cylinder No., then tighten the connecting rod and cap to the
specified torque.
: 226 - 245 N·m {23.0 - 25.0 kgfzm, 166 - 181 ftzlbf}
Calculate the clearance between the crank pin O.D. and bearing
shell I.D. from the measured values.
Unit: mm (in)
EP5-17
0.046 - 0.112 (0.0018 - 0.0044) 0.20 (0.0079)
EP-3-8
INSPECTION
Bend and twist

Mount the connecting rod fitted with the connecting rod cap to the
connecting rod aligner, and insert the piston pin into the small end
bushing. Measure the clearance at the aligner pin (A) and (B) to
check the bend and twist of the connecting rod. If the dimensions
of the pins A and B are other than 250 mm (9.84 in), calculate the
bend or twist when they are 250 mm (9.84 in) by using the following
equation:
250 (9.84) ZEP003A

Bend or twist = X Measured value
Distance between [mm (in)]
(A) and (B)
Unit: mm (in)
Bend Less than 0.05 (0.0020) — When the distance

between pins is
Twist Less than 0.06 (0.0024) — 250 mm (9.84 in).
ZEP004A
Side clearance between connecting rod and crank pin

Check the value (A) measured when the engine was disas-
sembled.
Unit: mm (in)
0.20 - 0.45 Measure with one side
—
(0.0079 - 0.0177) set to zero
ER5-151
Reassembling piston and connecting rod

1. Install the piston rings using a piston ring tool (99630 Z0001).
NOTE
+ Be sure to install with the manufacturer’s mark facing
upward.
2. Reassemble the piston, piston pin, snap ring and connecting
rod.
NOTE
+ Reassemble so that the piston I.D. and the cylinder No.
stamped on the connecting rod face the same direction. ER5-116
3. Install the piston, piston pin, snap ring and connecting rod.
NOTE
+ The balancer weight fitted side of the connecting rod small
end and the mark ‘‘IN’’ stamped side of the piston must
face toward the same direction.
ZEP057A
EP-3-9
INSPECTION
CAMSHAFT
End play
If the end play measured during disassembly of the engine has
reached the specified service limit, replace the locating plate with a
new one.
Unit: mm (in)
0.07 - 0.23 (0.0028 - 0.0091) 0.50 (0.0197)
ER4-148
Disassembly of camshaft gear

j
1 Nut j
4 Locating plate
j
2 Washer j
5 Key
j
3 Camshaft gear j
6 Camshaft
WEP004A
Outside diameter of the journal

Measure the outside diameters of each journal.
Unit: mm (in)
Journal No. Maintenance standard Service limit
65.69 - 65.78 65.43
No. 1
(2.5862 - 2.5898) (2.5760)
65.89 - 65.98 65.63
No. 2
(2.5941 - 2.5976) (2.5839)
66.09 - 66.18 65.83 EEP3-025
No. 3
(2.6020 - 2.6055) (2.5917)
66.29 - 66.38 66.03
No. 4
(2.6098 - 2.6134) (2.5996)
66.49 - 66.58 66.23
No. 5
(2.6177 - 2.6213) (2.6075)
Clearance between journal and bushing

Calculate the clearance between the journal O.D. and the camshaft
bushing I.D. previously measured under the heading ‘‘Cylinder
block’’. If the clearance has reached the service limit, replace the
camshaft bushing.
Unit: mm (in)
0.02 - 0.11 (0.0008 - 0.0043) 0.20 (0.0079)
EP-3-10
INSPECTION
Height of cam profile

Unit: mm (in)
Type Maintenance standard Service limit
56.76 - 56.80
Intake —
(2.2346 - 2.2362)
55.67 - 55.71
Exhaust —
(2.1917 - 2.1933)
EEP3-026
Runout
Support the No. 2 and No. 4 journals, and measure the runout of
the No. 1, No. 3 and No. 5 journals.
Unit: mm (in)
Support the No. 2 and
Less than 0.03 (0.0012) 0.06 (0.0024)
No. 4 journals.
ER3-7
GEAR TRAIN
Check all gears for damaged teeth or abnormal wear. Replace
faulty gears.
Gear train backlash
Check the backlash between gears measured during disassembly
of the engine proper. If it has reached the service limit, replace the
gears with new ones.
Unit: mm (in)
Type Maintenance standard Service limit
ZDR107A
A, B, C, 0.07 - 0.14
—
D, E (0.0028 - 0.0055)
0.09 - 0.22
F, G —
(0.0035 - 0.0087)
0.06 - 0.14
I —
(0.0024 - 0.0055)
Idler gear end play

Check the end play of the idler gear measured during disassembly
of the engine proper. If it has reached the service limit, replace the
idler shaft and plate or idler gear with new ones.
Unit: mm (in)
0.05 - 0.20 (0.0020 - 0.0079) 0.30 (0.0118)
ER3-150
EP-3-11
INSPECTION
Clearance between idler gear bushing and shaft

Calculate the clearance between the idler gear bushing I.D. and
idler shaft O.D. from the measured values.
Unit: mm (in)
0.03 - 0.06 (0.0012 - 0.0024) 0.20 (0.0079)
EEP2-021
FLYWHEEL
Check the flywheel for scratches. Also check for abnormal wear on
the contact surface of the clutch disc, damage or wear on the ring
gear teeth, and noise, damage or seizure of the ball bearing.
Repair or replace parts if faulty.
Lateral runout of clutch disc surface
Check the lateral runout of the clutch disc surface measured during
disassembly of the engine proper.
Unit: mm (in)
CCL1030C
Less than 0.10 (0.0039) 0.15 (0.0059)
Wear of the clutch disc surface

Unit: mm (in)
Standard depth from 5.9 - 6.1
8.0 (0.315)
flange end face (A) (0.232 - 0.240)
EEP2019G
FLYWHEEL HOUSING, REAR END PLATE, FRONT COVER

In principle, the oil seal and gaskets should be replaced with new
ones at time of overhauling. Do not use the old parts.
CRANK PULLEY AND DAMPER

Check the crank pulley for cracks and damage. Also check the
damper for damage, cracks, and separation from the disc.
EP-3-12
INSPECTION
V-BELT
Check the V-belt (drive belt) for cracks or damage. Replace if
faulty. If the belt contacts the bottom of the pulley groove, replace
the belt.
Deflection
Check belt deflection by depressing the midpoint of the drive belt
between the water pump (cooler compressor) and crank pulley with
a force of approximately 98 N {10 kgf, 22 lbf}. If belt deflection is not
within maintenance standards, adjust the belt. If beyond adjust-
ZEP049A
ment, replace.
Unit: mm (in)
Location Maintenance standard Service limit
j
A 11 - 14 (0.43 - 0.55) —
j
B 10.5 - 13.5 (0.413 - 0.531) —
EP-3-13
REPAIR AND REPLACEMENT

CYLINDER LINER REPLACEMENT
1. Using a cylinder liner tool (99600 97001), remove the faulty
cylinder liner and install a new one.
NOTE
+ Prior to insertion, be sure to clean the inside wall of the
cylinder block and the outer surface of the cylinder thor-
oughly and lightly apply a coat of engine oil to them.
ER5-140
+ Apply soapy water to the liner fitting surface and the

rubber ring, and make sure that the rubber ring is free from
twists or any other damage prior to installation.
+ Be sure to install the liner with the I.D. size mark (S, M, L)
on the top end of the flange facing toward the inside of the
bank at an angle of 45°.
2. After installing the cylinder liner, make sure that the inside
diameter, out-of-roundness, taper and flange projection are all
within the maintenance standards.
NOTE ZEP060A
+ Before measuring these, be sure to tighten the main
bearing cap to the specified torque.
: 412 - 441 N·m {42.0 - 45.0 kgfzm, 304 - 325 ftzlbf}
Unit: mm (in)
138.25
Inside diameter 138.00 - 138.03 (5.4331 - 5.4342)
(5.4429)
Out of roundness Less than 0.03 (0.0012) —
Flange protrusion 0.01 - 0.03 (0.0004 - 0.0012) —
Gap between adjoining cyl-
Less than 0.05 (0.0020) —
inder
CAMSHAFT CORRECTION
Grind the camshaft journal so that the clearance between the
journal O.D. and camshaft bushing I.D. will be within the mainte-
nance standards when an undersize camshaft bushing is used.
Clearance between the journal O.D. and bushing I.D.
Unit: mm (in)
0.02 - 0.11 (0.0008 - 0.0043) 0.20 (0.0079)
EP-4-1
Journal O.D. when a 0.2 mm (0.008 in) undersize bushing is

used
Unit: mm (in)
Location Journal grinding dimension
No. 1 65.52 - 65.54 (2.5795 - 2.5803)
No. 2 65.72 - 65.74 (2.5874 - 2.5882)
No. 3 65.92 - 65.94 (2.5953 - 2.5961)
No. 4 66.12 - 66.14 (2.6031 - 2.6039)
No. 5 66.32 - 66.34 (2.6110 - 2.6118)
CAMSHAFT BUSHING REPLACEMENT

