99406-14100 - Service Manual S16R-PTAA2 - March 2012

SERVICE MANUAL
1COVER
March 2012
Pub. No. 99406-14100
INTRODUCTION
This service manual describes the maintenance and adjustment procedures, and specifi-
cations for Mitsubishi diesel engines.
To maintain the performance of the engine for many years and to ensure safe operation,
it is important to use the engine correctly and conduct regular inspection and maintenance,
and it may also be necessary to take appropriate measures which involve in disassembly,
inspection, repair and assembly work of the engine and engine parts.
Read through this manual carefully and understand the work procedures fully before dis-
assembling, inspecting, repairing or assembling the engine.
The contents of the manual are based on the engine models that are being produced at the
time of publication. Due to improvements made thereafter, the actual engine that you work
on may differ partially from the one described in this manual.
I
INTRODUCTION
How to use this manual

This service manual consists of several chapters, which are arranged so as to allow you to make reference quickly to specifica-
tions, maintenance standards, adjustment procedures and service procedures including methods for disassembly, inspection,
repair and assembly of the Mitsubishi Diesel Engine (standard model for land use).
A short summary describing the content of each chapter is given in the General Contents page, and there is also a detailed table
of contents at the beginning of each chapter.
Regarding the procedures for operation and periodical maintenance of the engine, refer to the Operation and Maintenance Man-
ual. For information on the engine components and ordering of service parts, refer to the Parts Catalogue. Structure and func-
tion of the engine are described in the relevant training manuals.
Methods of presentation
(1) Index numbers allotted to parts in exploded views are not only a call-out of part names listed in the text but also an indica-
tion of the sequence of disassembly.
(2) Inspections to be conducted during disassembly process are indicated in boxes in the relevant exploded views.
(3) Maintenance standards required for inspection and repair works are indicated in the appropriate positions in the text. They
are also collectively indicated in Group 2, the General Contents group.
(4) Fasteners to be tightened in "wet" condition, or with engine oil applied, are identified by [Wet] placed after tightening
torque values. If no such indication is suffixed, the fastener should be tightened in "dry" condition, or without lubricating
with engine oil.
(5) In this manual, important safety or other cautionary instructions are emphasized with the following marks headed.
Indicates an immediately hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
Indicates a potentially hazardous situation which, if not avoided, can result in property
damage.
Note Emphasizes important matter, or indicates information useful for operation or maintenance
of the engine.
II
INTRODUCTION
Terms used in this manual

Nominal
means the basic size of a part to be measured.
Standard
means the quantitative requirement for dimension of a part, clearance between parts and performance. This is given in a form of
tolerance. Therefore, the values shown are not in agreement with the design values.
Limit
means that, if this value is reached, the part must be repaired or replaced with a new part.
Abbreviations
BTDC: Before Top Dead Center
ATDC: After Top Dead Center
BBDC: Before Bottom Dead Center
ABDC: After Bottom Dead Center
TIR: Total Indicated Runout
API: American Petroleum Institute
ASTM: American Society for Testing and Materials
JIS: Japanese Industrial Standards
LLC: Long Life Coolant
MIL: Military Specifications and Standards (U.S.A.)
MSDS: Material Safety Data Sheet
SAE: Society of Automotive Engineers (U.S.A.)
P/N: Part Number
Units of measurement
Measurements are based on the International System of Units (SI), and their converted metric values are indicated in parenthe-
ses { }. For metric conversion, the following rates are used.
Pressure :1 MPa = 10.197 kgf/cm2
Torque:1 N•m = 0.10197 kgf•m
Force:1 N = 0.10197 kgf
Horsepower:1 kW = 1.341 HP = 1.3596 PS
Meter of mercury:1 kPa = 0.7 cmHg
Meter of water:1 kPa = 10.197 cmH2O (cmAq)
Rotation speed:1 min-1 = 1 rpm
III
INTRODUCTION
Safety Cautions
Fire and explosions
Keep flames away Watch out for fuel, oil and exhaust gas
Do not use flames near the engine (in leaks
the engine room). Spilled fuel, oil and If any fuel, oil or exhaust gas leakage is found, imme-
LLC may ignite and cause a fire. Wipe diately take corrective measures to stop it. Such leak-
off spilled fuel, oil and LLC immedi- ages, if left uncorrected, can cause fuel or engine oil to
ately and thoroughly. Spilled fuel, oil reach hot engine surfaces or hot exhaust gas to con-
and LLC may ignite and cause a fire. Store fuel and tact flammable materials, possibly leading to personal
engine oil in a well ventilated designated area. Make injury and/or damage to equipment.
sure that the fuel and engine oil container caps are
Use explosion-proof lighting apparatus
tightly closed.
When inspecting fuel, engine oil, coolant, battery elec-
Keep engine surrounding area tidy and trolyte, etc., use a flameproof light. An ordinary lighting
clean apparatus may ignite a gas and cause an explosion.
Do not leave combustible or explosive materials, such Prevent electrical wires from short-circuit-
as fuel, engine oil and LLC, near the engine. Such
ing
substances can cause fire or explosion. Thoroughly
Avoid inspecting or servicing the electrical system with
remove dust, dirt and other foreign materials which are
the ground cable connected to the battery. Otherwise,
accumulated on the engine and the area around the
a fire could result from short-circuiting. Be sure to dis-
engine. Such materials can cause fire or the engine to
connect the battery cable from the negative (-) termi-
overheat. In particular, clean the top surface of the bat-
nal before beginning work. Short-circuits, possibly
tery thoroughly. Dust can cause a short-circuit. Always
resulting in fire, may be caused by a loose terminal or
place the engine at a position at least 1 m [3.28 ft.]
damaged cable/wire. Inspect the terminals, cables and
away from buildings and other equipment to prevent
wires, and if any faulty parts are found, repair or
possible fire caused by engine heat.
replace prior to work.
Do not open side cover until engine cools
Keep fire extinguishers and first-aid kit
Do not attempt to open the side cover of the crabkcase
handy
before the engine cools down. Wait at least 10 minutes
Keep fire extinguishers handy, and
after stopping the engine. Opening the cover when the
become familiar with their usage.
engine is hot allows fresh air to flow into the crab-
Keep a first-aid kit at the designated
kcase, which can cause oil mist to ignite and explode.
place where it is easily accessible by
anyone at any time. Establish
response procedures to follow in the event of fire or
accident. Provide an emergency evacuation route,
contact points, and means of communication in case
of emergency.
IV
INTRODUCTION
Stay away from rotating and moving parts
Install protective covers on rotating parts Lockout and tagout

after inspection/maintenance work Be sure to lockout and tagout before starting inspec-
Make sure the protective covers of tion and maintenance. Lockout and tagout are effec-
the engine are correctly installed. tive methods of cutting off machines and equipment
Repair any damaged or loosed cov- from energy sources. To accomplish the lockout/
ers. Never remove the protective cov- tagout, remove the starter switch key, set the battery
ers of rotating parts during operation. switch to OFF and attach a "Do Not Run" or similar
When the engine is coupled to the radiator or other caution tag to the starter switch. The starter switch key
equipment, install protective covers around the must be kept by the person who performs inspection
exposed connecting belt and coupling. and maintenance work.
Check work area for safety Be sure to stop the engine before inspec-
Before starting the engine, make sure that no one is tion and maintenance work.
near the engine and that tools are not left on or near Be sure to stop the engine before proceeding to
the engine. Verbally notify persons within the immedi- inspection and maintenance work. Never attempt to
ate area when starting the engine. When the starter make adjustments on the engine parts while the
device is posted with a warning sign saying "DO NOT engine is running. You can get caught in rotating parts
START-UP," never operate the engine. and seriously injured.
Stay away from moving parts while engine Always restore engine turning tools after
is running use
Keep away from the rotating parts Be sure to remove all turning tools used during inspec-
while engine is running. Do not leave tion and maintenance work. Remember also that the
any objects that may get caught in turning gear must be returned to the operating position
rotating parts. If clothes or tools get before starting the engine. If the engine is started with
caught in rotating parts, it could result a turning tool inserted or if the engine is started under
in serious injuries. the turning condition, it can not only cause the damage
to the engine, but also lead to personal injuries.
V
INTRODUCTION
Be careful of exhaust fume poi- Be careful of falling down

soning
Lift engine carefully
Operate engine in a well-ventilated area To lift the engine, always use a cor-
If the engine is installed in an rect wire rope capable of withstanding
enclosed area, and the exhaust gas is the engine weight. Attach the wire
ducted outside, ensure that there is rope to the lifting hangers provided on
no exhaut gas leak from duct joints. the engine using a correct sling. Dur-
Exhaust gas from the engine contains ing lifting process, keep the engine in
carbon monoxide and other harmful substances. a well-balanced position by taking the center of gravity
Operating the engine in an ill-ventilated area can proof the engine into consideration.
duce gas poisoning. The hangers equipped with the engine are designed
for lifting the engine only. In the case where the gener-
Protect ears from noise
ator, marine gear, etc. are installed to the engine,
make consideration so that additional weight will not
Wear ear plugs
affect the hangers of the engine.
Always wear ear plugs when entering
Keep the angle formed by slings attached to hangers
the machine room (engine room).
within 60°. If the angle exceeds this limit, excessive
Combustion sound and mechanical
load could be imposed on the hangers and this could
noise generated by the engine can
damage the hangers and result in a serious accident.
cause hearing problems.
When the wire rope comes into contact with the engine
directly, place a cloth or other soft pad to avoid dam-
age to the engine and wire rope.
Do not climb onto the engine

