Hino Manual W04DW04C TW04C T

DIESEL ENGINE FOR
V,
MARINE USE
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FOREWORD
This workshop manual has been prepared to provide information covering repair procedures on Hino Marine Engine.
Applicable models: W04D, W04C-T, and W04C-T1 engine
When marking any repair of your engine, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Operation Hand Book.
All information and specifications in this manual are based upon the latest product information available at the time
of printing.
Hino Motors reserves the right to make changes at any time without prior notice.
HINO MOTORS, LTD.

:
INDEX: ENGINE GROUP
Him GENERAL
INTRODUCTION
ENGINE
!
ELECTRICAL
DRKSHOP EQUIPMENT
\NUAL
'
TURBOCHARGER
INJECTION
PUMP
1
INJECTION PUMP
!
1
GOVERNOR
!
GENERATOR
STARTER
INJECTION PUMP
CALIBRATION
3T0RS, LTD.
| reserved. This manual may not be
p or copied in whole or in part, with-
jrritten consent of Hino Motors, Ltd.
1
i
i
GENERAL INTRODUCTION GI-1
GM5BE-01
CHAPTER Gl
GENERAL INTRODUCTION
GENERAL PRECAUTIONS GI-2
HOW TO USE THIS WORKSHOP MANUAL GI-3
IDENTIFICATION INFORMATION GI-4
SPECIFICATIONS GI-5
TIGHTENING TORQUE OF STANDARD BOLT GI-15
RECOMMENDED LUBRICANTS GI-16
m
GI-2 GENERAL INTRODUCTION
GENERAL PRECAUTIONS
Some recommended and standard maintenance services for your engine are mentioned in this section.
When performing maintenance on your engine be careful not to get injured by improper work.
Improper or incomplete work can cause a malfunction of the engine which may result in personal injury and/or property
damage.
WARNING
When working on your engine, observe the following general precautions to prevent personal injury and/or property
damage in addition to the particular NOTES or WARNINGS,
Most threaded fasteners are metric.
Be careful not to mix with threaded fasteners using the inch system.
O Always wear safety glasses or goggles to protect your eyes.
O Remove rings, watches, ties, loose hanging jewelry and loose clotfling before starting work on the engine.
o Bind long hair securely behind the head.
O To avoid serious burns, keep yourself away from hot metal parts such as the engine, exhaust manifold, radiator,
muffler, exhaust pipe and tail pipe.
O Keep yourself, your clothing and your tools away from moving parts such as the cooling fan and V-belts when
the engine is running.
O Always stop the engine by pulling out the engine stop knob. Leave the knob pulled out as long as the engine
is stopped. And turn off the starter switch, unless the operation requires the engine running. Removing the
key from the switch is recommended.
O Run the engine only in a well-ventilated area to avoid inhaling of carbon monoxide.
O Do not smoke while working on the engine since fuel and gases from the battery are flammable.
O Take utmost care when working on the battery. It contains corrosive sulfuric acid.
O Large electric current flows through the battery cable and starter cable. Be careful not to cause a short which
can result in personal injury and/or property damage.
O Be careful not to leave any tool in the engine compartment. The tool may be hit by moving parts and can
cause personal injury.
HOW TO USE THIS WORKSHOP MANUAL.
This workshop manual is designed as a guide for servicing

engine.
An INDEX is provided on the first page of each chapter.
TROUBLESHOOTING is dealt with each chapter.
When beginning operations, refer to the sections on for
guide to appropriate diagnoses.
SPECIAL TOOLS are dealt with in each chapter.

SLIDING HAMMER DESCRIPTION When ordering a special tool, make sure that the parts number
is correct.
09420-1442 PART NUM8ER
REPAIR PROCEDURES
Repair procedures which are self-explanatory such as simple
installation and removal of parts have been omitted. Illustra¬
tions such as the one below have been provided to make such
simple procedures clear. Only essential procedures requiring
directions have been dealt with explicitly.
TIMING GEAR AND CAMSHAFT

EXAMPLE:
\
T = 190-260 (14-18) 1 0
13
V- I.
12 I
2
'1 %
rs
m
T = 1,100-1,300 (80-94)
/ W
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f% -
5 lily
4-4
V-V'1 T =ÿ
190 -260
(14-18)
6
QJ
-
T = 1,100-1,300 (80-94)
ys-y 9
14
T = Tightening torque kg-cm (Ib.ft)
1. Thrust bearing 5. Bushing 9. Crankshaft gear 13. Front end plate gasket
2. Camshaft gear 6. Idler gear thrust plate 10. Injection pump drive gear 14. Front end plate
3. Oil pump drive gear 7. Straight pin 11. Idler gear thrust plate
4. Idler gear 8. Idler gear shaft 12. Camshaft
■
G 1-4 GENERAL INTRODUCTION
In some cases, illustrations may be of parts which differ in

some nonessential way from the parts found on your par¬
ticular engine. In such cases, however, the principal or
procedure being illustrated applies regardless of such non-
essential differences.
IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBERS
Please quote these numbers when ordering spare parts or
reporting technical matter as they will give you prompt service
ifH
■<<
:'\N attention.
V The engine serial number is engraved on the engine cylinder
i; block.
YS .V
V
t" I
GENERAL INTRODUCTION G 1-5
SPECIFICATIONS
DIESEL ENGINE FOR MARINE USE
HINO W04D 4.009 liters, 4-cycle,

4-cyl., water-cooled
•ENGINE DESCRIPTION
1 . Max. output, pleasure craft 82 kW ( 1 10HP)/3,000 rpm
2. Max. output, work boat 69 kW (92 HP)/3,000 rpm
(light duty)
3. Type Diesel, 4-cycle, 4-cyl., in-line, over-head valve, water-cooled
4. Aspiration Natural aspirate
5. Combustion system Direct injection
6. Cylinder
Bore x Stroke 1 04 x 118 mm (4.09 x 4.65 in.)
7. Piston displacement 4.009 liter (244.6 cu.in.)
8. Compression ratio 17.9
9. Direction of rotation Counter-clockwise viewed from flywheel
10. Dimensions without marine
gear (L x W x H) Approx. 1,026 x 691 x 790 mm
(40.4 x 27.2 x 31.1 in.)
1 1. Dry weight without marine
gear Approx. 385 kg (850 lb)
•FEATURES
1. Cylinder block Mono block cast iron with replaceable dry liner
2. Cylinder head Single piece cast iron
3. Crankshaft Induction hardened die forged special steel with counter
weights
4, Piston and rings Heat resistance aluminum alloy
Two compression rings, chrome plated
One oil ring, chrome plated with coil expander
5. Camshaft Induction hardened carbon steel
6. Valves Heat resistance steel
G 1-6 GENERAL INTRODUCTION
•
•
EQUIPMENT
ENGINE
1. Flywheel housing SAE No. 3
2, Flywheel SAE 111/2
3. Fuel injection pump BOSCH "A" type with all speed governor
4. Fuel filter Paper element type
5. Water separator Equipped
6. Lube oil pump Full forced pressure feed by gear pump
7. Lube oil filter Paper element type (Full flow)
8. Lube oil cooler Multi plate type, Fresh water cooled
9. Fresh water pump Forced-circulation by volute pump
10. Raw water pump Self priming, Rubber impeller type
11, Intake manifold Inlet position at rear, with air cleaner
12. Exhaust manifold Fresh water-cooled exhaust manifold, integrated heat
exchanger with expansion tank
13. Starter 12V, 2.5 KW
14. Alternator 12V, BOA, with built-in voltage regulator
15. Engine stop solenoid Equipped
16. Emergency stop relay Equipped
17. Starter block relay Equipped
18. Glow plug Equipped
19. Rigid mount bracket Equipped
20. Exhaust riser Cooled by raw water
• INSTRUMENT PANEL
1. Battery switch
2. Starter switch with key
3. Instrument panel lamp switch
4. Tachometer (with hourmeter and trip meter)
5. Coolant temperature gauge
6. Oil pressure gauge
7. Fuel gauge
8. Volt meter
9. Pre-heater indicator lamp
10. Coolant temperature warning lamp
11. Charge warning lamp
12. Oil pressure warning lamp
MEMO
■
MEMO
SPECIFICATIONS
W04C-T
3.839 liters, 4-cyc(e,
HINO 4-cyl., water-cooled,
turbocharged
• ENGINE DESCRIPTION
1. Max. output, pleasure craft 112 kW (150 HP)/3,000 rpm
(light duty)
4. Aspiration Turbocharged
6. Cylinder
Bore x Stroke 104 x 113 mm (4.09 x 4.45 in.)
7. Piston displacement 3.839 liter (234.2 cu.in.)
10. Dimensions with marine
gear (LxWxH) Approx. 1,134 x 661 x 790 mm
(44.6 x 26.0 x 31.1 in.)
11. Dry weight with marine
gear Approx. 465 kg (1,025 lb)
• FEATURES
weights
4. Piston and rings Heat resistance aluminum alloy
G 1-1 0 GENERAL INTRODUCTION
•ENGINE
EQUIPMENT
•
2. Flywheel SAE 11%
3. Fuel injection pump BOSCH "A" type with all speed governor
7. Lube oil filter Paper element type {Full flow)
11. Intake manifold Inlet position at rear
13. Turbocharger Cooled by fresh water, with air cleaner
15. Alternator 12V, 50A, with built-in voltage regulator
18. Starter- block relay Equipped
19. Grow plug Equipped
22. Marine gear Equipped
1. Battery switch
3. Instrument panel lamp switch
7. Fuel gauge
8. Volt meter
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LEFT SIDE VIEW
NOTE: These specifications are subject to change without notice.
Jiiso, HINO MOTORS, LTD. TOKYO, JAPAN

MEMO
GENERAL INTRODUCTION G 1-13
SPECIFICATIONS
W04G-TI
3.839 liters, 4-cycle,
HINO 4-cyl., water-cooled,
turbocharged and intercooled
•ENGINE DESCRIPTION
1 . Max. output, pleasure craft 157 kW (210 HP)/3,000 rprn
(light duty)
4. Aspiration Turbocharged and intercooled
6. Cylinder
Bore x Stroke 104 x 113 mm (4.09 x 4.45 in.)
7. Piston displacement 3.839 liter (234.2 cu. in.)
10. Dimensions with marine
gear (LxWxH) Approx. 1 ,152 x 694 x 790 mm
(45.4 x 27.3 x 31.1 in.)
11. Dry weight with marine
gear Approx. 540 kg (1,191 lb)
•FEATURES
weights
4. Piston and rings Heat resistance aluminum alloy
■
GI-14 GENERAL INTRODUCTION
•
•
EQUIPMENT
ENGINE
2. Flywheel SAE 1 VA
3. Fuel injection pump BOSCH "AD" type with all speed governor
7. Lube oil filter Paper element type (Full flow)
11. Intake manifold Inlet position at rear
13. Turbocharger Cooled by fresh water, with air cleaner
14. Intercooler Cooled by raw water
16. Alternator 12V, 50A, with built-in voltage regulator
19. Starter block relay Equipped
20. Glow plug Equipped
23. Marine gear Equipped
1. Battery switch
3. Instrument panellamp switch
7. Fuel gauge
8. Volt meter
GENERAL INTRODUCTION G 1-1 5
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LEFT SIDE VIEW
NOTE: These specifications are subject to change without notice,
Jiim HINO MOTORS, LTD. TOKYO, JAPAN
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TIGHTENING TORQUE OF STANDARD BOLT
Unit: kg-cm (Ib.ft)
Bolt
Bolt
diameter
identifica¬ 4 16 18 20
tion Tightening (mm) 6 8 10 12 14 22 24
conditions
Even tightening area. Bolt nut,

coating, naked bolt, lubricant, etc.
10 - 15 36 - 53 88- 128 174 - 25S 304 - 445 486 - 712 758 - T.110 1.040 - 1.530 1.480 - 2,170 2.030 - 2.980 2.560 - 3.750
<0.8 - 1.0) <2.7 - 3.8) (7 91- (13 - 181 (22 - 32) (36-51) <55 - 80) (76 - 110) (108 - 1561 <147 - 215) (186 - 271)
Optimum conditions.
W Cast iron or aluminum tightening

surface. Washers.
14 - 20 48 - 71 117 -
172 232 - 340 405 - 592 647 - 950 1.010- 1.480 1.390- 2.040 1.970 - 2,900 2.700- 3.970 3.410 - 5.000
<1.1 - - 24) - 42) - 287) - 361)
co
1.4) 13.5-5.1) <9- 121 <17 (30 (47 - 68) (74 - 107) <101 - 147) (143 - 209) (196 (247
Medium conditions.
Tightening area having black

coarse surface. Rusty. Naked 17-25 60 - 88 146 - 214 290 - 425 506 - 742 809- 1.180 1,260 - 1.850 1.740 - 2 .540 2.460- 3.620 3.380 - 4.950 4.260- 6,250
bolt or lubricant unavailable. (1.3 - 1.8) (4.4 - 6,3) (11 - 15) (21 - 30) (37 - 53) (59-85) 192 - 133) <126 - 183) <178- 261) <24S - 358) <309 - 452) m
Poor tightening conditions. z
m
ID
coating, naked bolt, lubricant, etc.
16-24 58-83 138 - 201 273 - 400 477 - 700 764 - 1.120 1.190 - 1,750 1.640 -2.400 2.320- 3.410 3.180- 4.680 4.020-5.360
Optimum conditions.
<1.2 - 1.7) 14 2- 6.0) (10 - 14) (20 - 28) (35 - 50) 156-01) (87 - 126) <119- 1731 (168 - 246) -
<231 338) (291 - 387) 2
6 ID
Cast iron or aluminum tightening O
surface. Washers.
22 - 32 7S - 110 183 - 270 364 - 533 636 - 932 1 .020- 1 .500 1.590 - 2.330 2,180-3,200 3,100- 4.550 4,250- 6.210 5.360 - 7.850 o
(1.6 -2.3) <5.5 - 7.9) (14 - 19) (27 - 38) (47 - 67) 174 - 108) (116- 168) (158-231) (225 - 329) <308 - 449) (386 - 567) C
Medium conditions. n
-H
7 Tightening area having black o
/ 2
coarse surface. Rusty. Naked 27 - 40 94 - 138 229 - 336 455 - 667 795- 1,165 1.270 - 1.870 1,990 - 2.920 2.730-4.000 3.870- 5.680 5.310 - 7.800 6.700-9,850
bolt or lubricant unavailable. (2.0 - 2.8) (6.8 - 9.9) (17-24) (33 - 48) (58-84) <92- 135) (144 - 211) (198 - 2891 (200 - 410) (385-564) <485 - 712)
Poor tightening conditions.

8 coating, naked bolt, lubricant, etc.
24 - 32 82-110 200 - 267 397 - 574 694 - 925 1.010 - 1.480 1.730-2,310 2.380 - 3,170 3.380 -4.510 4.630 -6.170 5.850 - 7.790
Optimum conditions.
(1.8 - 2.3) <6.0 - 7.9) (15- 19) (29-41) (51 - 66) (74
- 107) (126 - 167) (173- 229) (244 - 326) (335 - 446) (424 - 563)
y
9
Cast iron or aluminum tightening
surface. Washers.
32 - 42 110 - 146 267 - 356 529 - 706 925 - 1.230 1,480 - 1.970 2.310 - 3.080 3.170 - 4,230 4.510 - 6.010 6.170 - 8.230 7.790- 10.390
(2 4 - 3 0) (8 0 - 10 5) (19 - 25) (39 - 51) (67 - 88) (108 - 142) (168 - 222} (230 - 305) (327 - 434) (447 -595) (564 -751)
Medium conditions.
10
Tightening area having black
coarse surface. Rusty. Naked 40 - 53 137 - 183 334 - 445 662 - 882 1.160 - 1.540 1.850- 2.470 2.890 - 3.050 3.970 -5,290 5.640 - 7.510 7.720 - 10.290 9.740- 12.990
11 bolt or lubricant unavailable. (2.9 - 3.8) (10.0 - 13.2) (25 - 32) <48 - 63) (84-111) 034 - 178) (210 - 278) (288 - 382) (408 - 543) (559 - 744) (705 - 939)
Poor tightening conditions.
NOTE: The torque values given in this table should be applied where bolt torque is not specified.
Tlina RECOMMENDED LUBRICANTS FOR ALL HINO ENGINE HINO MOTOHS, LTD.
OVERSEAS OPERATIONS
SERVICE OIV.
TOKYO. JAPAN
ATMOS
LUBRICANTS S A E
POSITIONS PHERlC BP CALTEX CASTROl ESSO GULF MOBIL SHELL TOTAL
NO.
TEMP.
HPM 0610 -100 Oil Castrol Oi u
I Myiina Oil 40. TOTAL
Above Esso•V.LK Mobil Del vac 1 340
Vanciius C • 3 SAE 40 or 15W/40 CAO 4 O.Tuifbofnd* Golt Super Duly 2OW-40. 15W 40 Rubia S 40
32C 40
40 RPM OELO 300 Oil 0 3 40 Moifcil Oetvac Super
190' F) Castrol M Oil 40 t :SW 40 Rioitifa X Oil 40 TOTAL
SAE 40 RX Super 40 15'W/4CJ XD 3 40 1*W 40
Rimufa CT 40 Rubia TM 15W40
ENGINE OIL
IA PI CD! RPM OELO 400 Oil Myiina Oil 30.
Castrol o TOTAL
Pre.vioos Classification 32' OC VeneUus CD SAE 30 or I bW/40 CRO 30 EssolL.be Mobil Delvac 1330 20W-40, 1SW-40
30 Golf Super Duly R ubia S 30
IA P I DS) 190' 32'FJ I0 RPM OELO 300 Oil Castrol D 3 30. »r 0.1 30. HSW 40
Mobil De'v Rimula X 04 30.
X03 30 15W- 40 10W-30 TOTAL
(MIL- 1-2104C1 SAE 30 RX Super 30. 15W /40 Rubia TM 1 5W40
(Mil L 4519901 Rimula CT30
RPM OELO 400 0.1
Cdsi.ul or Oeusol
CRO 20W/20 Essolubc Mobil Oclvac 1310
Myr.r.d Oil 20. TOTAL
0‘ 12'C Van elms C ! 5AE 20/20W. I6W/40 Gull Super Duty 20W 40.15W 40 fi Libia S 20
20 Casirol or Oeusol 0-3 20W. Mobil Oulv
132 10 Fl 70V RPM OELO 300 0.1 .r Oil 20. IS5W 40 flinu.id X Oil 20 TOTAL
RX Super 20W/20. XO 3 15W 40 15W 40
Cylinder Block SAE 20/20W Rimula CT20 Nubia TM 15W40
15W/40 CT
Injection Pi..tip
An Clear* RPM OELO 200 Oil Casuol or Oc-usoi m
32‘C 40 Vanetius SAE 40 CRX 40 Essolube
HOX 40.
Golf lube Mo( 0.1 Mobil ac 1240
Rotella TX40.20W 50
RoielII 3 SX
S 0.1 40. TOTAL z
1907FI
40 RPM OELO 100 Oil Castrol or Oeusol HOX Plus 40
XHD' 40 1&W 40 Mobil Delv sc 1 140
20Wr 40 Rubn* IH 40 m
SAfc 40 RX Super 40. >5W 40 33
ENGINE l HI
(API CC)
32' OC
RPM OELO 200 Oil
SAE 30
Casuol or Oeusol
CRX 30 Essolube Gottiube Mol 0.1 Rolclla TX30.2 OW 50
>
Previous Classification 30
Vanolius
IIDX 30.
Mobil Delvac 1230
Rotella SX 0.1 DO. TOTAL
(A P I DM} 190 32 F( 30 RPM DEL0 100 0>l Casirol or Deusol XHD 30 15W 40 Mobil Delvac 1 130 Hubia H 30
HOX riu» 30 20W40
(MIL L 461521 SAE 30 RX Super 30 l SW-40
(MIL L 2104B1
RPM OELO 2l00 Oil Castro! c H
O’ 12C Vanellus M SAE 20/20W
CRX 20W'20 Essolube Rotella TX20.20W S0 DJ
Gultlube Moior Oil
132' 10F1 20
20W RPM OELIo ioo o-i Casirol Oeusol HOX 20.
XHO 20 . 1 5W-40
Mobil Detvac 1220
Mobil Ootvac I 1 20 Rotella SX 0<l TOTAL
Rubia H ?0 o
SAE 20/20W
RX Sup 20W'?0.
15W40
HDX Plus 20W 20 20/20W.20W 40 a
c
COOLANT PUMP Esso CT
finer grease Mull.purpose 2 Casirol LM Mob fl«liftd« A TOTAL
BEARING GREASE Coola»i Pump Bearing
L 2 v ariak Greas
Multipurpose Guillen Poly
MP ;7.MS Alvania Grease R2 M ULTIS 2
=j
J (Mil -G 10924B1 AH Pjiposc 2 a
Bushing . ClulCh. z
Duve Shall.
STARTER GREASE
.
Shift Love
& R erl.iCHon Gu.i
Grea:sc EP2
Mobilg.oase 29 Ae.o Shell Grease 1 7
GENERATOR 8. STARTER Generator Bearing £n«r grease RPM

Mobilgreese 26 Aero Shell Grease 7
BEARING GREASE Starter Bearing LT 2 SRI 2
Ma.lak
INJECTION PUfMP €ner grease Mull■ purpose 2 Casirol LM
Esso Mobilgrcase Retina* A TOTAL
TIMER GREASE Injection Pump Tuner Multipurpose Gutlle* Poly
L-2 or Marfdk Grease MP. 7 7.MS Alvan.a Grease R2 Mult.s EP 1
1MIL-G 1092461 All Purpose 2
Grease
ShctlionolU S A 1
1 Cast rOl Ann -Free Esso
Cru.se Master Glycoshell Plus
ANTI FREEZE Engine. Radiator AF Enginu Antifreeze Mobil (Europian Countries) TOTAL
Am. Frost Casuol Long Lite Ant. Freeze
I MI L H-5559AI itani And Sumr Pe.miirone Sheiisafe ANTlGEI
Coolant Coolant Am, -Freeze P281
Coolguard
Note: Lubricants emandod according classification by A P t LA mar Petroleum Institute) 62-12 200 (T.S 01(*1
CT
*y
MEMO
ENGINE EN-1
EN-135E-02
CHAPTER EN
ENGINE
Models W04D, W04C-T and W04C-TI
DATA AMD SPECIFICATIONS..

TROUBLESHOOTING
ENGINE OVERHAUL CRITERIA
ENGINE MOVING PARTS
CYLINDER HEAD
TIMING GEAR, CAMSHAFT AND OIL PAN
PISTON, CRANKSHAFT, CYLINDER BLOCK
AND FLYWHEEL HOUSING
__ EN-DS7A
EN-MP7A
- 1
EN-TS1C - 1
EN-OC3C - 1
EN-MP7A - 1
EN-MP7A -16
EN-MP7A -23
- 5
LIQUID GASKET AND APPLICATION PARTS... EN-MP7A -38

LUBRICATING SYSTEM EN-LS7A - 1
OIL PUMP EN-LS7A - 3
OIL COOLER AND OIL FILTER EN-LS7A - 5
FUEL SYSTEM EN-FS6B - 1
INJECTION NOZZLE EN-FS6B - 2
FUEL FILTER EN-FS6B -
4
COOLING SYSTEM EN-CS7A - 1
COOLANT PUMP EN-CS7A - 3
HEAT EXCHANGER EN-CS7A - 6
THERMOSTAT ; EN-CS7A - 8
AIR INTAKE AND EXHAUST SYSTEM EN-IE2A - 1
ENGINE COMPONENT PARTS DISMOUNTING
AND MOUNTING EN-CP5B - 1
FUEL INJECTION PUMP EN-CP5B - 1
GENERATOR EN-CP5B - 3
STARTER EN-CP5B -
4
ENGINE TUNE-UP EN-TU5A - 1
PROCEDURE FOR INSTALLING AND
GASKETS OF ENGINE PARTS EN-PR1B - 1
MARINE TRANSMISSION MOUNTING
AND DISMOUNTING EN-MT1A - 1
ENGINE EN-DS7A-1
DATA AND SPECIFICATIONS
Model W04D W04C-T W04C-TI
Type Diesel, 4-cycle, vertical,

4 cylinder, in-line,
overhead valve, water-
cooled
Aspiration Natural aspirate Turbo charged Turbocharged and
intercooled
Combustion system Direct injection
Bore and stroke .. 104x 118 mm 104 x 113 mm
(4.09 x 4.65 in) (4.09 x 4.45 in)
Piston displacement 4.009 liters (244.6 cu.in) 3.839 liters (234.2 cu.in)
Compression ratio . 17.9 16.5
Firing order 1—3— 4— 2
(A number of a cylinder
is to be counted in order
from the timing gear side)
Direction of rotation Counter-clockwise viewed
from flywheel
Maximum revolution (at full load) . 3,000 rpm
Idling revolution 775—825 rpm 750—800 rpm
Dry weight with marine transmission. Approx. 430 kg (948 lb) Approx. 465 kg (1,025 lb) Approx. 520 kg (1,146 lb)
Valve timing (flywheel travel),
Intake opens 16° before T.D.C. <*-
Intake doses 40° after B.D.C.

Exhaust opens 55° before B.D.C.
Exhaust closed 13° after T.D.C.
Valve clearance (when cold),
Intake 0.30 mm (0.0118 in) 0.35 mm (0.0138 in)
Exhaust 0.40 mm (0.0157 in) 0.45 mm (0.0177 in) 0.50 mm (0.0197 in)
Injection nozzle opening pressure . 220 kg/cm2 (3,129 Ib/sq.in)
Injection timing 14° before T.D.C. for No.1 17° before T.D.C. for No.1 <r-
cylinder on compression cylinder on compression

stroke stroke
■
EN-DS7A-2 ENGINE
Model W04D
PERFORMANCE CURVE
PLEASURE CRAFT RATING LIGHT DUTY RATING

SAE J1349 (GROSS) SAE J1349 (GROSS)
A:BRAKE HOSE POWER A: 8 RAKE HOSE POWER
5
8: SHAFT HOSE POWER B: SHAFT HOSE POWER
* C: TYPICAL PROPELLER LOAD (EXPONENT 3.0) C: TYPICAL PROPELLER LOAD (EXPONENT 3.0)
£ 10° | 100
120 120
80 ao
100 A : RATED BHP 100
A: RATED 8HP
}_ 80 60 80 60
CL ji a
sy
D 60 kB : RATED SHPX D 60 y
o
4Q
40
z o
40
40
B: RATED SHP
20 C : POWER-PROPELLER LOAD —I 20
I I
20
!I 1
20
|i § C : POWER-PROPELLER LOAD
- s p
0 0
FUEL CONSUMPTION
50
I| 0 0 50 <
£
CL
5
t 10
ya « FUEL CONSUMPTION 40 1« 5
FUEL-PROPELLER LOAD
\ 00 8 §
\"X O
30-8
FUEL-PPOPELLER LOAD
o
20
■
6
«
°
-I I 20
6
4 LLJ
'0
2 EL 10
2 2
0 Jo o Jo
1.40O 1.800 2.200 2.600 3.000 1.400 1 .800 2,200 2,600 3.000
ENGINE SPEED (rPm) F-213 ENGINE SPEED {rpmj F-214
NOTE:
Engine performance at SAE standard J1349 conditions of 90m (300ft) altitude (100 kPa [29.61 in.Hg] baro¬
metric pressure), 25°C (77°F) air intake temperature, and 1 kPa (0.30 in.Hg) water vapor pressure with No.2
diesel fuel wll be within 5% of that shown at the time of engine shipment. Actual performance may vary with
different ambient conditions,
ENGINE EN-DS7A-3
Model W04C-T
PERFORMANCE CURVE

SA£ J1349 (GROSS) SAE J1349 (GROSS)
A: BRAKE HOSE POWER
II
A; BRAKE HOSE POWER
B: SHAFT HOSE POWER
C: TYPICAL PROPELLER LOAO (EXPONENT 3.0)
II B: SHAFT HOSE POWER
C: TYPICAL PROPELLER LOAD (EXPONENT 3.0)
1 60 120 160 120
140
100
A : RATE0SHP
ZZ7 140
100
A: RATED BHP
H
120
3
CL
120
80
V*
CL
5 100
80
/ 7 ID
o
too
O / B: RATED SHP
/ 80 60
80 60
z
B : RATED SHP
I 60
I
60 £ 5 z ? Z
40
/
& O 40 =t
1
40 C: POWER-PROPELLER LOAD SO
O
< CL 40
s
Z \ C : POWER-PROPELLER LOAD
50 <
£
P
CL
2
2 S
FUEL CONSUMPTION
40 13 20 - -f -1 - 40 10
ID
CO
X
20 TlO CO 20 FUEL CONSUMPTION
20 z 30 8
Z
FUEL-PROPELLER LOAD. 8 O
30
6
O
U
FUEL-PROPELLER LOAO
i
Y 6 O
20 0 0 20
0 0 4 til
4 til
10 3
10 LL 2 LL
2
0 0 J0
0
3,000 1,400 1.800 2.200 2,600 3.000
1.400 1 ,800 2.200 2.600
ENGINE SPEED F-215 ENGINE SPEED (rpm) F-216
NOTE:
Engine performance at SAE standard J1349 conditions of 90m (300ft) altitude (100 kPa [29.61 in.Hg] baro-
different ambient conditions.
DESCRIPTION
S,
03 ll l ; @©
OKiy Hi
0 !P
o
i: '0
a
o o P o, o
(o) a m* •y o 0
r i °i
o 0 o
a
O
(o i "oj
% fb o
.O, B
r li o o d) lo O :
s V, fOD
T JZI
0 -a_
kil O IIJ
(o) U
k.
T
B
DHF-226 DHF-227
■
EN-DS7A4 ENGINE
Model W04C-T1
PERFORMANCE CURVE

SAE J1349 (GROSS) SAE J1349 (GROSS)
r
£
A: BRAKE HOSE POWER
B : SHAFT HOSE POWER ?
A: BRAKE HOSE POWER
8 : SHAFT HOSE POWER
i 200
C: TYPICAL PROPELLER LOAO (EXPONENT 3.0) £ 200
~ C : TYPICAL PROPELLER LOAD (EXPONENT 3.0)
250 180 250

180
A: RATED BHP
160 160
200 200
140 140 •A: RATED BHP'
ss
Q.
150
120
7
f-
3
0-
150
120
/1
j**
100 100
3 K a : RATED SHPÿ Z> KB: RATED SHP7
O 1 00
80
60 t s''
7
I
€
O
10(7 80
SO
7 f
50 40
,C : POWEft-PHQPELLER LOAO
£
9
t12 50 40 Z i §
U1
\C :POWER-PROPELLER LOAO a <a
I-
d 2
20
FUEL CONSUMPTION 14
2 20
i
0 0 so
12
CL
S
0 0 so }u a
40 3 FUEL CONSUMPTION ■’* |
Z 10 40
CD 10 cn
30 8
2 z
O 30 8 O
6 O O
20 6
20
4 LU 4 UJ
10
2
20
LL 10
=>
t
\ FUEL-PROPELLER LOAO
0
t FUEL- PROPELLER LOAO
2
0 0 0
1,400 1.800 2.200 2,600 3.000 1.400 1,800 2.200 2.600 3.000
ENGINE SPEED ('P™> F'21 7 ENGINE SPEED (rpm) F-218
NOTE:
Engine performance at SAE standard J 1349 conditions of 90m (300ft) altitude (100 kPa [29.61 in.Hg] baro¬
different ambient conditions.
DESCRIPTION
t 7
(f§ "I
TM
b d
j
irrrn
i
O
/ 4 7
m
i
i a
C
A <s> 0
CTXL m la
O
p o :
(-0 ro) o
-Si— E
loj IT HZ O\_/0 ITFb

A L.
DHF-228 DHF-229
ENGINE EN-TS1C-1
TROUBLESHOOTING
Symptom Possible cause Remedy/Prevention
Engine overheating Coolant
• Insufficient coolant Add coolant.
• Defective thermostat Replace the thermostat.