Driving out camshaft bushing
Using a cam bushing remover (99590 97002), drive out the
camshaft bushings.
1. Drive out the No. 1, No. 2, No. 3 and No. 4 camshaft bushings
in that order.
2. Drive out the No. 5 camshaft bushing.
ET14011K
Driving in camshaft bushing

Drive in the camshaft bushings using a cam bushing replacing tool
(99590 97003).
NOTE
+ When driving in the bushings, be sure to align the oil hole
of each bushing to the oil way of the block, with the cut-out
portion on the chamfered side facing the right side of the
cylinder block.
No. Tool name Tool number
j
1 - j
6 Cam bushing replacer assembly 99590 97003
j
1 99594 97000 (No. 1)
j
2 99594 97001 (No. 5)
j
3 Cam bushing replacer 99595 97006 (No. 2)
j
4 99595 97007 (No. 3)
j
5 99595 97008 (No. 4)
j
6 Cam bushing replacer bar 99597 97000
1. Drive in the No. 4, No. 3 and No. 2 camshaft bushings in that

order.
2. Drive in the No. 1 and No. 5 camshaft bushings. ET14013K
EP-4-2
CRANKSHAFT CORRECTION
Journal
Grind the crankshaft journal so that the clearance between the
undersize main bearing shell I.D. and the journal O.D. are within
the maintenance standard.
Pin
Grind the crankshaft pin so that the clearance between the
undersize bearing shell I.D. and the crankshaft pin O.D. are within
the maintenance standard.
Grinding dimension
The grinding dimensions for the journal and pin are as follows.
NOTE
+ Be careful to prevent the width of the journal and crank pin
sections from increasing.
+ Finish both the rounding corners as shown in the figure.

R=5 mm (0.20 in)
+ Be sure to keep the out-of-roundness and taper within
maintenance standards.
Unit: mm (in)
Out-of-roundness Less than 0.005 (0.0002) 0.06 (0.0024)
EEP3-018
Unit: mm (in)
Clearance between main bearing 0.04 - 0.12 0.20 (0.0079)
shell and crankshaft journal (0.0016 - 0.0047)
Clearance between large end bear- 0.046 - 0.112 0.20 (0.0079)
ing and crankpin (0.0018 - 0.0044)
Journal
Unit: mm (in)
Size identification
Grinding dimension of journal Remarks
mark
S.T.D.
Grinding not necessary
0.07 U.S.
S.T.D.: Standard
0.25 U.S. 109.62 - 109.64 (4.3157 - 4.3165)
U.S.: Undersize
0.50 U.S. 109.37 - 109.39 (4.3059 - 4.3067)
0.75 U.S. 109.12 - 109.14 (4.2961 - 4.2958)
EP-4-3
Pin
Unit: mm (in)
Size identification Grinding dimension of journal Remarks
mark
S.T.D.
Grinding not necessary
0.07 U.S.
0.25 U.S. 89.64 - 89.66 (3.5291 - 3.5299) S.T.D.: Standard
U.S.: Undersize
0.50 U.S. 89.39 - 89.41 (3.5193 - 3.5201)
0.75 U.S. 89.14 - 89.16 (3.5094 - 3.5102)
CRANKSHAFT ACCESSORIES REPLACEMENT

CRANK GEAR
1. Using a puller, remove the crank gear.
2. Warm the crank gear in a bath of oil maintained at approx.
200°C (390°F), and install it onto the crankshaft by aligning its
keyway with the straight pin.
WARNING
+ Be careful not to touch the crank gear with bare hands EEP2001C
because it is hot; otherwise, you may be burned.
NOTE
+ Be sure to install the crank gear with ‘‘j’’ stamped on the
end face facing toward the front side.
ZEP016A
FRONT OIL SEAL SLEEVE

1. Using a puller, remove the oil seal sleeve.
2. Using a sleeve replacer (99691 97004), press the oil seal
sleeve onto the crankshaft until it comes in contact with the
crank gear.
3. Make sure that the oil sleeve is pressed to within the mainte-
nance standards.
Unit: mm (in)
Oil seal sleeve press-fit length ‘‘L’’ 12 (0.47) — EEP2014C
REAR OIL SEAL AND OIL SEAL SLEEVE

1. Using a puller (99692 97000), remove the sleeve together with
the oil seal.
NOTE
+ When removing the oil seal, be careful not to damage the
inner surface of the flywheel housing.
+ If there are burrs or scratches on the inside of the flywheel
housing hole or on the shaft surface, correct with emery
paper, etc.
+ The oil seal and sleeve cannot be reused. Be sure to EEP2-013
replace with new parts as a set.
EP-4-4
2. Apply Loctite 222 to the outer periphery of the crankshaft.

NOTE
+ Do not use any other sealant than Loctite 222.
ZEP058A
3. Using a replacer (99691 97005), press the sleeve together with

the oil seal onto the flywheel housing. The oil seal is also
pressed onto the flywheel housing.
EEP2014D
4. After installing, make sure the sleeve and oil seal are correctly
installed. Confirm that the difference in protrusion of the oil seal
and sleeve is within 0±0.3 mm (0±0.0012 in).
ZEP059A
EP-4-5
REMOVING AND INSTALLING BALANCER WEIGHT

Construction, Exploded illustration
ZEP055A
Removing
1. Put an alignment mark on each balancer weight and crank-
shaft.
2. Loosen the bolt with a hexagonal wrench, and remove the
balancer weight.
Installation
1. Align the alignment marks which were put on before removal,
and install the balancer weight.
NOTE
+ Apply engine oil to the threaded portion and seating
surface of the mounting bolt. Be careful not to allow dirt or
dust to attach to the contact surface of the balancer weight
and the crankshaft.
+ Align the bolt holes and install balancer weight A. Install
the other balancer weights so that their machined surface
faces the journal.
EP-4-6
2. Tighten the balancer weight mounting bolts.

Tightening se-
Tightening method Tightening torque
quence
1 98 {10, 72}
2 147 {15, 108}
Preliminary tightening
3 177 - 186 {18.0 - 19.0, 130 - 137}
4 0 {0, 0} (Loosen)
1 98 {10, 72}
Tightening 2 147 {15, 108}
3 177 - 186 {18.0 - 19.0, 130 - 137}
1 Tap (Fit)
Additional tightening
2 177 - 186 {18.0 - 19.0, 130 - 137}
CONNECTING ROD REPLACEMENT

After the connecting rod has been replaced with a new one, stamp
the cylinder number in the same position as before.
EEP3-027
REPLACING CONNECTING ROD SMALL END BUSHING

Use a remover assembly (99740 97002) and replacer (99740
97004) replace the connecting rod small end bushing.
REPLACING
1. Removing connecting rod end bushings
+ Place a stand (at least 40 mm (1.57 in) in height) in position via
a V-block being careful not to obstruct the hole from which the
bushing is removed.
+ Place the connecting rod on the stand, set in position using the
set pin and tighten the bolt via a holder.
NOTE
+ Always place the connecting rod on the stand with the
large chamfered side of the large end facing down.
EP-4-7
+ Set the remover in position and press the bushing out.

j
1 Bolt j
5 Bushing
j
2 Holder j
6 Set pin
j
3 Connecting rod j
7 Stand
j
4 Remover assembly
EEP2-025
2. Installing connecting rod end bushings