Do not climb onto the engine, nor step on any engine
parts located on the lateral sides. To work on parts
located on the upper section of engine, use a ladder,
stool, etc., that is firmly secured. Climbing on the
engine may not only damage engine parts but also you
may fall down from the engine and get injured.
Always prepare stable scaffold

When working on the upper part of
the engine and other hard-to-reach
places, use a stable work plat-
form.Standing on a decrepit stool or
parts box may result in personal
injury.Do not place any unnecessary objects on a work
platform.
VI
INTRODUCTION
Be careful when handling fuel, en- Be careful of burns

gine oil or LLC
Do not touch the engine during or immedi-
Use specified fuel, engine oil and long-life ately after operation
coolant (LLC) only. Do not touch any parts of the engine
Use the fuel, oil and LLC specified in this manual only, during or immediately after operation.
and handle them carefully. Use of any other fuel, oil or You can get burned. Before conduct-
LLC, or improper handling may cause various engine ing maintenance and inspection work,
problems and malfunctions. Obtain the Material Safety check the water temperature gauge to make sure that
Data Sheets (MSDS) issued by the fuel, oil and LLC the engine has cooled down.
suppliers, and follow the directions in the MSDSs for Do not open the radiator cap when the
proper handling. engine is hot
Handle LLC carefully Never open the radiator cap while the engine is run-
When handling LLC, always wear rubber gloves and a ning or immediately after the engine stops. Stop the
protective face mask. If LLC or cooling water contain- engine and give a sufficient time to allow the coolant to
ing LLC comes into contact with your skin or eyes, or if cool down before opening the cap. When opening the
it is swallowed, you would suffer from inflammation, radiator cap, slowly open the cap so as to release
irritation or poisoning. Should LLC be accidentally internal pressure. To prevent hot steam scalds, wear
swallowed, induce vomiting immediately and seek thick rubber gloves or cover the cap with a cloth. When
medical attention. Should LLC enter your eyes, flush closing the radiator cap, firmly tighten the cap. Do not
them immediately with plenty of water and seek medi- open the radiator cap during engine running or just
cal attention. If LLC splashes onto your skin or cloth- after the engine stops. Otherwise hot steam and cool-
ing, wash it away immediately with plenty of water. ant gush out and can cause scalds.
Keep flames away from LLC. The LLC can catch Refill coolant only after the coolant temper-
flames, causing a fire. Coolant containing LLC is a
ature dropped
hazardous material. Do not dispose of it in unauthor-
Do not add coolant immediately after the engine stops.
ized manner. Abide by the applicable law and regula-
Wait until the coolant temperature lowers sufficiently to
tions when discarding drained coolant.
avoid a risk of burns.
Proper disposal of waste oil, LLC and cool-
Never remove heat shields
ant
The exhaust system, which becomes extremely hot
Do not discharge waste engine oil, LLC and coolant
while the engine is operating, is provided with various
into sewerage, river, lake or other similar places. Such
heat shields. Do not remove these heat shields. If any
a way of disposal is strictly prohibited by laws and reg-
of these heat shields have been removed due to
ulations. Dispose of waste oil, LLC, coolant and other
unavoidable circumstances during the work, be sure to
environmentally hazardous waste in accordance with
restore them after the work is completed.
the applicable law and regulations, or consult a Mit-
Be careful of burns when changing oil
subishi dealer.
Wear gloves when draining oil or changing oil filters. If
your skin gets contact with hot oil or hot parts, you get
burned.
VII
INTRODUCTION
Service battery When abnormality occurs
Handle the battery correctly Do not add coolant immediately after a sud-
Never use flames or allow sparks to den stop due to overheating
generate near the battery. The bat- If the engine stops suddenly or if you have no choice
tery releases flammable hydrogen but stop the engine suddenly due to overheating, do
gas and oxygen gas. Any flames not add coolant immediately. If water is added immedi-
or sparks in the vicinity could ately, parts such as cylinder heads can be damaged
cause an explosion.
due to the sudden drop of temperature. Add coolant
Do not use the battery if its fluid level is below the
gradually after the engine has completely cooled.
lower limit line. Using such batteries could result in
an explosion. Avoid immediate restart after abnormal
Do not short the battery terminals with a tool or other stop
metal object. If the engine stops abnormally, do not restart the
When disconnecting battery cables, always remove engine immediately. If the engine stops giving alarm
the cable from the negative (-) terminal first. When sound, inspet the engine and remedy the cause of the
reconnecting the cables, always connect the positive problem before restarting. If the engine is kept operat-
(+) terminal first.
ing in such condition, it can result in serious engine
Charge the battery in a well-ventilated area, with all
failure.
battery plugs removed.
Make sure the cable clamps are securely installed on Immediately stop the engine when engine
the battery terminals. A loose cable clamp can oil pressure drops
cause sparks that may result in an explosion. If engine oil pressure drops dangerously low, stop the
Before servicing electrical components or conducting engine immediately, and inspect the lubrication sys-
electric welding, set the battery switch to the [Open/ tem to locate the cause. Continuous engine operation
OFF] position or disconnect the cable from the nega- with low oil pressure may cause bearings and other
tive (-) battery terminal to cut off the electrical cur-
parts to seize.
rent.
Electrolyte (battery fluid) contains dilute sulfuric acid.
Stop the engine immediately if belt is bro-
Careless handling of the battery can lead to the loss ken
of sight and/or skin burns. Also, do not swallow bat- If the belt breaks, stop the engine immediately. Contin-
tery fluid. uous engine operation with the broken belt could
Wear protective goggles and rubber gloves when cause the engine to overheat and thereby the coolant
working with the battery (such as adding water or to boil into steam, which may gush out from the
charging). reserve tank or radiator, and you could get burned.
If battery electrolyte is spilled onto the skin or cloth-
ing, immediately wash it away with lots of water. Use
soap to thoroughly clean.
Battery fluid can make you blind if gotten into your
eyes. If it gets into the eyes, immediately flush it
away with plenty of clean water, and seek immediate
medical attention.
If the battery fluid is accidentally swallowed, gargle
with plenty of water, then drink lots of water, and
seek immediate medical attention.
VIII
INTRODUCTION
Other cautions
Never modify engine Never break the seals

Unauthorized modification of the engine will void the To ensure proper engine operation, the fuel control
warranty even if the warranty period has not expired. link is provided with seals that protect the fuel injection
Modification of the engine may not only damage the volume and rotation speed settings against tampering.
engine but also could lead to personal injuries. If these seals are broken and the settings are
changed, the proper operation of the engine will no
Perform all specified pre-operation inspec-
longer be guaranteed, and the following problems will
tions and periodic inspections
occur.
Conduct the pre-operation inspections and periodic
Rapid wear of moving and rotating parts
inspections as described in this manual.
Engine troubles such as damage and seizure of
Failure to conduct the specified inspections may cause
engine parts
various engine problems, damage to parts, and seri-
Drastic increase of fuel and lubricating oil consump-
ous accidents. tion
Work clothing and protective gear Degradation of engine performance due to improper
Wear a hardhat, face shield, safety shoes, dust mask, balance between fuel injection volume and governor
gloves and other protective gear as needed. When operation or overrunning of the engine which could
result in a serious accident
using compressed air, wear safety goggles, a hardhat,
gloves and other necessary protective gear. Works Inspect the engine after operation
without wearing proper protective gear could result in After engine operation, inspect each part of engine
serious injuries. once again. If any abnormalities are found, repair
immediately.
Break-in the engine