Overflow of coolant due to leakage of . .
• exhaust Repair.
into cooling system
• Coolant leakage from cylinder head gasket Replace gasket.
• Defective coolant pump Repair or replace.
Heat Exchanger
• Clogged with rust and scale Clean heat exchanger.
• Clogged with iron oxide due to

leakage of exhaust into cooling
Clean coolant passage and
correct exhaust leakage.
system
• due
Clogged or corroded heat exchanger
to mud or other debris
Clean or replace heat exchanger.
• valve
Defective heat exchanger cap pressure Replace heat exchanger cap.
Abnormal combustion
• Incorrect injection timing . Adjust injection timing.
• Reduced injection pressure Adjust injection pressure.
• Poor fuel Use good quality fuel.
• Poor nozzle spray Adjust or replace nozzle.
• Unsatisfactory automatic timer advance angle .. Repair or replace timer.

Other problems
• Defective or deteriorated engine oil . Change engine oil.
• Unsatisfactory operation of oil pump Replace or repair.
• Insufficient oil Add oil.
• Brake drag Repair or adjust.
Cooling system
Defective sea water pump Repair or replace.
Loose or slipping V-belt Adjust V-belt tension or replace.
Closed sea water intake valve (Seacock) Open intake valve.
Clogged sea water strainer Clean strainer.

EN-TS1C-2 ENGINE
Symptom Possible cause Remedy/Prsvention
Excessive oil consumption Pistons, cylinder liners, and piston rings
• Wear of piston ring and cylinder liner Replace piston rings and
cylinder liner.
• Worn, sticking or broken piston rings Replace piston rings and

cylinder liner.
• Insufficient tension on piston rings Replace piston rings and

cylinder liner.
• Unsatisfactory break-in of piston rings Replace piston rings and

cylinder liner.
• Unsuitable oil (viscosity too low) Change oil as required and replace
piston rings and cylinder liners.
• (upside
Incorrectly fitted piston rings
down)
Replace piston rings.
• Gaps of piston rings in line with each other .... Reassemble piston rings.
Valve and valve guides
• Worn valve stem Replace valve and valve guide.
• Worn valve guide Replace valve guide.
• Incorrectly fitted valve stem seal Replace the stem seal.
• Excessive lubricant on rocker arm Check clearance of rocker arm

and shaft.
-1 Excess oil feed |
• Defective oil level gauge Replace oil level gauge.
• Oil level too high . . . . Drain excess oil.
Cooling system
• Overcooled engine . . . Warm up engine before moving

(low temperature wear) boat.
Check cooling system.
Other problems
• Oil leakage from miscellaneous parts Repair.
Piston seizure Operation
• atAbrupt stoppage
highspeed
of engine after running Operate engine properly.
ENGINE ENTS1C-3
Piston seizure Oil
• Insufficient oil Add oil.
• Dirty oil Change oil.
• Poor quality oil Replace with proper engine oil.
• High oil temperature Repair.
• Low oil pressure Repair.
• Defective oil pump Repair oil pump.
• oil
Reduced performance due to worn
pump
Replace oil pump.
• Suction strainer sucking air Add oil and/or repair strainer.
Abnormal combustion See Symptom: "Engine over¬

heating."
Coolant See Symptom: "Engine over¬

heating."
Lack of power Injection pump Refer to CHAPTER IP,

FUEL INJECTION PUMP.
Intake
• Clogged air cleaner Clean element or replace

element.
Overheating See Symptom:

"Engine overheating."
Fuel and nozzlel
• Poor nozzle spray Adjust or replace injection

nozzle.
• Clogged nozzle with carbon Clean nozzie.
• Wear or seizure of nozzle . Replace nozzle.
• Air in fuel, system Repair and bleed air from fuel

system.
• Clogged fuel filter Replace element.
• Use of poor fuel . Use good quality fuel.
-1 Abnormal combustion! See Symptom:

"Engine overheating."
-) Piston, cylinder liners, and piston rings See Symptom "Engine over¬
heating."
Other problems
• Breakage of turbine or blower Replace the turbine or blower

or turbocharger.
■
EN-TS1C-4 ENGINE
Difficulty starting engine Electrical system
• Discharged battery Charge battery.
• Defective wiring in starter circuit . Repair wiring of starter.
• Loose or open-circuit battery cable Tighten battery terminal connec¬

tions or replace battery cable.
• Breakdown of starter Replace starter.
• Break of glow plug or intake

air heater {If so equipped)
Replace
Injection pump Refer to CHAPTER IP,

Air cleanerl
• Clogged element Clean the element or replace the
element.
Fuel system
• No fuel in tank Supply fuel and bleed air from

fuel system.
• Clogged fuel line Clean fuel line.
• fuel
Air sucked into fuel
line connections
system through . Tighten fuel line connections.
• Clogged fuel filter Replace element.
• Loose connection in high-pressure line Tighten sleeve nut of high pres¬

sure line.
• Water in fuel Drain and clean fuel system
Difficulty starting engine Nozzles
• Seized nozzle Replace nozzle.
• Broken or fatigued nozzle spring Replace spring.
-[Oil system |
• Oil viscosity too high Use proper viscosity oil, or

install an oil immersion heater
and warm up oil.
Other problems
• Seized piston . Replace piston, piston rings, and

liner.
• Seized bearing . Replace bearing and/or crankshaft.
• Reduced compression pressure . Overhaul engine,
• Ring gear damaged or worn . . Replace the ring gear and/or

starter pinion.
• accelerator
Improperly adjusted or broken
cable
. Adjust or replace the accelerator
cable.
ENGINE EN-TS1C-5
Symptom Possible cause R emedy/Prevention
Rough idling Injection pump Refer to CHAPTER IP,

Nozzles
• Uneven injection pressure . . Adjust.
• Poor nozzle spray Adjust or replace nozzle.
• Carbon deposit on nozzle tip Remove carbon.
• Seized needle valve Replace nozzle.
Engine proper
• Improper valve clearance . . . Adjust valve clearance.
• Improper contact of valve seat Replace or repair valve and valve

seat.
• Idling speed too low Adjust idling speed.
• Coolant low
temperature too Warm up engine.
Compression pressure of cylinders . .
• markedly Overhaul engine.
different from one another
Leakage of exhaust Cylinder head gasket |
• Fatigued gasket (aging) Replace gasket.
• Damage Replace gasket.
• Improper installation . Replace gasket.
Cylinder head bolts
• Loose bolts Tighten bolt.
• Elongated bolts Replace bolt.
• tightening
Improper tightening
sequence
torpue or Tighten properly.
Cylinder block
• Cracking Replace cylinder block.
• Surface distortion Repair or replace.
• portion
Fretting of cylinder liner insertion
(insufficient projection of
Replace cylinder liner or
cylinder block.
cylinder liner)
Cylinder head
• Cracking Replace cylinder head.
• Surface distortion Repair or replace.
■
ENTS1C-6 ENGINE
Leakage of exhaust Cylinder liners
• Cracking Replace cylinder liner.
• Corrosion Replace cylinder liner.
• Insufficient projection of cylinder liner Replace cylinder liner.
Other problems
• Incorrect injection timing Adjust injection timing.
Seawater discharge is not Seawater pump

sufficient
• Sucking air . Supply seawater and bleed air
from cooling system.
• Damaged impeller Replace impeller.
• seawater
Clogging of suction pipe and/or
strainer
Clean suction pipe and strainer.
Abnormal noise or vibration Seawater pump
• Worn bearing Replace bearing.
• Foreign material in the pump Repair or replace.
• Incomplete mounting Mount completely.
Bearing wears frequently Seawater pump
• Too tight V-belt tension Adjust V-belt tension.
Damage of impeller Seawater pump
• When it has been operated for a long period .... Replace impeller.
■ When it has been operated without seawater ... Replace impeller.
• When it has been operated at higher RPM Replace impeller and operate
atnormal RPM.
• Too high or low water temperature Replace impeller and operate

atnormal temperature.
• When it has not been operated for an

extended period
Replace impeller.
• Foreign material in the pump Repair or replace.

ENGINE EN-0S3C-1
ENGINE OVERHAUL CRITERIA

SPECIAL TOOL
Prior to starting an engine overhaul, it is necessary to have these special tools.
COMPRESSION GAUGE COMPRESSION GAUGE COMPRESSION GAUGE

ADAPTOR (NOZZLE HOLDER) ADAPTOR (GLOW PLUG) ADAPTOR
<0
.0
©
09408-1041 09552-1051 09552-1070
FACTORS WHICH DETERMINE WHEN AN ENGINE OVER-

HAUL IS NEEDED.
1. Lowered compression pressure
a. Before the measurement
a) Correct the valve clearance.
b) Warm up engine (Bring the coolant temperature to about 80°C
( 1 7 6° F ) ] .
c) Charge the battery fully.
d| Remove the air cleaner.
b. Measurement
1) Measure at nozzle holder hole.
a) Remove the nozzle holders.
SAMPLE
0 b) Install the gauge adapter in the nozzle holder hole.
Special Tool: Compression Gauge Adapter (09408-1041)
(09552-1070)
2) Measure at glow plug hole.
a) Remove the glow plug.
R b) Install the gauge adapter in the glow plug hole.
Special Tool: Compression Gauge Adapter (09552-1051)

(09552-1070)
SM3-388
c) Connect a compression gauge to the gauge adapter.
d) Drive the engine with the starter and read the compression
pressure.
NOTE: Do not continuously operate the starter for more than 15
seconds at a time.
e) Measure the compression pressure for each cylinder. If the
compression pressure is low, be sure to repeat the measuring.
NOTE : Be sure not to leak through sealing face.
Unit: kg/cm2 (Ib/sq.in)
Compression pressure Difference between Engine speed
Engine model
Standard Limit each cylinder (rpm)
W04D 25 (355)
33-36 (469-511)
W04C-T Less than 3 (43) 350
W04C-TI 30-33 (427-469) 22 (313)
W06D 33-36 (469-511) 25 (356)
W06E 280
W06D-TI 30-33 (427-469) 22 (313)
EN-0S3C-2 ENGINE
2. Decreased oil pressure

SAMPLE
Check the oil pressure warning lamp when the oil and coolant
temperature is hot [about 80°C ( 1 76° F ) ] .
I 1 3. If the warning lamp is lighted, check the oil level.
I
iI b. Check oil deterioration.
I I If oil quality is poor, replace with a suitable grade oil.
I OIL I c. Remove the oil pressure switch and install the oil pressure
i
gauge.
d. Measure the oil pressure at coolant temperature 80°C (176°F)
or more.
SM3-349
Standard oil pressure: 0.5— 5.0 kg/cm2 (7.11—71.10 Ib/sq.in)
Service limit: Less than 0.5 kg/cm2 (7.11 lb/sq.in}
ATMOSPHERIC TEMPERATURE
S.A.E. 3. Other factors
GRADE -10 0 32 50 70 90100 °F
-23-18 0
+
10 21 32 39 °c
a.
b.
The blow-by gas increases.
The engine does not start easily.
40 c. Engine output decreases.
d. Fuel consumption increases.
30 e. Engine makes greater noise.
20W/20
X
f.. Excessive oil consumption.
15W/40
u iVim
ENGINE EN-MP7A-1
EMGINE MOVING PARTS
DESCRIPTION
Representative engine model W04C-TI
2
'a
zr l
1.
2.
Heat exchanger cap
Heat exchanger
3. Generator
4. Engine coolant pump
5. Crankshaft pulley
p ol 6. Seawater pipe
7. Seawater pump
■6
3' 8. Oil pan
ol o' 9. Water separator
.0
) 10. Fuel filter
11. Engine stop solenoid
x>. <§>
o ■7 12. Oil level gauge
13. Intercooler
4 O
14. Fuel feed pump
15. Fuel injection pump
16. Starter
®
5
8
4J
9 1 2 10 11 12 13
A
Y
iec ■'tr
L
fqw P o (o V
K
_r 0
tc itr®
io I
t P ¥
f
111
14 15 16 8 6
■
EN-MP7A-2 ENGINE
SPECIAL TOOL
Prior to starting an engine overhaul, it is necessary to have the following.
ADAPTOR ADAPTOR
SLIDING HAMMER (USED WITH 09420-1442) (USED WITH 09420-1442)
09420-1442 09462-1370 for model W04D 09462-1130 for models W04C-T

and W04C-TI
EYE BOLT
CYLINDER HEAD BOLT WRENCH (USED WITH 09470-1022) WIRE
/ ai
&
09411-1260 09433-1070 09491-1010
VALVE SPRING PRESS VALVE LAPPING TOOL VALVE STEM SEAL PRESS
&
c
Q 1
09470-1022 09431-1010 09472-1650
CRANKSHAFT PULLEY
PULLER TIMER SETTING TOOL IDLER GEAR SHAFT PULLER
09420-1500 09512-2090 for model W04D 09420-1100

09512-2100 for models W04C-T
and W04C-TI
i
ENGINE EN-MP7A-3
TIMING GEAR COVER OIL

SEAL PRESS PISTON RING EXPANDER CYLINDER LINER PULLER
V ■s
09482-1530 09442-1180 09420-1460
CYLINDER LINER GUIDE GUIDE PRESS SUBASSEMBLY
Q,
\
o. w
O
09480-1120 09481-1130 09402-1450
WING NUT SPINDLE SPINDLE
9233-10360 09402-1470 for models W04C-T 09402-1460 for model W04D

and W04C-TI
GUIDE GUIDE BOLT
09481-1140 for models W04C-T 09481-1120 for model W04D 9 191-08252

and W04C-TI
■
EN-MP7A-4 ENGINE !
f
!
FLY WHEEL HOUSING OIL SEAL

PISTON RING HOLDER PRESS
&
c
09441-1260 09482-1540
I
!
i
ENGINE EN-MP7A-5
CYLINDER HEAD
OVERHAUL
ME! 1-040-00X02 (1310)
T = 190-260 <14-18)
T = 190-260 (14-18)
5
4
3
i
i
§
IL <y> L
gg; '9
■is
(g§)— 10
/3)
11 1
•12 k.J
2
©
m
6
r>
0
v,
M <?
~Z)<
<?
1
n 0
15
16
&
T = Tightening torque kg-cm (lb. ft)
1. Cylinder head 7. Push rod 13. Valve stem oil seal

2. Rocker arm shaft 8. Tappet 14. Valve spring lower seat
3. Bushing 9. Cotter key 15. Exhaust valve
4. Rocker arm 10. Valve spring upper seat 16. Intake valve
5. Rocker arm support 11. Inner valve spring (For W04D)
6. Valve clearance adjusting screw 12. Outer valve spring
■
EN-MP7A-6 ENGINE
OVERHAUL
T= 450-500 (33-36)
T = 130—190 (10-13)
3
2 T = 1,300-1,400 (94-101)
IS
D T = 130-190(10-13)
s Tÿ-n '4
I
S'
(So
-Os 14
o A
12
"V
o O
1
Q3
o
O
fife 12
13
3 O
0
c
\6V w ©X-
'o,
a
'e. m-11
o.
if® 63
e,
S-1.
5
-S'
©
*©,
©
e. ®X9
©j
©
e, T = Tightening torque: kg-cm (Ib.ft)

e 63
1
1. Cylinder head
2. Oil filler cap
8 3. Cylinder head cover
6
'M 0 4.
5.
6.
Cylinder head cover gasket
Cylinder head gasket
Valve guide
o. 7. Valve seat
o 8. Expansion plug
o
C 3;
2
c.
,_o!
o
m? \
9.
10.
11.
Nozzle holder gasket
Packing ring
Shim
© o- ©o 12. Nozzle holder
,'o' ro 0 13. Nozzle
(9
S 8
14. Nozzle holder adapter
o 7
ENGINE EN-MP7A-7
IMPORTANT POINTS - DISASSEMBLY

CLEAN OFF SURROUNDING AREA OF THE NOZZLES AND
«2ÿ THE FUEL LINE CONNECTORS.
s>
W
m
•SI
NOTE: If foregin matter is allowed to enter the combustion
chamber, engine trouble may result.
//)-
/ rC~ SM3-879
REMOVE THE INJECTION PIPES.

NOTE: Cover open ends of the pipes to prevent entry of dirt.
Vl
V
IfJ
SM3-886
REMOVE THE NOZZLE ASSEMBLY.
/: Using a special tool, if the nozzle is difficult to remove by

hand.
rJeP,i!aap
Special Tool: Sliding Hammer (09420-1442)
Adapter (09462-1370) for W04D
(09462-1130) for W04C-T, W04C-TI
m NOTE: o After removal of the nozzle holder, cover the nozzle
holder with cloth. Also cover the cylinder head with a
H0> cloth to prevent dust from getting in.
SM3-200
REMOVE THE CYLINDER HEAD ADDITIONAL BOLTS AND

ROCKER ARM SUPPORT BOLTS.
9 8 6
Loosen the cylinder head additional bolts and rocker arm
1 3 5 4 2
support bolts in the numerical order as shown.
(o' {SYSj'o' (o fo
&
j — ----— o & .©
SM3-830
LOOSEN THE CYLINDER HEAD BOLTS AND REMOVE THEM.

EXHAUST SIDE
Loosen the cylinder head bolts little by little in three stages
©. © ® „© and in the numerical order as shown.
© © © Special Tool: Wrench (09411-1260)
© © © ©
i
© \ ® i ©
i ?( ! I
* Mark position (Cylinder head additional bolts)
©
(3K .©
INTAKE SIDE SM3-201
■
EN-MP7A-8 ENGINE
LIFT THE CYLINDER HEAD FROM THE DOWELS ON THE

CYLINDER BLOCK AND PLACE IT ON WOODEN BLOCKS
o ot) /: 'CHISEL
°0°o o o|o 1. If the cylinder head is difficult to lift off, pry with a chisel
o oo° 0°0 Cj IPLACE CHISEL between the cylinder head and block.
AT THIS
o "oO ° P ° P ° CORNER ONLY
0
NOTE: Do not damage the machined surface of the head or block
when removing the cylinder head.
PLY UP AND DOWN
b 0 0 0 ti Special Tool: Eye Bolt (09433-1070)

Wire (09491-1010)
CYLINDER BLOCK
SM3-892
REMOVE THE VALVE SPRINGS.

1. Remove the valve stem cotters, upper valve seats, and inner
i (for W04D) and outer valve springs from cylinder head.
,0 9
* Special Tool: Valve Spring Press (09470-1022)
im 2. Remove the intake and exhaust valves.
j fu
o
~r~ SM3-824
3. Tag valves to identify their cylinder numbers and to eliminate

valve lapping.
IN
« A§ CLS>«
EX
llsiliili
1 2 3 4
SM3-893
IMPORTANT POINTS - ASSEMBLY

CLEAN THE CYLINDER HEAD THOROUGHLY WITH A SUIT¬
ABLE SOLVENT.
NOTE: Be careful not to damage the cylinder head surface.
o>
ooo-»©o o
T SM3-825
IF NECESSARY, HAND-LAP THE VALVE AND VALVE SEAT.

Lightly apply lapping compound to the valve face. Install
!' the valve with a special tool, tap and rotate the valve against
the seat. ;
Special Tool: Valve Lapping Tool (09431-1010)
.
V1>
o o«
SM3-364
ENGINE EN-MP7A-9
IF NECESSARY, GRIND THE VALVES AND VALVE SEATS.

NOTE: o Grinding of valves and valve seats should only be per¬
formed when hand-lapping does not result in proper
seating.
o After grinding, always recheck the valve sink.
CJI
o T-
XT
SM3-707 SM3-708
Standard:
Valve Seat (Intake) 30° - 30°30'
LU Valve Face (Intake)
Valve Seat (Exhaust) :
29°45'-30°15'
45° - 45°30'
Valve Face (Exhaust): 44° 45' - 45° 15’
30»ÿ 45°
INTAKE EXHAUST
SM3-894
o= IF NECESSARY, REPLACE THE VALVE SEAT.

1. Cut the circumference of a valve head at three places with
a grinder and install it into the seat as shown and weld the
valve to the seat. Then drive the valve and the seat out with
VALVE SEAT
a hammer and a brass block.
ff
VALVE ARC WELDING
CUT THESE
POSITIONS SM3-895
2. Valve seat section machining specifications. Unit: mm (in)

Intake Exhaust
\ J ■o
qj
-| A
46.500-46.516
(1.8308-1.8313)
41.000-41.016
(1.6142-1.6148)
IE
A
INTAKE EXHAUST
-! V450 II
u
B
8.8— 9.0
(0.3465-0.3543)
7.2— 7.4
(0.2835-0.2913)
h -C- - •c—
I 46.585-46.600 41.130-41.145
P |D~ Z ! I! C
(1.8341-1.8346) (1.6193-1.6198)
30°v/ INTAKE 45ÿ/ EXHAUST
SM3-896 41
> =5 D
7.5— 7.7
(0.2953-0.3031)
6.0— 6.2
(0.2363-0.2440)
3. Valve seat installation
Heat the cylinder head to 80°— 100°C (176— 212°F) with
hot water. On the other hand, cool the valve seat with dry
ice or liquid freon for approx. 30 minutes. Hold the seat
*
O
with pincers and place it into the heated cylinder head.
SM3-826
■
EN-MP7A-10 ENGINE
IF NECESSARY, REPLACE THE VALVE GUIDE,

VALVE
GUIDE CYLINDER HEAD 1. Remove the valve stem seal.
/ .1
u
SSS
2. Using a brass rod and hammer, drive out the valve guide.
3.
I
Install the valve guide as shown.
NOTE: Apply engine oil lightly to the valve guide outer circum¬
( T
CO
III ference before installing.
\r <
L1 <mo
SM3-389
IF NECESSARY, REPLACE THE VALVE STEM SEAL.

1. Remove the valve stem seal.
i 2. Install the valve stem seal.
on
\A
$
/r
© First, install the lower spring seat (for stopper of special tool)
and valve. Then apply engine oil to the lip of the stem seal and
drive the special tool until it hits the lower spring seat.
|(i
Special Tool: Valve Stem Seal Press (09472-1650)
SM3-827
NOTE: O After installing stem seal, make sure that check the
RU8BER COAT OIL rubber position for cracks or any other damage.
o Do not use the special tool if its tip (surface contacting
lower spring seat) is worn or deformed.
0
SM3-709
ASSEMBLE THE CYLINDER HEAD.

NOTE: o Apply engine oil to contact surfaces of all parts.
O Make sure that the valves are installed in the correct
cylinders.
o Install the valve springs with their painted side down,
since they have variable pitches.
'W PAINTED
SIDE
I SM3-402 SM3-897
Press upper spring seats and install the valve stem keys securely
in the upper spring seats.
[ Special Tool: Valve Spring Press (09470-1022)
«**
-y- NOTE: o When pressing with the valve spring press, be careful not
to damage the stem seals by contacting the upper seats.
N o Drive the valve stem lightly with a hammer to assure
proper fit the valve stem key.
o
C_D
SM3-824
ENGINE EN-MP7A-11
ASSEMBLE THE ROCKER ARM.

NO. 5
ARROW MARK SUPPORT Lubricate the rocker arm shaft and bushing.
NOTE: Confirm that oil hole of rocker arm assembly No. 5 support
aligns with shaft oil hole. Improper installation will result
in burning of the entire valve assembly.
TIMING GEAR SIDE o
INTAKE EXHAUST
INSTALL THE TAPPETS IN THE CYLINDER BLOCK IN COR¬

RECT ORDER.
OIL HOLE
NOTE: Apply engine oil to the tappet faces and tappet guide when
installing them in the cylinder block.
G
Oj
U
II
ROCKER ARM SHAFT
NO. 5 SUPPORT
4
SM3-204 SM3-828
■
INSTALL THE CYLINDER HEAD AND ROCKER ARM ASSEM¬
I BLY.
i
1. Install the cylinder head gasket.
NOTE: Always use new cylinder head gasket after cleaning the
i i
surfaces of the cylinder head, cylinder block and head
~n
/ T gasket free of all dirt, water and grease.
mmmm0
\
9ÿ3 2. Install the cylinder head over the dowels on the cylinder
block.
SM3-S29
3. Insert the push rods in correct order, after applying engine oil
to both ends.
L-\ Tÿ'l
4. Mount the rocker arm assembly on the cylinder head, make
sure that the push rods interlock with the adjusting screws.
s\
m3 /
NOTE: Always loosen the lock nut and raise the adjusting screws
fully to the top.
c
1.
JH I
v.* —
SM3-427
5. Tighten the cylinder head bolts little by little in three stages

EXHAUST SIDE
and in the numerical order as shown.
©. © © © NOTE: Apply engine oil to the bolt threads and under the bolt
ID' © © © head.
© © © \ © * Mark bolts (cylinder head additional bolt): <p 10 mm (0.39 In)
1 I
‘
© © © t ® J © No. 1 — No. 18 Bolts (Cylinder head bolt): <f> 12 mm (0.47 in)
©/ © SpecialTool: Wrench (09411-1260)
INTAKE SIDE SM3-201 A
■
EN-MP7A-12 ENGINE
6. Tighten the cylinder head additional bolts and rocker arm

support bolts little by little in three stages and
in the nu¬
3 2 4
merical order as shown.
9 7 5 6 8 Tighten the bolts to the specified torque.
T3 5
HL (5W&- rdviafc.
SM3-830
7. Retighten the cylinder head bolts.

NOTE: Refer to SECTION ENGINE TUNE-UP.
ENGINE EN-MP7A-13
INSPECTION AND REPAIR

Unit: mm (in)
Inspection Item Standard Limit Remedy Inspection Procedure
Cylinder Head Flatness Less than 0.05 0.1 Regrind or

(0.0019) (0.0039) replace
oo
SM3 -831
Cylinder Head Height 87.0 86.8 Replace 3?

(3.425) (3.417)
PS
<%
V »7 f
NW1 SM3-887
Cylinder Head Cracks and Replace, if

Damage necessary
%
* Using a Dye Penetrant
\ X
00 w
O
-x .,.w .-
©oO oCXJO'O
SM3-832
Valve Seating Condition There should be good Hand-lap with

* Using Red Lead Marking contact around entire lapping com¬
Compound circumfrence of valve pound
head.
SM3-833
Valve Seat Angle Intake 30°— 30°30' Regrind or

replace valve
I
Exhaust 45°— 45°30' and/or valve
seat
Valve Angle Intake 29°45'-30°15'

As”
Exhaust 44°45'— 45°15' INTAKE EXHAUST
SM3-899
Nozzle Protrution from 2.75-3.25 Replace nozzle

Cylinder Head Surface (0.1083-0.1279) gasket
CYLINDER HEAP
SM3-391
Intake Valve Sink W04D -0.15 - -0.45 -0.55 Replace valve "0" tS CYLINDER ©
(-0.0059 - -0.0177) (-0.0216) and/or HEAO SURFACE
t
valve seat
W04C-T 0.05 - 0.35 -0.05
W04C-T1 (0.0019-0.0137) (-0.0019)
T
Exhaust Valve Sink -0.47 - -0.77 -0.87 v 0
(-0.0185 - -0.0303) (-0.0342)
SM3-236|
K
EN-MP7A-14 ENGINE
:!
■I
Unit : mm (in)
Intake Valve Stem Diameter 8.95-8.97 8.90 Replace valve

(0.3524-0.3531) (0.3903) guide and/or
iso'
valve
Exhaust Valve Stem Diameter 8.93-8.95 8.80
(0.3516-0.3524) (0.3464)
O vp; (p5
Intake and ExhaustValve Guide 9.000-9.015 A&B: Ol o' OV
Diameter (0.3544-0.3549) 9.05 o1 o O

(0.3562)
C: A: 5 (0.197)
SM3-834
9.10 B: 25 (0.984)
(0.3582) C: 45(1.771}
Clearance between Valve Stem 0.035-0.068 A8tB:
and Valve Guide (Intake) (0.0004-0.0026) 0.10
(0.0040)
C:
0.18 a Z.
■>
(0.0071) -F— A
Clearance between Valve Stem 0.050-0.083
A&B:
— 8
(L -i1
and Valve Guide (Exhaust) (0.0020-0.0032) 0.12
(0.0047)
C:
— C
0.2
(0.0078) SM3-835
a!
Rocker Arm Shaft Diameter 18.97-18.98 18.95 Replace rocker
(0.7469-0.7472) (0.7461) arm bushing
and/or shaft
Clearance between Rocker Arm 0.036-0.079 0.1
Shaft and Rocker Arm Bushing (0.0015-0.0031) (0.0039)
SM3-291
Inner Valve Spring Setting Load 8.8 kg (19.4 lb) at 8.0 kg Replace
(For W04D only) 43.0 mm (1.69 in) (17.6 lb)
Outer Valve Spring Setting Load 27.4 kg (54.5 lb) at 25.5 kg \ '
45.5 mm (1.79 in) (56.2 lb)

!>»•
23-024
Valve Spring Straightness 2.0 Replace
(Inner and Outer) (0.0787)
SM3-303
Valve Spring Seat for Wear A: 2.5 Repalce
(0.0984)
B: 5.0
(0.1969)
C: 1.0 u
(0.0394) i J} [l
T
SM3-909
ENGINE EN-MP7A-15
Unit: mm (in)
Valve Stem Tip Surface for Resurface or Visual Check

Wear replace
Valve Stem Contact Surface

of Rocker Arm for Wear
SM3-837
Push Rod Bend 0.3 Replace

(0.0118)
SM3-292
Tappet Diameter 26.95-26.97 Replace tappet

(1.0611-1.0618) -si
Tappet Guide Inside Diameter 27.00-27.02

(1.0630-1.0637) 1 i
|o
Clearance between Tappet and 0.025-0.071 0.1 :
Tappet Guide (0.0010-0.0029) (0.0039)
SM3-420 SM3-293
Tappet for Wear Should not be worn Replace, if

unevenly. necessary
Visual Check
EN-MP7A-16 ENGINE
TIMING GEAR, CAMSHAFT AND OIL PAN
OVERHAUL
21
- -17
©
<s>
■i (0
18 1
22
7 o2ÿ 15
2
T2> 3
4
©
20 5
19
6 &
t‘Q> ov
$
*
few
»SvA
sKJlaB ma
'"tii
m
I
\Q>
OS
Q2 Ax)
$8
A
11 §
/A
12
14
7
<sr
/ 0
13
■i- T - 190-260
7 14 (14-18)
8
sj*. 9
10 T- 190-260(14-18)
.X1
T = 4,800-5,700 (348-412)
T = Tightening torque: kg-cm (Ib.ft)
1. Cylinder block 9. Ball bearing 17. Oil drain plug

2. Gasket 10. Bearing holder case 18. Oil drain hose
3. Timing gear plate 11. Oil seal 19. Connector bolt
4. Connector 12. Crankshaft pulley 20. Soft washer
5. Expansion plug 13. Plain washer 21. Oil level gauge
6. Timing gear cover 14. Oil pan 22. Oil level gauge guide
7. O-ring 15. Tachometer drive assembly
8. Retainer ring 16. Connector
ENGINE EN-MP7A-17
OVERHAUL
T= 1,100-1,300 (80-94)
T = 190-260 (14-18)
A
2 A
3
\ 'A
1
4
3e
m
yo
T = 190-260 (14-18)
6
18
5 7 17
11 16
A
15
13
14 &
7
0
0 13
0
0)
10 wn
0 12 y
8
9
ft A
.01
T = 1,100-1,300 (80-94)
T = 300-350 (22-25)
1. Camshaft 7. Idler gear thrust plate 13. Injection pump drive gear
2. Key 8. Straight pin 14. Coupling flange
3. Thrust bearing 9. Idler gear shaft 15. O-ring
4. Camshaft gear 10. Bearing 16. Timer cover
5. Thrust washer 11. Idler gear 17. Soft washer
6. Oil pump drive gear 12. Crankshaft gear 18. Plug
■
EN-MP7A-18 ENGINE
u
REMOVE THE CRANKSHAFT PULLY.
1. Remove the nut and spacer.
© 2. Using a special tool, remove the pulley,
-is
©
(A. ©„
(l
(0) 1 Special Tool: Crankshaft pulley Puller (09420-1500)
JJ SM3-838
DISMOUNT THE FUEL INJECTION PUMP.