+ Attach a new bushing to the replacer and tighten with the bolts
via a bushing holder.
+ Set the replacer assembly in position using the bushing set pin.
+ Lightly press the head of the replacer to remove the bushing set
pin.
+ Apply a coat of engine oil to the outer perimeters of the bushing
and holder.
+ Press the bushing into place.
NOTE
+ Ensure the bushing is 1 mm inside the small end surface of EEP2025A
the connecting rod after installation.
j
1 Bolt j6 Bushing holder
j
2 Holder j7 Bolt
j
3 Connecting rod j9 Bushing set pin
j
4 Replacer assembly j8 Stand
j
5 Bushing j
10 Connecting rod set pin
3. After pressing in the bushing, machine it to the shape shown at

right.
NOTE
+ Bushings for service parts are cylindrical. Machine them
as shown at right.
4. Machine the inside of the bushing so that the inside diameter is
within the maintenance standard.
Unit: mm (in)
Inside diameter of bush- 50.03 - 50.04 ZEP054A
—
ing (1.9697 - 1.9701)
EP-4-8
IDLER GEAR (A) BUSHING REPLACEMENT

1. Press in the bushing with the end face of the boss section on
the engine front side aligned with the bushing end face.
NOTE
+ When aligned with the engine front side, the height differ-
ence (i.e. ‘‘H’’ in the following figure) is 3.0 mm (0.118 in).
ZEP056A
2. Ream the inside diameter of the bushing within the mainte-

nance standard after installing the bushing.
Unit: mm (in)
Bushing A 50.00 - 50.02 (1.9685 - 1.9693) —
FLYWHEEL CORRECTION
Grind or machine the clutch disc so that the runout of the
contacting surface will be within the maintenance standards.
However, replace the flywheel with a new one when the runout of
the clutch disc contacting surface has exceeded the service limit.
Unit: mm (in)
Standard depth from 5.9 - 6.1
8.0 (0.315)
flange end (A) (0.232 - 0.240)
EEP2019G
PISTON COOLING OIL JET

Before installing an oil jet, check its identification mark to ensure
the oil jet meets the engine model.
ZEP052A
EP-4-9
ELECTRICAL SYSTEM
CONTENTS
SERVICE DATA ........................................... EE-1- 1 ALTERNATOR ............................................. EE-3- 1
SPECIFICATIONS ....................................... EE-1- 1 CONSTRUCTION ........................................ EE-3- 1
SERVICE DATA ........................................... EE-1- 2 TROUBLESHOOTING ................................. EE-3- 3
TIGHTENING TORQUE .............................. EE-1- 3 REMOVAL .................................................... EE-3- 5
STARTING MOTOR ................................... EE-2- 1 DISASSEMBLY ............................................ EE-3- 6
CONSTRUCTION ........................................ EE-2- 1 INSPECTION ............................................... EE-3- 8
TROUBLESHOOTING ................................. EE-2- 2 PERFORMANCE TEST .............................. EE-3-10
DISASSEMBLY ............................................ EE-2- 3 AIR HEATER ................................................ EE-4- 1
INSPECTION ............................................... EE-2- 4 CONSTRUCTION ........................................ EE-4- 1
ADJUSTMENT ............................................. EE-2- 8 INSPECTION ............................................... EE-4- 1
PERFORMANCE CHECK ........................... EE-2- 8
SERVICE DATA
SERVICE DATA
SPECIFICATIONS
STARTING MOTOR
Model
0350 702 0610 0350 702 0620
Item
Type Shift
Output V-kW 24-7.0
Rated time Second 30
Manufacturer Sawafuji
ALTERNATOR
Model
0201 102 2973 0201 172 0221
Item
Output V-A 24-40 24-60
Type of regulator IC transistor (Built-in)
Manufacturer Sawafuji
AIR HEATER
Type Ribbon
Rated current V-A 22-83x2
Rated time Second Less than 60
EE-1-1
SERVICE DATA
SERVICE DATA
STARTING MOTOR
Model 0350 702 0610, 0350 702 0620
Unit: mm (in)
Part Item Maintenance standard Service limit Remarks
Metal inside Front 19.0 (0.748) 19.2 (0.756)

diameter Holder 28.0 (1.102) 28.2 (1.110)
Bracket sec-
tion Inside diameter at Commutator side 35.0 (1.378) 35.1 (1.382)
bearing Gear side 52.0 (2.047) 52.1 (2.051)
Outside diameter 44.0 (1.732) 42.0 (1.654)
Runout 0.05 (0.0020), max. 0.1 (0.004)
Commutator
0.5 - 0.8
Undercut depth 0.2 (0.008)
(0.020 - 0.031)
Brush height 22.0 (0.886) 13.0 (0.512)
Brush
Brush spring tension N {kgf, lbf} 17.7 {1.8, 4.0} 11.8 {1.2, 2.6} When spring is set
Series coil resistance Ω 0.13 - 0.15 —
Magnetic Shunt coil resistance Ω 0.6 - 0.8 —
switch 1.0 - 2.0
Contactor point deflection —
(0.039 - 0.079)
Shaft runout 0.05 (0.0020), max. 0.1 (0.004)
Gear shaft 0.1 - 0.5
Thrust gap —
(0.004 - 0.020)
Insulation re- Armature, field MΩ 1.0, min. 0.5, min.

sistance Brush holder MΩ 1.0, min. 0.5, min.
Clearance between pinion gear and pin- 0.3 - 0.5
Pinion gear —
ion stopper (0.012 - 0.020)
Current A 120, max. —
Performance Terminal voltage 24V
test Motor speed rpm 3,000, min. —
(no load) Pinion pop out voltage V 16, max. —
ALTERNATOR
Model 0201 102 2973
Unit: mm (in)
Between two phases
Stator coil 0.36 - 0.44 —
Coil Resistance Ω [At 20°C (68°F)]
Field coil 7.0 - 9.0 — At 20°C (68°F)
Shaft O.D. of the front part 25.00 (0.9843) 24.98 (0.9835), max.
Rotor
Shaft O.D. of the rear part 17.00 (0.6693) 16.98 (0.6685), max.
I.D. of front bearing fitting hole 62.0 (2.441) 62.1 (2.445), min.
Bracket
I.D. of rear bearing fitting hole 23.8 (0.937) 23.80 (0.9370), min.
Output current A 40, min. — 28V, 5,000 rpm
Regulating voltage V 28.0 - 29.0 — With light load
While cold at normal
Speed required to increase voltage to 27 volts rpm 900, max. —
temperature
EE-1-2
SERVICE DATA
Model 0201 172 0220

Unit: mm (in)
Between two phases
Starter coil 0.14 - 0.18 —
Coil Resistance Ω [At 20°C (68°F)]
Field coil 5.6 - 6.8 — At 20°C (68°F)
Shaft outside diameter of the front part 25.00 (0.9843) 24.98 (0.9835), max.
Rotor
Shaft outside diameter of the rear part 17.00 (0.6693) 16.98 (0.6685), max.
Inside diameter of front bearing fitting hole 62.0 (2.441) 62.1 (2.445), min.
Bracket
Inside diameter of rear bearing fitting hole 23.8 (0.937) 23.80 (0.9370), min.
28V, 5,000 rpm
Output current A 60, min. —
[At 20°C (68°F)]
Regulating voltage V 28.0 - 29.0 — At 20°C (68°F)
Speed required to increase voltage to 27 volts rpm 950, max. — At 20°C (68°F)
TIGHTENING TORQUE
STARTING MOTOR
Model 0350 702 0610, 0350 702 0620
Part Tightening torque Remarks
C terminal 1.9 - 2.5 {0.19 - 0.25, 1.4 - 1.8}
B and M terminals 16.2 - 22.1 {1.65 - 2.25, 11.9 - 16.3}
Magnetic switch mounting bolt 14 - 16 {1.4 - 1.6, 10 - 12}
Through bolt 16 - 18 {1.6 - 1.8, 12 - 13}
Brush holder mounting bolt 4 - 5 {0.4 - 0.5, 2.9 - 3.6}
ALTERNATOR
Model 0201 102 2973
Pulley mounting nut 96 - 127 {9.8 - 13.0, 71 - 94}
Through bolt 6 - 9 {0.6 - 0.9, 4.3 - 6.5}
Heat sink assembly mounting bolt 1.9 - 2.5 {0.19 - 0.25, 1.4 - 1.8}
Coil assembly mounting bolt 1.9 - 2.5 {0.19 - 0.25, 1.4 - 1.8}
Model 0201 172 0221