To break in new engines or overhauled engines, oper-
ate the engine at a speed lower than the rated speed
in a light load condition during the first 50 hours of
operation. Operating a new engines or overhauled
engines in a severe condition during the break-in
period shortens the service life of the engine.
IX
INTRODUCTION
Warm up the engine before use Protection of the engine against water entry
After starting the engine, run the engine at low idling Do not allow rainwater, etc. to enter the engine
speeds for 5 to 10 minutes for warming-up. Start the through the air inlet or exhaust openings. Do not wash
work after this operation is completed. Warm-up oper- the engine while it is in operation. Cleaning fluid
ation circulates the lubricant through the engine. (water) can be sucked into the engine. Starting the
Therefore, individual engine parts are well lubricated engine with water inside the combustion chambers
before they are subjected to heavy loads. Warm-up can cause the water hammer action which may result
operation circulates lubricants in the engine and con- in internal engine damage and serious accidents.
tributes to a longer service life and economical opera- Conduct proper maintenance of pre-cleaner
tion. Do not conduct warm-up operation for a longer or air cleaner
time than necessary. Prolonged warm-up operation
The major cause of abnormal wear on engine parts is
causes carbon build-up in the cylinders that leads to
foreign materials from intake air. Worn parts produce
incomplete combustion.
many problems such as an increase of oil consump-
Never operate the engine in an overloaded tion, decrease of output and starting difficulties. For
condition effective removal of dust from intake air, maintain the
If the engine shows an overloaded condition such as air cleaner according to the following instructions.
black exhaust smoke, reduce the load immediately to Never perform maintenance on the air cleaner or pre-
operate the engine at an appropriate output and load. cleaner while the engine is running. Operating the
Overloading causes not only high fuel consumption engine without the air cleaner/pre-cleaner allows for-
eign materials to enter the turbocharger and could
but also excessive carbon deposits inside the engine.
result in serious damage.
Carbon deposits cause various problems and will
Be careful when removing the air cleaner or pre-
shorten the service life of the engine.
cleaner so that dust and foreign materials accumu-
Conduct cooling operation before stopping lated on the air cleaner or pre-cleaner do not enter
the engine the engine. After removing the air cleaner or pre-
Before stopping the engine, idle the engine for 5 to 6 cleaner, immediately cover the opening (inlet port of
minutes to cool down. Stopping the engine immedi- air cleaner; port in body for pre-cleaner) with plastic
ately after high-load operation will cause engine parts sheet or similar means to prevent foreign materials
from entering the engine.
to heat up and shorten the service life of the engine.
If the engine is equipped with a dust indicator, con-
During cooling operation, check the engine for abnor-
duct maintenance only when the clog warning sign
malities.
appears.
X
INTRODUCTION
Observe safety rules at work site Cautionary instructions for transporting the
Observe the safety rules established at your work- engine
place when operating and maintaining the engine. Do When transporting the engine on a truck, consider the
not operate the engine if you are feeling not well. engine weight, width and height to ensure safety.
Inform your supervisor of your condition. Operation of Abide by road traffic laws, vehicle road acts, vehicle
the engine with reduced awareness may cause restriction ordinances and other pertinent laws.
improper operation that could result in accidents. Do not operate engine continuously under
When working in a team of two or more people, use low load
specified hand signals to communicate among work-
Load low continuous operation (less than 30%) must
ers.
be limited to one hour or less. Otherwise, incomplete
Use proper tools for maintenance work combustion may occur due to the carbon buildup
Always keep in mind to select most appropriate tools inside the cylinder. Also, after low load operation is
for the work to be performed and use them correctly. If conducted for approx. 1 hour, conduct load operation
tools are damaged, replace with new tools. at 50% or more load for more than 30 minutes.
Avoidance of prolonged time of starter Ventilation of engine room

operation Always keep the engine room well-ventilated. Insuffi-
Do not use the starter for more than 10 seconds at a cient intake air amount of the engine can cause an
time. If the engine does not start, wait for at least 1 increase in the engine temperature, and could result in
minute before cranking again. Cranking the starter a decrease in the output power and poor performance.
continuously could lead to a flat battery or starter burn- It is highly recommended to calculate the required
ing out. amount of air supply to the engine and install an ade-
quate ventilation system before installing the engine.
Do not turn off the battery switch during
operation Do not touch high pressure injection fuel
Do not turn off battery switch during operation. If the If fuel leaks or sprays out from the high pressure injec-
battery switch is turned OFF when the engine is run- tion pipe, do not touch the fuel. Fuel in the fuel injec-
ning, not only various meters will stop working but also tion pipes is under high pressure and if the fuel contact
the alternator may have its diode and transistor deteri- your skin, it goes into deep tissues and may result
orated. gangrene.
XI
INTRODUCTION
Warning labels
Maintenance of warning labels

Make sure all warning/caution labels are legible.
Clean or replace the warning/caution labels when the description and/or illustration are not clear to read.
For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvents, gasoline or
other chemicals to prevent the letters from getting blurred or the adhesion from being weakened.
Replace damaged or missing labels with new ones.
If any engine part on which a warning label is attached is replaced with a new one, attach a new identical warning
label to the new part.
To obtain new warning labels, contact a dealer of Mitsubishi Heavy Industries, Ltd.
Warning labels
XII
INTRODUCTION
Tips on disassembling and assem- Tips on assembling

Wash all engine parts, except such parts as oil seals, O-
bling
This service manual specifies the recommended procedures rings and rubber seats, in cleaning oil and dry them with
to be followed when servicing Mitsubishi engines. The compressed air.
Use correct tools and instruments.
manual also specifies the special tools that are required for
Use only high-quality lubricating oils and greases of
the work, and the basic safety precautions to follow when
appropriate types. Be sure to apply oil, grease or adhesive
working. Note that this manual does not exhaustively cover
to designated surfaces.
potential hazards that could occur during maintenance,
Use a torque wrench to tighten parts correctly when their
inspection and service work of engine.
tightening torques are specified. Refer to "Tightening
When working on the engine, follow the relevant instruc-
torque table."
tions given in this manual and also observe the following: Gaskets, packings and O-rings should, as a rule, be
Tips on disassembling replaced with new ones. Also, adhesive should be applied
Use correct tools and instruments. Serious damage to the as required. Use only the proper amount of adhesive.
engine can result from using the wrong tools and instru- Use protective gloves when you touch overheated or
ments. cooled parts. Touching the overheated parts with hands
Do not use jack bolts having sharp edge, as they may cause directly can cause burns.
damage to the surface.
Use an overhaul stand or work bench if necessary, and fol-
low the disassembling procedures described in this man-
ual. Do not place the engine parts on the floor directly.
Place them on the work bench in an orderly manner.
Keep the engine parts in order of removal to prevent losing
them. Arrange parts in order during disassembly.
When reusing the engine parts, unless there are special rea-
sons, install them to the positions where they were.
Pay attention to assembling marks. Put your marks on the
parts, if necessary, to ensure correct assembling.
Carefully check each part for defects during disassembling
or cleaning. Do not miss symptoms which can not be
detected after disassembling or cleaning.
When lifting or carrying heavy parts, exercise utmost cau-
tion to ensure safety. Pay attention to the balancing of
heavy parts when handling. (Get help, and use jacks,
chain blocks and guide bolts as necessary.)
Use protective gloves when you touch overheated or
cooled parts. Touching the overheated parts with hands
directly can cause burns.
XIII
GENERAL CONTENTS
Chapter 1 GENERAL
1. External View
2. System flow diagrams
3. Contents of plate and label
4. Main specifications
Chapter 2 SERVICE DATA

1. Maintenance service data
2. Tightening torque table
Chapter 3 SERVICE TOOLS

1. Special tools
Chapter 4 OVERHAUL INSTRUCTIONS

1. Determining overhaul timing
2. Compression pressure - Measure
Chapter 5 DISASSEMBLY OF BASIC ENGINE

1. Cylinder heads and Valve mechanisms - Disassemble and Inspect
2. Rear equipment - Disassemble and Inspect
3. Front equipment - Disassemble and Inspect
4. Cylinder liner, Piston and Connecting rod - Disassemble and Inspect
5. Crankcase, Crankshaft and Main bearing - Disassemble and Inspect
Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

1. Cylinder head and Valve mechanism - Inspect and Repair
2. Rear equipment - Inspect and Repair
3. Front equipment - Inspect and Repair
4. Piston and Connecting rod - Inspect and Repair
5. Crankcase and Crankshaft - Inspect and Repair
Chapter 7 ASSEMBLY OF BASIC ENGINE

1. Crankshaft and Main bearing - Install
2. Cylinder liner, Piston and Connecting rod - Assemble
3. Front equipment - Assemble
4. Rear equipment - Assemble
5. Cylinder head and Valve mechanism - Assemble
Chapter 8 FUEL SYSTEM

1. Fuel system - Remove and Inspect
2. Fuel system - Disassemble and Inspect
3. Fuel system - Install
Chapter 9 Lubrication system

1. Lubrication system - Remove and Inspect
2. Lubrication system - Disassemble, Inspect and Assemble
3. Lubrication system - Install
Chapter 10 Cooling system

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

1. Inlet and exhaust systems - Remove and Inspect
2. Inlet and exhaust systems - Install
Chapter 12 ELECTRICAL SYSTEM

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

1. Engine - Adjust
2. Break-in operation
3. Engine Test and Adjustment
Chapter 1 GENERAL
1. External View ........................................................................................................... 1-3
2. System flow diagrams............................................................................................. 1-5
2.1 Outline of fuel system ............................................................................................................... 1-5
2.2 Outline of lubrication system..................................................................................................... 1-5
2.3 Outline of cooling system.......................................................................................................... 1-6
2.4 Outline of inlet and exhaust system.......................................................................................... 1-6
3. Contents of plate and label..................................................................................... 1-7
3.1 Name plate ............................................................................................................................... 1-7
3.2 Caution plate ............................................................................................................................ 1-7
3.3 Emissions certification label...................................................................................................... 1-7
4. Main specifications.................................................................................................. 1-8
1-1
Chapter 1 GENERAL
1. External View
Chapter 1 GENERAL
Engine coolant outlet (To radiator)
Air outlet (To radiator)
Thermostat case
Water pump
Damper
Oil pump
Oil pan
Engine coolant inlet

(From radiator)
Oil drain port Air inlet (From radiator)
Engine front
Turbocharger Turbocharger
Air inlet Air inlet
Breather Breather
Rotational direction
Flywheel
Oil drain port
Engine rear
1-3
Chapter 1 GENERAL
Fuel filter Rear hanger
Front hanger Exhaust pipe,

exhaust outlet
Front Rear
Oil cooler Stop lever
Actuator (Governor)
Fuel injection pump