TIMER COVER
1. Remove the plug from the port on the timer cover.
2. Turn the crankshaft counter-clockwise viewed from flywheel
side to align the injection timing mark.
MARK\ \ POINTER SM3-884
3. Lock the coupling flange with a special tool.

Special Tool: Timer Setting Tool
(09512-2090) for W04D
(09512-2100) for W04C-T, W04C-TI
c NOTE: Do not loosen the injection pump drive gear fitting bolts.
&
4. Loosen the timer cover fittting bolts and then remove the injec¬
tion pump with timer cover.
SM3-250 NOTE: Do not loosen the injection pump body fitting nuts.
REMOVE THE CAMSHAFT WITH GEAR.

J
NOTE: Pull out the camshaft, slowly turning it so as not damage
the bearings.
,0
A a
1
0 ijj
SM3-839
REMOVE THE IDLER GEAR SHAFT.

111 n Using a special tool, remove the idler gear shaft.
X
Special Tool: Sliding Hammer (09420-1100)
\ Ml
3ÿ
X
V-> SM3-840
ENGINE EN-MP7A-19
IF NECESSARY, REMOVE THE CAMSHAFT GEAR,

1. Hold the camshaft with a vice through wooden plates.
2. Remove the bolt and plain washer, then using a gear puller,
V remove the gear.
V
SM3-841

IF NECESSARY, REPLACE THE TIMING GEAR CASE COVER
", OIL SEAL.
1. Using a screwdriver, remove the oil seal.
n /
Mmu iL
/Qr 2. Using a special tool, install the new oil seal.
Special Tool: Press (09482-1530)
f/y
SM3-718
ASSEMBLE THE CAMSHAFT GEAR AND SHAFT.

Install the camshaft gear with thrust bearing,
NOTE: When installing the gear to the camshaft:
S' o Heat the gear in hot water [Approx. 100°C (212°F)J,
then install the gear to the camshaft by using a press.
O When tightening the bolt, apply engine oil to the threads
and plate surface of the bolt
i
"o
S M3 -842
INSTALL THE CAMSHAFT.

Lubricate all journals of the camshaft and insert the camshaft
assembly into the cylinder block.
NOTE: o Insert the camshaft, slowly turning while Inserting so that
\
the bearing will not be damaged.
o When installing the camshaft, be sure that the match
marks of the oil pump drive gear and camshaft gear are
aligned correctly.
n o V
SM3-232
7
'V
■
EN-MP7A-20 ENGINE
INSTALL THE IDLER GEAR SHAFT.

Install the idler gear shaft with thrust plate using a plastic
hammer.
NOTE: Be sure that the oil hole is downward, if installed the
& :> wrong way, damage to the idler gear shaft and bearing
o
ys
r c> 0
can result.
*
£32
3
!Ps
O OIL HOLE
A
CRANKSHAFT
y SM3-843
INSTALL THE IDLER GEAR.

o o NOTE: When installing the idler gear, be sure that the matching
V
Q o o marks of the crankshaft gear, oil pump drive gear and idler
gear are aligned correctly.
o,
2 o o o ©
ni SM3-232
o o a INSTALL THE INJECTION PUMP TEMPORARILY.

NOTE: When installing the injection pump, be sure that the match
marks of the idler gear and injection pump drive gear are
&o
aligned correctly.
)
♦
O D
D O © 5M3-232
MEASURE THE GEAR BACKLASH.

Measure the backlash of each gear using a dial indicator.
Replace the gear if necessary.
Refer to INSPECTION AND REPAIR.
SM3-844
INSTALL THE TIMING GEAR CASE.

1. Clean the faces.
2. Apply the liquid gasket as shown and install the timing gear
cover within 20 minutes.
d NOTE: If leaving it more than 20 minutes, clean the liquid gasket
% completely and reapply the liquid gasket.
\
fp;r 0 o JZPSI’ Coating Width (A): 1.5 - 2.5 mm (0.06 - 0.10 in)
LS&
SM3-247
ENGINE EN-MP7A-Z1
INSTALL THE OIL STRAINER.

Refer to "OIL PUMP AND OIL STRAINER" in SECTION
TIMING GEAR PLATE LUBRICATING SYSTEM.
INSTALL THE OIL PAN.

1. Cut the protrusion of the timing gear plate gasket from the oil
pan mounting surface.
CYLINDER
TIMING GEAR BLOCK
CASE
l SM3-268
2. Clean the faces.

3. Apply the liquid gasket as shown and install the oil pan within
20 minutes.
3 NOTE: If leaving it more than 20 minutes, clean the liquid gasket
.9,
1 i
A
completely and reapply the liquid gasket
4 mm (0.12 — 0.15 in)
Coating Width (A): 3 —
l
)
1
INSTALL THE CRANKSHAFT PULLEY.
SM3-214A, NOTE: Apply engine oil to the nut threads.
INSPECTION AND REPAIR Unit: mm |in)
Gear Teeth for Pitting or Wear Replace, if Visual check

necessary
SM3645
Idler Gear Shaft Diameter 49.95-49,97 49.94 Replace bushing

(0.9311-1.9318) (1.9307) and/or shaft
Idler Gear Bushing Inside 50.00-50.03 50.05

Diameter (1.9685-1.9696) (1.9705) SM3-846
>Jj/>.
Clearance between Idler Gear 0.03-0.08 0.1

Shaft and Bushing (0.0012-0.0031) (0.0039)
SM3-847
Idler Gear End Play 0.04-0.10 0.15 Replace thrust
(0.0016-0.0039) (0.0059) plate
r>
§8 c
mj
SM3-421
■
EN-MP7A-22 ENGINE
Unit: mm (in)
Inspection Item Standard Limit Remedy Impection Procedure
Camshaft Bend 0.05 Replace A :

0
(0.0020)
.-c
SM 3-858
Camshaft Cam Height 49.44 48.44 Replace
(Inta ke) (1.9465) (1.9071)
Camshaft Cam Height 49.50 48.50

(Exhaust) (1.9488) (1.9095)
SM3-374
Camshaft end Play 0.10-0.18 0.3 Replace thrust
(0.0040-0.0070) (0.0118) plate .r
t SM3-848
&
Camshaft Journal Diameter No. 1: 57.0 56.85 Replace shaft
Journal No. : (2.2441) (2.2382) and/or hearing
No. 2: 56.8 56.65
(2.2362) (2.2303)
No. 3: 56.6 56.45
(2.2283) (2.2224)
Camshaft Journal Bearing No. 1: 57.0 57.15 SM3-849

Inside Diameter (2.2441) (2.2500)
Journal No. : No. 2: 56.8 56.95
0
—35ÿ
(2.2362) (2.2421 ) -/
No. 3: 56.6
)
56.75 V
V V x-A-
(2.2283) (2.2342)
Clearnace between Camshaft 0.03-0.12 0.15

(0.0059) N£.
Journal and Bearing (0.0012-0.0047)
SM3-850
Crankshaft Gear
— Idler Gear 0.068-0.194
(0.0027-0.0076)
0.3
(0.0118)
Replace gear,
if necessary
-£ Idler Gear — Oil Pump Gear

0.065-0.182
<Q
(0.0026-0.0071) /
OQ
(5
CD
U
Oil Pump Gear
Gear
— Camshaft
*v
C
E Idler Gear
— Injection Pump 0.065-0.232
M
Bk
H Gear (0.0026-0.0091)
SM3-844
ENGINE EN-MP7A-23
PISTON, CRANKSHAFT, CYLINDER BLOCK

AND FLYWHEEL HOUSING
OVERHAUL
-1
s
(3!? 2 e
15 i
o°.l .a
4
3VP%i; !
a
f
IBP
16
14
10 11 ,V\J
.a
6
T = 1,220-1,280 (89-92)
J
&ÿ
v?f ■f
0
\\0 tnS 17
fl
9 S
8 1—18
7
T = 1,400-1,600 (102-115),
12
12
13 T = Tightening torque kg-cm (Ib.ft)

SM3-1284
1. Piston ring 7. Crankshaft gear 13. Crankshaft bearing

2. Piston 8. Key 14. Camshaft bearing
3. Piston pin 9. Crankshaft 15. Cylinder liner
4. Retainer ring 10. Connecting rod cap 16. Expansion plug
5. Connecting rod 11. Collar 17. Cylinder block
6. Connecting rod bearing 12. Crankshaft thrust washer 18. Bearing cap
■
EN-MP7A-24 ENGINE
OVERHAUL
T = 450-500 (33-36)
A*
T = 1,800-2,000(131-144)
ja®. N
f
T = 1,000-1,300 (73-94)
/
3 & 7
8
K 6
M 5
T = 450—500 (33—36)
Li
O
■o\ lo)
1 o'
4
W ✓V
\\V 0
2
V
i *<
&
10
\
1
9
1. Cylinder block 5. Ring gear 9. Intermediate flange

2, Flywheel housing 6. Flywheel 10. Bracket
3. Timing port cover 7. Torsion-elastic coupling
4. Oil seal 8. Spacer
ENGINE EN-MP7A-25

0
0 0 REMOVE THE PISTONS WITH CONNECTING RODS.
0
O 1. Remove the carbon from the upper end of the cylinder liner
with a scraper or emery paper (recommended: No. 150} in a
1>
> » I circular direction.

0
U 0 0
SM3-359
O-MARK 2. Extract the piston and connecting rod assembly out through
s the top of the cylinder.
NOTE: o Arrange the piston and connecting rod caps in order.
©MARK
MATCH MARK
SM3-407
REMOVE THE CRANKSHAFT.

NOTE: Arrange the caps, bearings and thrust bearings in order.
1
FRONT
r
.Vs 3
4
5
1 2 SM3-852
REMOVE THE CONNECTING ROD.

1. Remove the retainer ring installed on both ends of the piston
\\ pin, by means of retainer ring pliers.
2. Apply a metal pad to the pin and strike out the pin with a
hammer.
hi
If NOTE: Warm up the piston first in hot water 80— 90°C (176—
194°F) for approx. 5 minutes before removing the pin.
i
m ■i
SM3-294
REMOVE THE PISTON RINGS

/ Special Tool: Piston Ring Expander (09442-1180)
NOTE: O Handle the piston rings carefully because they are made
of a special casting which is easily broken.
o Keep the rings for each cylinder separate.
7
r
SM3-295
■
EN-MP7A-26 ENGINE
REMOVE THE CYLINDER LINER.

O 1. Place the match marks with a pen on the cylinder block and
liner flange, before removing the cylinder liners.
NOTE: Do not put the match marks with a punch.
MATCH
MARK
©
<s> o
'c
■'f
'1 SM3-851
2. Using a special tool, remove the cylinder liners.

Special Tool: Cylinder Liner Puller (09420-1460)
NOTE: After removing the cylinder liners, put numbers on their
periphery or arrange them in sequence.
\0)
SM3-852
©;cz — c o
INSERT THE CYLINDER LINER INTO THE CYLINDER BLOCK.
1. When a new cylinder liner is used, make sure that the liner
X T
has the same mark as the mark on the cylinder block.
NOTE: O There are 4 different liner and cylinder block matches.
The flange section of each liner has a marking any,
W, X, V AND Z MARK W, X, Y, Z, or indicating the size of the outer diameter
of the liner on which it is stamped. The markings W,
X, Y and Z, indicating the inner diameter of the cylinder
bore supporting the liner on the sides and top of the
2 cylinder block (the boss section for attaching the cool¬

ant gallery cover), are inscribed on each cylinder.
M
W, X, V AND Z MARK
SM3-387
2. When reusing a liner, insert the liner its original position

w aligning the marking marked before disassembly.
O
«V o
o
© o©
Li '<?
1 SM3-851
ENGINE EN-MP7A-27
Apply a small amount of fresh engine oil on the outer

SPECIAL
TOOL
t periphery of the liner, and apply pressure on the entire flange
section of the liner. If insertion by hand is difficult, use a
cylinder guide, and the cylinder liner will easily be pushed in.
Special Tool: Cylinder Liner Guide (09480-1120)
NOTE: o Do not us8 a liner that has been dropped.
O Take extra care when handling the liner since the liner
is easily deformed.
SM3-853
MEASURE THE PROJECTION OF THE CYLINDER LINER.

Tighten a special tool with a tightening torque of 100 kg-cm
(7.23 Ib-ft) and measure the amount of projection of the top
end of the liner from the cylinder block with a dial gauge or
7'
straightedge and a thickness gauge.
Special Tool: Cylinder Liner Puller (09420-1460)
V Tightening Torque: 100 kg-cm (7.23 Ib.ft)
Assembly Standard: 0.01-0.08 mm (0.0004—0.0031 in)
o
SMS-854
Unit: mm (in) IF NECESSARY. GRIND THE CRANKSHAFT AND USE UNDER

Under Outddti diameter SIZE BEARINGS.
size Crankpin Journal
61 .69—61.71 72.69-72.71
0.25 (2.4288-2.4295) (2.8619 -2.8625)
0.50 61.44-61.46 72.44-72.46

(2.4189-2.4196) (2.8520-2.8527)
0.75 61.19-61.21 72.19-72.21

(2.4091 -2.4098) (2.8422- 2.8429)
1.00
60.94-60.96 71.94-71.96
(2.3992-2.4000) (2.823-2.8330)
Dimension of Fillet R:
Crank pin: 3.50 — 4.00 mm (0.1378 — 0.1574 in)
Journal : 3.05 - 3.50 mm (0.1201 - 0.1377 in)
R
V
CORRECT WRONG
SM3-441
■
EN-MP7A-28 ENGINE
INSTALL THE CRANKSHAFT.

1. Install the crankshaft bearings on the cylinder block and
bearing cap.
NOTE: Apply fresh engine oil to each bearing surface.
%
SI //I
! i U/ !a!
!
I i
a
yy
i
i
a
u
a
.
\ \
/ m
is 2. Install the crankshaft on the cylinder block.
■
•A.
\
7I
/
w 3. Insert the crankshaft thrust bearings along the groove of the
cylinder block.
■'
4. Install the thrust bearings on the No. 4 bearing cap sides.

IV/ /
w
NOTE: Apply fresh engine oil to each thrust bearing surface.
SM3-378
5. Install the crankshaft bearing caps.

■o No. 4
Install the bearing caps in numbered order from timing gear i
side with the arrow point toward the timing gear side.
TIMING GEAR ARROW

SIDE I S
No. 1, 2. 3, 5
SM3-855
1_ 2 3 4 5
6. Tighten the cap bolts in three stages following the tightening
order.
LFHJ o
to
O
NOTE: Apply engine oil
head.
to the bolt threads and under the bolt
9 9 @ @ Tightening order: 3— 2— 4— 1—5
-- o NOTE: o Make sure that the crankshaft rotates smoothly.

o Inspect the crankshaft end play. <
'
SM3'856
ENGINE EN-MP7A-29
IF NECESSARY, REPLACE THE PISTON PIN BUSHING.

“I 1. Prepre the special tools.
Assemble the guide and press sub assembly inserting its pin
WING NUT into the guide, then secure them with the wing nut.
GUIDE
\ PIN
Special tools: Guide (09481-1130)
1
Press sub assembly (09402-1450)
Wing nut (9233-10360)
PRESS SUB ASSEMBLY

/ NOTE: o Bring leter "W" punched on the guide above the pin.
SM3-1565 o Make sure to align both supporting surface of the
guide and press sub assembly flush on a flat plane.
2. Using a special tool, remove the piston pin bushing.

CONNECTING ROD a. Set the connecting rod assembled without crank pin bore
bearing on the guide and press sub assembly.
a i
GUIDE PRESS SUB ASSEMBLY
SM3-1566
b. Set the spindle on the bushing.

Model W04D
-SPINDLE Special Tool: Spindle (09402-1460) for W04D
GROOVE (09402-1470) for W04C-T and W04C-TI
-BUSHING
NOTE: Align the grooving of the spindle with the oil hole of the
■CONNECTING bushing.
OIL HOLE
fPSf (
ROD
■PRESS SUB
I ASSEMBLY
I
|;!n. .; •
SM3-1567B
Models W04C-T and W04C-T1

SPINDLE
GROOVES-
BUSHING
-CONNECTING
|j
m ROD
I
OIL HOLES- i /-PRESS SUB
: ASSEMBLY
i
:
i
■Y'i.ii-:] I;*/
SM3-1567 A
a
EN-MP7A-30 ENGINE
PRESS
c. Using a hydraulic press, remove the bushing.
*
NOTE: Always operate the press slowly and smoothly.
SPINDLE.
CONNECTING ROD
\
i
i
V//.
I
i
SM3-1568
3. Assemble the piston pin bushing.

Chamfer one edge of the bushing hole at the small end of the
•C. 0.5— C. 1.0 mm
connecting rod uniformly by C 0.5— 1.0 mm (0.0196—0.0393
in).
NOTE: O Irregular chamfering can cause out-of-roundness of the

pressed bushing, which may result in jamming during
insertion.
o Remove dust from the inner surface of the small-end
CONNECTING hole.
ROD
SM3-1569
Model W04D
4. Mount the bushing on the spindle.
a. Set the bushing and guide on the spindle aligning oil hole (A)
in the bushing the grooves on the both the spindle and guide.
m GROOVE b. Secure the bushing and guide with the bolt.
OIL HOLE Special Tool: Spindle (09402-1460) for W04D
(A)
(09402-1470) for W04C-T and W04C-TI
OIL HOLE Guide (09481-1120) for W04D
GUIDE (A) (09481-1140) for W04C-T and W04C-TI
BUSHING Bolt (9191-08252)
80 LT SM3-1570B
NOTE: o Be sure to slip the bushing over the spindle in the
proper direction so that oil hole (A) will later align
Models W04C-T and W04C-TI with the oil path in the connecting rod.
SPINDLE O Apply fresh engine oil to the bushing and guide.
ri GROOVE
OIL HOLE
(A)
OIL HOLE
GUIDE (A)
BUSHING
BOLT
SM3-1570
5. Install the bushing in the connecting rod.

PRESS Position the bushing-special tool assembly so that oil hole (A)
align with the oil path through the connecting rod.
NOTE: o Fully coat the bore in the connecting rod with fresh
OIL HOLE (A) engine oil.
O Always operate the press slowly and smoothly.
OIL PATH
SM3-1571C
ENGINE EN-MP7A-31
6. Inspect the bushing position after installation.
BUSHING
NOTE: OMake sure that the oil holes of the bushing and connect¬
ing rod are aligned.
O Insert a pin of 3 mm (0.1181 in) dia. into an hole at
the end of the connecting rod, and make sure that the
<1 1 V,
pin fully penetrates.
If there is any deviation in the alignment of the oil
PIN
holes correct it with a drill of 3 mm (0.1181 in) dia.
O Misalignment of the oil holes can lead to insufficient
CONNECTING ROD lubrication, which may result in seizure.
SM3-1572
o Insert a new piston pin and rotate it slowly to make
sure that there is no rattling.
\v.
SM3-424
O-MARK ASSEMBLE THE PISTON AND CONNECTING ROD.

Make sure that the O-mark at the top of the piston and the
(0)
E£g| connecting rod match marks in opposite directions.
MARK NOTE: o Use the new retainer rings.

O Heat the piston to 80— 90° C (176— 194°F) in hot water
approx. 5 minutes.
MATCH MARKS
SM3-407
■
EN-MP7A-32 ENGINE
INSTALL THE PISTON RING.

1. Install the piston rings in the sequence oil ring, second ring and
RING
UP FACE top ring with the identification mark at the top of the ring
facing up.
(T NOTE: O Identification mark of second ring and oil ring is applied
1
with gold paint.
Q DISCRIMINATION
MARK
i o Apply oil to the piston rings.
Special Tool: Piston Ring Expander (09442-1180)
(W04C-T, W04C-TI) 2. Connect the ends of the coil expander and then fit the coil
inside the piston ring after ensuring that the gap of the piston
ring is 180° away from the joint of the coil.
TOP RING SECOND RING OIL RING
(W04D)
JOINT
GAP
SM3-295 SM3-408 SM3-443
. O-MARK 3. Arrange the piston rings so that their gaps are equally spaced.
OIL RING
TOP RING
SECOND RING SM3-270
INSTALL THE PISTON IN THE CYLINDER LINER.

O 1. Apply engine oil to the piston, cylinder liner and connecting
O' rod bearing surface.
7? oV,
2. Using a special tool, hold the piston rings and push the piston
with connecting rod assembly with a wooden rod.
i o
o o °-
NOTE: Check the piston that the O-mark on the top is on the
MARK tappet chamber side.
Special Tool: Piston Ring Holder (09441-1260)

TAPPET CHAM8ER
SM3-8S7 SM3-444
INSTALL THE CONNECTING ROD CAP.

O-MARK 1. Apply engine oil to the cap bearing surface.
pip- 2. Align the match marks on the connecting rod and cap.
<8> 3,
MARK Apply engine oil to the bolt threads and under the bolt head.
4. Tighten the cap bolt in three stages.
MATCH MARKS
B SM3-407
ENGINE EN-MP7A-33
INSTALL THE OIL SEAL IN THE FLYWHEEL HOUSING.

Using a special tool, press in the oil seal in the flywheel hous¬
ing.
Special Tool: Press (09482-1540)
SM3-218
INSTALL THE FLYWHEEL HOUSING.

1. Clean the faces.
/0°
2. Apply the liquid gasket as shown and install the flywheel
JPgf housing within 20 minutes.

NOTE: If leaving it more than 20 minutes, clean the liquid gasket
IF completely and reapply the liquid gasket
roV . S
Coating Width: 1.5— 2.5 mm {0.06—0.10 in)
SM3-271
INSTALL THE FLYWHEEL.

Install the flywheel and tighten the bolts through several
repetitions of the tightening order so as to reach specified
t> torque evenly and gradually, then slacken and tighten them
one by one to the specified torque.
NOTE: o Align the "O" mark on the flywheel and crankshaft
%
collar knock-in.
O When tightening the bolt, apply engine oil to the threads
and flywheel surface of the bolts.
SM3-1698
TIGHTENING
ORDER
1 BOLT
0 3
.0 0
0
$M3-1697
■
EN-MP7A-34 ENGINE ;

Unit: mm (in)
!
Inspection Item Standard Limit Remedy Inspection Procedure i
Piston Diameter 103.860-103.884 Replace piston

(4.0890-4.0899) and/or liner
n
Cylinder Liner Inside 104.008-104.040 104.15 50 mm (1 .97 in.)

Diameter (4.0949-4.0960) (4.1003)
SM3-910
1- Si
Clearance between Piston 0.140-0.172 80 mm {3.15 in.}

and Cylinder Liner (0.0056-0.0067)
SM3-432 SM3-313
Piston Pin Diameter W04D 34.989-35.000 34.980 Replace piston
(1.3776-1.3779) (1.3771) and/or piston pin •V
36.987-37.003 36.98
W04C-T
W04C-TI (1.4562-1.4568) (1.4559) JC
Piston Pin Hole Inside W04D 34.987-35.003 35.02
Diameter (1.3775-1.3780) (1.3787) SM3-859
W04C-T 36.987-37.003 37.02
W04C-TI (1.4561-1.4568) (1.4574)
a £
Clearance between Piston 0.013T— 0.014L 0.04
Pin and Piston Pin Hole (0.00052T — 0.00055L) (0.0015)
T: Tight %
L: Clearance
SM3-1585
Crankshaft end Play 0.05-0.22 0.4 Replace thrust
(0.0020-0.0086) (0.0157) bearing * r
VtV :
E
SM3-362
Connecting Rod W04D 35.015-35.025 35.080 Replace bushing ■
Small End (1.3786-1.3789) (1.3811) and/or piston pin

>
Bushing Inside W04C-T 37.015-37.025 37.080
Diameter W04C-TI (1.4573-1.4575) (1.5172)
Piston Pin Diameter W04D 34.989-35.000 34.980

(1.3776-1.3779) (1.3771)
W04C-T 36.987-37.003 36.98 SM3-296

W04C-TI (1.4562-1.4568) (1.4559)
Clearance between Piston 0.015-0.036 0.1 •31

Vf
Pin and Connecting Rod (0.00016-0.0014) (0.0039) \
M
flea
Small End Bushing !
i
SM3-297
ENGINE EN-MP7A-35
Unit: mm (in)
Connecting Rod Big end 65.985-66.000 Replace

Inside Diameter (2.5979-2.5984) connecting rod
(Without bearings) assembly
SM3-300
Crank Pin Diameter 61.94-61.96 -0.20 Regrind and use
(2.4386-2.4393) (-0.0078) undersize bearing
CilJjkJ
60.76 Replace crankshaft

(2.3921)
SM3-860
Clearance between Connecting 0.031-0.082 0.12 Replace bearing

Rod and Crank Pin (0.0013-0.0032) (0.0047)
SM3-300
Connecting Rod End Play 0.20-0.52 0.6 Replace connect¬ to)
(0.0079-0.0204) (0.0236) ing rod
0]
A OJ
S M3 -86 2
Connecting Rod Straightness 0.1 Replace
(0.0039)
Per
200
(7.8740)
SM3-541
Connecting Rod Twist 0.1 Replace
(0.0039) 1
Per
200
(7.8740)
SM3-542
I
EN-MP7A-36 ENGINE
Unit: mm (in)
Connecting Rod Bearing 67.05-67.55 Replace

Spread Dimension (2.6398-2.6594)
r
Crankshaft bearing 79.00-79.60
spread dimension (3.1102-3.1339)
41
SM3-298
Crankshaft Bend 0.04 Repair or
(0.0015) replace
jl
SM3-861
Crankshaft Main Bearing 77.985-78.000 Replace
Cap Inside (3.0703-3.0709)
Diameter (Without Bearing) !
\
SM3-436
Crankshaft Journal Diameter 72.94-72.96 -0.20 Regrind and use
(2.8717-2.8724) (-0.0078) undersize bearing ;
71.76 Replace
(2.8521) crankshaft
SM3-860
Clearance between Crankshaft 0.039-0.090 0.13 Replace bearing
Journal and Main Bearing (0.0016-0.0035) (0.0051)
l-
4 1
\
mi
SM3-436
Crankshaft Main Bearing 79.00-79.06 Replace
Spread Dimension (3.1103-3.1125)
%
SM3-298
I
ENGINE EN-MP7A-37
Unit; mm (in)
Piston Ring Top W04D 2.47-2.49 2.32 Replace

Breadth (0,0972-0,0980) (0.0914)
W04C-T
W04C-TI
2nd W04D 1.97-1.99 1.82
(0.0776-0.0783) (0.0716) i]
W04C-T 2.47-2.49 2.32
W04C-TI (0.0972-0.0980) (0.0914)
Oil 4.97-4.99 4.95
(0.1957-0.1964) (0.1948)
SM3-379
Piston Ring Top W04D 2.57-2.59 2.74 Replace piston

Groove (0,1012-0.1019) (0.1078) ring and/or
Breadth W04C-T piston
W04C-TI
2nd W04D 2.03-2.05 2.20
(0.0800-0.0807) (0.0866)
W04C-T 2.53-2.55 2.70
W04C-TI (0.0996-0.1004) (0.1063)
Oil 5.01-5.03 5.08
(0.1973-0.1980) (0.2000)
Clearance between Piston Top: 0.08-0.12 0.3

Ring and Piston Ring Breadth (0.0032-0.0047) (0.0118)
Ring No.: (Model W04D only)
2nd: 0.04-0.08 0.3 SM3-301
(0.0016-0.0031) (0,0118)
Oil: 0.02-0.06 0.08
(0.0008-0.0023) (0.0031)
Piston Ring Gap All Rings: 0.3-0.45 1.2 Replace

* Insert the Piston Rings (0.0119-0.0177) (0.0472)
Where the Wear of the Liner
is Small.
(I
SM3-302
Cylinder Block Flatness Less than 0.05 0.1 Regrind and/or
(0.0019) (0.0039) replace S'.
jO F'
E
V
SM3-216
Flywheel Face Alignment 0.15 Regrind and/or
(0.0059) replace
t x
SM3-908
EN-MP7A-38 ENGINE
LIQUID GASKET AND APPLICATION POINTS
The W04D, W04C-T and W04C-TI type engine use liquid gasket (Three Bond TB1207C 04132 1207) instead of con¬
ventional sheet gaskets. Apply liquid gasket, therefore, taking the following items into account.
1. LIQUID GASKET APPLICATION POINTS AND COATING WIDTH

Unit: mm (in)
Parts name Application point Coating width
(a) Oil pan Flange face which mates with cylinder block 3-4
and timing gear cover (0.12-0.16)
im
t A
SM3-214A
(b) Timing gear cover Faces which mates with timing gear plate 1.5 -2.5
(flange face, boss face) (0.06-0.10)
*♦
SM3-247
(c) Flywheel housing Faces which mates with cylinder block 1.5- 2.5
(flange face, boss face) (0.06-0.10)
ap
0)
SM3-271
i
ENGINE EN-MP7A-39
Unit: mm (in)
Parts name Application point Coating width
-y-
rrnhr
(d) Oil cooler Flange face which mates with cylinder 1.5 - 2.5
block (0.06-0.10)
,0'
T,
70)
Yo.
r0,
SM3-269
(e) Coolant pump Flange face which mates with gear cover 1.5 -2.5
(0.06-0.10)
(f) Thermostat case Flange face which mates with cylinder head 1.5 -2.5
(0.06-0.10)
(g) Seal plate Flange face which mates with gear cover 1.5 -2.5
(0.06-0.10)
(h) Intake pipe Flange face wh ich mates with intake mani¬ 1.5 -2.5
fold (0.06-0.10)
2. COATING LIQUID GASKET AND PARTS ASSEMBLY PROCEDURE

(1) Completely remove old liquid gasket from each part and the respective mating part, and remove oil, water, and
dirt using a cloth.
(2) Be careful not to apply excessive or insufficient liquid gasket. Also, be sure to overlap the start and end of each
coating.
(3) When assembling coated parts, be careful that there is no misalignment between mating parts. If there is any
misalignment, coat the parts again.
(4) Assemble the various parts within 20 minutes after applying liquid gasket. If more than 20 minutes have elapsed,
remove the liquid gasket and apply it again.
(5) After assembling the various parts, wait for at least 15 minutes before starting the engine.
■
EN-MP7A-40 ENGINE
3. REMOVING PARTS
When removing each part, do not attempt to pry one portion of the flange alone but use the flange collar or clearance
several points alternately.
to pry the flange at
Pry
■*- 7k-
Clearance
Thermostat case
Collar 'oeaÿ
O
O
O
0 Timing gear
0
cover
Coolant pump o
SM 3-1 933
4. TIMING GEAR PLATE GASKET
When replacing the gear plate gasket, cut it so that no steps are formed in it, then liberally apply liquid gasket to the
cut face and assemble the oil pan.
Cylinder block
[=> Cylinder block
Liquid gasket
Timing gear plate gasket
Cut using a cutter or the like, taking Oil pan
care that no steps are formed.
SM 3-1932
NOTE: The flange of the oil pan may sometimes become deformed preventing it from being reused. To prevent
this, therefore, first insert plates with a thin edge at several points around the periphery of the oil pan, I
then remove the oil pan using a screwdriver. i
ENGINE EN-LS7A-1
LUBRICATING SYSTEM