Part Tightening torque Remarks
Pulley mounting nut 127 - 157 {13 - 16, 94 - 116}
Through bolt 6.5 - 9.3 {0.66 - 0.95, 4.8 - 6.9}
Field coil assembly mounting bolt 1.9 - 2.5 {0.19 - 0.25, 1.4 - 1.8}
Heat sink mounting bolt 1.9 - 2.5 {0.19 - 0.25, 1.4 - 1.8}
EE-1-3
STARTING MOTOR 0350 702
STARTING MOTOR
= UNIT NAME 0350 702 0610, 0350 702 0620 =
CONSTRUCTION
ZEE047A
EE-2-1
Engine does not start. No Check battery for charging condition N.G. *1
c Does starting motor turn? c and battery terminals for connections c + Charge or replace battery.
and corrosion. + Repair connections and corrosion of battery
Yes
terminals.
. . . O.K.
Does engine turn by Does gear shaft turn? Can you hear starter relay operating? No Check and repair wiring system of starter relay.
cranking? No (Starter relay equipped mode only) c + Key switch.
O.K.
+ Starter relay.
Yes Yes
. + Connections.
.
Check pinion roller clutch for damage. Replace if Can you hear magnetic switch if starting No + Check and repair wiring up to magnetic switch.
necessary. motor operation? c + Repair or replace magnetic switch.
TROUBLESHOOTING
Yes
. N.G. + Force pinion out and adjust position.
Is meshing condition of pinion and ring c + Check shift lever for deformation, return spring
gear O.K.? for fatigue and pinion for sliding condition.
+ Correct meshing condition of pinion and ring
O.K.
gear. Replace if necessary.
.
Remove starting motor from engine. No + Check armature assembly, field coil, and
Does starting motor turn under no load c brush.
by connecting battery (+) terminal to M Replace if necessary.
terminal of starting motor and battery
(−) terminal to starting motor body?
EEE1-003-R
Yes
N.G. (Turns slowly)

.
EE-2-2
Does engine turn Check battery for charging condition N.G. Check magnetic switch contacts.
normally? c and battery terminals for connections c *1 c Replace if necessary.
and corrosion.
O.K.
. . O.K.
STARTING MOTOR
Check ignition system and Does engine turn by replacing starting Yes
fuel system. motor with a new one? c Repair or replace starting motor.
. No
Check inside of engine.
: Check item : Problem or

Starting motor does not Repair or replace key switch, starter relay or corrective
stop if key switch is c magnetic switch.
action
turned off.
If any abnormality is found, immediately dis-
connect battery negative terminal.
0350 702
DISASSEMBLY
ZEE052A
j
1 Magnetic switch assembly j8 Gear case j
15 Lever assembly
j
2 Rear bracket j9 Packing j
16 Center holder
.j
3 Brush holder assembly j
10 Retaining ring j
17 Shim washer
j
4 O-ring j
11 Hook j
18 Pinion assembly
j
5 Yoke assembly .j
12 Pinion stopper j
19 Pinion case
j
6 Armature assembly j
13 Holder j
20 Cover
j
7 O-ring j
14 Shaft j
21 Metal
Marks ‘‘.’’ and ‘‘>’’ indicate that key points of operation are explained in the text.
EE-2-3

3 Brush holder assembly
j
Contact the negative side of the brush spring to the side of the
brush. Lift the brush from the armature commutator surface.
Extract the positive side of the brush from the brush holder. Then,
remove the brush holder assembly.
EEE1-024
12 Pinion stopper
j
Move the pinion stopper toward the pinion. Using a screwdriver,
pry off the pinion stopper clip. Then, extract the pinion assembly
and center plate.
EF10-015
INSPECTION
BRUSH
Brush height
Unit: mm (in)
22.0 (0.866) 13.0 (0.512)
EP10-37
Brush spring tension

Unit: N {kgf, lbf}
17.7 {1.8, 4.0} 11.8 {1.2, 2.6} When spring is set
EEE1031A
EE-2-4
COMMUTATOR
Outside diameter
Unit: mm (in)
44.0 (1.732) 42.0 (1.654)
NOTE
+ If the commutator surface is rough, grind with No. 500 to
600 sandpaper and then measure the outside diameter.
EP10-76
Runout
Unit: mm (in)
0.05 (0.0020), max. 0.1 (0.004)
EEE3-002
Undercut depth
Unit: mm (in)
0.5 - 0.8 (0.020 - 0.031) 0.2 (0.008)
ZEE007A
GEAR SHAFT
Shaft runout
Unit: mm (in)
Less than 0.05 (0.0020) 0.1 (0.004)
EEE2-007
Thrust gap
Unit: mm (in)
0.1 - 0.5 (0.004 - 0.020) —
EE-2-5
BRACKET
Metal inside diameter (Front)
Unit: mm (in)
19.0 (0.748) 19.2 (0.756)
Metal inside diameter (Holder)

Unit: mm (in)
28.0 (1.102) 28.2 (1.110)
Inside diameter at bearing (Commutator side)

Unit: mm (in)
35.0 (1.378) 35.1 (1.382)
Inside diameter at bearing (Gear side)

Unit: mm (in)
52.0 (2.047) 52.1 (2.051)
ARMATURE COIL
Continuity test
Make sure there is no continuity between the commutator and
armature assembly.
EEE3-003
Insulation test
Unit: MΩ
More than 1.0 More than 0.5
ES10-23
EE-2-6
FIELD COIL
Continuity test
Make sure there is continuity between the field coil terminals.
EP10-35
Insulation test
Unit: MΩ
More than 1.0 0.5
EP10-36
BRUSH HOLDER
Insulation test
Unit: MΩ
More than 1.0 More than 0.5
EP10-39
MAGNETIC SWITCH
Continuity test (Series coil resistance)
Perform the continuity test between the M and C terminals.
Unit: Ω
0.13 - 0.15 —
EEE3002A
Continuity test (Shunt coil resistance)

Check the continuity between the C terminal and coil case.
Unit: Ω
0.6 - 0.8 —
EEE1075A
EE-2-7
Contactor point deflection

Check deflection when the contactor makes contact.
Unit: mm (in)
1.0 - 2.0 (0.039 - 0.079) —
PINION GEAR
Clearance between pinion gear and pinion stopper
Unit: mm (in)
0.3 - 0.5 (0.012 - 0.020) —
ADJUSTMENT
Measure dimension L moved towards the thrust direction of the
pinion when the magnetic switch pushes out the pinion.
1. Connect the S terminal to the battery positive terminal through
the magnetic switch. Ground the M terminal midway and then
connect it to the battery negative terminal.
EP10-49
2. Turn on the switch and make sure the magnetic switch pushes
out the pinion. Then, push back the pinion lightly and measure
dimension L.
Unit: mm (in)
Dimension L 0.3 - 0.5 (0.012 - 0.020) —
3. If dimension L exceeds the maintenance standard, replace the

starting motor assembly with a new one.
E11-17
PERFORMANCE CHECK
1. Connect as shown in the illustration. Turn off the key switch and
turn the starting motor. Under these conditions, measure the
current and the number of rotations. (Terminal voltage: 24
volts)
Current A 120, max. —
Motor speed rpm 3,000, min. —
WEE005A
EE-2-8
2. Check that the pinion gear pops smoothly out and in when the
switch is turned on and off.
3. Measure the minimum voltage which is necessary for the pinion

to pop out. Prepare a variable resistor and battery voltmeter as
testing equipment. Set the resistance higher at first so that a
lower voltage applies to the starting motor. Then, slowly lower
the resistance and measure the voltage when the pinion pops
out.
Unit: V
16, max. —
EEE1078A
EE-2-9
ALTERNATOR 0201 102, 0201 172
ALTERNATOR
CONSTRUCTION
Model 0201 102 2973
EEE3-064B
EE-3-1
ALTERNATOR 0201 102, 0201 172
Model 0201 172 0221
EEE008A
EE-3-2
The battery runs down.
No Check the battery relay. Abnormal Replace the battery relay.

c c
Normal Check the wiring. Abnormal Repair the wiring.