Bypass oil filter
Fuel feed pump
Starter
Oil filter
Oil filler Fuel return port
Oil level gauge Fuel inlet port
Engine left view
Fuel injection pump

Front hanger
Rear hanger
Oil cooler
Stop solenoid
Alternator
Rear Front
Coolant drain cock
Fuel feed pump
Breather Fuel filter
Engine right view
1-4
Chapter 1 GENERAL
2. System flow diagrams

2.1 Outline of fuel system
Fuel leak-off pipe
Fuel injection nozzle
Fuel injection pump
Check valve
Fuel feed pump
Fuel injection pipe To the right side of engine
From the right side of engine
Fuel filter
From fuel tank To fuel tank
Outline of fuel system
2.2 Outline of lubrication system
Rocker shaft
Piston
Turbocharger
Main gallery Camshaft
Relief valve
Piston cooling nozzle
Oil cooler
Timing gear
Water pump
Oil thermostat Fuel injection pump
Safety valve Crankshaft
Oil pump
Oil filter bypass valve
Bypass oil filter Oil strainer Oil filter
Outline of lubrication system
1-5
Chapter 1 GENERAL
2.3 Outline of cooling system
Water pump Oil cooler Water jacket
Water outlet pipe

Thermostat
(Rocker case)
Radiator
Bypass pipe Oil cooler Water jacket
Outline of cooling system
2.4 Outline of inlet and exhaust system
Exhaust Exhaust pipe

Intake air
Turbocharger outlet Turbocharger
Exhaust
(4 turbo) (4 turbo)
From pre-cleaner From pre-cleaner
Intercooler
(radiator)
Cylinder
Outline of inlet and exhaust system
1-6
Chapter 1 GENERAL
3. Contents of plate and label

3.1 Name plate
The name plate is attached on the lateral side of the engine,
and shows the following information: Left
Engine serial number location
Date manufactured 16 15 14 13 12 11 10 9
Displacement Rear Front

Engine output
8 7 6 5 4 3 2 1
Rated speed
Right
Cylinder No.
Name plate
3.2 Caution plate
The caution plate is attached to the top face of the rocker
cover of No. 1 cylinder and shows the following informa-
tion:
Valve clearance

Firing order
Fuel injection timing VALVE CLEARANCE (COLD)
Connecting rod weight rank INLET 0.6 O O ':*#756 0.8 O O
FIRING ORDER
1-9-6-14-2-10-4-12-8-16-3-11-7-15-5-13
FUEL INJECTION TIMING BTDC
CON-ROD RANK
Caution plate
3.3 Emissions certification label
The emission certification label that shows compliance with
emission requirement is affixed to the engine.
1-7
Chapter 1 GENERAL
4. Main specifications
Engine model S16R-PTAA2
Type Water cooled, 4 cycle diesel engine, turbocharged with aircooler
No. of cylinders - arrangement 16-V
Combustion system Direct injection system
Valve mechanism Overhead
Cylinder bore × stroke 170×180 mm [6.69×7.09 in.]
Displacement 65.37 L [3989 cu. in.]
Compression ratio 14 : 1
Fuel Diesel fuel
Firing order 1-9-6-14-2-10-4-12-8-16-3-11-7-15-5-13
Direction of rotation Counterclockwise as viewed from flywheel side
Length 3975 mm [156.49 in.]
Dimensions Width 2392 mm [94.17 in.]
Height 3276 mm [128.97 in.]
Dry weight 6443 kg [14204 lb.]
Type PS8 PS8A
Plunger outside diameter ø17 mm [0.67 in.]
Fuel injection pump Idling 2.3 mm [0.091 in.]
Pre-stroke 4 mm [0.157 in.]
Rated point 3.7 mm [0.146 in.]
Cam lift 15 mm [0.59 in.]
Type Bosch Corporation: KD-Z type
Fuel feed pump
Cam lift 12 mm [0.47 in.]
Woodward Governor (Japan), Ltd.
Governor Type
Proact governor system (electric type)
Fuel injection nozzle Type Bosch Corporation: hole type
Fuel filter Type Paper element type (spin-on)
Lubrication method Forced circulation (oil pump pressure feed system)
Specification Class CF oil (API service classification)
Engine oil Whole engine: approx. 230 L [60.76 U.S. gal.],
Capacity
Oil pan: approx. 200 L [52.83 U.S. gal.]
Oil pump Type Gear pump type
Relief valve Type Piston valve type
Oil cooler Type Water-cooled, multi-plate type (housed in the crankcase)
Full-flow oil filter Type Paper element type (spin-on)
Bypass oil filter Type Paper element type (spin-on)
Oil thermostat Type Wax type
Cooling method Water-cooled, forced circulation
Coolant capacity (engine) Approx. 170 L [44.91 U.S. gal.]
Waterpump Type Centrifugal
Water thermostat Type Wax type
Type TD13
Turbocharger
No. of units 4
Voltage, Grounding system 24V, body earth type
Starter Type Nikko Electric Industry Co., Ltd.: Pinion shift (Reduction type)
Mitsubishi Electric Corporation: 3-phase alternating generator,
Alternator Type
Internal IC regulator
1-8
1. Maintenance service data ....................................................................................... 2-3
1.1 Engine general ......................................................................................................................... 2-3
1.2 Basic engine ............................................................................................................................. 2-4
1.3 Fuel system .............................................................................................................................. 2-8
1.4 Lubrication system.................................................................................................................... 2-9
1.5 Cooling system ......................................................................................................................... 2-9
1.6 Electrical system..................................................................................................................... 2-10
2. Tightening torque table......................................................................................... 2-11
2.1 Tightening torque for Basic engine ......................................................................................... 2-11
2.2 Tightening torque for Fuel system .......................................................................................... 2-12
2.3 Tightening torque for Lubrication system................................................................................ 2-13
2.4 Tightening torque for Cooling system ..................................................................................... 2-13
2.5 Tightening torque for Inlet and exhaust system...................................................................... 2-13
2.6 Tightening torque for Electrical system................................................................................... 2-13
2.7 Tightening torque for Standard bolts and nuts........................................................................ 2-14
2.8 Tightening torque for Standard eyebolts................................................................................. 2-15
2.9 Tightening torque for Standard union nuts ............................................................................. 2-15
2.10 Tightening torque fo Fuel injection pipe.................................................................................. 2-15
2-1
1. Maintenance service data

1.1 Engine general

Item Nominal Standard Limit Remarks
Rated speed 1800 min-1
Minimum speed 600 min-1
1.27 MPa {13 kgf/cm²} When cranking
Compression pressure 1.8 MPa {18.5 kgf/cm²} [263 psi]
[185 psi] (Approx. 120 min-1)
0.49 to 0.64 MPa
0.29 MPa {3 kgf/cm²}
{5 to 6.5 kgf/cm²} [71 to 92 psi]
[42 psi]
(at rated) At oil temperature range from 90
Engine oil pressure
0.20 to 0.29 MPa to 100°C [194 to 212 °F]
0.15 MPa {1.5 kgf/cm²}
{2 to 3 kgf/cm²} [28 to 43 psi]
[21.6 psi]
(at idling)
Inlet opens BTDC 63°
Inlet closes ABDC 35° When valve clearance is 0 mm
±2°
Exhaust opens BBDC 53° [0 in.]
Exhaust closes ATDC 45°

Valve timing
Inlet opens BTDC 25°
Inlet closes BBDC 3° When valve clearance is 2 mm
Exhaust opens BBDC 21° [0.08 in.]
Exhaust closes ATDC 7°

0.6 mm
Inlet
Valve clearance [0.024 in.]
(when cold) 0.8 mm
Exhaust
[0.032 in.]
BTDC
Check the caution plate on No. 1
Fuel injection timing 28±1°
rocker cover.
(crank angle)
2-3
1.2 Basic engine