Oil pump
Type Full forced pressure feed by gear pump
Drive By gear
Oil cooler
Type Multi plates type, water-cooled
LUBRICATING SYSTEM DIAGRAM
! i 13 1. Oil pan
U U 2. Oil strainer
3. Oil pump
14 12! 4. Oil cooler
A
l n f
11 5. Oil filter
6. Main oil hole
az: n 4H ■
:
10
7. Camshaft
m
: 8. Rocker arm shaft
LT r\. IJ 9. Rocker arm

10. Crankshaft journal
“T . ■JL ]6
11. Crankshaft pin
12. Connecting rod
----
13. Piston
—
r fTH-r-i-n
LJ J-LJ— LJ -- r~>-H-|-nrH~h-r>-
LH-FUh-l— U-
1
!7
J
14. Idler gear
15. Fuel injection pump drive
16.
gear
Fuel injection pump
17.Turbocharger
C 8
A. Oil cooler safety valve
:
9 B. Oil filter safety valve
fkfl■-)( n rs n
C. Regulator valve
D. Check valve
15 16
J J A
1 5
8
flÿl
3
C<fe D
2
/ \ 1
SM3-1820
EN-LS7A-2 ENGINE
OVERHAUL
HEl 1—040— 00X07 (1400) 11
X20 10
T = 190-260 (14-18)
9
8
o 1 $
&
(<y
%
3 m
2
%
fo.
i
"SA/C
a P
r/ fo w
fO,
T= 200-250 (15-18)
'Ey JC,
5 4
o
a-
4
6
7
f /
-&/
2-O To.
<5Y
B-
13
/
14 =?o
&>ÿ
15-
1. Oil filter 6. Plug. 11. Oil pump driven gear

2. O-ring 7. Connector bolt 12. 0-ring guide
3. Oil cooler 8. Oil pump cover subassembly 13. Oil strainer
4. Soft washer 9. Gasket 14. Oil strainer screen
5. Connector pipe 10. Bushing 15. Snap ring
ENGINE EN-LS7A-3
OIL PUMP
DESCRIPTION
1 4
s 5
1. Drive gear (Inside)
w 2. Driven gear
3. Gasket
4. Drive gear (Outside)
5. Drive shaft
6. Driven shaft
6
2
0 0
DISCHARGE DISCHARGE £> DISCHARGE
PORT PORTIA PORT
A,
IAl
SUCTION
PORT
IQ SUCTION
PORT
Q SUCTION
PORT
[OPERATION]
IMPORTANT POINT - MOUNTING
'o
;°°©
o
INSTALL THE OIL PUMP.
1. Apply oil liberally to cylinder block pump case and bearing
O before installing oil pump.
2. Confirm smooth rotation of oil pump after tightening bolts.
Q oVxQ
5 SM-864
■
EN-LS7A4 ENGINE

Unit: mm ( in)
Impaction Item Standard Limit Remedy Impaction Procedure
Gear Backlash 0.09-0.21 0.30 Replace gear

(0.0036-0.0082) (0.0118)
m
i
i
SM3-867
Drive Gear Shaft Diameter 18.088-18.106 18.060 Replace
(0.7122-0.7128) (0.7110)
9?
SM3-870
Drive Shaft Bearing Inside 18.146-18.173 ia20 Replace
Diameter (0.7145-0.7154) (0.7165)
Clearance between Drive Shaft 0.040-0.085 0.1 Replace bearing

and Bearing (0.0080-0.0033) (0.0039) and/or shaft
L= \
SM3-1070
Driven Gear Shaft Diameter 17.979-17.997 17.970 Replace
(0.7079-0.7085) (0.7074)
'&\5>
.//
SM3-S68
Driven Gear inside Diameter 18.037-18.054 18.070 Replace
(0.7102-0.7107) (0.7114) !
Clearance between Driven Gear 0.040-0.075 0.1 Replace bearing

and Shaft (0.0080-0.0023) (0.0039) and/or shaft
SM3-869
Gear Teeth Pitting or Wear Replace, if Visual check
necessary
Q
SM3-845
ENGINE EN-LS7A-5
OIL COOLER AND OIL FILTER
SPECIAL TOOL
WRENCH
o
09553-1010
For spin-on type oil filter
OVERHAUL
1419M 1425G
]-No.21 I— No. 20
T = 250-350 (19-25) T = 100-150 (8-10)

o
1
V.
5--o ro.
0.
% o) 8
5
2
3
°y%f o)p oo.
6
b)
4
5
oF
7 <o\wy I
by —
O 5
nI — 6
6 6 [Oy
3 0/
4
B
5—ct> 3 8
.ÿV 6-® 9
A
T = Tightening torque: kg.cm (lb.ft)
1. Oil filter 7. Oil cooler case A. Oil filter safety valve

2. Oil filter cover 8. Gasket 1.3 kg/cm2 (18.5 Ib/sq.in)
3. Valve 9. Oil cooler element B. Oil cooler safety valve
4. Spring 4.0 kg/cm2 (56.9 Ib/sq.in)
5. O-ring C. Regulator valve
6. Plug 4.0 kg/cm2 (56.9 Ib/sq.in)
EN-LS7A-6 ENGINE
IMPORTANT POINT - DISMOUNTING

REMOVE THE SPIN-ON TYPE OIL FILTER.
Using a special tool, unscrew the oil filter.
Special Tool; Wrench (09553-1010)
••i
IMPORTANT POINTS - MOUNTING

INSTALL THE OIL COOLER.
1. Clean the faces.
A
I
to' 2. Apply the liquid gasket as shown and install the oil cooler
within 20 minutes.
I
.4, Mÿ°! NOTE: If leaving it more than 20 minutes, clean the liquid gasket
*— V completely and reapply the liquid gasket.
&
% Coating Width (A): 1.5-2.5 mm (0.06-0.10 in)
o,
to,
SM3-269
INSTALL THE SPIN-ON TYPE OIL FILTER.

i
1. Apply a slight amount of engine oil to the gasket of the new
filter.
2. Tighten the new filter by hand until the gasket touches the
cover and the tighten another 3/4 to 1 full turn with a special
tool.
Special Tool: Wrench (09553-1010)
Valve and Springs of Replace, if Visual check

Oil Filter. necessary.
Wear or Damage.
:
ENGINE EN-FS6B-1
FUEL SYSTEM

Injection nozzle
Type Multi-hole nozzle type
Opening pressure 220 kg/cm2 (3,129 Ib/sq.inl
FUEL SYSTEM DIAGRAM
1
ft
4 1. Water separator
(If so equipped)
fl V Q) 5 2. Fuel injection pump
3. Fuel feed pump
lUXLijj 4. Injection nozzle
5. Fuel filter
A. To fuel tank
B. From fuel tank
A
B
2 3
SM3-227A
NOTE: Figure illustrates 4-cylinder engine.
_ o
AIR BLEEDING FROM FUEL SYSTEM.
Wl 1. Loosen the bleeder plug on the fuel filter.

2. Loosen the priming pump knob,
3. Operate the priming pump knob until the air will not come out
from the bleeder plug.
4, Tighten the bleeder plug.
v Tightening Torque: 40—60 kg-cm (3—4 Ib.ft)
NOTE: The bleeder plug should be tightened while the priming
pump knob is operated.
SM3-502
5. Once again, operate the priming pump knob several times.

6. Push back the priming pump knob and tighten it.
NOTE: Wipe off any splashed fuel.
mwi
c
SM3-501
1
EN-FS8B-2 ENGINE
INJECTION NOZZLE
OVERHAUL
4
1530V
I— No. 20 7
3
For W04C-T, W04C-TI,
8
W06D, W06D-TI, W06E 9 :
0 10
11
(0) -3
10
1 2 3
I
6
O'
fa
!
For W04D
7
iS §
4 8
3
5
9
11
i
13 :
12
SM3-1238A
1. Connector 6. Retainer ring 11. Distance piece
2. Packing ring 7. Shim 12. Noz2le
3. Gasket 8. Spring 13. Nozzle retaining nut
4. Joint bolt 9. Nozzle holder pressure pin
5. Nozzle holder 10. Pin
IMPORTANT POINTS - DISMOUNTING

REMOVE THE NOZZLE HOLDER ASSEMBLY.
Refer to Section ENGINE MOVING PARTS.
ENGINE EN-FS6B-3

TEST THE NOZZLE SKINKING.
L /
Wash the nozzle proper with diesel fuel oil, then immerse it in
diesel fuel oil.
Next slide the needle inside the nozzle proper and ensure that
60”
it move smoothly. The needle valve should fall under its own
weight when withdrawn vertically about 1/3 and released. If
its motion is sluggish, replace the nozzle with a new one.
SM 3-905
ADJUST THE INJECTION PRESSURE.
i 1. Connect the nozzle holder with a nozzle tester and move the
lever at the rate of about 50 to 60 times per minute.
Injection Pressure: 220 kg/cm3 {3,129 Ib/sq.in)
r.i
WARNING
O Diesel fuel is flammable.
This nozzle adjusting should be done a well ventilated room
and away from any open flames or electric spark.
SM3-816 O The spray must always be covered. Keep your face and
body away from the spray. This is because of the risk of
fuel oil getting in your eyes or passing into your body.
2. If the injection pressure is not within specification, change the
0 ©
f,
!.
SHIM shim.
TEST THE SPRAY PROFILE.

In the case of the new nozzle, operate the lever at the rate of
30 to 60 strokes per minute, and for a used nozzle, operate the
0 lever at the rate of 15 to 60 strokes per minute.
( I
J 4
GOOD COARSE COARSE COARSE
SM3-450
TEST THE FUEL LEAKAGE.

When checking for fuel leakage from the nozzle, apply a
dU 'U' pressure of about 10 to 20 kg/cm3 (142—284 Ib/sq.in) lower
than the correct injection pressure to the nozzle by means of
the nozzle tester, If there is no fuel leakage, the nozzle is
normal.
w
GOOD
w
FAULTY
SM3-881
■
!
EN-FS6B-4 ENGINE
■
FUEL FILTER
SPECIAL TOOL
WRENCH
80 mm
(3.15 in)
I SM3-1960
09503-1040
For spin-on type fuel filter

FUEL FILTER
REMOVE THE SPIN ON TYPE FUEL FILTER.
f( Using a special tool, unscrew the fuel filter.
WRENCH
NOTE: O Be careful not to spill diesel fuel.
ion O When removing the fuel filter for W04C-TI and W06D-
Tl, use a suitable wrench.
Special Tool: Wrench (09503-1040) for W04D, W04C-T, W06E
SM3-1865

INSTALL THE SPIN-ON TYPE FUEL FILTER.
1. Apply a small amount of diesel fuel to the gasket of a new ■
fuel filter. !
2. Manually tighten the new fuel filter until its gasket touches
the cover and then tighten another 2/3 turn with a special
tool. j
NOTE: When installing the fuel filter for W04C-TI and W06D-TI,
use a suitable wrench.
Special Tool: Wrench (09503-1040) for W04D, W04C-T, W06E
ENGINE EN-CS7A-1
COOLING SYSTEM

Coolant pump
Type Forced circulation by volute pump
Drive By V-belt
Seawater pump
Type Self priming type (Flexible impeller pump)
Drive By gear
Thermostat
Type Wax type, bottom bypass system
Valve opening temperature 76.5°C (170°F)
COOLING SYSTEM DIAGRAM
4
I 12
I
-if) ff=>
3
10
5 9
2
( L
1
13 3J
6
V
8 /T
/ JC
{
u 77 n D
// 7
/
— ENGINE COOLANT WATER
--SEA WATER
SM3-1854
1. Seawater intake valve (Seacock) 7. Water cooled exhaust manifold 13. Engine oil cooler
2. Seawater filter 8. Exhaust pipe 14. Water cooled turbocharger
3. Seawater pump 9. Coolant pump 15. Coolant filler cap
4. Intercooler 10. Cylinder block 16. Air bleeder plug
5. Transmission fluid cooler 11. Cylinder head 17. Coolant drain plug
6. Heat exchanger 12. Thermostat
ENCS7A-2 ENGINE
!
9.
OVERHAUL
HE11-038-00X0
8
7
7
8 tK: 13
9
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_ i
.
7 J 8
i t,
6
x X
«ÿ©>8 P
10 3
4
o 14
5 fo 1
(gpgVo-
1
12\f
lai &
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T
10
2
V5
3
I
£
£i
$
T= 75-110 (S.5-7.9)ÿ T= 190-260 (14-18)
1. Coolant pump 6. Coolant manifold 11. O-ring

2. Coolant pump pulley 7. Connector bolt 12. Hose
3. Thermostat 8. Soft washer 13. Clamp
4. Thermostat gasket 9. Pipe 14. Engine hanger
5. Thermostat case 10. Connector
ENGINE EN-CS7A-3
COOLANT PUMP
OVERHAUL
1659N
I— No. 21 6
5
4
1 <Q
■a
O'
0
t)
0
$
1. Pulley center 4. Slinger

2. Pump case 5. Coolant seal
3. Shaft subassembly 6. Vane
p
o REMOVE BY PRYING LOOSE WITH SCREWDRIVER AT THE
2 POINTS ON THE FLANGE.
m
OJ
O
Q
O
f\
o.
SM3-87 3

yj REMOVE VANE FROM SHAFT BY SCREWING IN A BOLT.
Bolt Size;
Diameter: 10 mm (0.394 in)
Pitch: 1.5 mm (0.059 in)
f
SM3-874
EN-CS7A-4 ENGINE
USING A PULLER, REMOVE THE PULLY CENTER FROM THE

SHAFT.
SM3-875
STEEL PIPE USING A STEEL PIPE AND PRESS, REMOVE THE SHAFT
H A FROM BODY.
Steel Pipe Dimention: A: More than 57 mm (2.244 in)
B: 18 - 21 mm (0.7087 - 0.8267 in)
u C C: Less than 29.5 mm (1.161 in)
SM3-223 SM3-237

USING A STEEL PIPE AND PRESS, INSTALL THE SHAFT TO
THE CASE.
NOTE: Bearing face must be aligned with edge of body.
rA
SM3-224 SM3-273
USING A PRESS, INSTALL THE PULLEY CENTER.

DIMENSION (A): 61.5 mm (2.421 in) for W04D, W04C-T
90 mm (3.543 in) forW04C-TI
KWWWV?
A
mm SM3-225
INSTALL THE NEW COOLANT SEAL.

1. Apply a little liquid sealer to the coolant seal outer
circumference and coolant pump body.
i 2. Install the slinger and coolant seal.
SM3-876
ENGINE EN-CS7A-5
m USING A PRESS, INSTALL THE VANE TO THE SHAFT.

NOTE: Apply a little engine oil to the coolant seal face.
d AFTER THE COOLANT PUMP HAS BEEN ASSEMBLED, CHECK

THAT THE SHAFT ROTATES SMOOTHLY.
73
SM3-226

INSTALL THE COOLANT PUMP TO THE TIMING GEAR COVER.
mm 1. Clean the contacting surface of the coolant pump and timing
gear cover free of old sealer, water and oil.
2. Apply the liquid gasket as shown and install the coolant pump
within 20 minutes.
completely and reapply the liquid gasket
SM3-877 Coating Width: 1.5-2.5 mm (0.06-0.10 ini
EN-CS7A-6 ENGINE
HEAT EXCHANGER
i
DESCRIPTION
i
1 2 3 4
JTA Q
c •5
(E=C
'’
0 0 0 T0 0 0
i
[ZZJ
l B
Te 0
C=3
0 0 0
D T5T w "E2T "W
5 SM3-1819
j
i
OVERHAUL
'
2 8 I
6
1 IS'
oj
o
7
$ Q i
3 10
4 \
8
e> of !
3 PP>;
0
o 'o
J) <?©
<T' o
■‘S’*
9
ttf-4 $5
■o
*«>
a,
o,
10
O, J
5
10
1. Housing 6. Filler pipe seat A. Engine coolant inlet

2. Cap 7. Gasket B. Engine coolant outlet
3. Element 8. Water gallery cover C. Seawater inlet
4. O-Ring 9. Coolant pipe D. Seawater outlet
5. Engine coolant drain cock 10. Plate
ENGINE EN-CS7A-7

ASSEMBLE THE HEAT EXCHANGER.
© NOTE: o Replace the O-rings and gasket with new ones.
B O Before installing the plates "A" and "B", apply sealing
06 compound (Three bond No. TB-1207C or equivalent).
o When installing the plate "A" on the heat exchanger,
0 the "O" mark should face outside.
& A

Unit: mm (in)
Heat exchanger Less than 0. 1 0.5 Resurface or

(Exhaust Manifold). (0.0039) (0.019) replace.
/
Flatness
V SM3-1858
Element. Clean with Visual

Clogged. compressed air check
or
sodium hydroxide lislsls
|S
SM3-1800
Coolant filler cap valve

opening pressure.
0.4— 0.6 kg/cm2
(57-8.5 Ib/sq.in)
Replace
LM
A1fCnT—
m
f!
SM3-823
EN-CS7A-8 ENGINE
THERMOSTAT
IMPORTANT POINT - ASSEMBLY

A
INSTALL THE THERMOSTAT.
B 1. Remove water and dirt adhering to the thermostat case.
i
2. Replace the gasket without fail if it is corroded, damaged or
flattened.
3. Before installing the thermostat, apply sealing compound to
t C
4.
the hose installation portion of the coolant manifold.
Assemble the thermostat, gasket, case and coolant manifold
as shown.
>° •>
(gX 1
ioi
i
A: To HEAT EXCHANGER
:
B: From HEAT EXCHANGER )
C: To COOLANT PUMP SM3-1860

4

I INSTALL THE THERMOSTAT CASE.
i
1. Clean the faces.
2. Apply the liquid gasket as shown and install the thermostat
<• case on the cylinder head within 20 minutes.
S
completely and reapply the liquid gasket.
Coating Width: 1.5— 2,5 mm (0.06—0.10 in}
SM3-267
INSPECTION AND REPAIR Unit: mm (in)
Thermostat Valve Opening 74.5-78.5° C

Temperature (166— 173°F)
STIRRING ROD THERMOMETER

Thermostat Valve Lift At least 10(0.4) \
THERMOSTAT THERMOSTAT
at 90° C (194°F) SUPPORTER
Replace
thermostat
Thermostat Closing Fully opened valve
Condition should close com¬
pletely within 5
minutes when ther¬
HEATER
mostat is immersed
in water of normal
temperature.
SM3-888
ENGINE EN-IE2A-1
AIR INTAKE AND EXHAUST SYSTEM
OVERHAUL
ME 11-040-00X07 (1320)
Model W04D
2
<\0
1
o
3
L
X n §L
12 i
\ 11
I '
\> \ V 12
\
l
& AiJ F-]
a®
r ,0 10 13
BJ ■fi&m 9
S.
3 3 (57g?.
v* 14
4
5 T = 190—260 (14-18)
T - 450—500 (33-36) ©
oj
1 1
6 /
/
7 /
/
m
'v.
iO, (
/
/
I
10
8 9 0«?
oJ)
-0
A '"'fl
0 5
4.
(§r A;
j
SM3-1837
T = Tightening torque: kgcm (lb.ft)
1. Heat exchanger (Exhaust maniflld) 8. Heat exchanger bracket

2. Exhaust manifold gasket 9. Water pipe
3. Water hose 10. 0*ring
4. Intake manifold gasket 11. Exhaust pipe
5. Intake manifold 12. Gasket
6. Intake pipe 13. Exhaust pipe bracket
7. Air cleaner 14. Drain cock
W
EN-IE2A-2 ENGINE
OVERHAUL 1. Heat exchanger

DJ (Exhaust manifold)
HE11-038-00X03 ? 12/13 2. Exhaust manifold gasket
Model W04C-T ■4
3. Water hose
6
§
12
llh~i7 4. Clamp
4 5. O-ring
16 6. Water pipe
7. Engine coolant drain
k
« 17 cock
4 8. Intake manifold gasket
H 18 9. Intake manifold
10. Intake air pipe
11 11. Oil pipe
12
U 12. Soft washer
11 14
13. Air bleeder plug
6 5ÿ12 14. Engine coolant drain
1 a plug
2
0 15. Gasket
0
\o\ 2ÿ( 0,
16. Turbocharger
17. Air hose
m
3 ■■0■0
15.
T
•©
19
18. Air cleaner
19. Exhaust pipe
4 20. Exhaust pipe bracket
F PNX- Pi 21. Heat exchanger bracket
m /
*XD f<5
5
u 0
3ÿ 21
B,
19
15
20-
OP.
5
§
(T
6
V® /•
T= 450-500
(33-36) /
1 n
./
T = 450—500
3 6 /
7 10_(gb
(33—36)
r
8 9
<§X
:0s a« v
j
T=> 190-260 (14-18) L
T = Tightening torque: kg-cm (Ib.ft) SM3-1838

ENGINE EN-IE2A-3
OVERHAUL
HE11-039-00X05, 06
Model W04C-TI
..10 1. Heat exchanger
D:
-L/ /5 (Exhaust manifold)
? 12,13 .19
Y ■4
DJ
2. Exhaust manifold gasket
6
3
isr"17 17
4
3.
4.
Water hose
Clamp
15
6
I .x"4 .16
4 5.
6.
O-ring
Water pipe
'1 7. Engine coolant drain
ai
I
L
H
4 OK 20 8.
cock
Intake manifold gasket
18
i#-i5 :fo o
ty
9.
10.
Intake manifold
Intake air pipe
11 11. Oil pipe
12 * oJ
12. Soft washer
W 2
8
0
w \0\
•j/
,1
21
13.
14.
15.
Air bleeder plug
Engine coolant drain
plug
Gasket
0 16. Turbocharger
m ■v'T 15.
■
A 17. Air hose

3 21 18. Air cleaner
4 —cO V W 19. Intercooler
F
Pi 22 JT
20. Intercooler bracket
21. Exhaust pipe
22. Exhaust pipe bracket
3
4 o r v®V ®(G 23. Heat exchanger bracket
21\<;
23 15 sQf
22
15
drÿ 22
©
yp T = 450-500
,JS> 6 1/A; (33-36)
./
/
1
v& (T
&
T = 450-500 s>/
/
3 6 (33-36)
10
r
7
8
9
■\/(D
J
"5
ixfi| a
L i
T = 190-260 (14-18) T = Tightening torque: kg-cm (Ib.ft) SM3-1839
EN-IE2A-4 ENGINE
W04D IMPORTANT POINTS - MOUNTING

2 INSTALL THE EXHAUST PIPES.
1 1. Install the connector and turbocharger on the heat exchanger
o (For W04C-T and W04C-TI).
Tightening Torque: 450—500 kg-cm (33—36 Ib-ft)
2. Temporarily install the mounting brackets and exhaust pipes.

3. Tighten the bolts to the specified torque in the tightening
order as shown.
Tightening Torque:
t>) For W04D
O' <# 1: 500-600 kg.cm (37-43 Ib.ft)
2: 500-600 kg-cm (37-43 Ib.ft)
3: 500-600 kg-cm (37-43 Ib.ft)
4: 450-500 kg-cm (33-36 Ib.ft)
3. .4 5: 450-500 kg-cm (33-36 Ib.ft)
6: 1,000-1,300 kg-cm (73-94 Ib.ft)
% ■6
0[
3 5
SM3-1837
For W04C-T
W04C-T
1 190-270 kg-cm (14-19 Ib.ft)
2 400-600 kg-cm (37-43 Ib.ft)
3 500-600 kg-cm (37-43 Ib.ft)
3 4 450-500 kg-cm (33-36 Ib.ft)
2
5 350-400 kg-cm (26-28 Ib.ft)
6 350-400 kg-cm (26-28 Ib.ft) l
7 350-400 kg-cm (26-28 Ib.ft)
1
8 450-500 kg-cm (33-36 Ib.ft)
9 1,000-1,300 kg-cm (73-94 Ib.ft)
10 500-600 kg-cm (37-43 Ib.ft)
7
5
6
8 5 9
Cf
4 10
SM3-1838
ENGINE EN-IE2A-5
For W04C-TI
W04C-TI
1 190-270 kgcm (14-19 Ib.ft)
2 500-600 kg cm (37-43 Ib.ft)
3 3 500-600 kg.cm (37 -43 Ib.ft)
4 450-500 kg.cm (33-36 Ib.ft)
2 5 350-400 kg-cm (26-28 Ib.ft)
6 350-400 kg-cm (26-28 Ib.ft)
iT 7 350-400 kg-cm (26-28 Ib.ft)
8 1,000-1,300 kg.cm (73-94 Ib.ft)
1
9 350-400 kg.cm (26-28 Ib.ft)
6 10 450-500 kg-cm (33-36 Ib.ft)
9
10
5
<i 7
.oCflW
8
SM3-1839
MEMO
I
I
i
ENGINE EN-CP5B-1
ENGINE COMPONENT PARTS DISMOUNTING

AND MOUNTING
SPECIAL TOOL
TIMER SETTING TOOL V-BELT TENSION GAUGE
SM3-266
09512-2090 for W04D 09444-1210
09512-2100 for W04C-T, W04C-TI
W06D, W06D-TI, W06E
FLYWHEEL HOUSING FUEL INJECTION PUMP

\ FLYWHEEL
/ CRANKSHAFT
m
\
TURNING REMOVE THE FUEL INJECTION PUMP.
DIRECTION
1. Disconnect the fuel lines, oil lines and engine control lines.
2. Turn the crankshaft counter-clockwise viewed from the fly¬
wheel side to align the injection timing mark on the flywheel
at A° before top dead center for No.1 cylinder on compression
--- 'l
"*1!
POINTER
Zi
SM3-885B
stroke with the pointer on the flywheel housing.
Injection Timing (A°): Refer to SECTION DATA AND SPECIFI¬
CATIONS.
NOTE: In case of marine engine equipped with seawater pump,
never rotate crankshaft in reverse direction (Clockwise
viewed from the flywheel side).
Reverse rotation may damage impeller in seawater pump.
3. Remove the timing inspection hole plug.

TIMER COVER Check that the injection timing mark on the automatic timer is
aligned with timer cover pointer.
MARK\ \ POINTER
SM3-884
■
EN-CP5B-2 ENGINE
4. If not, remove the timing gear cover and then loosen the drive
gear fitting bolts.
NOTE; Do not remove the drive gear fitting bolts.
h 5. Rotate the drive gear clockwise to align the injection timing

/ and then tighten the drive gear fitting bolts.
m Tightening Torque: 300-350 kg-cm (22-25 lb. ft)
SM3-866

SETTING TOOL
Special Tool:
% \
Timer Setting Tool
(09512-2090) for W04D
c § (09512-2100) for W04C-T, W04C-TI, W06D, W06D-TI,

W06E
&
TIMER COVER
SM3-250
7. Loosen the timer cover fitting bolts (B) and then remove the
injection pump with timer cover.
i?
<a e ;! NOTE: Do not loosen the injection pump body fitting nuts (C).
IIMr
O
o
C
B C
SM3-1777
FLYWHEEL HOUSING IMPORTANT POINTS - MOUNTING
\ FLYWHEEL INSTALL THE INJECTION PUMP.

1. Check that the injection timing mark on the flywheel is
aligned with flywheel housing pointer.
Injection Timing (A°): Refer to SECTION DATA AND SPECIFI¬
■A* CATIONS.
~"l!
-
POINTER--
fl
1 SM3-885B
2. Check that the injection timing mark on the automatic timer

TIMER COVER is aligned with timer cover pointer.
If not, adjust the injection timing.
MARK\ \POINTSR
SM3-884
ENGINE EN-CP5B-3

SETTING TOOL Special Tool:
N _ Timer Setting Tool
(09512-2090) for W04D
c s (09512-2100) for W04C-T, W04C-TI, W06D, W06D-TI,

W06E
TIMER COVER
£
3?
SM3-250
ModeM/V04D" 4. Install the injection pump with timer cover.

Fitting Bolts Tightening Torque:
sz 190-260 kg-cm (14-18 Ib.ft)
0 0 0
\\
gsrriga 5. Remove a special tool and install the timing inspection hole
plug.
o
1r 6. Connect the fuel lines, oil lines and engine control lines.
SM3-1 777
GENERATOR
INSTALL THE GENERATOR ON THE ENGINE.
1. Install the V-belts, and adjust the belt tension.
NOTE: O Do not under any circumstances apply the lever directly
against the generator body owing to the risk of damag¬
ing the generator.
o When installing a new V-belt or adjusting the tension,
be sure to repeat the adjustment two or three times,
after running the engine for several minutes each time.
2. V-belt deflection
SAMPLE
Apply a load of about 10 kg (22 lb) by pressing with your
finger or a special tool.
•A
Assembly Standard (A): 10—15 mm (0.40—0.59 in)
Special Tool: V-belt tension gauge (09444-1210)
NOTE: If the belt is excessively tensioned, there is a risk of damag¬
f®)
ing the bearings of the generator or coolant pump and also
shorting the life of the V-belt.
Conversely, if there is insufficient tension on the V-belt,
C-048 the belt, will slip, unusual noise will be emitted, the battery
may run down and the engine may overheat.
Through Bolt Tightening Torque:

450-500 kg-cm (33-36 Ib.ft)
■
EN-CP5B-4 ENGINE
STARTER
%
REMOVE THE STARTER FROM THE ENGINE.
V
\ir 1. Turn off the battery switch (If so equipped).
a 2. Put the match marks on the harness and starter terminals
with a pen and then disconnect the harness.
3. Remove the starter from the engine.
©

INSTALL THE STARTER ON THE ENGINE.
1. Install the starter on the engine.
Fitting Bolt and Nut Tightening Torque:
12 mm (0.47 in) dia. : 650-900 kg-cm (47-65 Ib.ft)
14 mm (0.55 in) dia. : 1,100-1,500 kg-cm (80-108 Ib.ft)
2. Connect the starter harness to match the marks.
'
ENGINE EN-TU5A-1
ENGINE TUNE-UP
NOTE: In case of marine engine equipped with seawater pump,
never rotate the crankshaft in reverse direction (Clock¬
wise viewed from flywheel). Reverse rotation may damage
impeller in seawater pump.
VALVE CLEARANCE
FLYWHEEL
INSPECTION AND ADJUSTMENT OF THE VALVE CLEARANCE
1. Set the No. 1 piston to top dead center on compression stroke.
X/> r, JÿFLYWHEEL HOUSING

&rT/TER
J s,
S, J
J
TOP DEAD CEATERÿ' N. i*"'.SM3-882
2. With the No. 1 piston positioned at top dead center and of

the compression stroke, adjust the No. 1 valve clearance using
a thickness gauge.
The thickness gauge should move with a very slight pull.
-
Valve Clearance: Refer to SECTION DATA AND SPECIFICA¬
TIONS.
177 3. Adjust the other valves.
Turn the crankshaft counter-clockwise 180° viewed from fly¬
wheel side. Adjust the valve clearance for each cylinder in the
CS) o firing order.
Firing Order: 1—3— 4— 2
VALVE
IT CLEARANCE
SM3-715
METHOD FOR DETERMINING IF THE NO. 1 OR NO. 4 PISTON

IS AT THE TOP DEAD CENTER ON COMPRESSION STROKE.
Turning the crankshaft, align the mark "1—4" on the flywheel
with the pointer on the flywheel housing. In this position
either the No. 1 or No. 4 piston is at the top dead center on
compression stroke.
1. If both the No. 1 intake and exhaust rocker arms can be
\ moved easily by hand, the No. 1 piston is at top dead center
on compression stroke.
SM3-1773
■
EN-TU5A-2 ENGINE
2. If the injection timing mark is nearly aligned with the pointer,

TIMER COVER
the No. 1 piston is at top dead center on the compression
stroke.
\ NOTE: If not, turn the crankshaft one complete revolution and
align marks as above.
MARK\ \ POINTER
SM3-884
3. While locking at the push rod of No. 1 and No. 4 pistons. Turn
the flywheel counter-clockwise and clockwise about 30° to
40° (see left figure).
m G3 If the piston whose exhaust and intake push rods do not move
during the interval, it is at the top dead center on the compres¬
sion stroke.
J \
If the piston whose push rods have moved, it is at the comple¬
PUSH RODS: STANDING PUSH RODS: MOVE
tion of the exhaust and begun of the intake stroke (overlapp¬
(Overlapping stroke) (Compression stroke) ing stroke).
NOTE: Always loosen the lock nut and raise the adjusting screws
fully to the top. If the adjusting screws are too low, the
30° to 40° piston and valves may strike each other during valve
clearance adjustment.
1
X)'
SM3-713A
INJECTION TIMING
FLYWHEEL HOUSING
\ FLYWHEEL
TZT7J"
INSPECT THE INJECTION TIMING.
1. Turn the crankshaft counter-clockwise viewed from the fly¬
wheel side to align the injection timing marks on the flywheel
\ at A° before top dead center for No. 1 cylinder on compres¬
A° sion stroke with pointer on flywheel housing.