c c
. c To *A
Is the voltage across alternator ter- No Does voltage exist? No j Is the fuse blown? Abnormal j Replace the fuse.
TROUBLESHOOTING
c c c
minals B and E above 22V? j Is the wiring between the alter- j Repair the wiring.
(When the key switch is ON and Yes nator and battery normal?
engine is stopped.)
Normal
Yes .
. To *A
*A Abnormal
Is the belt broken? j Change the belt.
c
Is the belt slipping? j Adjust the belt tension.
Normal
.
. To *A
Does voltage exist across alternator No Is the key switch normal? Abnormal j Replace the key switch.
c c
terminals IG and E?
(Key switch is ON) Normal
c Is the fuse blown? Abnormal j Replace the fuse.
c
Yes
EE-3-3
Normal
*B .
. To *B
ALTERNATOR
Is the voltage across alternator ter- No Faulty alternator j Repair the alternator.
c c
minals B and E over 27V? (Replace the diode, stator or
(Engine speed: 1,000 rpm) regulator.)
Yes
.
Measure the alternator charging No Increase the electrical load (Turn on No Faulty alternator
c c c
current at B terminal. Is it over all the lights.)
35A? Is the charging current over 35A?
(Engine speed: 2,000 rpm)
Yes
. Yes
Normal alternator b
.
(Check the battery and its related
parts.)
0201 102, 0201 172
The battery becomes overcharged. (Battery fluid decreases)
(The battery fluid decreases.)
.
Is the voltage across alternator ter- Yes Faulty alternator (Regulator) j Repair the alternator
c c
minals B and E over 29V? (Faulty regulator)
(Engine speed: 1,000 rpm) (Broken internal wiring)
. No
Normal alternator
.
(Check the battery and its related : Check item : Problem or corrective action
parts.)
EE-3-4
ALTERNATOR
0201 102, 0201 172
ALTERNATOR 0201 102, 0201 172
REMOVAL
Key point of removal
Before removing the alternator from the engine, be sure to turn the
key switch off, then disconnect the battery cable from the negative
terminal of the battery.
EE-3-5
ALTERNATOR 0201 102, 0201 172
DISASSEMBLY
Model 0201 102 2973
WEE015A

j
1 Cover j8 Bearing cover j
15 IC-regulator
j
2 Rear bracket assembly j9 Felt j
16 Heat sink (+)
.j
3 Front bracket assembly j
10 Plate j
17 Heat sink (−)
.j
4 Pulley assembly j
11 Ball bearing j
18 Coupler
j
5 Fan j
12 Plate j
19 Stator assembly
j
6 Collar j
13 Felt j
20 Coil assembly
j
7 Rotor j
14 Connector assembly j
21 Roller bearing
EE-3-6
ALTERNATOR 0201 102, 0201 172
Model 0201 172 0221
ZEE053A
.j
1 Front bracket assembly j7 Rotor assembly j
12 Regulator
.j
2 Pulley assembly j8 Rear bracket j
13 Charge light circuit assembly
j
3 Fan j9 Stator assembly j
14 Heat sink
j
4 Collar j
10 Field coil assembly j
15 Heat sink
j
5 Bearing j
11 Cover j
16 Terminal
j
6 Retainer
EE-3-7
ALTERNATOR 0201 102, 0201 172

j3 Model 0201 102 2973
j1 Model 0201 172 0221 }
Front bracket assembly
To separate the front bracket, insert a screwdriver into the
clearance between the front bracket and stator core.
NOTE
+ Be careful not to damage the stator coil with the screw-
driver tip.
EF10-036
j
4 Model 0201 102 2973
j
2 Model 0201 172 0221 } Pulley assembly
When separating the pulley assembly, secure the rotor periph-
ery with a vise. Then, remove the pulley nut, pulley, fan and
collar. If the pulley is difficult to remove, use a general-purpose
puller.
EEE3-006
INSPECTION
STATOR COIL
Continuity test of the stator coil
Unit: Ω
Maintenance
standard
0201 102 2973 0.36 - 0.44 At 20°C (68°F)

— Between two
0201 172 0221 0.14 - 0.18 phases EEE1-080
If there is no continuity, the stator coil may be broken. Replace the

stator coil as an assembly.
Insulation test of the stator coil

Make sure there is no continuity. If there is continuity, the stator coil
may be shorted. Replace the stator coil as an assembly.
EEE3034A
EE-3-8
ALTERNATOR 0201 102, 0201 172
FIELD COIL
Continuity test of the field coil
Unit: Ω
0201 102 2973 7.0 - 9.0
— At 20°C (68°F)
0201 172 0221 5.6 - 6.8
If there is no continuity, the field coil may be broken. Replace the

field coil as an assembly. EEE2-016
Insulation test of the field coil

Make sure there is no continuity. If there is continuity, the field coil
may be shorted. Replace the field coil as an assembly.
EEE2-017
ROTOR
Unit: mm (in)
Shaft O.D. of the front part 25.00 (0.9843) 24.98 (0.9835), max.
Shaft O.D. of the rear part 17.00 (0.6693) 16.98 (0.6685), max.
BRACKET
Unit: mm (in)
I.D. of front bearing fitting hole 62.0 (2.441) 62.1 (2.445), min.
I.D. of rear bearing fitting hole 23.8 (0.937) 23.80 (0.9370), min.
EE-3-9
ALTERNATOR 0201 102, 0201 172
PERFORMANCE TEST
NOTE
+ Use leads with a cross-sectional area greater than 8 mm2
(0.0124 sq in) and a length less than 2.5 m (8.2 ft) to
connect the line between the alternator’s B terminal and
positive battery terminal, the E terminal and battery
ground terminal, and the L terminal and battery ground
terminal.
+ Use switches with as small a contact resistance as pos-
sible in the circuit. EEE014A
+ Conduct performance test in areas where ambient tem-
perature is maintained at 20°C (68°F).
Start-up revolution
1. Install the alternator on a vehicle or connect to a variable
velocity motor and connect the leads as shown in the figure.
2. Turn switches SW1 and SW2 ‘‘ON’’, then gradually increase
alternator speed.
3. When the voltmeter registers a voltage higher than the voltage
when the alternator is stopped, turn switch SW1 ‘‘OFF’’.
4. While observing the voltmeter, increase alternator speed.
5. Read alternator speed (rpm) when the voltmeter registers 27 EEE015A
volts.
Unit: rpm
Maintenance
standard
0201 102 2973 900, max.
— At 20°C (68°F)
0201 172 0221 950, max.
Measuring of regulating voltage

Turn switch SW1 off and turn switch SW2 on. Increase the
alternator speed up to the rated rpm of 5,000. Then, measure the
voltage.
Unit: V
28.0 - 29.0 — At 20°C (68°F)
Measuring output current

1. Adjust the variable resistor to zero and turn switches SW1 and
SW2 on.
2. Keep the alternator speed at the rated rpm and adjust the
variable resistor so that the terminal voltage is at the specified
value. Then, read the current.
Terminal voltage: 28V - 5,000 rpm
Unit: A
Maintenance
standard
0201 102 2973 40, min. 28V, 5,000 rpm
—
0201 172 0221 60, min. [At 20°C (68°F)]
EE-3-10
AIR HEATER
AIR HEATER
CONSTRUCTION
ZEE049A
INSPECTION
+ Check the condition of the wiring for breaks. If broken, replace
the air heater assembly with a new one.
+ Check the ribbon element for accumulation of carbon. If
necessary, clean it. Also check it for breaks. If broken, replace
the air heater assembly with a new one.
EE-4-1
CYLINDER HEAD AND
VALVE MECHANISM
CONTENTS
SERVICE DATA ............................................. HV-1-1 REPAIR AND REPLACEMENT ............... HV-7-1
SERVICE DATA ............................................. HV-1-1 REPAIRING CYLINDER HEAD ..................... HV-7-1
TIGHTENING TORQUE ................................ HV-1-3 REPAIRING VALVE ....................................... HV-7-1
TOOLS ............................................................. HV-2-1 REPAIRING VALVE INSERT ......................... HV-7-2
REPLACING VALVE INSERT ....................... HV-7-2
CONSTRUCTION ......................................... HV-3-1 LAPPING THE VALVE AND
REMOVAL ....................................................... HV-4-1 VALVE INSERT ............................................. HV-7-3
DISASSEMBLY ............................................. HV-5-1 REPLACING VALVE GUIDE ......................... HV-7-4
DISASSEMBLY .............................................. HV-5-1 REPLACING VALVE ROCKER BUSHING ... HV-7-4
INSPECTION ................................................. HV-6-1 REASSEMBLY .............................................. HV-8-1
INSTALLATION ............................................. HV-9-1
SERVICE DATA
SERVICE DATA
SERVICE DATA
Unit: mm (in)
Posi- Maintenance
tion standard
Grinding tolerance:
Cylinder head height 110 (4.33) 109.5 (4.311)
Cylinder head
0.5 mm (0.020 in)