Unit: mm [in.]
36.000 to 36.040
Rocker bushing inside diameter ø36 [1.42] 36.090 [1.4209]
[1.4173 to 1.4189]
Rockers
35.966 to 35.991
Rocker shaft outside diameter ø36 [1.42] 35.940 [1.4150]
[1.4160 to 1.4170]
9.940 to 9.960
Valve stem outside diameter ø10 [0.39] 9.910 [0.3902]
[0.3913 to 0.3921] Same for both inlet and
10.000 to 10.015 exhaust valves.
Valve Valve guide inside diameter ø10 [0.39] 10.060 [0.3961]
[0.3937 to 0.3943]
Clearance between the bottom face of valve
2.1 [0.083]
bridge and the top face of valve rotator
Valve seat angle 30°
Seat width
-0.1 to 0.1
Valve sinkage 0 1.0 [0.040]
[-0.004 to 0.004]
2.3 2.21 to 2.42
Seat width 2.8 [0.110]
[0.091] [0.0870 to 0.0953] Valve
Valve
seat
Valve margin
3.0 2.8 to 3.2 angle
Valve margin 2.5 [0.098] sinkage
[0.118] [0.110 to 0.126]
Inside diameter of valve seat fitting portion 60.000 to 60.030
Valve seat and 60.120 [2.3669]
[2.3622 to 2.3634]
valve
60.100 to 60.130
Standard 2 lines, brown
[2.3661 to 2.3673]
Valve seat
0.03 60.130 to 60.160
Outside 3 lines, brown
[0.0012] [2.3673 to 2.3685]
diameter
0.06 60.160 to 60.190
4 lines, brown
[0.0024] [2.3685 to 2.3697]
0.070 to 0.130
Valve seat interference
[0.0028 to 0.0051]
Free length 73 [2.87] 71 [2.80]
A=1.5° or less A
B = less than 1.9 B=2.2 [0.087] B
Squareness
Inlet [0.0748] over entire length Lf
valve spring Lf=73 [2.87]
66.0[2.60]/289 to 319
Installed length/load
{29.45 to 32.55}
(mm [in.]/N{kgf} [lbf])
[64.97 to 71.71]
Free length 90.6 [3.567] 88.12 [3.4693]
A=2.0° or less A
B = less than 3.2 B=3.7[0.146] B
Squareness
[0.126] over entire length Lf
Inner spring
Lf=90.6 [3.567]
56.0[2.20]/137 to 152
{14 to 15.5}
Exhaust valve [30.80 to 34.17]
spring Free length 96.57 [3.8020] 93.92 [3.6976]
A=2.5° or less A
B = less than 4.2 B=4.9 [0.193] B
Squareness
[0.165] over entire length Lf
Outer spring
Lf=96.57 [3.8020]
62.0[2.44]/496 to 549
{50.6 to 56.0}
[111.5 to 123.4]
Push rod Runout 0.50 [0.0197] or less TIR
Distortion of bottom surface 0.03 [0.0012] or less 0.07 [0.0028]
Cylinder
head 154.9 to 155.1
Height Reference value
[6.098 to 6.106]
2-4
Unit: mm [in.]
170.000 to 170.040
Inside diameter ø170 [6.69] 170.500 [6.7126]
[6.6927 to 6.6943]
Roundness 0.02 [0.0008] or less Single condition
Cylindricity 0.02 [0.0008] or less Single condition
Cylinder 0.11 to 0.20
liner Flange protrusion
[0.0043 to 0.0079]
14.16 to 14.20
Flange thickness
[0.5575 to 0.5591]
0.16 to 0.24
Top ridge height
[0.0063 to 0.0094]
Measure the outside diame-
ter at a height of 40 mm
169.765 to 169.805 169.66
Outside diameter ø170 [6.69] [1.57 in.] from the lower
[6.6835 to 6.6850] [6.6795]
end of piston with right
angles to the piston pin.
Piston Within ±10 g [0.35

Weight difference
oz.] in one engine
70.002 to 70.015
Piston pin bore inside diameter ø70 [2.76] 70.040 [2.7575]
[2.7560 to 2.7565]
0.03 to 0.63
Protrusion
[0.0012 to 0.0248]
Cylinder head 1.77 to 1.83
Thickness when tightened 1.8 [0.071]
gasket [0.0697 to 0.0720]
Piston cooling 0.10 to 0.15 MPa
nozzle Valve opening pressure {1.0 to 1.5 kgf/cm2}
[14 to 21 psi]
Piston and cyl- 1.25 to 2.00
Top clearance
inder head [0.0492 to 0.0787]
No.1 0.6 to 0.8
2.0 [0.078]
compression [0.024 to 0.032]
Piston No.2 0.6 to 0.8
End gap 2.0 [0.078]
Ring compression [0.024 to 0.032]
0.3 to 0.45
Oil 2.0 [0.078]
[0.012 to 0.0177]
69.987 to 70.000
Piston pin Outside diameter ø70 [2.76] 69.970 [2.7547]
[2.7554 to 2.7559]
Inside diameter of the 70.020 to 70.040
ø70 [2.76] 70.070 [2.7587]
connecting rod bushing [2.7567 to 2.7575]
0.05/100 [0.0020/
Bend and twist
3.94] or less
0.6 to 0.9
End play 1.4 [0.055]
[0.024 to 0.035]
Connecting Minimum:
rod 131.000 to 131.025 130.950 [5.1555]
Inside diameter of big end bore ø131 [5.16]
[5.1575 to 5.1585] Maximum:
131.050 [5.1594]
Roundness for inside diameter of
0.100 [0.0039]
big end bore
59.7 to 59.8
Big end side (width)
[2.3504 to 2.3543]
2-5
Unit: mm [in.]
3.000 2.957 to 2.970
Standard 2.930 [0.1154]
[0.1181] [0.1164 to 0.1169]
0.25 3.125 3.082 to 3.095
3.055 [0.1203]
[0.0098] [0.1230] [0.1213 to 0.1219]
Connecting
Thickness at 0.50 3.250 3.207 to 3.220
rod 3.180 [0.1252]
center Under- [0.0197 ] [0.1280] [0.1263 to 0.1268]
bearing
size 0.75 3.375 3.332 to 3.345
3.305 [0.1301]
[0.0295 ] [0.1329] [0.1312 to 0.1317]
1.00 3.500 3.457 to 3.470
3.430 [0.1350]
[0.0394 ] [0.1378] [0.1361 to 0.1366]
Face runout 0.336 [0.0132] or less Reference value
Flywheel
Radial runout 0.130 [0.0051] or less Reference value
Face runout 0.5 [0.020] or less Reference value
Damper
Radial runout 0.5 [0.020] or less Reference value
Inside diameter of 110.000 to 110.035
ø110 [4.33]
bearing fit in the oil pump bearing cover [4.3307 to 4.3321]
Inside diameter of 109.987 to 110.022
ø110 [4.33]
bearing fit in the pump plate [4.3302 to 4.3316]
Oil pump 109.985 to 110.000
Outside diameter ø110 [4.33]
drive [4.3301 to 4.3307]
Bearing
49.988 to 50.000
Inside diameter ø50 [1.97]
[1.9680 to 1.9685]
Outside diameter of 49.993 to 50.013
ø50 [1.97]
bearing fit in the oil pump gear [1.9682 to 1.9690]
Backlash between crank gear and rear idler 0.12 to 0.28
0.50 [0.0197]
gear [0.0047 to 0.0110]
Backlash between idler gear and camshaft 0.12 to 0.18
0.50 [0.0197]
gear [0.0047 to 0.0071]
Backlash between idler gear and injection 0.12 to 0.18
0.50 [0.0197]
Front idler pump gear [0.0047 to 0.0071]
gear 50.000 to 50.025
Front idler bushing inside diameter ø50 [1.97] 50.060 [1.9709]
[1.9685 to 1.9695]
49.950 to 49.975
Front idler shaft outside diameter ø50 [1.97] 49.900 [1.9646]
[1.9665 to 1.9675]
0.20 to 0.40
Front idler gear end play 0.60 [0.024]
[0.0079 to 0.0157]
0.12 to 0.28
Backlash 0.50 [0.0197]
[0.0047 to 0.0110]
65.000 to 65.030
Rear idler bushing inside diameter ø65 [2.56] 65.060 [2.5614]
[2.5591 to 2.5602]
Rear idler gear
64.951 to 64.970
Rear idler shaft outside diameter ø65 [2.56] 64.900 [2.5551]
[2.5571 to 2.5579]
0.3 to 0.5 1.0
Rear idler gear end play
[0.0118 to 0.0197] [0.040]
9.260 to 9.340
Cam lift (major axis - minor axis) 8.45 [0.3327]
[0.3646 to 0.3677]
Runout 0.05 [0.0020] or less 0.08[0.0031] TIR
83.92 to 83.94
Journal diameter ø84 [3.31] 83.87 [3.3020]
Camshaft [3.3039 to 3.3047]
Camshaft bushing inside diameter 84.000 to 84.035
ø84 [3.31] 84.100 [3.3110]
(as installed in crabkcase) [3.3071 to 3.3085]
0.10 to 0.25
End play 0.40 [0.0157]
[0.0039 to 0.0098]
2-6
Unit: mm [in.]
124.930 to 124.950
Standard 124.890 [4.9169]
[4.9185 to 4.9193]
0.25 124.680 to 124.700
124.640 [4.9071]
[0.0098] [4.9087 to 4.9094]
Crankpin
0.50 124.430 to 124.450
Outside ø125 [4.92] 124.390 [4.8972]
Under- [0.0197] [4.8988 to 4.8996]
diameter
size 0.75 124.180 to 124.200
124.140 [4.8874]
[0.0295] [4.8890 to 4.8898]
1.00 123.930 to 123.950
123.890 [4.8775]
[0.0394] [4.8791 to 4.8799]
Standard 169.920 to 169.940
169.880 [6.6882]
[6.6898 to 6.6905]
0.25 [0.0098] 169.670 to 169.690
169.630 [6.6783]
[6.6799 to 6.6807]
Crankshaft
0.50 [0.0197] 169.420 to 169.440
journal out- ø170 [6.69] 169.380 [6.6685]
[6.6701 to 6.6709]
side diameter Under-
size 0.75 [0.0295] 169.170 to 169.190
169.130 [6.6586]
[6.6602 to 6.6610]
1.00 [0.0394] 168.920 to 168.940
168.880 [6.6488]
[6.6504 to 6.6512]
Deviation of 0.01
Parallelism of journal and crankpin [0.0004] or less over 0.03 [0.0012]
entire pin length
Diameter difference
Circularity of journal and crankpin 0.03 [0.0012]
0.01 [0.0004] or less
Diameter difference
Cylindricity of journal and crankpin 0.03 [0.0012]
0.01 [0.0004] or less
Crankshaft
6.8 to 7.0
Fillet radius of pin R7 [0.28]
[0.268 to 0.276]
R8.5 8.3 to 8.5
Fillet radius of journals
[0.335] [0.327 to 0.335]
Hardness of journals and crankpins Hv > 590
Finishing accuracy Ra 0.2 μm [0.008 µin.]
Angular deviation between pins ±20'
120.20 to 120.30
Crankpin width 120 [4.72]
[4.7323 to 4.7362]
67.00 to 67.03
Standard
[2.6378 to 2.6390]
One 67.25 to 67.28
0.25 side [2.6476 to 2.6488]
[0.0098 ] Both 67.50 to 67.53
sides [2.6575 to 2.6587]
Rearmost
One 67.50 to 67.53
crank journal 67 [2.64]
Under- 0.50 side [2.6575 to 2.6587]
width
size [0.0197] Both 68.00 to 68.03
sides [2.6772 to 2.6783]
One 67.75 to 67.78
0.75 side [2.6673 to 2.6685]
[0.0295] Both 68.50 to 68.53
sides [2.6968 to 2.6980]
Runout 0.04 [0.0016] or less 0.10 [0.0039] TIR
End play 0.200 to 0.400
0.500 [0.0197]
(width between webs and thrust bearings) [0.0079 to 0.0157]
2-7
Unit: mm [in.]
4.500 4.467 to 4.480
Standard 4.425 [0.1742]
[0.1772] [0.1759 to 0.1764]
0.25 4.625 4.592 to 4.605
4.550 [0.1791]
[0.0098] [0.1821] [0.1808 to 0.1813]
Thickness at 0.50 4.750 4.717 to 4.730
Main bearing 4.675 [0.1841]
center Under- [0.0197] [0.1870] [0.1857 to 0.1862]
size 0.75 4.875 4.842 to 4.855
4.800 [0.1890]
[0.0295] [0.1919] [0.1906 to 0.1911]
1.00 5.00 4.967 to 4.980
4.925 [0.1939]
[0.0394] [0.1969] [0.1956 to 0.1961]
5.00 4.83 to 4.90
Standard 4.76 [0.1874]
[0.1969] [0.1902 to 0.1929]
0.25 5.25 5.08 to 5.15
5.01 [0.1972]
[0.0098] [0.2067] [0.2000 to 0.2028]
Thrust plate Thickness
Under- 0.50 5.55 5.38 to 5.45
5.31 [0.2090]
size [0.0197] [0.2185] [0.2118 to 0.2146]
0.75 5.75 5.58 to 5.65
5.51 [0.2169]
[0.0295] [0.2264 ] [0.2197 to 0.2224]
Distortion of top surface 0.1 [0.004] or less 0.2 [0.008]
179.000 to 179.025
Inside diameter of main bearing bore ø179 [7.05] 179.045 [7.0490]
[7.0472 to 7.0482]
Crankcase 14.00 to 14.05
Depth of counterbore in crankcase
[0.5512 to 0.5531]
The height from the center of crank journal 549.45 to 549.55
Reference value
to the top of crabkcase [21.6318 to 21.6358]
1.3 Fuel system