Injection Timing (A0): Refer to section DATA AND SPECIFICA¬
"'T
--•*!
TIONS.
POINTER 1 SM3-885B
BTDC: Refer Top Dead Center
2. Check that the injection timing mark on the automatic timer is

TIMER COVER aligned with timer cover pointer.
'N If not, adjust the injection timing.
\ NOTE: When adjusting the injection timing, refer to "FUEL
INJECTION PUMP" in section ENGINE COMPONENT
PARTS DISMOUNTING AND MOUNTING for details.
MAR K \ \ POINTER
SM3-884
ENGINE EN-TU5A-3
INJECTION NOZZLE
INSPECT AND ADJUST THE INJECTION PRESSURE.
rep Refer to "INJECTION NOZZLE" in SECTION FUEL
SYSTEM.
TEST THE SPRAY PROFILE.
Refer to "INJECTION NOZZLE" in SECTION FUEL
SYSTEM.
V
TEST THE FUEL LEAKAGE.
Refer to "INJECTION NOZZLE" in SECTION FUEL
SM3-81 6
SYSTEM.
SAMPLE
THERMOSTAT
THERMOSTAT INSPECT THE THERMOSTAT FUNCTION.
STIRRING ROD
\
1. Place the thermostat in hot water and check the opening
THERMOMETER temperature and the lift.
T\ 2. Using a thermometer, check to see the thermostat opens at the

specified temperature: Refer to "THERMOSTAT" in SEC¬
TION COOLING SYSTEM.
3. Immerse the thermostat in hot water and measure the lift of
the pellet after a period of 5 minutes using vernier calipers.
HEATER- Measure the position of the bottom of the pellet before and
SM3-888
after heating the thermostat.
Valve Lift: Refer to "THERMOSTAT" in SECTION COOLING
Tt : Valve opening temperature SYSTEM.
T, : Valve opened temperature
4. Immerse a heated thermostat in water of normal temperature.
10 MM If it completely closes within 5 minutes it is satisfactory. If it
l
t remains even slightly open, it is defective and must be re¬
t placed.
0°C j—10°C TEMP.

VC Tj °C SM3-1 133
COOLANT FILLER CAP
V/ © INSPECT THE FILLER CAP FUNCTION.

Check the filler cap pressure using a cap tester.
1 D-
0.5 : 0.4— 0.6 kg/cm2 (5.7— 8.5 lb/$q.in)
f 0.9 : 0.75-1.05 kg/cm2 (10.7-14.9 Ib/sq.in)
vlL~
m NOTE: O The filler cap pressure is shown on the filler cap, and it
should be confirmed.
O If the cap pressure is incorrect, there is a risk of ab¬
normally high pressure being generated in the cooling
SM3-823
system, which may cause the hose to drop off or burst
and, in turn, damage the engine.
WARNING
Do not remove the cap while the engine and cooling system are
still hot.
If the cap is removed while the engine and cooling system are still
hot, scalding water and steam under pressure can be blown out.
This can result personal injury.
EN-TU5A4 ENGINE
ENGINE CONTROL
ADJUST THE SOLENOID (ENGINE STOP) LINK ROD.
SOLENOID
1. Adjust the link rod length so that the clearance between the
NUT(C) stopperof the governor case and the engine stop lever becomes
"A" when the solenoid plunger is fully pushed in.
\ P Assembly Standard “A": 2—3 mm (0.08-0.11 in)

NOTE: O Install the link rod with the nut(c) at the top.
— V- ENGINE
LINK ROD O If the clearance adjustment is unsatisfactory or the
action of the solenoid is sluggish, solenoid seizure,
STOP insufficient output or engine stoppage may result.
LEVER
2. After the above adjustment is over, move the link rod by hand
and make sure that it moves lightly.
3. When the engine is running, the clearance between the engine
Q G stop lever and the stopper becomes "B".
P/ u Assembly Standard "B": 0 mm (0 in)
B
A
SM3-1908
ADJUST THE ENGINE IDLING SPEED.

CONTROL LEVER
When straight drive navigation is not smoothly made at the
IDLING SPEED time of a sea trial in engine at idle, adjust it according to the
STOPPER BOLT
following procedures.
SEAL CAP
o 1. Disconnect the throttle control cable from engine port (left)
I
side and the starboard (right) side.
2. Loosen the idling speed stopper bolt lock nut.
MAXIMUM SPEED'' ENGINE
STOP 3. Adjust through varying the engine speed using the idling
STOPPER BOLT
LEVER speed stopper bolt on the injection pump so that straight
F-189 drive navigation is made.
NOTE:
Increase in engine speed: Turn the idling speed stopper bolt
clockwise.
Decrease in engine speed: Turn the idling speed stopper bolt
counter-clockwise.
Engine Idling Speed: Refer to section DATA AND SPECIFI¬
CATIONS.
4. Upon completion of adjustment of engine idling speed, lock
the stopper bolt with nut and apply paint on the stopper bolt
and nut.
NOTE: When adjusting the all adjusting devices on the fuel injec¬
tion pump governor, except the idling speed stopper bolt,
refer to CHAPTER GV, INJECTION PUMP GOVERNOR.
ENGINE EN-TU5A-5
ENGINE TUNE-UP ON TEST BENCH
NOTE: In case of marine engine equipped with seawater pump

o Never rotate the crankshaft in reverse direction (Clock¬
wise viewed from flywheel).
H: R N
S Reverse rotation may damage impeller in seawater
pump.
GENERATOR O Oo not run engine without water in the seawater cool¬
i eJl
ing system. The seawater pump damage can result.
®r Starting the engine when the generator is not connected
to the battery may damage the generator. Always
TYPICAL BATTERY connect to the battery.
DIAGRAM SM3-907
SET THE ENGINE ASSEMBLY ON A TEST BENCH.

1. Add the proper amount of the specified engine oil through the
oil filler cap on the cylinder head cover.
2. Add coolant.
Ws-
iS o
e-031 F-145
i > NOTE: In case of engine equipped with water-cooled turbocharger,

BLEEDER PLUG
bleed air from bleeder plug.
.\ r0
7-7 I -)> M F-176
BLEED AIR FROM FUEL SYSTEM.

Refer to section FUEL SYSTEM.
CHECK THE INJECTION TIMING.

Refer to "FUEL INJECTION PUMP” in section ENGINE
COMPONENT PARTS DISMOUNTING AND MOUNTING.
CHECK THE VALVE CLEARANCE.
■
EN-TU5A-6 ENGINE
START THE ENGINE.

1
NOTE: Before starting the engine, mark sure that the fuel cut lever
A 8 of the fuel injection pump is operating normally.
1. Check the oil feed to rocker arms.
a. Set the engine speed: Refer to SECTION DATA AND SPECI¬
i
FICATION.
b. Within one minute after starting the engine, oil should flow to
r the head (Face A) of all push rods and the head (Face B) of all :
valves. If the time required for the oil to flow to the rocker
SM3-399A arms is long, various troubles such as seizing, abnormal wear
and unusual noize may occur.
2. Check the contact of the rocker arm and valve stem caps.
CONTACT FACE After running the engine, a contact of approx. 8 mm (0.315
in) should be obtained at the cap contact face of the rocker
arm.
If the contact face is one sided, the valve will tilt, resulting in
valve seizure, breakage, damage, or wear of the rocker arm !
„_
UK
j
stem cap.
SM3-1782
3. Retighten the cylinder head bolts.

EX-HAUST
After tightening cylinder head bolt to specified torque, run
the engine for about 30 to 40 minutes at a water temperature
©. © of about 80°C. Then loosen cylinder each head bolt 1/8— 1/4
w
©
i
©
©
( u ©
©
©
©
i
©/
©
©
i
©
©
®
i
NOTE:
turn and retighten, in sequence, to specified torque.
Special Tool: Socket wrench (09411-1260)
Q In case of marine engine equipped with heat exchanger

(exhaust manifold), loosen the heat exchanger bracket
fitting bolts before retightening the cylinder head bolts.
INTAKE SM3-201 A O Be sure to loosen one bolt at a time, then retighten it
before going on to the next bolt.
O By retightening, face pressure of cylinder head is re¬
stored from point B to C as shown.
O Retighten at the first 30 hours following servicing which
LOOSE
involves the loosening or removal of any cylinder head
00 bolt. Such servicing includes replacement of the cylinder

head gasket, servicing of the valve gear parts, and the
like.
TIGHT
SM3-457
.Prauure on satket
Prmure lost attar aaumbling
on
$asket
, Racovarv of preuore
„/ on gasket
A c/ (BY RE-TIGHTENING)
■Minimum necetwry
30-40 | pressure on Baikal
minutes
Prwsura drops after
enginefiring
— Assembling Engine firing

- — Tim
ne
SM3-1180
RECHECK THE VALVE CLEARANCE, WHEN ENGINE IS COLD.
ENGINE EN-PR1B-1
PROCEDURE FOR lIMSTALLIPslG JOINTS AND GASKETS OF

ENGINE PIPES
1. Gasket seal type (aluminum + rubber, asbestos or copper).
Location of gasket seal Tightening torque chart
JOINT Clamping screw size

JOINT (Diameter)
Tightening torque
■BOLT BOLT kg-cm (Ib.ft)
JOINT
GASKET
JOINT
■ [
rnrf GASKET
mm (in)
8 (0.315) 120-170( 9-12)
10 (0.394) 180-230 (13-16)
I 12 (0.472)
14 (0.551)
230-280 (17-20)
230-280 (17-20)
JOINT JOINT 16 (0.630) 300-350 (22-25)
BOLT BOLT 18 (0.709) 400-450 (29-32)
20 (0.787) 400-450 (29-32)
GASKET
GASKET 22 (0.866) 530-600 (38-43)
JOINT 24 (0.945) 720-800 (52-57)
PIPE
28 (1.102) 1,300-1,500 (94-108)
f-y-'V NUT
GASKET
J l
2. Metal seal type (Flares connector type).

Tightening torque chart
Location of metal seal
Clamping screw size
BRACKET (Diameter) Tightening torque
CONNECTOR
P=T)
FLARE NUT NUT \
WMJC
3 WAY JOINT
mm (in)
12 (0.472)
kg-cm (Ib.ft)
200-220 (15-16)
14 (0.551) 330-360 (24-26)
16 (0.630) 400-500 (29-36)
LOCK
WASHER 0 18 (0.709)
20 (0.787)
600-700 (43-51)
650-700 (47-51)
BRACKET FLARE NUT
NUT
LOCK WASHER
■
EN-PR1B-2 ENGINE
3. Metal seal type (Nipples connectors type)
Tightening torque chart

Location of metal seal
GASKET NUT NUT Clamping screw size
Tightening torque
(Diameter)
A kg-cm (lb.ft)
-wc
mm (in)
— n-H
1 10 (0.394)
20 (0.787)
100-150 (7-10)
200-250(14-18)
FLARE CONNECTOR
FLARE CONNECTOR
CONNECTOR CONNECTOR
NOTE: o Before installing the joints, ensure that there is no dirt or burrs adhering to the various seat faces (pipe joints,
gaskets, etc.)
o Because the pipes can move relatively free during installation and the seat faces are liable to tilt, first temporarily
tighten the pipes, then tighten them to specification and ensure that there is no leakage from them.
o When tightening two pipes together, be very careful that they do not rotate together.
O After installing the pipes, apply the correct pressure to each pipe joint and ensure that there is no leakage.
o Ensure that the various tightening torques conform to the above table.
O If a soft washer #4840 FR-N (aluminum + rubber and carbon press fit part) is loosened or removed subsequent
to being installed, be sure and replace it with a new one.
There is no need to replace it, however, for normal retightening.
ENGINE EN-MT1A-1
MARINE TRANSMISSION DISMOUNTING

AND MOUNTING
OVERHAUL
1. Marine transmission
2. Fluid cooler
2 3. Remote control
o 4. Connection for
'b CP
o
temperature gauge
o'
3 /<3 5. Neutral safety switch
9 6. Connection for shifting
o'
Ol o pressure control
'l
[f 7. Marine transmission
Tr oil
e -y,
€ jA.
h Oi 11
output flange
8. Propeller shaft
9. Support bracket
rap* 10 10. I ntermeidate flange
4®6" iÿC 9 11. Torsion-elastic coupling
■■
12. Clutch, side A
I
fa 13. Loose gear
(
14. Clutch, side B
A
15. Intermediate shaft
16. Output shaft
SM3-1821
8
OPERATION
A B
0 y
•rc op5| 51
obS ouol
{? /"A
14
12 13
13
s
_ paiLSTI
a
Mil
'O’
15 15
16 16
SM3-1822
Position of shifting lever when driving forward

Propeller pitch [ Propeller ratio Shifting lever in position
Right hand Opposite to engine rotation A
Left hand As engine rotation B
■
EN-MT1A-2 ENGINE

/ PUMPING OUT MARINE TRANSMISSION FLUID.
m
t •A
1. Turn the filter cover counter-clockwise to loosen the fluid
fine filter (Item A).
2. Remove the filter cover complete with fluid fine filter.
a c
B
3. Pump out old marine transmission fluid through suction pipe
(Item B) in the filter compartment.
NOTE: Max. outside diameter of suction hose is 16 mm (0.625

ST
in) (Item C).
2
SM3-1823 — SM3-1824
DISCONNECT THE PROPELLER SHAFT (Item D) FROM THE

MARINE TRANSMISSION OUTPUT FLANGE.
REMOVE THE FLUID COOLER WITH PIPES (Item E).
NOTE: Plug the openings of the line and marine transmission to

prevent dirt entering.
E-
DISCONNECT THE REMOVE CONTROL (Item F) FROM SHIFT¬

F
G ING LEVER.
DISCONNECT THE ELECTRICAL LINE AND FLUID LINES.
REMOVE THE SUPPORT BRACKET (Item G).

[7? G
SM3-1821
REMOVE THE MARINE TRANSMISSION.

1. Put the match mark on the marine transmission and inter¬
HANGER
HOLE
via MATCH
MARK 2.
mediate flange with a pen.
Suspend the marine transmission.
NOTE: The marine transmission without fluid and fluid cooler
l< weights approx. 44 kg (97 lb).
£05
3. Remove the marine transmission fitting bolts.
\Tp 4. Pull the marine transmission away from the engine.
SM3-1825
REMOVE THE INTERMEDIATE FLANGE FROM THE FLY¬

WHEEL HOUSING.
Put the match mark on the intermediate flange and flywheel
&
housing before removing.
<0
REMOVE THE TORSION-ELASTIC COUPLING FROM THE
?{m FLYWHEEL.
MATCH MARK
SM3-1836
ENGINE EN-MT1A-3
IMPORTANT POINTS - MOUNTING

INSTALL THE TORSION-ELASTIC COUPLING.
'/////////A
k>=0—' H 1.
2.
Install the torsion-elastic coupling to the flywheel.
Check the axial tolerances of the connection between marine
transmission and engine.
a. Attach caliper linkage (Item H) to damper plate.
b. Apply base of caliper at right angles to plane surface of fly¬
wheel housing.
c. Pretension the gauge and set to "0".
d. Turn the flywheel slowly. The gauge reading must not exceed
0.1 mm (0.004 in).
"X" : Mounting surface of engine flywheel housing.
7 "X"
zzzzzzzzzzzzZ
SM3-1826
3. Check the radial tolerances of the connection between marine

transmission and engine.
'ZZ/ZZZZZ?/ a. Attach caliper linkage (Item H) to damper plate.
b. Apply base of caliper at right angles to entering surface of
H
flywheel housing.
0 c.
d.
Pretension the gauge and set to "0”.
Turn the flywheel slowly. The gauge reading must not exceed
0.1 mm (0.004 in).
"X" : Mounting surface of engine flywheel housing.
T_
r
"X"
7
z/zz/z///ZZZz.
SM4-1827
■
EN-MT1A-4 ENGINE
INSTALL THE INTERMEDIATE FLANGE.

1. Locate the intermediate flange on the flywheel housing
to align the match mark.
2. Check the axial tolerances of the intermediate flange (Con¬
H centricity).
a. Attach caliper linkage (Item H) to the damper plate (Item D).
b. Apply base of caliper at right angles to centering surface of
& intermediate flange (Item K).
c. Pretension the gauge and set to "0".
d. Turn the flywheel slowly. The gauge reading must not exceed
EEEP 0.15 mm (0.0059 in).
//////////// is K
SM3-1828
2. Check the radial tolerances of the intermediate flange (parallel

running).
a, Attach caliper linkage (Item H) to the damper plate (Item J).
b. Apply base of caliper at right angles to plane surface of the
intermediate flange (Item K).
C. Pretension the gauge and set to "0".
d. Turn the flywheel slowly. The surface deviation must not
H exceed 0,05 mm (0.0019 in) 100 mm (3.937 in) measured
diameter.
£
j
////////?77/A£k.
SM3-1829
INSTALL THE MARINE TRANSMISSION.

1. Apply grease containing molybdenum disulfide to the input
L
shaft spline I Item L).
X
to i
SM3-183Q
:
ENGINE EN-MT1A-5
2. Install the marine transmission to the intermediate flange.

Tightening Torque: 380—500 kg-cm (28—36 lb. ft)
'/////////£. Axial Play (M): Minimum 1 mm (0.04 in)
LI*
as 1
NOTE: Assure clearance of axial play of the crankshaft.
\2i zn.
£ xrr.
M >
A
3
SM3-1831
INSTALL THE SUPPORT BRACKET (Item G).
CONNECT THE PROPELLER SHAFT (Item D) TO THE MARINE

TRANSMISSION OUTPUT FLANGE.
CONNECT THE ELECTRICAL LINE AND FLUID LINES.

E'
CONNECT THE REMOVE CONTROL (Item F) TO THE SHIFT¬
F ING LEVER.
G
INSTALL THE FLUID COOLER WITH PIPES (Item E).

SL
gr ■ G
SM3-1821
FILL WITH AUTOMATIC TRANSMISSION FLUID (ATF).

NOTE: The filter element must be renewed whenever the fluid is
$
t 1.
changed.
Turn filter cover counter-clockwise and pull.
2. Fill with 4.0 liters (1.06 US gallon) of Automatic Trans¬
mission Fluid (ATF).
Type of Fluid: ATF (Automatic Transmission Fluid)
e.g. DEXRON ll-D, FORD M 2 C-33G,
"3 I k~ ALLISON C-3
SM3-1823 SM 3-1832' No other fluids unless authorized by HURTH
EN-MT1A-6 ENGINE
3. Remove filter element (Item N) from cover (Item P). :

s
4. Check O-ring (Item Q) and place new filter element onto ■
G cover.
5. Check O-ring (Item R) and insert filter cover with fluid fine
filter to its stop into the marine transmission housing.
/V"-R
m
■M P
N
SM3-1833
a 6. Lock filter cover in place by turning clockwise and pushing.

NOTE: When inserting the filter cover, make sure that flat side
of cover {Item S) matches with lug (Item T) in the filter.
[3 T
n
SM3-1834
7. Loosen fluid dipstick (Item U) turning the handle counter¬

clockwise.
Si K
8. Wipe dipstick with a clean and dustfree cloth and insert
Wm
dipstick to its stop.
■u
9. Remove dipstick and check fluid level.
10. Insert the dipstick to its stop and lock it by turning the
handle clockwise.
A-MAX.
L-
-MIN.
SM3-1830 SM3-1835
11. Let engine run at idle speed with shifting iever in neutral
position until fluid cooler and all pipelines are filled in fluid.
12. Shut down engine and check fluid level again. If necessary,
top up to the marking on the dipstick.
(K.P.)
ELECTRICAL EQUIPMENT EE-1
EE-185E-02
CHAPTER EE
ELECTRICAL EQUIPMENT
DATA AND SPECIFICATIONS EE- 2
LOCATION OF ELECTRICAL EQUIPMENT EE- 2
TROUBLESHOOTING EE- 3
GENERAL INSTRUCTION EE- 5
BATTERY EE- 6
ENGINE STARTING CIRCUIT EE- 7
PRE-HEAT CIRCUIT EE- 8
ENGINE STOP AND WARNING LAMP CIRCUIT EE- 8
METER AND GAUGE CIRCUIT EE-10
ELECTRICAL WIRING DIAGRAM
■
EE-2 ELECTRICAL EQUIPMENT
Electrical system
Voltage Direct current 12 volts or 24 volts
Ground Negative (— ) ground
Warning and indicator lamp . 1.4W 4 pieces
Gauge illumination lamp ... 1.7W 4 pieces
Tachometer illumination lamp 3.4W 2 pieces
LOCATION OF ELECTRICAL EQUIPMENT
2 3
L
o o
Z o
1.
2.
Water temperature receiver gauge
Engine tachometer
Fuel receiver gauge
,v ' 1 1 /,
TEMP
20ÿ
EXrxt _
- FUEL
3.
4. Volt-meter
10 [fg|oT5IC(l
5. Starter switch
11 © © 3°'
35-
RPUXtOO
' IQ 12
7. Battery charge warning lamp
8. Water temperature warning lamp
9. Intake air heater indicator lamp
■
4
10. Illumination lamp switch
"LAMFÿ 11. Oil pressure receiver gauge
|yy|-I-llQ 12. Emergency stop relay
13. Intake air heater relay
14. Battery main relay
o o o 15. Starter block relay
16. Intake air heater timer
10 9 8 7 6 5 17. Relay
18. Sensor amplifier
12 13 14 15
19. Water temperature switch
20. Water temperature sender gauge
S> 21. Oil pressure sender gauge
22. Oil pressure switch
23. Glow plug
24. Solenoid
16 <1
20
19
s
\ 23
6
ts <ÿ) 1
17 18 24
3 r
L
TROUBLESHOOTING
Symptom Possible cause Remedy /Prevention
A lot of exhaut is emitted - ■j Auxiliary starting device

but the engine does not
start or is difficult to start. Loose wiring of heater signal or defective Repair or replace.
(Auxiliary starting device: heater signal.
Standard specifications) Defective heater plug Replace.
Defective wiring between heater and plug Repair.
(Auxiliary starting device: Defective power relay Repair or replace.

Option specifications)
Defective heater plug Replace.
Defective wiring between heater and plug Repair.
Defective sensing resistor Replace.
■ Defective heater control timer Replace.
Solenoid does not operate ] Emergency stop relay |

when engine is running,
even if abnormal signal • Alternator malfunctions Repair or replace.
is input. • Insufficient battery voltage Charge or replace.
(Engine does not stop.)
• emergency
Faulty connection at N terminal of
relay
Repair.
• Defective solenoid Replace.
Solenoid operates when \ Emeragency stop relay |

starter switch is turned
ON • Faulty connection at R1 terminal . . . Repair.
• Faulty connection at B and C terminals Repair.
When the starter switch — ■j Battery

is turned OFF, the battery
relay switch goes OFF • Insufficient voltage Charge or replace.
and the solenoid fails to
operate. k -[Alternator |
• Malfunctions Repair or replace.
Starter chattering or ■] 8attery

improper plunging
• Insufficient voltage Charge or replace.
-1 Starter block relay]

• Faulty connection at terminals
• Internal circuit abnormal . . . .
• improper
Relay switch abnormality (faulty contacts)
sliding between rod and moving
core, or open-circuit or burnt out coil
.....
Repair.
Replace.
Repiace.
-1 Starter switch
• Faulty connection at terminals
I
EE4 ELECTRICAL EQUIPMENT
Improper disengagement - -{Alternator |

of starter or defective hold
function when engine is • Defective (correct voltage not generated) Repair or replace.
rotating
Starter block relay
• Improper terminal connection Repair.
• Reverse connections to terminals B and C Repair.
Re-plunging during Starter block relay

inertial rotation
• Reverse connections to terminals B and C Repair.
GENERAL INSTRUCTION
WARNING
Be sure to disconnect the ground cable before servicing the
electrical circuits.
EXAMPLE:
WIRING CODE
3WB 1. Wiring colors are indicated by a code.
B : Black Lg : Light green
Br : Brown R : Red
G : Green W : White
3 mmJ L : Blue Y : Yellow
<0.0047 sq.in) 2. The first letter indicates the ground wire color and second
letter indicates the stripe color.
3. Arabic numerals indicats the cross sectional area of wire.
3 : 3 mm1
CONNECTOR
o The connectors exist as male and female connectors.
c~-:
FEMALE
5s?r
MALE
o
o
Male and female connectors are classified according to the
shape of the terminals in the connector {refer to the figure on
the left).
Male and female connectors are provided with a lock, so that
they can not be separated easily.
LOCK O For connector separation, hold the connector, unlock the
lock and separate the connector.
NOTE: When the connector is pulled by pulling the wires, the
connection between the terminals and the wires will be
damaged.
Remove the terminal from the connector.

SM20-344
a. Insert a minature screwdriver or a terminal puller between
terminal and connector and' unlock the leek between ter¬
minal and connector.
b. When the lock has been released, pull the wire to remove
the terminal.
Ct-'
S3 DETAIL
2. Install the terminal in the connector.
\ si a. Insert the terminal into the connector until the clicking sound
of lock engagement can be heard.
b. Pull the wire to confirm correct lock engagement.
SM20-347
FUSE
o The power supply must be switched off for fuse replacement.
o Use a fuse with a suitable amperage.
NOTE: Wire burning may be caused when a fuse with an exces¬
sively large current capacity is used.
c If the fuse should blow frequently, investigate the cause and
SM20-348 remove it.
■
BATTERY
SPECIFIC GRAVITY : CONVERSION FORMULA FOR SPECIFIC GRAVITY.
V -
ENSURE THAT THE 1 .250 1 270
BATTERY IS O The specific gravity of electrolyte changes according to the
ALWAYS FULLY temperature of the electrolyte itself, hence it is based on
CHARGED
a temperature of 20°C (68°F).
Consequently, if the temperature is not 20°C when the
,l7§O 9 9 8 1) specific gravity is measured, it is necessary to convert the
r measured value to the equivalent value at 20° C.
O O
Temperature conversion formula: S20 = St + 0.0007 (t — 20)
Where,
• S20 is the specific gravity at 20°C (reference temperature)
• St is the specific gravity at the measuring temperature
• t is the temperature during measurement
• 0.0007 is the temperature coefficient of the electrolyte
NOTE: As a rough guide. If the temperature of the electrolyte
rises or falls by 15°C (59°F), the specific gravity of the
electrolyte will vary by about 0.01.
BATTERY CHARGING
45Crr
i
r ==4 m
o
D
Be careful of the following points.
While the battery is being charged, ensure that the temperature
of the electrolyte does not rise above 45°C (113°F).
2) While the battery is being charged, be particularly careful to
keep it away from sources of fire.
3) The amount of electrolyte must be within the specified level.
•
—
Specific gravity when battery is fully charged: 1.250 1.270 at 20°C
(68°F)
SM20-088C
CLEANING THE BATTERY
o If the terminals at the top of the battery are dirty, clean them
with cold water or lukewarm water.
o Apply a light coating of grease to the terminals to prevent
them from rusting so as to prevent faulty contact.
CONNECTING THE BATTERY CABLES

o Clamp the cables securely to prevent improper contact be¬
tween the cables and the battery terminals.
o Be very careful not to connect the (+) and (— ) leads in reverse.
(because this may cause equipment run off the battery to be
damaged.)
I
ENGINE STARTING CIRCUIT
M
CHECK THE CONTINUITY OF THE STARTER SWITCH.
C
B Check the continuity between terminals.
if continuity is not correct, replace the starter switch.
Terminal
Ri M B Switch position \ 8 R» R2 M BR C
BR C PRE-HEAT o o ■o
OFF
ON o ■o
BR R1 SM20-1317 START O O o ■o ■o
CHECK THE OPERATION OF BATTERY RELAY.

I
4] 2
'
1. Check that there is continuity between terminals 1 and 2.
•"t
'll3/® 2. Check that there is no continuity between terminals 3 and 4.
3. Connect the positive (+) lead from the battery to terminal 1.
Connect the negative (— } lead to terminal 2. Check that there
3 4 is continuity between terminals 3 and 4.
w 1
4. If operation is not correct, replace the battery relay.
3 L_!±$
SM20-1305
CHECK THE OPERATION OF THE STARTER BLOCK RELAY.
c 1. Check that there is no continuity between terminals C and B.

-Q- 2. Connect the positive (+) lead from the battery to terminal
S. Connect the negative (— ) lead to terminal E. Check that
“
there is continuity between terminals C and B.
£ v .-f- I, 3. Connect the positive (+) lead from the battery to terminal
P. Connect the negative (— ) lead to terminal E. Check that
there is no continuity between terminals C and B.
e 1 B 4. If operation is not correct, replace the relay.
E
S p w
□ i
F ]pe no
F no
S {TO
ALTSRNA TOR TERMINAL)
EARTH J
STARTER $W. )
a H
i
0ATTERY ( 12V 1
CIRCUft DIAGRAM
ft
EE-8 ELECTRICAL EQUIPMENT 1
FRE-HEAT CIRCUIT
CHECK THE OPERATION OF THE INTAKE AIR HEATER
F s RELAY.
p=>rj
BD-— j mm 1. Check that there is continuity between terminals SW and L.
2. Check that there is no continuity between terminals S and F.
L SW
3. Connect the positive (+) lead from the battery to terminal SW.
jO- iH Connect the negative |— ) lead to terminal L. Check that there
sw<
s p is continuity between terminals S and F.
tplb3 4. If operation is not correct, replace the relay.
F
S
H
S3
— <jI>r
s<{? o o—
L SW
.-Mf
Bj
SM20-1 306
CHECK THE CONTINUITY OF THE HEATER PLUG.

Check the continuity between terminal and body, ground.
If there is no continuity, replace the glow plug.
A
SM20-394
ENGINE STOP AND WARNING LAMP CIRCUIT

LINK ROD
CHECK THE OPERATION OF THE SOLENOID AND ADJUST
'C THE LINK ROD.
NUT
r'(§ o
li o
\ 1. Connect the battery to the solenoid terminals and confirm
that the solenoid is drawn in.
2. Push in the plunger by hand and confirm that there is a
clearance between the stopper and the stop lever.
fol
TS TOP LEVER
3\ Standard clearance: 2 — 3 mm (0.01188 — 0.1181 in)
o If there is no clearance, perform adjustment with the link rod.
i
I
_L
u NOTE: o If the clearance adjustment is unsatisfactory or the
I action of the solenoid is sluggish, solenoid burnout,
H— Ml 1 I insufficient output or insufficient engine stoppage may
d-
3— STANDARD CLEARANCE result.
1 LINK ROD o Install the link rod with the nut at the top.
j '-STOP LEVER —
\ ■
°) -6-
r
STANDARO CLEARANCE
CHECK THE OPERATION OF THE WATER TEMPERATURE

SWITCH.
- Check the continuity between terminals.
If continuity is not correct, replace the temperature switch.
£2.
Terminal
1 2
Water temperature: °C (°F)
Not less than 98 ± 2 (205-212) o o
Between 95 (203) and 98 ± 2 (205-212)
SM20-1 151
CHECK THE OPERATION OF THE PRESSURE SWITCH.