Protrusion above the top surface of the cylinder
26.0 (1.024) —
head
Longitudinal direction Less than 0.05 (0.0020) 0.20 (0.0079)
Flatness
Transverse direction Less than 0.02 (0.0008) 0.20 (0.0079)
Intake 45° - 45°15′ —
Valve insert
Seat angle
Exhaust 45° - 45°15′ —
Intake 2.7 - 2.9 (0.106 - 0.114) 3.4 (0.134)
Contacting width
Exhaust 2.8 - 3.1 (0.110 - 0.122) 3.5 (0.138)
Intake 44°30′ - 45° —
Valve face angle
Exhaust 44°30′ - 45° —
9.960 - 9.975
Intake 9.83 (0.3870)
Outside diameter of (0.3921 - 0.3927)
valve stem 11.895 - 11.920
Exhaust 11.83 (0.4657)
(0.4683 - 0.4693)
Valve
Intake 2.0 (0.079) 1.8 (0.071)

Valve head thickness
Exhaust 1.5 (0.059) 1.3 (0.051)
0.58 - 1.07
Intake —
Distance between valve and bottom (0.0228 - 0.0421)
surface of the cylinder head 0.58 - 1.12
Exhaust —
(0.0228 - 0.0441)
Intake 0.4 (0.016)
Valve clearance While cold
Exhaust 0.6 (0.024)
10.00 - 10.02
Intake 10.15 (0.3996) Dimensions after in-
(0.3937 - 0.3945)
Inside diameter stalled into the cylin-
12.00 - 12.02
Exhaust 12.16 (0.4787) der head
Valve guide
(0.4724 - 0.4732)
0.025 - 0.060
Intake 0.20 (0.0079)
Valve guide and valve (0.0010 - 0.0024)
stem clearance 0.085 - 0.170
Exhaust 0.20 (0.0079)
(0.0033 - 0.0067)
Projection from top of Intake
20.5 (0.807) —
cylinder head Exhaust
Outer 89.50 (3.5236) —
Free length Intake and exhaust
Inner 86.40 (3.4016) —
When compressed to
Valve spring
404.0 - 447.2
Outer — 59.1 mm (2.327 in)
{41.2 - 45.6, 90.8 - 100.5}
Intake and exhaust
Tension N {kgf, lbf}
When compressed to
212.8 - 234.4
Inner — 56.6 mm (2.228 in)
{21.7 - 23.9, 47.8 - 52.7}
Intake and exhaust
Squareness — 3.0 (0.118) Intake and exhaust
HV-1-1
SERVICE DATA
Unit: mm (in)
Posi- Maintenance
tion standard
24.99 - 25.00
(0.9839 - 0.9843)
Runout Less than 0.03 (0.0012) 0.05 (0.0020)
25.02 - 25.04
Inside diameter of valve rocker bushing 25.10 (0.9882)
(0.9850 - 0.9858)
Rocker shaft
Clearance between rocker shaft and valve rocker bush- 0.02 - 0.06
0.20 (0.0079)
ing (0.0008 - 0.0024)
Free length of inside spring 112.0 (4.409) —
When compressed to
Tension of inside spring N {kgf, lbf} 45.1 {4.6, 10.1} 3.6 {0.37, 0.82}
82 mm (3.23 in)
Free length of valve rocker spring 29.0 (1.142) —
When compressed to
Tension of valve rocker spring N {kgf, lbf} 45.1 {4.6, 10.1} 35.3 {3.6, 7.9}
11 mm (0.43 in)
Cam follower Push rod
Length 236.73 (9.3201) —
Deviation Less than 0.3 (0.012) 0.5 (0.020)
23.94 - 23.97
(0.9425 - 0.9437)
0.03 - 0.08
Clearance between cam follower and hole 0.20 (0.0079)
(0.0012 - 0.0031)
Valve clearance adjusting sequence
Right bank (R) Left bank (L)

Cylinder No.
1R 2R 3R 4R 1L 2L 3L 4L
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Valve arrangement
Others
IN EX IN EX IN EX IN EX EX IN EX IN EX IN EX IN
No. 4 piston at TDC on com-
+ + + + + + + +
pression stroke
No. 4 piston at TDC on exhaust
+ + + + + + + +
stroke
HV-1-2
SERVICE DATA
TIGHTENING TORQUE
1st time 147 - 157 {15.0 - 16.0, 108 - 116}
Cylinder head bolt
2nd time 275 - 294 {28.0 - 30.0, 203 - 217}
Rocker shaft mounting bolt 39 - 49 {4.0 - 5.0, 29 - 36}
Exhaust manifold mounting nut 54 - 64 {5.5 - 6.5, 40 - 47}
M8 10 - 13 {1.0 - 1.3, 7 - 9}
Air intake manifold mounting nut
M10 19 - 23 {1.9 - 2.3, 14 - 17}
Injection nozzle holder mounting bolt 25 - 34 {2.5 - 3.5, 18 - 25}
Pump side 29 - 39 {3.0 - 4.0, 22 - 29}
Injection tube
Nozzle side 25 - 34 {2.5 - 3.5, 18 - 25}
Spill tube mounting bolt 29 {3.0, 22}
HV-1-3
TOOLS
TOOLS
Split collar tool Used to remove and install the split collar.
99620 97000
ETL1-013
Valve insert puller assembly For removal of valve insert

99660 97002
ER14-111
Valve insert replacer For installation of valve insert (cold fitting)

99665 97502 (Intake)
Valve insert replacer For installation of valve insert (cold fitting)

99665 97500 (Exhaust)
ETL1023A
Caulking tool assembly Used to caulk after the exhaust valve insert has been fitted to
99670 97001 the cylinder head.
EP14-115
Valve guide remover For removal of valve guide

99667 95000 (Intake)
ETL2-004
HV-2-1
TOOLS

Valve guide remover For removal of valve guide
99667 96000 (Exhaust)
ETL2004A
Reamer For finishing of valve guide inside diameter

99662 96000 (Both intake and exhaust)
ER14-150
Stem seal replacer Used to install the valve stem seal into the valve guide.
99674 97015 (Intake)
99674 97012 (Exhaust)
ET14031B
Valve guide replacer For installation of valve guide

99666 97003 (Intake)
99666 96004 (Exhaust)
ER14-114
Angle wrench Used for tightening cylinder head bolts (preset torque, tighten-
1800 WQL ing angle)
EHV003A
HV-2-2
CONSTRUCTION
CONSTRUCTION
ZHV023A
HV-3-1
REMOVAL
REMOVAL
For trucks, perform the dismounting operation with the engine
mounted.
1. Chock the wheels, then tilt the cab.
2. Turn the key switch off and disconnect the cable from the
negative terminal of the battery.
4. Remove the right and left side covers for the engine room.
5. Disconnect the water hose, tube and wire harness.
6. Remove the air intake duct and air heater assembly.
7. Remove the air bleeder pipe.
8. Remove the fuel system.
+ Remove the fuel filter assembly and bracket.
+ Remove the fuel lines.
+ Remove the injection nozzle tube and spill tube.
+ Remove the injection nozzle.
NOTE
+ When removing fuel lines, use a pan to catch dripping fuel
so that fuel does not get on engine parts. If any fuel is
spilled on engine parts, use a rag to completely remove all
spilled fuel.
9. Remove the accelerator linkage.
10. Remove the air intake manifold and gaskets.
11. Remove the thermostat housing.
12. Remove the alternator assembly.
13. Remove the alternator tension bracket and water duct.
14. Remove the exhaust system.
+ Disconnect the exhaust outlet and exhaust tube.
+ Remove the exhaust outlet.
+ Remove the turbocharger.
+ Remove the turbocharger adapter.
+ Remove the exhaust manifold, exhaust manifold shield and
gaskets.
15. Remove the head cover assembly with a rocker cover.
16. Remove the valve rocker assembly mounting bolts.
17. Remove the cylinder head bolts by loosening them gradually in
the order shown in the figure.
18. Remove the valve rocker assembly.
19. Pull out the push rod.
20. Remove the cylinder head assembly.
NOTE
+ Use a crane or other devices to dismount the cylinder
head.
ZHV024A
HV-4-1
DISASSEMBLY
DISASSEMBLY
DISASSEMBLY
CYLINDER HEAD
ZHV030A
j
1 Cylinder head bolt >j8 Valve spring (inner and outer) j
15 Inlet valve guide
j
2 Eye connector j9 Spring seat (lower) j
16 Bolt
j
3 Oil tube j
10 Exhaust valve j
17 Water tube adapter
j
4 Valve stem cap j
11 Inlet valve j
18 Rubber ring
>.j
5 Split collar j
12 Inlet valve insert j
19 Engine lifter
j
6 Spring seat (upper) j
13 Exhaust valve insert j
20 Plug
>j
7 Valve stem seal j
14 Exhaust valve guide
HV-5-1
DISASSEMBLY
Key points of disassembly