Unit: mm [in.]
Free length of nozzle spring 30 [1.18]
Squareness of nozzle spring Less than 0.6 [0.024]
Parallelism of top and bottom nozzle spring Less than 0.1 [0.004]
34.32 to 34.81 MPa
34.32 MPa
{350 to 355kgf/cm²}
Fuel injection starting pressure {350 kgf/cm²}
Fuel [4978 to 5049 psi]
[4978 psi]
injection (the value when it is new)
nozzle
P/N: 37560-37001 160°
Spray angle
P/N: 37860-15001 158°
No. of spray holes 10
P/N: 37560-37001 ø0.35[0.0138]
Spray-hole diameter
P/N: 37860-15001 ø0.29[0.0114]
89.987 to 90.022
ø90 [3.54]
[3.5428 to 3.5442]
Inside diameter of case to bearing fit
99.987 to 100.022
ø100 [3.94]
[3.9365 to 3.9379]
89.985 to 90.000
Small ø90 [3.54]
[3.5427 to 3.5433]
Outside diameter
Fuel 99.985 to 100.000
injection Large ø100 [3.94]
[3.9364 to 3.9370]
pump Bearing
accessory 44.988 to 45.000
Small ø45 [1.77]
drive [1.7712 to 1.7717]
Inside diameter
49.988 to 50.000
Large ø50 [1.97]
[1.9680 to 1.9685]
45.002 to 45.013
ø45 [1.77]
Drive shaft bearing fitting portion [1.7717 to 1.7722]
Outside diameter 50.002 to 50.013
ø50 [1.97]
[1.9686 to 1.9690]
2-8
1.4 Lubrication system

Unit: mm [in.]
0.100 to 0.200 0.400
Drive gear and driven gear backlash
[0.0039 to 0.0079] [0.0157]
0.100 to 0.148 0.350
Clearance between gear teeth and case bore
[0.0039 to 0.0058] [0.0138]
Clearance between gear width and case 0.040 to 0.116 0.210
depth [0.0016 to 0.0046] [0.0083]
29.887 to 29.900 29.840
Drive shaft outside diameter
[1.1767 to 1.1772] [1.1748]
29.947 to 29.960 29.920
Driven shaft outside diameter ø30 [1.18]
Oil pump [1.1790 to 1.1795] [1.1780]
30.000 to 30.021 30.055
Bushing inside diameter
[1.1811 to 1.1819] [1.1833]
1.3±0.13 MPa
Safety valve opening pressure {13±1.3 kgf/cm²}
[189±19 psi]
65.8 [2.591]/314 N
Safety valve 65.8 [2.591]/359 N
{32.0 kgf}
Spring installed length/load {36.6 kgf} [80.7 lbf]
[70.6 lbf]
Free length of safety valve spring 78 [3.07]
0.15 to 0.18 MPa
Oil filter alarm Differential pressure for activation of alarm {1.5 to 1.8 kgf/cm²}
[21 to 26 psi]
Relief valve Spring free length 188 [7.40]
80 to 84°C
Valve opening temperature
[176 to 183.2°F]
Oil thermostat
Temperature at which valve lift becomes
95°C [203°F]
11 [0.43] or more
1.5 Cooling system

Unit: mm [in.]
119.987 to 120.022
Pump case ø120 [4.72]
Inside diameter [4.7239 to 4.7253]
of bearing fit 110.005 to 110.040
Bearing cover ø110 [4.33]
[4.3309 to 4.3323]
Outside 119.985 to 120.000
ø120 [4.72]
diameter [4.7238 to 4.7244]
Large
Inside 54.985 to 55.000
ø55 [2.17]
diameter [2.1648 to 2.1654]
Bearing
Outside 109.985 to 110.000
Water pump ø110 [4.33]
diameter [4.3301 to 4.3307]
Small
Inside 49.988 to 50.000
ø50 [1.97]
diameter [1.9680 to 1.9685]
55.011 to 55.024
ø55 [2.17]
[2.1658 to 2.1663]
Outside diameter of shaft to bearing fit
50.011 to 50.024
ø50 [1.97]
[1.9689 to 1.9694]
1.04 0.58 to 1.50
Impeller front clearance
[0.0409] [0.0228 to 0.0591]
69 to 73°C
[156.2 to 163.4°F]
Thermostat
Temperature at which valve lift 85°C
becomes 9 [0.35] or more [185°F]
2-9
1.6 Electrical system

Unit: mm [in.]
30.002 to 30.011
Rear shaft outside diameter ø30 [1.18]
[1.1812 to 1.1815]
18.90 to 18.94
Pinion Shaft Front shaft outside diameter ø19 [0.75]
[0.7441 to 0.7457]
0.2 to 0.8
End play
[0.008 to 0.032]
19.000 to 19.033
Front bearing ø19 [0.75]
[0.7480 to 0.7493]
Bearing
19.000 to 19.033
Pinion ø19 [0.75]
[0.7480 to 0.7493]
Voltage drop between terminals B and M
0.3 V
(under load current of 100 A)
Starter 21 to 22 13
Brush length
[0.83 to 0.87] [0.51]
40.2 N
44.1 N
Brush spring load {4.1 kgf} With brush installed
{4.5 kgf} [9.9 lbf]
[9.0 lbf]
0.05
Shaft runout TIR
[0.0020]
Armature
0.15 to 0.75
End play
[0.0059 to 0.0295]
Outside diameter ø43 [1.69] 42 [1.65]
Runout 0.06 [0.0024] or less 0.1[0.004] TIR
Commutator
0.7 to 0.9
Undercut depth 0.2 [0.008]
[0.028 to 0.035]
25 A or more (when
the engine is cold)
1500
18 A or more (when
the engine is warm)
33 A or more (when
Rotational
Output current the engine is cold)
speed 2500
(27 V) 26 A or more (when
(min-1)
the engine is warm)
38 A or more (when
the engine is cold)
5000
30 A or more (when
Alternator
the engine is warm)
Regulator adjusting voltage
28.5 ± 0.5 V
(Alternator 5000 min-1, load at 5 A or lower)
Approx. 9
Resistance between slip rings
to 10.5 ohms
Brush length 21.5 [0.846] 8 [0.31]
When the center of the belt is
10 to 15 pushed with a force of approx.
Belt tension
[0.39 to 0.59] 98 to 147 N
{10 to 15 kgf} [22 to 33 lbf]
2-10
2. Tightening torque table