1. Check the continuity between terminal and body ground.
a. Check that there is continuity when engine is stopped.
b. Check that there is no continuity when engine is running.
2. If continuity is not correct, replace the oil pressure switch,
NOTE: Engine oil pressure should be more than 0.5 kg/cm2 (7.2/
sq.in.)
SM20-1290
CHECK THE OPERATION OF THE RELAY. (WATER TEMPERA¬

3 4 TURE WARNING LAMP RELAY)
3 4
1. Check that there is continuity between terminals 1 and 2.
2. Check that there is no continuity between terminals 3 and
1 2 4.
I
i 3. Connect the positive (+) lead from the battery to terminal
1. Connect the negative (— ) lead to terminal 2. Check that
I I
there is continuity between terminals 3 and 4.
1 2 4. If operation is not Gorrect, replace the relay.

SM20-1 312
METER AND GAUGE CIRCUIT

CHECK THE OPERATION OF THE TACHOMETER.
1. Connect a turn-up test tachometer, and start the engine.
2. Check the tester and tachometer indications.
If the indicated value of tachometer is not correct, replace
'10 l~Ji’c’r,ic|
©
prim is
© »1 UPS the tachometer.
Standard revolution (rpm) 600 1,800 3,000

RPM J IOO
Allowable value (rpm) ± 100 + 100 ± 100
p:
SM20-1307
■
CHECK THE OPERATION OF THE FUEL RECEIVER GAUGE.

?ÿ
1. Wire the receiver gauge, variable resistor and battery, as shown
If f
\rat in the figure at left. Check the indicated value on the receiver
!ÿÿ($) gauge at the reference resistance value.
SjToT
2. If the indicated value is not correct, replace the receiver gauge.
%-
Resistance: 33.5 103 240
Gauge reading F 1/2 E
I SM20-1308
Allowable value: %
+6
o +4 -5
0
CHECK THE OPERATION OF THE FUEL SENDER GAUGE.
7<
\ Measure the resistance between terminals.
If the indicated value is not correct, replace the sender gauge.
r
\
-(-ip) Float position F 1/2 E
1 /2
. Standard resistance: 30.1 103 250
Allowable value: fi ± 3.4 ± 10.3 ± 24
<
E
\i SM20-1314

RECEIVER GAUGE.
BO C ■* ■(
1 1. Wire the receiver gauge, variable resistor and battery, as shown
<ov\ '
TEMP
•Of lPGt
t©l in the figure at left. Check the indicated value on the receiver
§5 o gauge at the reference resistance value.
2. If the indicated value is not correct, replace the receiver gauge.
Resistance: Q 43.2 23.7

Gauge reading: °C (°F) 80 (176) 100 (212)
7%
SM20-1310 Allowable value: °C (°F) ± 3.5 (38) ± 5.5 (41)

SENDER GAUGE.
1. Wire the sender gauge and ohmmeter as shown in the figure
value of the sender gauge at the
at left. Check the resistance
reference water temperature.
2. If the indicated value is not correct, replace the sender gauge.
V
Water temperature: °C (°F) 50 (122) 80 (176) 100 (212)

Standard resistance: £2 130 48.5 26.7
SM20-042 Allowable value: £2 ± 4.2 ±2.5
CHECK THE OPERATION OF THE OIL PRESSURE RECEIVER

GAUGE.
. bar
1. Wire the receiver gauge, variable resistor and battery as shown
Ik - in the figure at left. Check the indicated value on the receiver
OIL
gauge at the reference current value.
: <s»
<i>i a )g//
2. If the indicated value is not correct, replace the receiver gague.
Resistance: 19 81 112
i l SM20-1311
Gauge reading: bar (psi) 0 4 (56)
+ 0.7 (9.7)
6 (84)
Allowable value: bar (psi) ±0.3 (4.1) -0.6 (8.4)
CHECK THE OPERATION OF THE OIL PRESSURE SENDER

GAUGE.
£2 1. Wire the ssender gauge and ohmmeter as shown in the figure
at left. Check the resistance between the sender gauge and
the body ground.
2. If the indicated value is not correct, replace the sender gauge.
Oif pressure kg/cm2 (ib/sq.in) 0 4 (57) 6 (85)

Standard resistance: n 19 80 110
SM20-1315 Allowable value: ±2 ±5 ±9
CEHCK THE OPERATION OF THE VAOLTMETER.

1. Wire the voltmeter and transformer as shown in the figure
at left. Check the indicated value on the voltmeter at the
V 10 12 14 •# Li! $ÿ reference voltage value.
71
JIS o,
2. If the indicated value is not correct, replace the voltmeter.
Gauge reading: V
Allowable value: V
12
± 0.5
14
±0.5
TRANSFORMER SM20-1309
CHECK THE OPERATION OF THE GENERALLY USE SWITCH

(ILLUMINATION LAMP SWITCH).
Check the continuity between terminals.
/ If operation is not correct, replace the switch.
/
Terminal
1 2
Switch position
1 ON o ■o
n 2
SM20-131 6
OFF
I
MEMO !
(KY)
TURBOCHARGER TU-1
TU-19E-Q2
CHAPTER TU
TURBOCHARGER
DATA AND SPECIFICATIONS TU-2
DESCRIPTION TU-2
TROUBLESHOOTING TU-3
OVERHAUL CRITERIA TU4
SPECIAL TOOL TU-5
TURBOCHARGER TU-6
TU-2 TURBOCHARGER
Type RHC 6
Turbine type Radial flow type
Blower type Centrifugal type
Lubricating method . External lubrication type
Bearing type Full floating type
Direction of rotating . Counterclockwise as seen from the turbine side
termperature
DESCRIPTION
i 4 5 2 4 5
V \
\
q
\\i
I I
T\C
SM51-100 SM51-101
1. Turbine case 4. Blower impeller

2. Turbine rotor 5. Blower case
3. Bearing case
TURBOCHARGER TU-3
TROUBLESHOOTING
Dense black smoke Insufficient air intake
• Air cleaner is choked with dust, . . . Disassemble and clean or replace

causing greater intake air resistance. the air cleaner element.
• Air inlet is choked Repair.
• Air is leaking from intake manifold Repair.
Turbocharger does not rotate smoothly.
• Engine oil impurities deposited on Overhaul and clean turbocharger

rotor, resuiting in heavy rotation and/or change engine oil.
or sticking.
Bearing sticking
Insufficient lubrication or blockatge . . Check lubricating oil system,

of lubricating oil lines. and/or repair.
Abnormal wear or damage of seal . . . Repair.
ring caused by wear of journal bearing,
due to insufficient lubrication.
Temperature of lubricating oil too high Check cooling system.
Unbalanced rotating parts Change rotating parts.
Incomplete warming-up, failure Operate vehicle properly.
to idle before stopping engine, or
jack rabbit starts.
Loose or damaged turbine rotor or blower impeller.
• Over-rotation Check and adjust the engine.

• Temperature of exhaust gas too high Check and adjust the engine.
• Foreign matter present Remove foreign material.

Inspect the air cleaner and air
intake manifold.
Repair if necessary.
• Worn thrust bearing Overhaul and repair.
— —• Incomplete assembly Reassembly.
High volume exhaust -Exhaust gasinsufficient

leaking before turbocharger,
revolution.
Check and repair connections.
like noise. therefore
-Deformed or blocked exhaust gas lines . Repair.
therefore insufficient revolution.
White smoke' Choking defects, or deformation of .. Repair and replace the lines.
oil return lines so that oil leaks around
blower or turbine sides.
— Seal ring may be broken or worn due

to abnormal wear of thrust washer.
Replace the thrust washer.
TU4 TURBOCHARGER
Loss of power- --Gas leakage from exhaust system Repair.
- ..
Air leakage from air manifold Repair.
-Clogged air cleaner element . . . Clean or replace.

-Turbocharger dirty or damaged . Repair or replace.
Poor response of -side

Carbon accumulation on the turbine
seal ring and heavy rotation.
Change engine oil, clean
turbocharger.
turbocharger
-Poor combustion Check fuel

combustion.
system and improve
High pitched noise Noise

and vibration
• So called "surging" Overhaul and clean turbocharger.
Surging sometimes occurs when the gas
passage at the nozzle of the turbine
housing is choked or when compressed
air does not flow in proper responses to
acceleration.
• Loosen rotating parts Replace.
Vibration
• Joints loose between turbocharger . . Check the mounting and repair.

and intake, exhaust manifold or
oil lines.
-• imbalancedbearing,
Damaged loose rotating parts,
rotating parts, etc.
Repair.
OVERHAUL CRITERIA
CONDITIONS WHICH DETERMINE WHEN A TURBOCHARGER

OVERHAUL MAY BE NEEDED.
THE ENGINE LACKS POWER OR ENGINE EXHAUST EMITS
BLACK SMOKE.
BOOST PRESSURE IS BELOW THE NORMAL VALUE.

Inspect the turbocharger boost pressure according to the
following procedures.
NOTE: Before measurement
o Coolant temperature should approximately 80° C.
O Air cleaner element should be clean.
WARNING
When making a pressure test, be sure that personnel are adequate¬
ly protected against any stream of pressurized air that might be
released by a leak or the rupture of a hose.
TURBOCHARGER TU-5
1. Remove the blind plug on the intake pipe and install the hose
and pressure gauge {special tools),
/<"
Special Tools: Pressure Gauge (09444-1250)
C'i Hose (17108-1040)
SM51-015
3. Read boost pressure.

It the boost pressure is below the specified value, turbocharger
overhaul is needed.
Boost Pressure: Less than 0.13 kg/cm1 (1.85 Ib/sq.in) at no load
with maximum revolution.
OTHER FACTORS
r)
1. Noisy of excessive vibration of the turbocharger.
2. Excessive engine oil consumption.

3. Gas leakage at the turbine end or blower end.
SM51-016
4. Oil leakage from the turbocharger.
SPECIAL TOOL
Prior to starting an turbocharger overhaul, it is necessary to have these special tools.
ATTACHMENT FOR MEASURING

TURBINE SHAFT RADIAL PLAY BOOST PRESSURE GAUGE BOOST PRESSURE GAUGE HOSE
09444-1230 09444-1250 17108-1040

TU-6 TURBOCHARGER !
TURBOCHARGER
5
1881 M
1-N0.23
4 T = 280-290 (20.3-20.9)
2
3
m T = 52-60 (3.8-4.31
T = 75-85 (5.5-6.1)
13
o
LZ-
12
6
m 11
10
MW 8
9
17
18
7 T = 35-41 (2.6— 2.9)
T = 12-14 (0.9— 2.9)

16
15
14
14
1. T urbin casing 7. Reteiner ring 13. Blower casing

2. Turbin totor 8. Oil thrower 14. Bearing
3. Seal ring 9. Seal ring 15. Thurst spacer
4. Heat protector 10. Seal ring 16. Thurst bearing
5. Bearing casing 11. Seal plate 17. Blower impeller
6. Holding plate 12. Holding plate 18. Lock nut
IMPORTANT POINT (S) - BEFORE DISASSEMBLY
1. Rotate the blower impeller by hand to see if it turns smoothly.

If it does not turn smoothly, clean and inspect the bearing and
turbine rotor.
•n
SM51-002A
2. Check the turbine rotor for axial play (A).

If the axial play is greater than the service limit, replace the
thrust bearing and/or thrust spacer.
\\ H i a
.d-T, Axial Play: 0.06 - 0.09 mm (0.0024 - 0.0035 in)
Ii
Service Limit: 0.11 mm (0.0043 in)
M)f\
A SM5J-002
TURBOCHARGER TU-7
3. Check the turbine rotor for radial play using a special tool.
If the radial play is greater than the service limit, replace the
bearings and/or turbine rotor.
O Special Tool: 09444-1330
Radial Play: 0.10-0.15 mm (0.0039 - 0.0059 in)
SM51-002A
IMPORTANT POINT (S) — DISASSEMBLY
REMOVE THE BLOWER CASING.

NOTE: o Make matching marks on the blower case and bearing
case to aid alignment during reassembly.
o If the blower casing cannot easily be removed by hand,
k.— t_|l/ !o >
tap it carefully all around using a plastic hammer and
carefully remove it.
o Be careful not to damage the blower impeller.
MATCHING MARK
_ SM5 1-017
REMOVE THE TURBINE CASING.

NOTE: ,o Make matching marks on the turbine case and bearing
m case to aid alignment during reassembly.

o Because the bolts on the turbine side are exposed to high
7/ 7 temperature, if they have seized, do no apply an
unreasonable force to remove them because they may
break. Spray a lubricant onto them, then wait for about
15 minutes and loosen them.
O Be careful not to damage the turbine blades.
O If the turbine casing cannot easily be removed by hand,
SM51-057
tap it carefully all round using a plastic hammer and
carefully remove it.
REMOVE THE BLOWER IMPELLER.

1. Remove the blower impeller fitting nut.
H
NOTE: Turn the lock nut clockwise to loosen the nut (left-hand
threads).
o'
2. Remove the blower impeller by hand,
V
!
SM 5 1-058
REMOVE THE TURBINE ROTOR WITH HEATER PROTECTOR.
\\ H
J,
SM51-059
TU-8 TURBOCHARGER
REMOVE THE BEARING

1.
tr
Remove the seal plate.
Pull out the seal plate using the two screws.
A 2. Remove the oil thrower from the seal plate.
(m
y
<s> \
is? O O
-SM51 -060 SM 5 1-061
3. Remove the thrust bearing and thrust spacer.

T Loosen the bolt, then remove the thrust bushing using a
10 dia. copper rod.
NOTE: When removing the thrust bearing and thrust spacer, be
careful not to damage the thrust bearing hole in the bearing
case.
SM 5 1-022 SM 5 1-062
ILL 4. Remove the retainer rings of each bearing.

NOTE: When removing the retainer ring, be careful not to damage
(I •
the front face of the hole in the bearing case.
/
5. Remove the bearings.
- A 'N
o
V
SM51-063; SM51-C64
OIL THROWER TURBINE ROTOR

REMOVE THE SEAL RINGS.
NOTE: When removing the seal ring, be very careful not to damage
/1
the groove of the seal ring.
SM51-024 SM51-025
IMPORTANT POINT (S) -ASSEMBLY
CLEAN ALL PARTS.

8efore cleaning, the disassembled parts should be visually
inspected to check for burning, abrasion, carbon deposits,
gas and oil leakage.
2. Thoroughly clean all the parts with diesel fuel, using a soft
brush, and dry with compressed air.
NOTE: c Never use a caustic cleaning solution, as it may attack
aluminum.
o Never use a wire brush.
TURBOCHARGER TU-9
OIL INLET ASSEMBLE THE JOURNAL BEARINGS.

0 1. Install the first retainer ring in the bearing casing.
NOTE: o Bevelled edge of the retainer ring should be towards the
bearing.
T o Make sure that the retainer ring is securely fitted in the
groove.
TURBINE o Install the retainer ring with the gap facing as shown in
BLOWER
ROTOFIÿ 0||_ jQ|L IMPELLER the drawing.
| INLET IlNLET
\ 2. Install the bearing in the bearing case.
AW
T 1 NOTE: Apply clean engine oil.
3. Install the other retainer ring.
NOTE: The only nearest turbine side of the retainer ring should
O IL OUTLET
be installed according to the figure on the left.
4. Repeat step 1) through 4) to install the second bearing.
OIL INLET
0
VIEW FROM
V
TUR8INE ROTOR
>
SM 5 1-026 A
ASSEMBLE THE THRUST BEARING.

1 2
A
1. Install the thrust spacer, on the turbine shaft.
NOTE: Lubricate thrust spacer surface.
2. Coat the thrust bearing with clean engine oii and install the
thrust bearing.
NOTE: Always use new screws and lock washers.
SM51-027A SM51-028A
OIL INLET INSTALL THE SEAL PLATE.
£ 1. Insert two new seal rings on the oil thrower.

2. Install the oil thrower in the seal plate.
NOTE: The openings of seal rings should be positioned as shown.
m 45°
SM5 1-024 SM51-005A
3. Install the seal plate in the bearing case.

NOTE: o The oil return hole should face the oil outlet side.
Apply silicone R.T.V. sealer to the flanged surface of
the seal plate.
o Take care that the silicone sealer does not protrude from
the flange.
4. Tighten the four screws with lock washers.
NOTE: Always use new screws and washers.
SM5 1-030
TU-10 TURBOCHARGER
BEARING CASS ASSEMBLE THE TURBINE ROTOR.

1. Install a new seal ring in the seal ring groove of the turbine
r2\ shaft.
SEAL RING
2. Position the heat protector on the bearing case.

H«j|
#r \
HEAT PROTECTOR
TURBINE SHAPT SM51-065
3. Coat the journals of the turbine rotor with clean engine oil
SEAL RING GAP
OIL INLET and install the turbine rotor in the bearing case.
NOTE: o The gap in the seal ring of the turbine shaft must face
towards the oil inlet.
o Insert the seal ring concentric with the turbine shaft. If
1
it is inserted with unreasonable force, it may be

\a damaged.
o When inserting the turbine shaft, be very careful not to
damage the journal bearing.
SM51-066
FIT THE BLOWER IMPELLER ON THE TURBINE ROTOR AND

TIGHTEN THE LOCK NUT.
m NOTE: Remember that this nut has left-hand threads.
SM5 1-031
INSTALL THE TURBINE CASE TO THE BEARING CASE, BEING

SURE TO ALIGN THE MATCHING MARKS.
NOTE: Always use new lock plates.
ASSEMBLE THE BLOWER CASE.

1. Install the blower case to the bearing case referring to the
-k matching marks.
NOTE: Coat the flange face of the blower case with silicone R.T.V.
sealant.
SM5 1-032
2. Tighten the six fitting bolts.
ASSEMBLY TEST
1. Rotate the blower impeller by hand to see if it turns smoothly.
Refer to page TU-6.
2. Check the turbine rotor for axial play (A).
Refer to page TU-6.
3. Check the turbine rotor for radial play using a special tool.
Refer to page TU-7.
TURBOCHARGER TU-11

Unit: mm (in)
Turbine Shaft Diameter 10.39 Replace

(0.4090)
ir;m)
©9.V
SM51-033
Turbine Shaft Bend 0.011 Replace
(0.0004)
O J
SMS1-034
Seal Ring Groove Width 1.34 Replace shaft
of Turbine Shaft (0.0527) assembly.
W
SM51-035
(&MrJ
Bearing Case Inside A: Replace
*
Diameter 13.09
(0.515)
B:
15.10
(0.5944) Jn
SM5 1-006
Journal Bearing inside 10.45 ■
Replace F
Diameter (0.4114)
Journal Bearing Outside 14.98 Replace it

(0.5897)
Diameter
SM51-036 e SM51-037
Thrust Spacer Height 4.09 Replace

(0.1610)
SM51-007
Seal Ring Groove Width G1: Replace G1

of Oil Thrower 1.52
(0.0598)
G2:
1.32
(0.0519)
SM51-006A
TU-12 TURBOCHARGER

Unit: mm (in)
Thrust Bearing Thickness 3.98 Replace /

(0.1566)
■ /€VxV:
SMS 1-038
Sealing Bore of Seal Plate H1: Replace HI

)
14.05 I
(0.5531) 3S5
H2: \ \ \ tx
12.45
H?
(0.4901)
SM51-005B
)
(KY)
FUEL INJECTION PUMP IP-1
IP-121 E-01
CHAPTER IP
FUEL INJECTION PUMP
DESCRIPTION IP- 2
TROUBLESHOOTING IP- 3
SPECIAL TOOLS . . . IP- 6
INJECTION PUMP . . IP- 7
TIMER IP-15
FEED PUMP . IP-19
ADJUSTMENT IP-21
■
IP-2 FUEL INJECTION PUMP
DESCRIPTION
---
© 2
3
©
0 3
4
5
o
6
©
8
mV“ 9
)
10
11
FUEL INJECTION PUMP

1. High pressure pipe 5. Control rod 9. Cam shaft
2. Delivery valve 6. Control sleeve 10. Cam
3. Plunger barrel 7. Plunger spring 11. Fuel feed pump
4. Plunger 8. Tappet
TROUBLESHOOTING
Engine does not start Fuel not reaching injection pump
• Fuel lines clogged or damaged Clean or replace fuel lines.
• Fuel filter clogged Clean or replace the filter element.
Air in fuel caused by improper .

• connections Repair connections.
of fuel line between
fuel tank and feed pump
• ofFilter incorporated in inlet side

feed pump clogged
Remove foreign material.
• Faulty feed pump check valve Repair or replace it.
• Feed pump piston spring broken Replace it.
• Feed pump push rod or tappet sticking Repair or replace it.
Fuel reaching injection pump
• Faulty connection of accelerator

wire to pump adjusting lever.
Repair connection.
• Control rack faulty or sticking Repair it.
• Damaged camshaft bearing Repair it.
• Plunger worn or sticking Correct or replace it.
• stop
Faulty connection of engine
wire to pump stop lever.
Repair it.
Nozzle faulty
• nozzle
Fuel leakage caused by loosened
holder.
Inspect and tighten it.
• Low opening pressure of nozzle Adjust it.
• Nozzle pressure spring broken , Replace it.
• Nozzle needle sticking to nozzle body Correct or replace it.
Pump out of timing
• Improperly retarded injection timing Correct injection timing.
• Installation
Incorrect timing caused by improper
of pump.
Check engine timing and correct
it.
• Woodruff
off.
cut
key for pump camshaft Replace it.
• Improper pre-stroke adjustment Correct it to obtain specified

injection timing.
IP4 FUEL INJECTION PUMP .
Symptom Possible cause Rem edy/Pr ev en tion
Excessive smoke- Black smoke
• incorrect
Excessive fuel delivery caused by
adjustment of fuel load
Adjust fuel delivery on test
stand.
stopper screw,
• Excessively
timing.
advanced injection Correct it.
• Large spread in fuel delivery Adjust it.
• Bad nozzle fuel spray characteristics Check and correct them.
White smoke
• timing.
Improperly retarded injection Advance injection timing.
• Water in fuel Check and clean fuel lines.
Low idle speed Improper adjustment of idle button Correct it.

irregular
- Bad fuel spray characteristic of Check and repair them.
nozzles.
- Incorrect injection timing Correct it.
- Incorrect initial tension setting of

idling spring or the spring broken.
Adjust or replace it.
- Control rack not smoothly move Disassemble pump and repair it.
- Large spread in fuel delivery Adjust it.
- Plunger worn Replace it.
- Governor linkage not smoothly Correct it.

move.
- Defective feed pump Disassemble and repair it.
Engine always runs Accelerator cable sticking Check and correct it.
at hig speed
- Governor linkage sticking Disassemble and repair the
governor,
- Control rack sticking Check and correct it.
Engine starts and stops
n Fuel lines clogged
Air in fuel caused by damaged ....

fuel lines or improper connection of
Clean or replace fuel lines.
Repair fuel lines or replace fuel

lines and gaskets.
fuel lines.
Engine has low power Pump out of timing
• resulting
Excessive advanced timing,
in loud knocking.
Check and correct it.
• Excessively retarded timing

resulting in black smoke.
Check and correct it.
• valve.
Defective injection pump overflow Repair or replace it.
• Feed pressure too low Repair the feed pump.
• Inproper accelerator cable adjustment Adjust it.
Nozzle faulty
• Fuel leakage from nozzle holder Check and repair nozzle holder.
• Bad nozzle spray characteristic Repair or replace it.
• holder,
Loosened adjusting screw in nozzle . . .
resulting in low opening pressure.
Adjust it.
• Nozzle pressure spring broken Replace it.
Pump faulty
Fuel leakage from delivery valve Retighten the delivery valve

holder. holder if it is loosened or replace
O-ring if the O-ring is defective.
Defective seat of delivery valve Repair or replace it.

assembly.
Delivery valve spring broken Replace the spring.
Plunger worn Replace it.
Large spread in fuel delivery Adjust it.
Wear of tappet roller Replace the roller.
Camshaft bearing worn or broken Replace it.
Improper adjustment of governor Adjust it.

fuel load stopper screw.
Loud knocking Imprlper injection timing Correct it.
- Bad fuel nozzle spray pattern Check and correct it.

after-dribble.
- High nozzle opening pressure Adjust the opening pressure.
- Incorrect fuel deliveries to Readjust the fuel deliveries.

some nozzles.
SPECIAL TOOL
Prior to starting an injection pump overhaul, it is necessary to have these special tools.
PLUNGER CLAMP TAPPET CLAMP TAPPET ROLLER CLAMP
09512-1360 09512-1120 09512-1130
CAMSHAFT BEARING OUTER

RACE PULLER TAPPET INSERTER CAMSHAFT CLEARANCE GAUGE
09512-1160 (REAR) 09512-1380 09512-1150

09512-1430 (FRONT)
SPRING HOLDER TAPPET GAP INSTRUMENT HOLDING WRENCH
09512-1370 09512-1410 09512-1710
TIMER EXTRACTOR SPRING HOLDER
09512-1230 (SA-TYPE) 09512-1240

09512-1280 (SCZ-TYPE)
INJECTION PUMP
A-TYPE PUMP
[4-CYLINDER]
25
T = 350-400 (25-28) 26
6
1
7ÿ3
8" c5i 24 (sj
10 IS.
H? 28
18
M 29
23 30
22 31
21 27
-iiJi
o
T = 850-1,000 (62-73) 0>"1)
13
17 1?
16
11
12
.» 'i
\®
Q\ 41
\ % 42
43
v9) V/5 44
34
35 i
15 ©
45 36 -
14
46 37 - 33
38 -
T = Tightening torque kg-cm (Ib.ft)

1. Injection pump housing 17. Shim 33. Tappet assembly
2. Lock plate 18. Adjusting ring 34. Shim
3. 0-ring 19. Camshaft 35. Tappet
4. Delivery valve holder 20. Woodruff key 36. Retainer ring
5. Stopper 21. Control rod cover 37. Tappet roller pin
6. Delivery valve spring 22. Bolt 38. Tappet roller
7. Gasket 23. Nut 39. Roller bushing
8. Delivery valve 24. Stop wire bracket 40. Plug
9. Plunger 25. Overflow valve sub-assembly 41. Screw
10. Screw 26. Special washer 42. Control pinion
11. Nut 27. Bolt 43. Control sleeve
12. O-ring 28. Control rod 44. Plunger spring seat, upper
13. O-ring 29. Cover gasket 45. Plunger spring
14. Bearing cover 30. Cover 46. Plunger spring seat, lower
15. Gasket 31. Plain washer
16. Taper roller bearing 32. O-ring
IMPORTANT POINT (S) - DISASSEMBLY
WARNING
O Breaking of the lead seals or crimp caps by anyone other
than HINO or pump manufacture authorized service
stations to make these adjustment will void the warranty.
O If fuel pump or governor difficulties are suspected, consult
only HINO or pump manufacture authorized service
stations, where the problem can be corrected and the injec¬
tion pump lead seals and crimp caps can be reinstalled as
required.
O Measure and record the fuel delivery characteristics of the
pump before disassembling it.
O Keep the parts for each cylinder in separate groups and in
an orderly arrangement. Parts to be replaced and parts to
be used again must be kept separately.
REMOVE THE TIMER ASSEMBLY.

Refer to 'TIMER AND COUPLING".
REMOVE THE GOVERNOR.

Refer to "GOVERNOR".
INSERT THE TAPPET INSERTER IN THE TAPPET HOLE.

r TAPPET Turn the camshaft and insert the tappet inserters in each
INSERTER 0 tappet hole when their tappet is at the highest position.
o0 >- o.
Special Tool: Tappet Inserter (09512-1380)
&U)
SM4-201
MEASURE THE CAMSHAFT END PLAY.

CAMSHAFT END
PLAY GAUGE
§5
£ 1. Mount the camshaft end play gauge on the camshaft drive end
and be sure tighten "B".
r o o o c
Special Tool: Camshaft End Play Gauge (09512-1150)
2. By turning "A", create a clearance of about 1 mm (0.04in)
between "A" and the bearing cover.
8
o 3. Lightly strike the end "B" 3 or 4 times with a plastic hammer.
4. Lightly tighten "A" until it cames into contact with the bear¬
ing cover.
5. Lightly strike the camshaft governor end 3 or 4 times a plastic
ROUND NUT hammer.
6. Lightly turn "A” until it comes into contact with the bearing
cover, then read the clearance.
Assembly Standard: 0.03—0.05 mm 10.0012-0.0019 in)
tk mz
7. If the specification is not met, use appropriate shim plates

BEARING at the drive end of camshaft.
COVER
h
— —- I — — -J~ - ■
— 7'
SHIM
PLATE
(DRIVE END)
REMOVE THE TAPPET ASSEMBLY.

3
1. Push the tappet with the tappet roller clamp and remove the
tappet inspecter,
QBSES 13
Special Tool: Tappet Roller Clamp (0951 2-'1130)
R
SM4-205
2. Remove the tappet through the camshaft bearing hole.

1'
Special Tooi : T appet Clamp (0951 2-11 20)
0ÿ
Are \
,0
TAPPET CLAMP
SM4-206
PLUNGER CLAMP REMOVE THE PLUNGERS, SPRINGS AND CONTROL SLEEVE.

1. Use the plunger clamp hold the spring lower seat and remove
it together with the plunger.
3b Special Tool: Plunger Clamp (09512-1360)
LOWER SEAT SPRING

PLUNGER GROOVE
-4
A,
SM4-207
REMOVE THE TAPER BEARING FROM THE CAMSHAFT.

BEARING
REMOVER 1. Remove the taper bearing from the drive end of the camshaft.
Special Tool: Bearing Remover (09510-1160)
'(
'
SM4-124
2. Use the guide to remove the bearing at the governor side.
8EARING
GUIDE REMOVER
1
\J
GUIDE
SM4-125
3. Use the outer race puller, to tap out the outer race in the
OUTER RACE bearing cover.
PULLER
Special Tool: Outer Race Puller (09512-1430)
BEARING COVER
SM4-126
IMPORTANT POINT (S) - ASSEMBLY
WARNING
O Wash all parts with clean diesel fuel before installing them,
and any defective or damaged parts must be replaced.
O Do not allow dust or other foreign matter to enter the
pump during assembly.
O Apply grease to O-rings and oil seals before installing them.
O Assemble the parts in correct order and to correct tighten¬
ing torques, assembled dimensions etc.
O Assembly takes place in the reverse order of disassembly.
INSTALL THE PLUNGER BARRELS.

1. Before install the plunger barrels should be inspect the plunger
barrels and plungers for wear, scratches, or discoloration.
SM4-213
2. Tilt the plunger to about 60°. Pull the plunger out approxi¬
mately 10 to 15 mm (0.39—0.59 in) and release it to see if it
slides down smoothly from its own weight.
:
SM4-257
3. Match the plunger notch with the injection pump housing

knock pin.
)
O
— ® © 01)
e * no
SM4-214
INSTALL THE DELIVERY VALVES, SPRINGS AND HOLDERS.