+ Measure the distance between the valve and the bottom
surface of the cylinder head prior to disassembling the cylinder
head assembly.
NOTE
+ Be sure to remove the carbon from the valve and the
bottom surface of the cylinder head.
EHV2-016
j
5 Split collar
Remove the split collar using a split collar tool (99620 97000).
ZHV026A
NOTE
+ All the parts removed should be grouped together for each
valve.
HV-5-2
DISASSEMBLY
ROCKER SHAFT ASSEMBLY
ZHV031A
j
1 Bolt j6 Washer j
11 Nut
j
2 Spring washer j7 Spring j
12 Adjusting screw
j
3 Bolt j8 Rocker arm j
13 Push rod
j
4 Spring washer j9 Spring j
14 Cam follower
j
5 Rocker shaft bracket j
10 Rocker shaft assembly
HV-5-3
INSPECTION
INSPECTION
CYLINDER HEAD
Flatness
Unit: mm (in)
Longitudinal direction Less than 0.05 (0.0020) 0.20 (0.0079)
Transverse direction Less than 0.02 (0.0008) 0.20 (0.0079)
EHV2-017
VALVE INSERT
Contacting width and contact pattern
Unit: mm (in)
Intake 2.7 - 2.9 (0.106 - 0.114) 3.4 (0.134)
Exhaust 2.8 - 3.1 (0.110 - 0.122) 3.5 (0.138)
ES-85
VALVE
Distance between the valve and the bottom surface of
the cylinder head
Check the value measured before disassembling the cylinder
head.
Unit: mm (in)
0.58 - 1.07
Intake —
(0.0228 - 0.0421)
0.58 - 1.12
Exhaust —
(0.0228 - 0.0441)
HV-6-1
INSPECTION
Valve head thickness

Unit: mm (in)
Intake 2.0 (0.079) 1.8 (0.071)
Exhaust 1.5 (0.059) 1.3 (0.051)
EHV2-018
Outside diameter of valve stem

Unit: mm (in)
9.960 - 9.975
Intake 9.83 (0.3870)
(0.3921 - 0.3927)
11.895 - 11.920
Exhaust 11.83 (0.4657)
(0.4683 - 0.4693)
EHV2-019
VALVE GUIDE
Valve guide and valve stem clearance
Unit: mm (in)
0.025 - 0.060
Intake 0.20 (0.0079)
(0.0010 - 0.0024)
0.085 - 0.170
Exhaust 0.20 (0.0079)
(0.0033 - 0.0067)
EHV-017
VALVE SPRING
Free length
Unit: mm (in)
Maintenance
standard
Outer 89.50 (3.5236) — Intake and
Inner 86.40 (3.4016) — exhaust
ES-87
Tension
Unit: N {kgf, lbf}
Item Maintenance Service limit Remarks

standard
404.0 - 447.2 When compressed to 59.1 mm
Outer {41.2 - 45.6, — (2.327 in)
90.8 - 100.5} Intake and exhaust
212.8 - 234.4 When compressed to 56.6 mm
Inner {21.7 - 23.9, — (2.228 in)
47.8 - 52.7} Intake and exhaust
EHV3-011
HV-6-2
INSPECTION
Squareness
Measure the squareness of the outer spring by calculating the
clearance difference between A and B in the figure.
Unit: mm (in)
Maintenance
standard
Outer — 3.0 (0.118) Intake and
Inner — 3.0 (0.118) exhaust
EHV3-012
ROCKER SHAFT
Outside diameter
Unit: mm (in)
24.99 - 25.00 (0.9839 - 0.9843) 24.90 (0.9803)
EHV3-013
Runout
Unit: mm (in)
Less than 0.03 (0.0012) 0.05 (0.0020)
ES-91
Inside diameter of valve rocker bushing

Unit: mm (in)
25.02 - 25.04 (0.9850 - 0.9858) 25.10 (0.9882)
EHV1-020
Clearance between rocker shaft and valve rocker bush-

ing
Unit: mm (in)
0.02 - 0.06 (0.0008 - 0.0024) 0.20 (0.0079)
HV-6-3
INSPECTION
Free length of valve rocker spring

Unit: mm (in)
Inside 112.0 (4.409) —
Valve rocker 29.0 (1.142) —
ES-87
Tension of inside spring

Unit: N {kgf, lbf}
When compressed to
Inside 45.1 {4.6, 10.1} 35.3 {3.6, 7.9}
82 mm (3.23 in)
Valve When compressed to
45.1 {4.6, 10.1} 35.3 {3.6, 7.9}
rocker 11 mm (0.43 in)
EHV3-011
PUSH ROD
Deviation
Measure the deviation while supporting the center of the spherical
surfaces at both ends of the push rod.
Unit: mm (in)
Less than 0.3 (0.012) 0.5 (0.020)
E4-14
Length
Unit: mm (in)
236.73 (9.3201) —
CAM FOLLOWER
Outside diameter
Unit: mm (in)
23.94 - 23.97 (0.9425 - 0.9437) 23.85 (0.9390)
EHV3-015
HV-6-4
INSPECTION
Clearance between cam follower and hole

Unit: mm (in)
0.03 - 0.08 (0.0012 - 0.0031) 0.20 (0.0079)
HV-6-5

REPAIRING CYLINDER HEAD
Using a surface grinder, grind the cylinder head. The amount of
grinding should not exceed 0.5 mm (0.02 in).
Unit: mm (in)
Item
(A) (B)
Cylinder head height 110 (4.33) 109.5 (4.311)
ER6-107
REPAIRING VALVE
1. Using a valve refacer, repair the valve face portion. If the
thickness of the valve face exceeds the service limit after
repaired, replace it with a new one.
NOTE
+ There should be no stepped wear on the valve face.
Unit: mm (in)
Maintenance
Item Service limit
standard
ES-95
Intake 44°30′ - 45° —
Valve face angle
Exhaust 44°30′ - 45° —
Valve head Intake 2.0 (0.079) —

thickness Exhaust 1.5 (0.059) —
2. Using a valve refacer or oil stone, repair the valve stem end.
NOTE
+ Finish the valve stem end surface so that it is perpendicu-
lar to the axis. Also, the finished surface should have no
scrape marks or scratches.
ES-94
HV-7-1
REPAIRING VALVE INSERT

Using a valve seat grinder, repair the seat surface of the valve
insert.
NOTE
+ There should be no stepped wear on the seat surface of
the valve insert.
Maintenance
Item Service limit
standard
Intake 45° - 45°15′ —
Valve seat angle ER-108
Exhaust 45° - 45°15′ —
REPLACING VALVE INSERT

1. Using a valve insert puller (99660 97002), remove the intake
and exhaust valve inserts.
EP6-110
2. Fit in the intake and exhaust valve inserts. Be sure to cold-fit

them.
<Cold-fitting procedure>
+ Keep the valve insert in dry ice for more than five minutes. Use
of alcohol will improve the cooling effect.
NOTE
+ Do not touch the cold valve insert or dry ice directly, or it
will cause chilblains.
EHV3-018
+ Immerse the cylinder head in hot water until its temperature

exceeds 80°C (176°F).
NOTE
+ Do not touch the cylinder head or hot water directly, or it
will cause a scald.
ZHV012A
HV-7-2
+ Take out the cylinder head and valve inserts, then fit the valve
inserts quickly into the cylinder head using a special valve
insert replacer (Intake: 99665 97502 and Exhaust: 99665
97500).
ER4-2
+ After fitting the valve inserts, caulk four locations around the
insert (on the exhaust side only) using a special valve insert
caulking tool (97670 97001).
NOTE
+ When caulking with a hammer, drop a 4-pound copper
hammer from a height of about 300 mm (11.81 in) once.
When a press is used, make the pressure 147,105 kPa
{1,500 kg/cm2, 21,330 psi}.
EHV3-020
LAPPING THE VALVE AND VALVE INSERT