2.1 Tightening torque for Basic engine
Thread size Tightening torque
Description Dia. × Pitch Remarks
(M-thread) N·m kgf·m
[Wet] 2-time tightening method, Note

Cylinder head bolt 22 × 2.5 539 ± 27 55 ± 2.75 398 ± 20
(a)
Apply Loctite 272 to the internal screw
Cylinder head nozzle gland (studs) 14 × 2.0 73.5 ± 4.5 7.5 ± 0.5 54 ± 3.6
thread of the cylinder head
Rocker case 12 × 1.25 108 ± 5.4 11 ± 0.55 80 ± 4.0
Rocker shaft 14 × 2.0 147 ± 7.4 15 ± 0.75 108 ± 5.46
Rocker arm (lock nut) 12 × 1.25 64 ± 3.2 6.5 ± 0.33 47 ± 2.4
Bridge (lock nut) 10 × 1.25 55 ± 2.8 5.6 ± 0.28 40.5 ± 2.07
Camshaft gear (rear) 12 × 1.25 127 ± 6.4 13 ± 0.65 94 ± 5 Use 12T bolt w/hard washer
Camshaft thrust plate 12 × 1.25 59 ± 5.9 6 ± 0.6 43 ± 4.3
Main bearing cap 24 × 3.0 588 ± 29.4 60 ± 3.0 434 ± 22 [Wet], Note (b)
Main bearing cap (side bolt) 20 × 2.5 392 ± 19.6 40 ± 2.0 289 ± 14 [Wet], Note (b)
20 × 1.5 392 ± 19.6 40 ± 2.0 289 ± 14
Hanger
16 × 1.5 216 ± 10.8 22 ± 1.1 159 ± 8
Piston cooling nozzle 12 × 1.75 34 ± 1.7 3.5 ± 0.18 25 ± 1.2 Note (c)
Timing gear case 16 × 1.5 255 ± 12.8 26 ± 1.3 188 ± 9.4 Use hard washer
12 × 1.25 108 ± 5.4 11 ± 0.55 80 ± 3.98
Rear plate
16 × 1.5 255 ± 12.8 26 ± 1.3 188 ± 9.4 Use hard washer
392 ± 19.6 40 ± 2.0 289 ± 14
Front mounting bracket 20 × 1.5 Right front mounting bracket:
245 ± 12.3 25 ± 1.25 180 ± 9
Front end lower bolt only
Rear mounting bracket 20 × 1.5 392 ± 19.6 40 ± 2.0 289 ± 14
Connecting rod cap 22 × 1.5 Note (d) [Wet]
Balance weight 22 × 1.5 490 ± 24.5 50 ± 2.5 361 ± 18 [Wet]
Flywheel 22 × 1.5 588 ± 29.4 60 ± 3.0 434 ± 22 [Wet]
Ring gear 10 × 1.25 33 ± 1.7 3.4 ± 0.17 24 ± 1.25
Damper 22 × 1.5 490 ± 24.5 50 ± 2.5 361 ± 18
Rear idler shaft 20 × 1.5 392 ± 19.6 40 ± 2.0 289 ± 14 Apply MOLYKOT
Rear idler shaft thrust collar
18 × 1.5 196 ± 9.8 20 ± 1.0 145 ± 7
(nut)
12 × 1.25 59 ± 3.0 6 ± 0.3 43 ± 2.2
Front gear case
16 × 1.5 255 ± 12.8 26 ± 1.3 188 ± 9.4 Use hard washer
Front plate 12 × 1.25 59 ± 5.9 6 ± 0.6 43 ± 4.3
Front idler shaft 12 × 1.25 108 ± 10.8 11 ± 1.1 80 ± 8.0
Front idler shaft
10 × 1.25 60 ± 3.0 6.1 ± 0.31 44 ± 2.2
Thrust plate
Oil pump and water pump mounting plate 12 × 1.25 59 ± 5.9 6 ± 0.6 43 ± 4.3
Oil pump and bearing cover for water
pump drive 12 × 1.25 108 ± 10.8 11 ± 1.1 80 ± 8.0
Bearing cover
Fuel injection pump acces- Case 12 × 1.25 108 ± 5.4 11 ± 0.55 80 ± 4

sory drive Gear (nut) 30 × 1.5 490 ± 24.5 50 ± 2.5 361 ± 18
2-11
Note:(a) For torque-angle tightening method of cylinder head bolts, follow the steps in sequence given below:
1) Tighten the bolts with a snug torque of 294 ± 14.7 N·m {30 ± 1.5 kgf·m} [217±11 lbf·ft].
2) Tighten to the angle 65± 3°.
3) Loosen all bolts, and then retighten them in the sequence shown in the above 1) and 2).(2-time tightening method)
For tightening procedure, refer to "Cylinder head bolt - Tighten" of "ASSEMBLY OF BASIC ENGINE".
(b) For tightening of main bearing cap bolts and main bearing cap side bolts, follow the specified sequence. Tentatively
tighten the all bolts to the half of specified torque, and after the tentative tightening of all the bolts is completed, then
finally tighten them to the specified torque.
For tightening procedure, refer to "Main bearing cap - Install" of "ASSEMBLY OF BASIC ENGINE."
(c) Piston cooling nozzle check valves should be tightened to the specified torque. Do not over-tighten. If the tightening
torque exceeds the specified torque, it could cause the check valve to malfunction, which may result in piston seizure.
(d) Connecting rod cap bolts should be tightened as shown in the table below.
Bolt Torque method Angle method
Part No.
mark (2-time tightening method) (2-time tightening method)
539 ± 27 N·m {55 ± 2.75 kgf·m}
2 37519-20301 Snug torque 245 ± 12.3 N·m
[398 ± 20 lbf·ft]
{25 ± 1.25 kgf·m} [180 ± 9 lbf·ft] → 60 ± 3°
AU 37519-21300
637 ± 31.9 N·m {65 ± 3.25 kgf·m}
[470 ± 24 lbf·ft] Snug torque 294 ± 14.7 N·m
AL 37519-11400
{30 ± 1.5 kgf·m} [217 ± 11 lbf·ft] → 60 ± 3°
(e) When [Wet] is indicated, apply engine oil to the threads and bolt seat surface.
(f) Parts (bolts/nuts) indicated by 2-time tightening method should be tightened as follows: tighten to the specified torque,
and loosen, then retighten to the specified torque.
2.2 Tightening torque for Fuel system

(M-thread) N·m kgf·m lbf·ft
Fuel injection pump

12 × 1.25 108±5.4 11±0.55 80 ± 4
Accessory drive case
Fuel injection pump
30 × 1.5 490±24.5 50±2.5 361 ± 18
Accessory drive gear (nut)
Fuel injection pump
14 × 1.5 172±5 17.5±0.5 126.6 ± 3.6 Tighten the slit portion.
Coupling shaft
Fuel injection pump 2-time tightening method
12 × 1.25 108±5 11±0.5 80 ± 3.7
laminated plate 10T bolt + Nut with washer
Fuel injection pump 12 × 1.25 108±5.4 11±0.55 80 ± 4
Fuel injection pump bracket 12 × 1.25 108±5.4 11±0.55 80 ± 4
Fuel injection pump
24 × 1.5 392±19.6 40±2.0 289 ± 14
Flywheel (nut)
Fuel injection pump
8 × 1.25 15±2 1.5±0.2 11 ± 1.4
Air vent plug
Plunger assembly 12 × 1.25 80.5±2.5 8.2±0.25 59.37 ± 1.8
Delivery valve holder 30 × 1.5 245±10 25±1 180 ± 7
Fuel injection pipe
18 × 1.5 59±10 6±1 43 ± 7
(nozzle and pump side)
Fuel rack control lever 8 × 1.25 25±1.25 2.5±0.13 18 ± 0.9 2-time tightening method
Fuel filter air vent plug 8 × 1.25 9±1 0.9±0.1 6.5 ± 0.7
Nozzle tip retaining nut 28 × 1.5 186.5±9.5 19 ± 1 137 ± 7.0
Nozzle inlet connector 16 × 1.5 69±5 7±0.5 50 ± 3.6
Nozzle holder cap nut 14 × 1.5 73.5±4.5 7.5±0.5 54 ± 3.3
Nozzle holder set screw 10 × 1.5 39±5 4±0.5 28 ± 3.6
Nozzle gland (nut) 14 × 1.5 98±4.9 10±0.5 72 ± 3.6
Note: Parts (bolts/nuts) indicated by 2-time tightening method should be tightened as follows: tighten to the specified torque, and
loosen, then retighten to the specified torque.
2-12
2.3 Tightening torque for Lubrication system