/ 1. Before install the delivery valves, inspect the delivery valves
for scratches on the valve seat or the piston sections.
\)
!i
SM4-258
■
1
2. Install the gasket, spring, shim and stopper on the delivery

TC7 valve.
l
T\
A
3. Provisionally tighten the delivery valve holder with a new
pi O-ring by hand.
a
a NOTE: Tighten the delivery valve holder after installing the plung-
cl ® 0
3 er.
EES
’O SM4-215
INSTALL THE CONTROL SLEEVES ON THE BARRELS.
f NOTE: Make sure that the control sleeve swings evenly right and
left when the control rack is moved to the right and left.
INSTALL THE PLUNGER AND TAPPET.
ri
2E; 1. Assembly the plunger and spring lower seat, inserting the
driving face marked with a number and the lower seat notch
n
$ part upward (cover plate side).
'C'
Special Tool: Plunger Clamp (09512-1360)
V
3)
SM4-216
2. Install the tappet to the pump housing with the adjusting

shim.
Special Tool: Tappet Roller Clamp (09512-1130)
Tappet Clamp (09512-1 120)
$
A
o,n
SM4-217
3. Using the tappet roller clamp to press in the tappet and hold
it in with the tappet inserter.
Special Tool: Tappet Inserter (09512-1380)
TAPPET INSERTER
o o
SHIM
YJ
SM4-218
NOTE: O Check that the driving face of the plunger fits to the
groove of the control sleeve before inserting the tappet.
CONTROL SLEEVE
/ O When inserting the tappet, check that the control rack
; slides smoothly and without catching.
E!M
!
/
pp
DRIVING FACE
TIGHTEN THE DELIVERY VALVE HOLDER.

XTT When one delivery valve holder is tightened, move the control
A rack to the right and left and inspect the tightness of the rack.
[jJ Tightening Torque: 400—450 kg-cm (29—32 Ib.ft)
cl
'O SM4-219
Plunger springs tension. 24.4 kg (49.4 lb) 21.0 kg Replace, spring.

at 41.4 mm (1.63 in) (46.3 lb)
b
Delivery valve springs tension. 3.1 kg (6.8 lb) 2.7 kg Replace, spring.
at17.0 mm (0.67 in) (6.01b)
Tappet wear. 0.3 mm Replace, tappet

(0.012 in) assembly.
Camshaft run-out. 0.15 mm Replace, cam¬

(0.006 in) shaft.
SCZ-TYPE TIMER
7
6
5
4
3
n
2 9 Q)
\l\
O y
&
a
b' 12
11
o, 10
8 9
1. Snap ring 7. Timer case

2. Shim 8. Timer driving flange
3. Drive gear 9. Timer spring
4. Adjusting shim 10. Spring seat
5. Spring seat 11. Timer weight
6. O-ring 12. Timer hub
IMPORTANT POINT (S) - DISMOUNTING

REMOVE THE TIMER ASSEMBLY FROM INJECTION PUMP.
0
’o Special Tool: Timer Extractor (09512-1230)
I
V
i
1 SM4-287
IMPORTANT POINT <S) - DISASSEMBLY

o REMOVE THE DRIVE GEAR FROM TIMER.
NOTE: Place matchmarks on the timer flange and timer hub.
„Q&
I
/1
MATCHMARKS
O
■
1. Remove the snap ring.

2. Pull up the timer flange.
NOTE: Be careful that the springs and shims do not fly out.
? 7
y f
LL

SPRING GUIDE SET THE TIMER SPRINGS.
Special Tool: Spring Guide (09512-1240)
o
ett*
INSTALL THE TIMER FLANGE WITH DRIVE GEAR.

1. Align the marks on the drive gear and timer hub.
2. Hold the drive gear so that the springs will not fall out.
Vi
MARKS
IMPORTANT POINT (S) - MOUNTING

INSTALL THE TIMER ASSEMBLY TO INJECTION PUMP.
\\ ie
v i
&
SM4-414
SHIM
ADJUSTMENT OF THE TIMER.
INSPECT THE TIMER ADVANCE.
9
© 0 1. Set a stroboscope on a pump tester.
9 2. Check the timer advance.
& Advance Angle: Refer to "CALIBRATION chart".
©
If angle is not within specification, adjust with proper shim,
0 TIMER TIMER
WEIGHT HUB
TIMER DRIVING
FLANGE
FP/KS-TYPE
M14,T = 130-150 (9-10)
Nylon gasket
M14, T ~ 200—250 (14-18)
Comet packing. Copper gasket
2
T = 400—450 (29-32)
8
2
3
mit
4
T - 500-550 (36-39)
__
5
6 5
sgra 10 9
-6
7 r 1
11 \
T = 800-900 (58-65) 12
1 V
\
\l
0)
15
© A2
-14
)
I
16 L. j
I
17
18 yj
19
B 20
T = 50-80 13.6—5.7)
21
T = Tightening torque: kg-em lib.ft)
1. Feed pump serial No. 12. Tappet

2. Joint bolt 13. Pin
3. Soft washer 14. Sliding block
4. Connector 15. Feed pump housing, push rod, & oil seal
5. O-ring 16. Piston
6. Check valve spring 17. Spring
7. Check valve 18. Gasket
8. Priming pump 19. Plug
9. Retainer ring 20. Soft washer
10. Tappet assembly 21. Filter
11. Roller
1
Valve Seat. Replace, Visual check

Wear, Damage if necessary.
ii 'rm SM4-517
Piston', Cylinder and Oil Seal. Replace, Visual check

Wear, Damage if necessary.
(
05 SM4-518
Filter, Clean Visual check
Clogged
SM4-516
ADJUSTMENT
PREPARATION
'1_f _ 1. Mount the injection pump correctly on the pump tester.

a a Remove the timer case in case of the SCZ type timer.
10, ;i Ml I
3 /’-toft
>o,
4a I SM4-836
2. Attach a rack measuring device to the control rack and set to
"0".
u 3. Install calibration nozzles and lines of the following specifica¬
tions.
a) Nozzle
o c Nozzletype: 1 2SD1 2 (BOSCH Type)
Opening pressure: 175 kg/cm (2,489 Ib.ft)
<
(I b) Line
■7
Outside diameter: 6.0 mm (0.24 in)
RACK MEASURING DEVICE Inner diameter: 2.0 mm (0.08 in)
Length: 600 mm (23.6 in)
4. Calibration oil
a) Calibration oil: SAE J967C
b) —
Oil temperature: 40— 45°C ( 1 04 1 13° F)
5. Install the cover on the feed pump mounting surface and fill
vjLsi u O
U
the pump camshaft chamber with engine oil.
Ogr,
'r
SM 4-224 SM4-225
ADJUSTING THE INJECTION TIMING
iVj its? 1, Preparation of the pre-stroke.
M
a) Remove the plate cover.
■Ssi s 4?.
b) Install a pre-stroke measuring instrument.
to
m Bring the tappet of the first cylinder to its bottom dead
m
_!
center, and set the pointer tip on the tappet.
"1
SM4-226
1
2. Measure the pre-stroke (Nor1 plunger)

OVERFLOW
or PIPE a) Set the control rack at full-load position.
HIGH PRESSURE b) Loosen the overflow screw of each nozzle holder.
c) Operate the high-pressure pump of the pump tester and let
fuel run out of the overflow line.
i
y. i loc i
Xj/C IK*
UUUIU
d) Move the angle dial to set the first cylinder of the pump to
bottom dead center and adjust the pre-stroke gauge to zero.
NOTE: Bottom dead center is the point at which the pointer of
r\ ft the dial gauge does not move even when the angle dial is
GUIDE w rotated while fuel is flowing from the overflow line.
GROOVE c
k ii Oi
i
i
SM4-227
OVERFLOW PIPE e) Turn the camshaft clockwise with the angle dial and read
the dial gauge when the fuel stops running out of the over¬
flow line. This reading is the pre-stroke value of the pump.
i rr Pre-stroke: Refer to "CALIBRATION chart"
i.
FUEL — s l CN
PLUNGER PRE-STROKE
BARREL
SPRING
f) If the pre-stroke value is not within specification, adjust by
HOLDER changing the tappet adjusting shim.
Special Tool: Spring Holder (09512-1370)
TWEEZERS
SHIMS V „
v) rs#®
Rs
W
ADJUST THE INJECTION INTERVAL.

1. Using the No.1 cylinder injection starting point as a base,
inspect and adjust the injection interval in the order of injec¬
V } tion.
/
m 0 o
4-cylinder
89°45'— 90°15’
Mmi Injection Interval:
Injection Order: 1-3-4-2
%
SM4-S33
2. If the injection intervals are not within specification, adjust

SPRING
HOLDER by using the same procedure as for pre-stroke adjustment.
PPM g /
-rwEEZfftS
SHIMS -i-
(W) m
si
3. Set the No.1 cylinder at the injection starting point, and check
\\
that the marks on the timer and the marks on the pump body
are aligned.
If the timing marks are not aligned, make a new mark on the
timer and erase the old mark.
y
POINTER
fillll hi
TIMING MARK Vj/f'"-
lO/
SM4-834
CHECK THE TAPPET TOP CLEARANCE.

1. Set the No.1 cylinder at the injection starting point, then
A r\ r move the tappet with the handle.
LJ.
Tappet Top Clearance: More than 0.2 mm (0.0079 in}
-7/ Special Tool: Tappet Handle (09512-1410)
i 2. Follow the above procedure to check the other cylinders

i (No. 2 through No.6).
3. If the tappet clearance is less than 0.2 mm (0.0079 in), re¬

TAPPET HANDLE check the pre-stroke.
SM4-259
MEASURING AND ADJUSTING THE INJECTION VOLUME.

Measure the injection volume for each control rack position
and pump revolution.
O
To
UJ
Injeciton Volume: Refer to "CALIBRATION chart."
1
§< O
_i a:
o<
o
t
To adjust the injection volume, loosen the pinion screw and
insert the adjusting pin into the hole in the control sleeve,
PINION then move the sleeve slightly.
SCREW
SLEEVE
Xj n
/O'
n
(KJM
II
MEMO .
v. •
GOVERNOR GV-1
GV-Q6E-03
CHAPTER GV
INJECTION PUMP GOVERNOR
(MODEL: RSV)
DESCRIPTION GV-2
GOVERNOR GV-3
SPECIAL TOOL GV-4

GV-2 GOVERNOR
DESCRIPTION
[MODEL: RSV]
1
12
2. ,13
3.
4.
•14
5
to'
6. ■15
'll
0
7
to n %
oj
5
\ -16
IF V.
<?
0
v2i/
8
g 11 19 18 17
10
[Representative model]
1. Governor spring 11. Sleeve

2. Control rod 12. Link
3. Knuckle 13. Start spring
4. Swivel lever 14. Guide lever
5. Maximum speed stopper bolt 15. Tension lever
6. Camshaft 16. Idle sub spring
7. Control lever 17. Full load stopper bolt
8. Stop lever 18. Idle spring
9. Supporting lever 19. Floating lever
10. Flyweight
GOVERNOR GV-3
GOVERNOR
2 1 9
.
£
O' [C ; 18
8
3 12
m
U.72
v 10
%
lv\ (O;
19
r 1
[c,
?- B
7
(0
r
I 17
19
16 20 21
0 A
4 &
5
6
r® ft 13 14
21 >
B0
15 7/ ji. i
J •v® *
cÿa
11 Sjl 23 IS
27 28
25 26 J
24
U 22 36
35
;
30 37
29
1. Governor housing 14. Idle spring 27. O-ring

2. Stopper bolt 15. Lock nut 28. Snap ring
3. Woodruff key 16. Governor cover 29. Stop lever
4. Flyweight 17. Swivel lever 30. Cap
5. Sleeve 18. Governor spring 31. Idle stopper bolt
6. Bearing 19. Gasket 32. Idle sub spring
7. Shim 20. Pin 33. Nut
8. Guide lever assy 21. Plug 34. Cap nut
9. Link 22. Control lever 35. Closing cover
10. Start spring 23. Woodruff key 36. O-ring
11. Supporting lever 24. Coder 37. Cap nut
12. Tension lever 25. Oil seal
13. Full load stopper 26. Bush
I
GV4 GOVERNOR
SPECIAL TOOL
Prior to starting an injection pump governor overhaul, it is necessary to have these special tools.
FLYWEIGHT EXTRACTOR ROUND NUT WRENCH
Yi
09511-1900 09511-1500

WARNING
O Breaking of the lead seals or crimp caps by anyother other
tion pump lead seals and crimp caps can be rainstalled as
required.
DISASSEMBLY THE GOVERNOR COVER FROM PUMP BODY.

1. Disconnect the shackle from the control rack.
NOTE: When remove the governor cover fitting bolt, hold the
governor cover.
L-J, %
Nil-
i1
SM 4-382 SM 4-304
2. Disconnect the start spring.
'V
SM4-383
GOVERNOR GV-5
REMOVE THE FLYWEIGHT ROUND NUT.

NOTE: Use the holding spanner to keep the camshaft from rotat-
(h ing.
e!
Special Tools: Round Nut Wrench (09511-1500)
II U
SM4-384
REMOVE THE FLYWEIGHT, USING THE FLYWEIGHT EX¬

c TRACTOR.
Special Tool: Flyweight Extractor (09511-1900)
e
a
/
&
©
SM 4-385
IMPORTANT POINT (S) - Assebmly

WARNING
O Wash all parts with clean diesel fuel before installing them,
O Apply grease to O-rings and oil seals before installing them.
ing torque, assembled dimensions etc.
INSTALL THE ADJUSTING LEVER

1. Install the shaft of the adjusting lever so that wide side of the
shaft head surface is toward the pump body.
aj NOTE: Installing in reverse may cause the floating lever to contact
the speed control spring, resulting in operational malfunc¬
tion.
TOWARD PUMP HOUSING
CHECK THE GOVERNOR LINKAGE FOR SMOOTH OPERA¬

TION.
t Hook under the guide lever, and pull upwards, using a spring
balance.
Starting force: 140— 180 g (4.9— 6.3 oz)
/
SM4-302
GV-6 GOVERNOR
INSTALL THE FLYWEIGHT TO PUMP CAMSHAFT.

Using a special tools, tighten the round nut.
ft '
i]
II (Cf
yp
it
SM4-384
INSTALL THE GOVERNOR HOUSING TO PUMP BODY,

1. Connect the start spring.
2. Connect the shackle to control rack.
0
UP
i
5$
vi
6%
SM4-382 SM4-303
ADJUSTMENT OF THE GOVERNOR

[MODEL; RSV]
1. PREPARATION
1. Connect the rack measuring device to the control rack and
set to "0".
2. Connect the fuel line.
3. Refill the camshaft chamber with engine oil.
4. Install the angle gauge on the adjusting lever.
2. STEPS IN GOVERNOR ADJUSTMENT.

MAXIMUM
SPEED STOPPER Perform governor testing and adjustment in the following
BOLT sequence (For values of N. and R Refer to "CALIBRATION
SWIVEL LEVER chart"):
ADJUST SCREW
1. Adjustment of maximum speed control.
r 2. Adjustment of speed droop.
CONTROL Adjustment of idling speed control.
LEVER 3.
T -12'
hi
«1
(o I&,
(5
fo)
1
hi a.
IDLING
SCREW
FULL LOAD
STOP LEVER STOPPER BOLT
IORINGSUB \
SETTING SCREW
SM4-386
GOVERNOR GV-7
ij
\C:
1. Adjustment of maximum speed control f
E NOTE: The control lever should be full load position.
e
a) Adjust the full load stopper bolt.
2 At a pump speed of Na rpm, adjust the rack position
t Ra to Ra
mm with the full load stopper bolt.
o
Q_
< i
CC o Na FULL LOAD
PUMP SPEED (rpm) STOPPER BOLT
SM4-386
b) Adjust the maximum speed stopper bolt.
£ At a pump speed of Nb rpm, adjust the rack position to Rb

£
z Rb
mm with maximum speed stopper bolt. \
2 NOTE: The control rack should start to be pulled.
o
o.
<
0
Nb
PUMP SPEED (rpm)
2. Adjust of speed droop.

At a pump speed of Nc rpm, adjust rack position to Rc mm
*
z Rb
with swivel lever adjusting screw.
2 P, ra>
R;
W Rc
CL.
/
*
<
l
SWIVEL LEVER
10 ADJUST SCREW
NNC
PUMP SPEED (rpml
SM4-387
3. Adjusting of idling speed control

a) At a pump speed of Na rpm, adjust the rack position to Rd
mm with idling screw.
NOTE: The control lever angle, refer to CALI BUR ATION chart.
b) At a pump speed of Ne rpm, adjust the rack position to Re
IDLING SUB
SETTING SCREW mm with idling sub setting screw.
IDLING SCREW SM4-386
GOVERNOR EXTERNAL LEAD SEALS AND CRIMP CAPS.
s rrT7n.
fS)
NOTE: All adjusting devices on the fuel injection pump governor,
are wired and lead sealed as a protection for the customer.
-{o
M o m
This is to prevent unauthorized readjustment which may
cause engine malfunction and/or engine failure. Periodical¬
ly check to insure that these seals are not broken as this
will void the warranty.
I S'
SM 4-368
(K.P.)
’ MEMO '
i
:
■
! ■
GOVERNOR GV-1
GV-23E01
CHAPTER GV
INJECTION PUMP GOVERNOR
(MODEL: RSV with BOOST COMPENSATOR)
GOVERNOR GV-2
SPECIAL TOOL GV-3
BOOST COMPENSATOR GV-7

GV-2 GOVERNOR
GOVERNOR
38
44
45
n
36 §53
3©"! rm& 18
43
41 42
40 17 free
39
37 38
35 36 ,©
C><ÿ3 -*l 2
5) 10
19
<J&4$
11
'vJ
gip rr 34 i
Oj
I o_
16
OlJ
20 'BJ
'0 ? «|cL I 1
.of
7
5
6
0ÿ
8
.-A 12
32
9
JJ 14 13
23
WKSSC
27 26
25T%kj JO-21
\ 28
15
18 ‘ "24
<sf 33 ¥✓
34
1. Governor housing 16. Swivel lever 31. Cap nut

2. Stopper bolt 17. Governor spring 32. Closing cover
3. Woodruff key 18. Gasket 33. O-ring
4. Flyweight 19. Pin 34. Cap nut
5. Sleeve 20. Plug 35. Cap nut
6. Bearing 21. Control lever 36. Lock nut
7. Shim 22. Woodruff key 37. Adjust screw
8. Guide lever assy 23. Coller 38. Cover fixing bolt
9. Link 24. Oil seal 39. Cover
10. Start spring 25. Bush 40. Diaphragm
11. Tension lever 26. 0-ring 41. Push rod
12. Full load stopper 27. Snap ring 42. Spring
13. Idle spring 28. Idle stopper bolt 43. Adjusting shim
14. Lock nut 29. Idle sub spring 44. Gasket
15. Governor cover 30. Nut 45. Union bolt
GOVERNOR GV-3
SPECIAL TOOL
Prior to starting an injection pump governor overhaul, it is necessary to have these special tools.
FLYWEIGHT EXTRACTOR ROUND NUT WRENCH
09511-1900 09511-1500

WARNING
O Breaking of the lead seals or crimp caps by anyother other
tion pump lead seals and crimp caps can be rainstalled as
required.
DISASSEMBLY THE GOVERNOR COVER FROM PUMP BODY.

A
1. Disconnect the shackle from the control rack.
NOTE: When remove the governor cover fitting bolt, hold the
governor cover.
%
rj
/
s!
i
' N
SM4-382 SM 4-304
2. Disconnect the start spring.
TO 0
13'
■:
SM4-383
GV-4 GOVERNOR
REMOVE THE FLYWEIGHT ROUND NUT.

NOTE: Use the holding spanner to keep the camshaft from rotat-
(ft TC
ing.
a
-w
m
SM4-384
REMOVE THE FLYWEIGHT, USING THE FLYWEIGHT EX¬

c £jv TRACTOR.
Special Tool: Flyweight Extractor (09511-19001
f
/
w
.9
SM4-385
IMPORTANT POINT (S) - Assebmly

WARNING
O Wash all parts with dean diesel fuel before installing them,
O Apply grease to O-rirgs and oil seals before installing them,
ing torque, assembled dimensions etc.
INSTALL THE ADJUSTING LEVER

1. Install the shaft of the adjusting lever so that wide side of the
O
shaft head surface is toward the pump body.
N
s''
O'
O' u) NOTE: Installing in reverse may cause the floating lever to contact
the speed control spring, resulting in operational malfunc¬
tion.
TOWARD PUMP HOUSING
CHECK THE GOVERNOR LINKAGE FOR SMOOTH OPERA¬

r TION.
-i
t4
A Hook under the guide lever, and pull upwards, using a spring
:r balance.
Starting force: 140— 180 g (4.9— 6.3 oz)
•if
u
7 SM4-302
GOVERNOR GV-5
INSTALL THE FLYWEIGHT TO PUMP CAMSHAFT.

Using a special tools, tighten the round nut.
(n 4
rt
SM4-384
INSTALL THE GOVERNOR HOUSING TO PUMP BODY.

1. Connect the start spring.
2. Connect the shackle to control rack.
I)
\\ V SM 4-382 SM4-303
ADJUSTMENT OF THE GOVERNOR

[MODEL; RSV]
1. PREPARATION
1. Connect the rack measuring device to the control rack and
set to "0".
2. Connect the fuel line.
3. Refill the camshaft chamber with engine oil.
4. Install the angle gauge on the adjusting lever.
2. STEPS IN GOVERNOR ADJUSTMENT.

MAXIMUM
SPEED STOPPER Perform governor testing and adjustment in the following
BOLT sequence (For values of N. and R Refer to "CALIBRATION
SWIVEL LEVER chart"):
ADJUST SCREW
1. Adjustment of maximum speed control.
fl 2. Adjustment of speed droop.
CONTROL /
Adjustment of idling speed control.
3.
LEVER
n:
Hi 7-ÿ
3 r 5»
1
fe
3
:
m 4
SI
m IDLING
i
SCREW
\
\
FULL LOAD
STOP LEVER STOPPER BOLT
IDRING SUB
SETTING SCREW
SM4-386
GV-6 GOVERNOR
1. Adjustment of maximum speed control

i % NOTE: The control lever should be full load position.
£ l
z a) Adjust the full load stopper bolt.
o At a pump speed of Na rpm, adjust the rack position to Ra
IsS B
T
•Z Ra
oo mm with the full load stopper bolt.
o
Q.
s; HJ
o I
<
tr 0
Na FULL LOAD
PUMP SPEED (rpm) STOPPER BOLT
SM 4-386
b) Adjust the maximum speed stopper bolt.
S At a pump speed of Nb rpm, adjust the rack position to Rb

mm with maximum speed stopper bolt.
z Rb
2 NOTE: The control rack should start to be pulled.
O
0.
Y
<
0
Nb
PUMP SPEED I rpm)
2. Adjust of speed droop.

c At a pump speed of Nc rpm, adjust rack position to Rc mm
i with swivel lever adjusting screw.
z Rb
2 Sdr fo
Rc
O
Si
/
o
<r SWIVEL LEVER
a0 ADJUST SCREW
Nb Nc
PUMP SPEED (rpm)
SM4-387
3. Adjusting of idling speed control

a) At a pump speed of Na rpm, adjust the rack position to Rd
mm with idling screw.
Pfo NOTE: The control lever angle, refer to CALIBURATION chart.
(S X4
■y
p. ' i\] W IDLING SUB
b) At a pump speed of Ne rpm, adjust the rack position to Re
It SETTING SCREW mm with idling sub setting screw.
I
Btr (DUNG SCREW SM4-386

GOVERNOR GV-7
BOOST COMPENSATOR
4
10
12 11
I
m)
9
8
•»
6
5
4
3
2
1. Cap nut 7. Push rod

2. Lock nut 8. Spring
3. Adjust screw 9. Adjusting shim
4. Cover fixing bolt 10. Gasket
5. Cover 11. Lock nut
6. Diaphragm 12. Union bolt
[i ADJUSTMENT OF BOOST COMPENSATOR

TEMPORARY FIXING OF ADJUST SCREW FOR BOOST COM¬
PENSATOR STROKE.
\
•Mfi.
1. Remove the cap nut (1) and loose the lock nut (2).
r
ft 2. Fully tighten the adjusting screw (3) and lock the lock nut (2)
temporarily.
ADJUSTMENT OF MAXIMUM SPEED CONTROL.
1. Adjustment of full load position.
2. Adjustment of maximum speed control point.
il
ADJUSTMENT OF SPEED CHANGE RATE.
ADJUSTMENT OF ANGLEICH.
GV-8 GOVERNOR
ADJUSTMENT OF BOOST COMPENSATOR STROKE.

!
1. Connect the air hose to union bolt (12).

bJ 2. Lock the control lever at the full load position.
m
Mm'S .. U-J,
fI 1
© Vl
•)
m
In
3. Keep the pump revolution with in "Na" rpm, then adjust
I
the control rack position "Rb" to "Ra" with adjust screw (3)
and lock it with lock nut (2).
QJr
NOTE: No need to pressurization with this adjustment.
tji1
Wmjjrt
\
i
2
t
V)
Rb
Ra ::;:rxz
O
O-
2
o aii
<
tr
o
x y
I-
2
O
O 0 Na
PUMP SPEED (rpm)
ADJUSTMENT OF BOOST COMPENSATOR SPRING (8).

z
o 1. Keep the pump revolution with in "Na" rpm then set the
t
(A control lever to full load position.
O
2. Raise the boost pressure gradually and when reaches the
*<
o "Pi" confirm of the control rack is start to move from "Ra"
rr Ra position to direction of "fuel delivery increase".
I
o
c
2 l
o 0 p,
o
BOOST PRESSURE (mmHg)
i j 3. In case of nonstandardized, replace with adjusting shim |9)

as follow.
*?> i) Remove the cover (5) with loosening three bolts of installing
r the cover (4).
V
\
Vc£ Vi J
GOVERNOR GV-9
i 2) Using a screw driver for hold the push rod (7) to not turn it
- when removing the nut (11).
& \
i
i
Y,
mlfT
3) Remove the gasket (10), diaphragm (6), and spring (8).
ft, :
71w
t
(
0 )j
V f
asÿ\
4) Replace the adjusting shim (9).
ft i
.M
z A: Replace the adjusting shim (9) with thick one.

o B : Replace the adjusting shim (9) with thin one.
Q-
A / /
< ¥
/
8
X /
_i Ra
O
QC
Z
0 p.
o
BOOST PRESSURE ImmHgl
z 4. Raise the boost pressure to "P2", confirm the control rack

2 Rd position is "Rb". In case of nonstandardized, replace the
'
g .
spring (8) with new one.
G_ I
y NOTE: In case of change the boost compensator stroke, when
< remove the cover for this adjustment, reconfirm the boost
a: compensator stroke.
_i Ra
O I
X I
I
z I
8 o Pi P2
BOOST PRESSURE ImmHg)
GV-10 GOVERNOR
GOVERNOR EXTERNAL LEAD SEALS AND CRIMP CAPS.

A NOTE: All adjusting devices on the fuel injection pump governor,
(c) O are wired and lead sealed as a protection for the customer.
O) This is to prevent unauthorized readjustment which may
& cause engine malfunction and/or engine failure. Periodical¬
ly check to insure that these seals are not broken as this
will void the warranty.
:oi !BI
P=>
r
( K.P.)
GENERATOR GE 1
G E-92E-G1
CHAPTER
GENERATOR
(12V, 50A)
DATA AND SPECIFICATIONS GE-2
DESCRIPTION GE-2
TROUBLESHOOTING GE-3
GENERATOR GE-4
GE-2 GENERATOR
:
MODEL 27040-1300
GENERATOR
Type Alternator
Rated voltage 12V
Rated output 50A
Operating output and speed 13.5V, 50A at 4,000 rpm (at cold)
Rotating direction Clockwise (Seen from pulley side)
REGULATOR
Type I.C. Regulator
;
DESCRIPTION
2 1 3 4 5 6
rui
O
\ uiu
p-
[ {o E3 \: n
0
I L Oljg 1
r
2
GENERATOR
1. Rotor assembly 4. I.C. Regulator assembly
2. Ball bearing 5. Brush holder assembly
3. Stator assembly 6. Slip ring
iii
GENERATOR GE-3
OP
1
I OB
r:- -T_ s 5
H — WV
iL JL i k i k
OIG
2
** ■6 —
OL
L s
4
3 Tfrr
tl
SM21-225
1. Condenser 4. I.C. regulator
2. Stator coil 5. Diode
3. Field coil
TROUBLESHOOTING
Charging warning lamp does- Fuse blown Determine cause and replace
not light with starter fuse
switch ON and engine off
-— Lamp burned out .... Replace lamp
— Wiring connection hose Tighten loose connections
— Charge lamp relay faulty Check relay

— IC regulator faulty .. . Replace IC regulator
Charge warning lamp does- Drive belt loose or worn Adjust or replace drive belt
not go out with engine
running
— Battery cable loose, corroded or worn Repair or replace cables
(Battery requires frequent — Fuse blown Determine cause and replace
recharging) fuse
— Fusible link blown Replace fusible link
— Charge lamp relay, IC regulator or

generator faulty
Check charging system
— Wiring faulty Repair wiring

!'! GE4 GENERATOR
GENERATOR
18248
!— NO. 22
4 T = 30-50
8 (2.2— 3.6)
T = 800-1,000 ©
(58-72) 3
2 CT
4
'SsH5
26
1 20
24
19 23
18 IS 22
!
21
:
io\
17
[m L T = 70-100(5.1-7.2)
16
15
14 T = 70-90 (5.1-6.5)
13
©-
12 1
10
I 11
j! u T = Tightening torque: kgcm (lb-ft)

(i
:i
1. Pulley 10. Rear bearing cover 19. Ball bearing
>; I
2. Fan 11. Stator assembly 20. Condenser
21. Brush
f
I
3.
4.
5.
Drive and frame
Collar
Felt washer
12. Rotor assembly
13. Rectifier
14. Insulator
22. Spring
23. Brush holder
6. Felt cover 15. Rear end frame 24. I.C. Regulator assembly
7. Ball bearing 16. Bush 25. Cover
8. Cover 17. Through bolt 26. Lead wire
■i! 9. Retainer ring 18. Cover
i
:
i
-
■i
.
;;
■
i
'
GENERATOR GE-5
IMPORTANT POINT(S) - DISASSEMBLY

REMOVE THE REAR END COVER.
Remove the rear end cover with bearings.
£3ÿ •o
SMGE-141 [
REMOVE THE t.C. REGULATOR AND BRUSH HOLDER.

1. Remove the bolts and disconnect the wires.
2. Remove the I.C. regulator and brush holder assembly.
3. Remove the through bolts and separate the front cover from
the stator.
m
t II
£
SMGE-141
REMOVE THE ROTOR.

M Using a press, remove the rotor and collar.
SMGE-118A
REMOVE THE FRONT BALL BEARING.

\ 1.
2.
Remove the retainer plate.
Using a press, remove the front ball bearing.
3. Remove the plate and felt.
Vÿr
\i
\
! SMGE-11 9
REMOVE THE STATOR AND RECTIFIER.

1. Remove the nuts, insulator and stator terminal with the
rectifier.
2. Unsolder the stator lead from the rectifier.
NOTE: Hold the rectifier terminal with long nose pliers.
(
GE-G GENERATOR
BAD IMPORTANT POINT (S) - TESTING
m
GOOO
1- "'-K RECTIFIER.
Test the each positive side rectifier condition.
s 0 s> © ft 0
Connect the circuit tester © lead to the rectifier holder and
the (~) lead to the rectifier terminal.
2/Q CMS,
'<a,
SM21-Q13AI
BAD
(+) lead to the rectifier terminal and (~) lead to the rectifier
GOOD
holder.
_-4
© ft Q © ft G
& &
.O'
.o' (m,
SM21 -013B
GOOD BAD Test the each negative rectifier condition.