After repairing or replacing the valve or valve insert, be sure to
perform valve lapping.
1. Apply grinding compound uniformly to the seat of the valve.
ER6-109
2. Apply a coat of engine oil to the valve stem, then insert the
valve into the valve guide. With the lapping rod coming into
contact with the valve head, lap the valve by rotating it while
lightly tapping the valve insert.
3. After oil lapping, coat the contacting surface of the valve with
red lead and repeat lapping operation in the same manner as
previously done with the grinding compound, then check the
condition of the valve surface. Repeat lapping until the valve
surface is properly corrected.
Unit: mm (in)
Item Maintenance standard Service limit ES-85
Contacting Intake 2.7 - 2.9 (0.106 - 0.114) 3.4 (0.134)

width Exhaust 2.8 - 3.1 (0.110 - 0.122) 3.5 (0.138)
HV-7-3
REPLACING VALVE GUIDE

1. Using a valve guide remover, drive out the valve guide from the
bottom side of the cylinder head.
Item Tool number
Intake 99667 95000
Valve guide remover
Exhaust 99667 96000
ER4-4
2. Using a valve guide replacer, drive the valve guide perpendicu-

larly into place until the lower end of the tool just touches the
surface of the cylinder head.
Item Tool number
Intake 99666 97003
Valve guide replacer
Exhaust 99666 96004
NOTE
+ Thoroughly clean the valve guide hole of the cylinder head
prior to driving in.
EHV2-026
3. After driving in the valve guide, finish the inside diameter to the
maintenance standard with a reamer (99662 96000).
Unit: mm (in)
Maintenance
Item Service limit
standard
25.02 - 25.04
Intake —
(0.9850 - 0.9858)
Inside diameter
25.02 - 25.04
Exhaust —
(0.9850 - 0.9858)
EHV3-023
REPLACING VALVE ROCKER BUSHING

1. Fix the valve rocker and drive the bushing out with a press tool.
NOTE
+ Mark the bushing clinching position on the valve rocker
prior to removing the bushing.
+ Take care so that the fitting surface of the bushing is not
damaged when the bushing is driven out.
HV-7-4
2. Correctly line up the bushing clinching mark on the valve rocker

with the bushing, and drive in the bushing using a press tool.
NOTE
+ After driving in the bushing, check to make sure that the
valve rocker and bushing oil holes are aligned.
ZHV027A
3. After driving in the bushing, finish the inside diameter of the

bushing with a reamer.
Unit: mm (in)
Inside diameter of valve 25.02 - 25.04
25.10 (0.9882)
rocker bushing (0.9850 - 0.9858)
HV-7-5
REASSEMBLY
REASSEMBLY
CYLINDER HEAD
+ Before reassembling, be sure to apply engine oil to each
sliding surface.
j7 Valve stem seal

1. Install the lower spring seat.
2. Using a special valve stem seal replacer, install the stem seal
to the valve guide.
Item Tool number
Intake 99674 97015
Stem seal replacer
Exhaust 99674 97012
NOTE EHV2-027
+ Be sure to push in the stem seal by hand.
j8 Valve spring (inner and outer)

Install the inner and outer valve springs and upper spring seat.
NOTE
+ When installing the inner and outer springs, be sure to
install them so that the side which has a smaller spring
winding pitch (i.e. the side painted in yellow) faces the
lower spring seat side.
EHV3-029
HV-8-1
REASSEMBLY
j5 Split collar
1. Using a split collar tool (99620 97000), install the split collar.
ZHV026A
2. Measure the distance between the valve and the bottom

surface of the cylinder head and check to make sure that it
does not exceed the maintenance standard.
Unit: mm (in)
Maintenance
Item Service limit
standard
Distance between 0.58 - 1.07

Intake —
the valve and bottom (0.0228 - 0.0421)
surface of the cylin- 0.58 - 1.12
der head Exhaust —
(0.0228 - 0.0441)
HV-8-2
INSTALLATION
INSTALLATION
1. Install the cylinder head assembly with the cylinder head
gasket in place.
NOTE
+ Use a crane or other devices to install the cylinder head.
2. Insert the push rod.
3. Place the valve rocker assembly on the cylinder head.
4. Insert the cylinder head bolts, then tighten them in two stages
uniformly following the sequence shown in the figure.
: 1st time ..................... 147 - 157 N·m
{15.0 - 16.0 kgfzm, 108 - 116 ftzlbf}
: 2nd time .................... 275 - 294 N·m
{28.0 - 30.0 kgfzm, 203 - 217 ftzlbf}
5. Tighten the valve rocker assembly mounting bolts.
: 39 - 49 N·m {4.0 - 5.0 kgfzm, 29 - 36 ftzlbf}
ZHV028A
6. Install the head cover assembly with the rocker cover.

7. Install the exhaust system.
+ Install the exhaust manifold with the exhaust manifold shield
and gaskets in place.
: 54 - 64 N·m {5.5 - 6.5 kgfzm, 40 - 47 ftzlbf}
+ Install the exhaust outlet and connect the exhaust tube.
8. Install the water duct, alternator tension bracket and alternator

assembly.
9. Install the air intake manifold with the gaskets in place.
10. Install the thermostat housing.
11. Install the water pipe.
12. Install the accelerator linkage.
13. Install the fuel system.
+ Install the injection nozzle.
+ Install the injection nozzle tube and spill tube.
+ Install the fuel filter bracket and fuel filter.
+ Install the fuel lines.
Injection nozzle holder 25 - 34 {2.5 - 3.5, 18 - 25}
Injection nozzle Pump side 29 - 39 {3.0 - 4.0, 22 - 29}

tube Nozzle side 25 - 34 {2.5 - 3.5, 18 - 25}
Spill tube 29 {3.0, 22}
14. Install the air bleeder pipe.

15. Install the air heater assembly and air intake duct.
16. Connect the water hose, tube and wire harness.
17. Install the right and left side covers for the engine room.
HV-9-1
INSTALLATION
18. Supply the engine cooling water from the water tank.
19. Connect the cable to the negative terminal of the battery.
water leakage from any part. Then check the cooling water
level.
HV-9-2

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COOLING SYSTEM

Item Maintenance Service Remarks

Outside diameter of shaft at impeller 20.051 - 20.060 —

Fit of impeller and shaft 0.023T - 0.053T — T: tight

Outside diameter of shaft at pulley 25.002 - 25.015 —

Water pump to crank pulley 11 - 14 —

COOLING SYSTEM DIAGRAM

Drive shaft remover Used to remove drive shaft.

Bearing replacer Used to remove ball bearing.

Water seal replacer Used to remove/install water seal.

Tool name and number Description Shape

Impeller replacer Used to install impeller.

Key point of disassembly

Fit of impeller and shaft

Outside diameter of shaft at pulley

Fit of pulley and shaft

Key point of reassembly

j6 Ball bearing, j 7 Spacer

2. Press the water seal into the impeller.

2. Disconnect the radiator hose from the water outlet, then

RADIATOR AND COOLANT RESERVOIR TANK

Valve opening pressure of coolant reservoir tank cap

Printed: May 1999

c The contents are listed on the first page of each chapter.

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

By-pass Filter paper

60 - 70 (140 - 158) [On-off type]

pump Governor Centrifugal (Mechanical RFD type)

Air cleaner Type Paper element (dry)

Exhaust Type Cylinder

0201 102 2973

Theoretical discharge cm3 (cu in) 425 (26)

Cooling method Water-cooled

C: With turbocharger and intercooler

RECOMMENDED SAE VISCOSITY NUMBER

GENERAL PRECAUTIONS ON SERVICING

+ When tilting the cab indoors, make sure that there is a

GENERAL PRECAUTIONS IN DISASSEMBLY

Work required during disassembly

Checks during disassembly

Keeping disassembled parts in order

Cleaning disassembled parts

Adjustment and operational checks

CLEANING AND INSPECTION

PROTECTION AGAINST CORROSION

TIGHTENING TORQUE OF STANDARD BOLTS

Standard tightening torque of tubing connector

Feeler gauge For adjusting valve clearance

Timing plate For measuring valve timing

Compression gauge For measuring compression pressure

Plate For fixing nozzle holder

Pin vice For cleaning nozzle orifice

Tool name and number Description Shape

Filter wrench For removal of fuel filter

PERIODIC MAINTENANCE SCHEDULES

Cylinder head and manifold bolts T T

I : After 200,000 km (125,000 miles)

Cylinder compression pressure I

Oil level and contamination I I I I I I I I I I I I I I

Oil R R: Every 10,000 km (6,000 miles) or 6 months (1)

Coolant (incl. anticorrosive) R R (3)

Coolant (incl. antifreeze) R (4)

Water tank cap I

Nozzle (injection pressure and pattern) I