Connect the Circuit tester (+) lead to the rectifier terminal
—ft and the Q lead to the rectifier holder.

ft
© Q
■&
& SL & »
SM21-012A
GOOD BAD (+) lead to the rectifier holder and Q lead to the rectifier
terminal.
—
® fl o >iie
,a
Its
SM21- , 2B
;;
■:
!: i
I
GENERATOR GE-7
IMPORTANT POINT(S) - ASSEMBLY

INSTALL THE STATOR AND RECTIFIER.
3
1. Install the stator lead to the rectifier.
NOTE: Hold the rectifier terminal with long nose pliers.
■N
Q/S
[T 2. Install the nuts, terminal insulator and stator with rectifier.
INSTALL THE FRONT BALL BEARING.

1. Install the felt and felt cover.
2. Using a press, install the front ball bearing.
J 3. Install the retainer plate.

NOTE: Apply the bearing grease to bearing and oil seal lip.
r-
->}
it
SMGE-124
INSTALL THE ROTOR.

Using a press, install the rotor,
IVI
■=TJ
\
SMGE-125
INSTALL THE I.C. REGULATOR AND BRUSH HOLDER.

1. Connect the front cover to the stator and tighten the through
bolts.
2. Install the I.C. regulator and brush holder assembly.
3. Install the bolts and connect the wires.
9
■L
SMGE-141
INSTALL THE REAR COVER.

Install the rear cover with bearings.
</
SMGE-141
GE-8 GENERATOR
PERFORMANCE TEST
NOTE: O Note the battery polarity carefully so as not to make
reverse connections.
If the connections are reversed, the diodes will short the
circuit and allow large current to flow through and
damage the diodes and 1C regulator as well as turn up
the wiring harness.
O Use care not to make wrong connections of terminals.
O When charging the battery with a quick charge.
Disconnect the battery terminals.
O Do not perform tests with high voltage insulation
resistance tester.
O When in operation, never disconnect the battery.
GENERATOR PERFORMANCE TEST.

1. Turn on switch SW, and off SW2 to increase the rotation of
the alternator slowly.
_
L
J) _ AMMETER
SW1
-O D-
OTTO V) >2 Vi
VARIABLE
MOTOR
-r
"[VOLT¬
TT
METER
H
SMGE-072A
2. When voltage reaches 13.5V, turn on switch SW2 regulate load

resistance, increase the rotation of the rotor keeping voltage
L at 13.5V.
.AMMETER
sfeKlG SW1
-o-o-
MAX Generator Speed: Less than 4,000 rpm at 13.5V, 50A
a
o
D
B
I CN
5
co
® i2vi
VARIABLE
MOTOR
VOLT¬
METER
a
SMGE-072A
VOLTAGE REGULATION TEST.

Turn on switch SWi and off SW2 to increase the rotation of
L
rotor to rpm.
AMMETER SW1
(+) Standard Voltage: 14.2— 14.8V
© oN,
o LB
I
a D ®VOLT¬ i2vi
■ir 9 co
VARIABLE
MOTOR
—
METER
I
SMGE-072A
GENERATOR GE-9

Unit: mm (in)
Brush length 20.0 (0.787) 5.5 Replace

(0.217)
SMGE-127
Function of the brush holder Replace, Visual check
if necessary.
\ SMGE-128
Checking of the rotor coil. About 2.9 £2 Replace.
SMGE-129A
Insulation between the slip If continuity
ring and the core. replace the rotor.
SMGE-130A
Diameter of the slip ring. 32.5 (1.280) 32.1 Replace.
(1.264)
8
SMGE-131A
Checking of the stator coil If not continuity,
i-
replace the stator
coil.
m &
r SM21-037
Insulation of the stator coil. If not continuity,
replace the stator CT
coil.
(Zf
SM21-Q38
GE-10 GENERATOR
Unit: mm (in)
inspection Item Standard Limit Remedy inspection Procedure
Condenser capacity. 0.5 pF Replace

1
<
! SMGE-114
Wear or damage of the Replace, Visual check

bearings. if necessary.
in
SMGE-083
Wear or damage of the felt. Replace, Visual check

if necessary.
If
I
j:
I" ‘
I
i;
:ÿ
b
!:
IK.P.I
:
I.
iJ
STARTER ST-1
ST-76E-02
CHAPTER ST
STARTER
(12V, 2.5 KW)
DATA AND SPECIFICATIONS ST-2
DESCRIPTION ,ST-2
TROUBLESHOOTING ST-3
STARTER ST-5
ST-2 STARTER
Model No. 28100-1561 28100-1960

Starter
Type Reduction gear type
Output 12V, 2.5 KW
Number of teeth of pinion 11
Module 3
Rotation Clockwise, viewed from pinion side
DESCRIPTION
3 4
(A
C ©
5
7
2
1 6
7 8
G 5 JR
1
T
\
!
Oi® !
f
!
/
11
I
1
!
9
12 10
1. Loead wire 7. Clutch gear

2. Brush 8. Overrunning clutch
3. Field coil 9. Pinion
4. Armature 10. Steel ball
5. Armature shaft gear 11. Spring
6. Idle gear 12. Magnetic switch
i
i
STARTER ST-3
TROUBLESHOOTING
Engine does not crank, ■(Key switch)

or cranks slowly.
• Poor contact Polish or replace contacts
-.Battery |
• Discharged battery Charge
• Short circuited between electrodes Replace battery
• Poor contact at battery terminal . Piish or retighten
-(Engine oiil
• Improper viscosity oil Change oil
-{Magnetic switchl
• Poor contact caused by burnt contact plate .... Polish or replace contact plate
• Contact plate worn out Repair
• Hold-in coil disconnected Replace field coil

(Overrunning clutch moves back and forth)
• Pull-in coil disconnected or short circuited .... Replace
Starter relay]
• (Defective or poor contact Repair or replace
— —{Starter j
• Brush worn out Replace
• Commutator burnt out Correct on lathe

• Commutator worn out . Correct by undercutting
• Field winding shorted or grounded . . . . Rewind or replace
• Armature winding shorted or grounded . Replace armature
• Insufficient brush spring tension .... . Replace brush spring
• Poor contact between magnetic switch . Repair

and field windings
• Armature contacts pole core because of worn . . Replace bearing brush or armature
bearing bush or bent armature shaft
• Overrunning clutch malfunction Replace
Engine does not crank ■(Overrunning clutch!

while starter is running
Overrunning clutch muifunction Replace
in good condition.
Pinion teeth worn Replace
* out
Poor sliding of spline teeth . . . Remove foreign materials, dirt, or

replace
ST4 STARTER
Symptom Possible causa Ramedy/Pravention
Starter does not stop JKey switch!

running.
• Contacts keep closing Replace
• Key switch sticks Replace
• Overrunning clutch sticks to armature Repair or replace overrunning

clutch or armature
-jStarter relay!
• Contacts keep closing Repair or replace
STARTER ST-5
STARTER
4
3
3
.
0 -t fjh
/
2 >-.9’ a
© WS 7
*K
?&§«# 6
5
©
1 t
10 \
18
9 17
16
- 15
'Of 14
\ j
1. Felt washer 10. Drive end frame

2. Armature assembly 11. Idle gear
3. Yoke assembly 12. Retainer
4. Brush holder 13. Roller
5. Steel plate 14. Overrunning clutch
6. Lead wire 15. Steel ball
7. Rear end flame 16. Return spring
8. Through bolt 17. Steel washer
9. Through bolt 18. Magnetic switch assembly
■
T;
ST-6 STARTER

T? REMOVE THE YOKE FROM THE MAGNETIC SWITCH.
STEEL 1. Disconnect the lead wire from the magnetic switch.
PLATE
2. Remove the through bolts from the magnetic switch.
£ /
l 3. Remove the steel plate from the magnetic switch.
A85144
REMOVE THE ARMATURE FROM THE YOKE.

I-
I:
I-
ft 1.
2.
Remove the rear end frame from the yoke.
Using a long-nose pliers, take off the brushes and remove the
! brush holder.
\
\
\ @ 6/p I 3. Loosen the two through bolts and detach the brush holder
from the armature shaft.
A 11
S
I
I
■
A 851 47
REMOVE THE BALL BEARING FROM THE ARMATURE.

PRESS
L P, 1. Using a press and a suitable tool, remove the ball bearing.
■v
TOOL
|
r
■
: BEARING
( L l
ARMATURE
i':
i AB5165
: ■ REMOVE THE OVERRUNNING CLUTCH.

i:
1. Remove the screws from the drive end frame.
;
/ } \ t
: / 2. Remove the drive end frame from the magnetic switch.
J mVJ 3. Remove the overruning clutch.
/ 4. Remove the steel ball from the overruning clutch.
V-
iI
— “
1
—'a f
1
\\\
\J
T STEEL
BALL
A85149 AB5152
: REMOVE THE IDLE GEAR.

/ A
y • / 7 1. Remove the idle gear, retainer with rollers, and steel washer
from the drive end frame.
\\
im NOTE: Do not drop the retainer and the rollers,
\\ J
V S' si
LT \ A85153
'
!
STARTER ST-7

BEFORE REASSEMBLING, APPLY THE RECOMMENDED
GREASE TO THE FOLLOWING:
y1'
Nippondenso No. 50 grease or equivalent.
i \ © Felt washer
© (2) Bearing
(3) Idle gear
® Retainer
(5) Roller
ms ©
Overruning clutch
Steel ball
: 1
© Return spring
1
©
1
STEEL BALL INSTALL THE STEEL WASHER, RETAINER WITH ROLLER,
RETURN
fed IDLER
GEAR
IDLE GEAR, RETURN SPRING, AND STEEL BALL IN THE
SPRING
g MAGNETIC SWITCH.
I ®
RETAINER
# ROLLER
C5 ,C©y. STEEL
WASHER
Atf-S
U INSTALL THE OVERRUNING CLUTCH IN THE DRIVE END
FRAME.
:
NOTE: Install the steel ball and the return spring.
J : I 111'
1 1. Connect the drive end frame to the magnetic switch and
LVS
rr— r
tighten the screws.
□
)
J
rA
INSTLL THE ARMATURE IN THE YOKE.

V
NOTE: Do not forget to place a felt washer on the armature shaft
1
-A' fe
li bearing.
3 LI” ■/
ST-8 STARTER
INSTALL THE BRUSH HOLDER ON THE YOKE.

POSITIVE BRUSH
1. Install the negative brush (brush holder side) to the brush
BRUSH SPRING
V INSULATOR
NEGATIVE BRUSH
holder negative hole (not insulated), and the positive brush
(yoke side) to the brush holder positive hole (separated from
Nifi
/n
plate with insulator). Make sure that the positive brush lead
wires are not grounded.
\ 2. When assembling the brush holder to the yoke, take care not
/ NEGATIVE BRUSH HODER HOLE
to damage and get oil on it.
POSITIVE BRUSH HOLDER HOLE
A85771
NOTE: Match the lead wire grommet with the rear end frame
groove.
i
Q.
\
GROOVE LEAD WIRE
GROMMET
INSTALL THE STEEL PLATE ON THE MAGNETIC SWITCH.

1. Install the steel plate on the magnetic switch.
SHI
f STEEL
PLATE
2. Securely put the rubber boot over the terminal.
!'
:
:i:
11
STARTER ST-9
TEST
MAGNETIC SWITCH TEST
The following test should be performed with the starter assem¬
bled and the field coil lead wire disconnected.
NOTE: o Each test should be performed for a short time only (3
to 5 sec.) to prevent the magnetic switch winding from
burning.
c Each test should be performed with the specified vol¬
tage applied.
— 1. Pull-in test
Connect the test leads as shown. When switch 1 (SW1) and
1 A 1 A switch 2 (SW2) are closed, the pinion should jump out.
SW1
I
ITT
'
SW2| / i-DISCONNECTED
r A
_ r i : LEAD WIRE
? i
I | Y
I
BATTERY TiT TTT
STARTER
J
Fig. 22-34
2. Hold-in test
In the same conditions as the pull-in test, open switch 1 (SW
SW1
\ A I A 1).
I 1 V I The pinion should remain in the jumped out position.
:
ISW2 1
n t
|
: — DISCONNECTED 777- i
I LEAD WIRE
T-
cn— P
V
BATTERY
777
LSTARTER
777
J
Fig. 22-35
3. Return test
In the same conditions as the hold-in test, open switch 2 (SW
2).
SW1 I A \ A Ir The pinion should return immediately,
jVVj
ITT
r2i / -'< DISCONNECTED

,\ ! x f
, LEAD WIRE
\ :
I
TTT 7TT
BATTERY L. STARTER J
PERFORMANCE TEST
13 50
“I
The following test should be carried out after reassembling the
(®) M T
fj starter. If suitable equipment is not available, at least the No-load
test should be carried out.
2
AMMETER
C.T
Jr 1. No-load test
With the starter securely clamped in a vice, and using a battery
( and suitable ammeter, connect the positive lead of the battery,
and the ammeter to the "50" terminal. Connect the negative
Tir
!
w
V lead to the starter body. The starter should show smooth and
l' ‘STARTER* AB5177
steady rotation immediately after jumping out of the pinion
BATTERY and should draw less than the specified current.
w
ST-10 STARTER
2. Load test
TO BODY TO *'C“ Read the ammeter and voltmeter when the specified torque is
GROUND TERMINAL
applied. The ammeter should indicate less than the specified
current, and the tachometer should indicate more than the
VOLTMETER
specified speed.
STARTER TO MAIN 3. Lock torque test
TERMINAL
A Read the torque meter and ammeter when the tachometer
RING GEAR EJ -f
reading becomes 0 rpm after appling the load. The torque
meter should indicate more than the specified torque and the
AMMETER BATTERY ammeter should indicate less than the specified current.
AB5178
Standard value of each test

Current Voltage Revolution & torque
More than
No load test Less than 180 A at 11V
3,500 rpm
More than
Load test Less than 600 A at 8V
1,100 rpm
More than
Lock torque test Less than 1,20OA at 3V
3.5 kg-m at 0 rpm
STARTER ST-11
Armature Short Circuit If the iron plate

Test is not vibrated, fo)l
the armature is __ _ <<22ÿ
good
SMST-091
Armature Insulation More than 1 M Q Less than Replace (S3
0.1 ML2
'1, m
■ ■ 4) V SMST-092
Commutator continuity Should be continuity Replace, if there
.•J m
at any point is no continuity
at any point
Commutator run-out Less than 0.02 0.05 Replace

(0.0008) (0.002)
Mik
SMST-093
Commutator Outside 36 35 Replace

(1.417) (1.378)
\
Diameter
SM22-055
Mica Depth 0.7 0.2 Replace COMMUTATOR UNDERCUT

(0.0276) (0.0078)
?
SM22-056
Conductance between the Should be conducted Replace

Field Coil and the Yoke
AB5166
■
ST-12 STARTER
Field Coil Insulation More than 1 M SI Less than Replace

0.1 Mf2
1
&I
: l
\\
AB5167
Wear or Damage of the Replace, if

Bearing necessary
V.
?.
A85164
Field coil and yoke Replace Visual check

damage
I
3 ©
r\
A85140
Brush length 20.5 13 Replace

(0.807) (0.512)
I 3SUSH
j UNGrM
AB5168
Insulation between the More than 1 Mfi Less than Replace

Brush Holder and the 0.1 MO \
Bracket 7
AB5169
Overrunning clutch test Replace
A B5170
Tension of the Brush 3.9 kg 1,9kg Replace

Springs (8.6 lb) (4.2lb)
1F* H
\ (KY)
CALIBRATION
CHAPTER C
INJECTION PUMP
CALIBRATION
"1
•f
I
i •
• !
j:
:
5
:
i:
l:
»
!
r.
!
;;
■t •
;<
*;
•i:
*
>;S'
:• ••
■
b
§.ÿ
T.
.V.
v!';
\ •* ;
i*
'?r| i
■
; .
1
: _
\;
i
V
.i
••
* :
•J
■
i
■
;
!
i
‘?
I
CALIBRATION C-1
C-99E-03
INJECTION PUMP NUMBER: 22030-2070B and 22030-2071A

Engine model W04D
Injection pump part number 22030— 2070B, 22030-2071 A
INJECTION Injection pump type N D-PES4A95D32 1 R N0 1 68
PUMP
SPECIFICATION Governor type RSV 400-1500
Timer type SCZ
Feed pump type ND-FP/KS
Test nozzle type 003400-0540 (DN12SD12A)
Test nozzle opening pressure 175 kg/cm2 (2,489 psi)
Outer diameter 6.0 mm (0.236 in)
TEST
CONDITION Injection pipe Inner diameter 2.0 mm (0.079 in)
Length 600 mm (23.6 in)
Type SAE J967C
Calibration oil
Oil temperature 40— 45°C (104-113° F)
Fuel feed pressure 2.0 kg/cm2 (28.4 psi)
OVERFLOW Opening pressure 1. 5-1.8 kg/cm2 (21.33-25.59 psi)
VALVE
Rotation Clockwise viewed from drive side
INJECTION Injection order 1-3-4-2
TIMING Injection interval 90° ± 30'
Pre-stroke 3.05-3.15 mm (0.120-0.124 in)
Rack position Pump speed Measuring Injection volume Max. variation limit
mm (in) (rpm) strokes cc (cu.in) cc (cu.in)
INJECTION A 9.2 (0.362) 1500 200 14.0-14.8 (0.171-0.451) 1.0 (0.061)
VOLUME About 6.3
B (0.248) 400 500 4.0-5.0 (0.123-0.152) 1.5 (0.091)
Adjusting lever position Pump speed (rpm) Advance angle

TIMER
ADVANCE 3/4 load 1300 Less than 0.8°
4/4 load 1600 3.0° - 4.0°
ADJUSTING POSITION CONTROL LEVER ANGLE
MAXIMUM SWIVEL LEVER IDLING SUB
SPEED STOPPER ADJUST SCREW SETTING
BOLT SCREW 40°
FULL IDLE
\ I 1
CONTROL
LEVER (•Jf X—*
GOVERNOR
ADJUSTMENT
»
Oj
(O. »
MM
h kw V.P.
NOTE:
• ANGLE: 1 . . . 13°±5°
3 2 . . , 16“ ± 5°
b f,
• Lever angle "V.P."
19 1 means. Vertical position.
IDLING
SCREW SM4-820
STOP LEVER FULL LOAD
STOPPER BOLT
C-2 CALIBRATION
Adjusting Adjusting Pump speed Control rack position

Adjusting position
item lever position (rpm) mm (in)
Na: 1500 Ra: 9.0-9.4 (0.354-0.370) Full load stopper bolt

I-
Maximum Rb: Should be start to Maximum speed stopper bolt
O LU Full load Nb: 1635 pulled control rack
2S speed
t—
UJt/3
>r> Nc: 1750 Rc: Less than 3.0 (0.118) *Swivel lever adjusting screw
0 7?
Q
i: CP
< Idling Idle Nd: 250 Rd: 6.4— 6.8 (0.252-0.267) Idling sub-spring set
speed
i
■:
*NOTE: Recommend setting of swivel adjusting screw:
;; 10 clinks from buttom end.
I
5 Governor characteristic diaphragm
* GOVERNING RANGE: 400-1500 rpm

14.0
I by limit sleeve
l Ra: 9.0— 9.4
; 1
S4
O
Rd: 6,4— 6.8
DC
6.1-6.5
O
X
\ Rb: 4.8— 5.8
z \
o \
\
\
\
Rc: Less than 3.0
0
s
c-t
o o
in
in
to
o
r-
-b'
Z z z z
PUMP SPEED (rpm) SM4-820
■j
:i
'i
;
, C-99E-03 (K.P.)
i
;
I
CALIBRATION C-1
C-98E-Q3
INJECTION PUMP NUMBER: 22020-3462A and 22020-3463A
Engine model W04C-TI

Injection pump part number 22020-3462A, 22020-3463A
INJECTION
PUMP Injection pump type NP-PES4A0100B320RS2
SPECIFI¬ Governor type RSV 200-1 600
CATION
Timer type Not equipped
Feed pump type NP-FP/KS-ADS
Test nozzle type 105780-8140
Outer diameter 6.0 mm (0.236 in)
TEST
Injection pipe Inner diameter 2.0 mm (0.079 in)
CONDITION
Type SAE J967C
Calibration oil
Oil temperature 40— 45°C (104— 113°F)
Fuel feed pressure 1 .6 kg/cm2 (22.8 psi)
OVERFLOW Opening pressure 1.5-1.8 kg/cm2 (21.33-25.59 psi)
VALVE
TIMING Injection interval 90° ± 30-
Pre-stroke 4.35-4.45 mm (0.172-0.175 in)
mm (in) (rpm) strokes cc (cu.in) %
INJECTION A 11.9 (0.469) 1500 500 64.2-66.2 (3.918-4.039) ± 3
VOLUME About 7.6
B (0.300)
400 500 7.5— 9.0 (0.458-0.549) ±15

SPEED STOPPER ADJUST SCREW SETTING
BOLT SCREW FULL 1 _ j— IDLING
SPEED
CONTROL
c: 2
LEVER •
49 |\
v
to
GOVERNOR o,
ADJUSTMENT
r m
0' V.P.
1
•j e, NOTE:
.9 • ANGLE: 1 . . . 26°±5°
2 . . . 22° ±5°
IDLING • Lever angle "V.P."
SCREW
STOP LEVER
means. Vertical position.
FULL LOAD
STOPPER BOLT SM4-816
!
■
C-2 CALIBRATION
Adjusting Adjusting Pump speed Control rack position

Adjusting position
item lever position (rpm) mm (in)
Na: 555-595 Ra: 11.9 (0.469 in) Full load stopper bolt
!—
O UJ Maximum Rb: Should be start to Maximum speed stopper bolt
Full load Nb: 1500-1510 pulled control rack
speed
£E|_
i LU CO
> Nc: 1600-1650 Rc: 6.0 mm (0.236 in) #Swivel lever adjusting screw
o r?
aa< Idling Rd: 7.6 mm (0.299 in) Idling sub-spring set
Idle Nd: 400
speed
*NOTE: Recommend setting of swivel adjusting screw:

10 clinks from buttom end.
:
; Governor characteristic diaphragm
i
GOVERNING RANGE: 400-1500 rpm
I
[ More than 14
! GOVERNOR SPRING SET
!
! IDLING SUB SPRING SET
I r— BOOST COMPENSATOR STROKE
Ra: 1 1 .9
A
i
1
E \\
u CM \
<
tn B \
Rd: 7.6 \
O Rc: 6.0
S\
QC
H
Z \ \
o \ \
<J
\
\ __
0 no 2
0)0
in
CT>
n in
8
co
n
TJ
z
n
n
7
o
7a •
n o o
in co
z -O o
Z 2
PUMP SPEED (rpm) SM4‘816
C-98E-03 (K.P.)
CALIBRATION C-1
C-97E-B3
INJECTION PUMP NUMBER: 22020-2731A and 22020-3590A
Engine model W04C-T

INJECTION Injection pump part number 22020-2731A, 22020-3590A
PUMP Injection pump type NP-PES4A95C321 R
SPECIFI¬
CATION Governor type RSV 200-1600
Feed pump type NP-FP/KS
TEST Outer diamter 6.0 mm (0.236 in)
CONDITION Injection pipe Inner diameter 2.0 mm (0.079 in)
Type SAE J967 C
Calibration oil
Oil temperature 40— 45°C (104-113°F)
Fuel feed pressure 1.6 kg/cm2 (22,8 psi)
OVERFLOW
VALVE
Opening pressure 1.5-1.8 kg/cm2 (21.33-25.59 psi)
Pre-stroke 3.17-3.23 mm (0.125-0.127 in)
mm (in) (rpm) strokes cc (cu.in) %
INJECTION A Ri 10.4 (0.409) 1500 500 47.0-49.0 (2.869-2.990) ± 3
VOLUME
About 7.1
B (0.280) 400 500 5.3— 6.8 (0.324-0.414) ± 4

SPEED STOPPER ADJUST SCREW SETTING 1
BOLT SCREW
CONTROL
Ql; 2
LEVER
GOVERNOR
V
o to) 9
ADJUSTMENT («
f
V.P.
1
3 t
NOTE:
• ANGLE: 1 . . . 24°;5°
2 . . , 17°i5°
IDLING
SCREW • Lever angle
"V.P."
STOP LEVER FULL LOAD means. Vertical position
STOPPER BOLT
SM4-815
! C-2 CALIBRATION
!
,
Governor characteristic diaphragm
s
|
GOVERNING RANGE: 400-1500 rpm
:
-
{ More than 14
5 GOVERNOR SPRING SET

\
■
I
£
E
IDLING SU8 SPRING SET
z Rj (10.4)
!
, 2 A
i
; tw
O
Q-
* 7.1 B
I U
<
ct
-J \ \\
I o
cc 5.1 \
h*
z \
o \
o
\
!• \
\
\
f-
LO
0 IflO
CD O 2+ o
i; O Lf>
o cn
in ca
PUMP SPEED (rpm)
i
' C-97E-03 IK.P.)
l
5
?
]
CALIBRATION C-1
C-S394E-01
Engine model W04C-TI

Injection pump parts number 22020-3841A
INJECTION
PUMP Injection pump type NP-PES4AD100B320RS2
SPECIFICA¬ Governor type RSV200-1600
TION
Feed pump type NP-FP/KS-ADS
Test nozzle opening pressure 17.2 MPa {175 kgf/cm2, 2,489 psi}
Outer diameter 6.0 mm {0.236 in.)
TEST Injection pipe Inner diameter 2.0 mm {0.079 in.)

CONDITION Length 600 mm (23.6 in.)
Type SAE J967C
Calibration oil
Oil temperature 40-45°C (104-113°F)
Fuel feed pressure 157 kPa {1.6 kgf/cm2, 22.8 psi)
OVERFLOW Opening pressure 255 kPa {2.6 kgf/cm2, 37.0 psi)
VALVE
Pre-stroke 4.35-4.45 mm {0.172-0.175 in.)
Rack position Pump speed Measuring Injection volume Max. Variation limit
mm {in.) r/min strokes cm3 {cu.in.} %
INJECTION A 12.2 {0.480} 1500 500 70.5-72.5 {4.301-4.423} ±3
VOLUME
B About 7.1 {0.280) 400 500 7. 5-9.0 {0.458-0.549} ±15
FULL 1 IDLING
►
SPEED
MAXIMUM SWIVEL LEVER IDLING SU8
SPEED STOPPER ADJUST SCREW SETTING 2
BOLT SCREW
CONTROL
LEVER
a fa
9
GOVERNOR fa %
ADJUSTMENT
(£ \
el *
V
9
V. V.P.
IDLING NOTE :
SCREW •ANGLE: 1...26°± 5°
STOP LEVER FULL LOAD
STOPPER BOLT 2...24°± 5°
•Lever angle “V.P.“
means Vertical position.
C-2 CALIBRATION
Load control Pump speed Control rack position Adjusting position

Adjusting item lever position (r/min) mm {in.}
Na: 600 Ra: 12.2 (0.480) Full load stopper bolt
Rb: should be start to Maximum speed
Maximum speed Full load Nb: 1530
pulled control rack stopper bolt
Nc: 1545 Rci 8.8-9.0 Swivel lever adjusting

(0.346-0.354) screw (When boost
I- pressure is 0 mmHg)
Z
LU N: 0 Rf: 10.1 (0.398) Control lever
5 Idling speed Idle
I- Nd: 255 Rd: 7.1 (0.280) Idling sub-spring set
W
2 Np: 700 R2: 12.2 (0.480) Adjusting screw
Q IMp: 700 Ri: 9.3-9.5
< (0.366-0.374)
ce
o When boost pressure is
z
CC
Pi: 9.3-14.7 kPa
LU (70-110 mmHg)
> control rack begins to
o move from Ri: 9.3-9.5
13 Boost compensator Full load (0.366-0.374) in the
direction of "Fuel
delivery increase".
Np: 700 When control rack Confirm
returns to position R2:
12.2 (0.480)
the available pressure
corresponds to P2
66.7 kPa (500mmHg)
Governor characteristic diagram
Z _ More than 14
_IDLING SUB SPRING SET
9 £
b £ GOVERNOR SPRING SET
V)
O
— BOOST COMPENSATOR STROKE
CL 13.5±0.1
2.8±0.1 mm
u Ra(R2): 12.2 Boost compensator
< /
cc Rf: 10.1
Rc: 8.9+0. 1
4 A
? E
9£
characteristic diagram
o X
DC Rd: 7.1 b~
I- co
z O R2: 12.2
O 2.7±0.4 \ CL
o \ V
u
<
cc Rc
O
9. 3-9.5
0 Nd:255 DC
/
400 500
Na:(600)
N b:{ 1530)
Nc: 1545
1655 I-
Z
O
0 1 2.0±2.7
{90+20}
(66.7)
({500})
u
Pi P2
PUMP SPEED {r/min} BOOST PRESSURE kPa {mmHg}

Hino Manual W04DW04C TW04C T

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Hino Manual W04DW04C TW04C T

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DIESEL ENGINE FOR

Applicable models: W04D, W04C-T, and W04C-T1 engine

HINO MOTORS, LTD.

INDEX: ENGINE GROUP

GENERAL PRECAUTIONS GI-2

HOW TO USE THIS WORKSHOP MANUAL GI-3

IDENTIFICATION INFORMATION GI-4

TIGHTENING TORQUE OF STANDARD BOLT GI-15

RECOMMENDED LUBRICANTS GI-16

O Always wear safety glasses or goggles to protect your eyes.

o Bind long hair securely behind the head.

HOW TO USE THIS WORKSHOP MANUAL.

This workshop manual is designed as a guide for servicing

SPECIAL TOOLS are dealt with in each chapter.

09420-1442 PART NUM8ER

TIMING GEAR AND CAMSHAFT

T = Tightening torque kg-cm (Ib.ft)

In some cases, illustrations may be of parts which differ in

HINO W04D 4.009 liters, 4-cycle,

NOTE: These specifications are subject to change without notice.

Jiiso, HINO MOTORS, LTD. TOKYO, JAPAN

LEFT SIDE VIEW

NOTE: These specifications are subject to change without notice,

Jiim HINO MOTORS, LTD. TOKYO, JAPAN

Even tightening area. Bolt nut,

W Cast iron or aluminum tightening

Tightening area having black

Even tightening area. Bolt nut,

GENERATOR 8. STARTER Generator Bearing £n«r grease RPM

DATA AMD SPECIFICATIONS..

LIQUID GASKET AND APPLICATION PARTS... EN-MP7A -38

DATA AND SPECIFICATIONS

Model W04D W04C-T W04C-TI

Type Diesel, 4-cycle, vertical,

Intake doses 40° after B.D.C.

cylinder on compression cylinder on compression

PLEASURE CRAFT RATING LIGHT DUTY RATING

PLEASURE CRAFT RATING LIGHT DUTY RATING

ENGINE SPEED F-215 ENGINE SPEED (rpm) F-216

PLEASURE CRAFT RATING LIGHT DUTY RATING

250 180 250

loj IT HZ O\_/0 ITFb

Symptom Possible cause Remedy/Prevention

Engine overheating Coolant

• Insufficient coolant Add coolant.

• Defective thermostat Replace the thermostat.

• Coolant leakage from cylinder head gasket Replace gasket.

• Defective coolant pump Repair or replace.

• Clogged with rust and scale Clean heat exchanger.

• Clogged with iron oxide due to

• Incorrect injection timing . Adjust injection timing.

• Reduced injection pressure Adjust injection pressure.

• Poor fuel Use good quality fuel.

• Poor nozzle spray Adjust or replace nozzle.

• Unsatisfactory automatic timer advance angle .. Repair or replace timer.

• Defective or deteriorated engine oil . Change engine oil.

• Unsatisfactory operation of oil pump Replace or repair.

• Insufficient oil Add oil.

• Brake drag Repair or adjust.

Defective sea water pump Repair or replace.

Loose or slipping V-belt Adjust V-belt tension or replace.

Closed sea water intake valve (Seacock) Open intake valve.

Clogged sea water strainer Clean strainer.