Oil pump 12 × 1.25 108 ± 10.8 11 ± 1.1 80 ± 8.0

Oil pump cover 10 × 1.25 33 ± 3.3 3.4 ± 0.34 25 ± 2.5
Safety valve plug 24 × 1.5 88 ± 10 9 ± 1.0 65 ± 7.4
Safety valve assembly 32 × 2.0 74 ± 10 7.5 ± 1.0 54 ± 7.4
Oil pan 12 × 1.25 59 ± 5.9 6 ± 0.6 43 ± 4.3
2.4 Tightening torque for Cooling system

Water pump 12 × 1.25 108 ± 10.8 11 ± 1.1 80 ± 8.0

Water pump shaft pulley (nut) 30 × 1.5 392 ± 19.6 40 ± 2.0 289 ± 14 For alternator driving
2.5 Tightening torque for Inlet and exhaust system

Exhaust manifold
8 × 1.25 20 ± 1.0 2 ± 0.1 14.7 ± 0.72
V clamp (Nut)
Exhaust manifold mounting bolt 10 × 1.5 98 ± 4.9 10 ± 0.5 72 ± 3.6
Turbocharger mounting bolt 12 × 1.25 108 ± 5.4 11 ± 0.55 80 ± 3.98
Exhaust pipe V clamp 1/4-28UFN 9 ± 0.45 0.9 ± 0.045 6.5 ± 0.33 Unify screw
2.6 Tightening torque for Electrical system

Starter 12 × 1.25 59 ± 5.9 6 ± 0.6 43 ± 4.3

Alternator pulley set nut 20 × 1.5 147 ± 15 15 ± 1.5 108 ± 11
Alternator 12 × 1.25 46 ± 8 4.7 ± 0.8 34 ± 5.0
2-13
2.7 Tightening torque for Standard bolts and nuts

Thread size Width across Strength classification
Threads Dia. × Pitch flats
(M-thread) (mm) 7T 10.9
7 10
N·m kgf·m lbf·ft N·m kgf·m lbf·ft
8 × 1.25 12 17 1.7 12 30 3.1 22
10 × 1.25 14 33 3.4 25 60 6.1 44
12 × 1.25 17 60 6.1 44 108 11.0 80
Metric automobile screw thread
14 × 1.5 22 97 9.9 72 176 17.9 129
16 × 1.5 24 145 14.8 107 262 26.7 193
18 × 1.5 27 210 21.4 155 378 38.5 278
20 × 1.5 30 291 29.7 215 524 53.4 386
22 × 1.5 32 385 39.3 284 694 70.8 512
24 × 1.5 36 487 49.7 359 878 89.5 647
27 × 1.5 41 738 75.3 544 1328 135.5 980
N·m kgf·m lbf·ft N·m kgf·m lbf·ft

10 × 1.5 14 32 3.3 24 58 5.9 43
12 × 1.75 17 57 5.8 42 102 10.4 75
Metric course screw thread 14 × 2 22 93 9.5 69 167 17.0 123
16 × 2 24 139 14.2 103 251 25.6 185
18 × 2.5 27 194 19.8 143 350 35.7 258
20 × 2.5 30 272 27.7 200 489 49.9 361
22 × 2.5 32 363 37.0 268 653 66.6 482
24 × 3 36 468 47.7 345 843 86.0 622
27 × 3 41 686 70.0 506 1236 126.0 911
Note:(a) The tightening torque listed in this table is for standard bolts and nuts.
(b) The numerical values in the table are the values when spring washers are used.
(c) The table shows the standard values with a maximum tolerance value of ±10%.
(d) Use the tightening torque in this table unless otherwise specified.
(e) Do not apply oil to threaded portions. (Dry)
2-14
2.8 Tightening torque for Standard eyebolts

Strength classification
Thread size
Width across flats
Dia. × Pitch 4T
(mm) [in.]
(M-thread)
N·m kgf·m lbf·ft
8 × 1.25 12 [0.47] 8±1 0.8 ± 0.1 5.79 ± 0.72
10 × 1.25 14 [0.55] 15 ± 2 1.5 ± 0.2 10.85 ± 1.45
12 × 1.25 17 [0.67] 25 ± 3 2.5 ± 0.3 18.08 ± 2.17
14 × 1.5 19 [0.75] 34 ± 4 3.5 ± 0.4 25.31 ± 2.89
16 × 1.5 22 [0.87] 44 ± 5 4.5 ± 0.5 32.55 ± 3.61
18 × 1.5 24 [0.94] 74 ± 5 7.5 ± 0.5 54.25 ± 3.61
20 × 1.5 27 [1.06] 98 ± 10 10.0 ± 1.0 72.33 ± 7.24
24 × 1.5 32 [1.26] 147 ± 15 15.0 ± 1.5 108.49 ± 10.85
27 × 1.5 41 [1.61] 226 ± 20 23.0 ± 2.0 166.35 ± 14.46
(Dry)
2.9 Tightening torque for Standard union nuts

Cap nut thread size
Width across flats
Nominal Dia. × Pitch N·m kgf·m lbf·ft
(mm) [in.]
(M-thread)
63 14 × 1.5 19 [0.75] 39 4 39.23
80 16 × 1.5 22 [0.87] 49 5 49.03
100 20 × 1.5 27 [1.06] 78 8 78.45
120 22 × 1.5 30 [1.18] 98 10 98.07
150 27 × 1.5 32 [1.26] 157 16 156.91
180 30 × 1.5 36 [1.42] 196 20 196.13
200 30 × 1.5 36 [1.42] 196 20 196.13
220 33 × 1.5 41 [1.61] 245 25 245.17
254 36 × 1.5 41 [1.61] 294 30 294.20
(Maximum tolerance value: ±10%, dry condition)
2.10 Tightening torque fo Fuel injection pipe

Cap nut thread size
Dia. × Pitch N·m kgf·m lbf·ft
(M-thread)
12 × 1.5 39 ± 5 4 ± 0.5 29 ± 3.6
14 × 1.5 49 ± 5 5 ± 0.5 36 ± 3.6
18 × 1.5 59 ± 10 6 ± 1.0 43 ± 7.2
(Dry)
2-15
1. Special tools............................................................................................................. 3-3
3-1
1. Special tools
Maintenance Tool name Part No. Illustration Usage

item
General Tool box 49160-90501 Tool box
(75 × 203 × 360 mm)
[2.95 × 7.99 × 14.17 in.]
Adjustable wrench F9611-15000 Max. open width 20 mm [0.79 in.]
Torque wrench 32191-03100 Tightening to the specified torque

Measurement range: 0 to 539 N·m
{0 to 55 kgf·m} [0 to 398 lbf·ft]
Ring pliers 45191-08400 Snap ring - installation/removal
3-3

item
Overhaul deter- Compression gauge 33A91-01700 Compression pressure - Measure
mination and test Measurement range: 0 to 7 MPa
{0 to 71 kgf/cm2} [0 to 1015 psi]
Gauge adapter 37591-02200 Compression pressure - Measure

U5/8
18-threads
Inspection Belt gauge 32591-09100 Belt tension - Measure

30
25
20
15
10
5
Basic engine Nozzle remover 33591-10101 Fuel injection nozzle - Remove
Eye nut 37591-02400 Cylinder head assembly - Install/

remove
M14 × 1.5
Valve spring 33591-04500 Valve spring - Install/remove

pusher Length of handle plate: 600 mm
[23.62 in.]
Rocker bushing tool 37591-02600 Rocker bushing - Replace
Valve guide remover 33591-04300 Valve guide - Remove

φ17 × L100 Applicable valve guide inside/outside
diameters:
ø10× 18 mm [0.39 × 0.70 in.]
φ10 × L50
Guide & seal installer 37191-11500 Valve guide and stem seal - Install
With single valve spring
3-4

item
Basic engine Guide & seal installer 37591-12300 Valve guide and stem seal - Install
With double valve spring
Valve lapper 30091-08800 Valve lapping
Valve seat cutter 37591-06400 Valve seat - Reface

(shaft) Gide shaft diameter ø10 mm [0.39 in.]
Width across flats: 32 mm [1.26 in.]
θ=30°
Applicable seat inside/outside diame-
ter: ø45 to 66 mm [1.77 to 2.60 in.]
W1 1/8 - 18
Valve seat cutter 37591-06430
W1 1/8 - 18
Head bolt plate 37598-08900 Cylinder head bolt - Angle-tighten
Valve seat puller 32591-04200 Valve seat - Remove
Jack bolt 64362-68500 Flywheel - Remove

Pump plate - Remove
Damper - Remove
M12 × 1.25㨺95mm
Idler bushing puller 32591-02500 Front idler bushing - Replace
Rear seal installer assembly 37791-06010 Rear oil seal - Install
3-5

item
Basic engine Slinger installer 37491-02100 Rear slinger - Press-fit: Use in com-
bination with installer guide.
Installer guide 37491-02200
Front seal installer assem- 37591-05010 Front oil seal - Install

bly
Piston remover 37591-02500 Piston - Remove

M10 × 1.25 mm
Ring expander 37191-03200 Piston ring - Install/remove

Range of use: ø101.6 to 177.8 mm
[3.4 to 7.0 in.]
Cylinder liner remover 37591-04100 Cylinder liner - Remove
Liner pusher 37591-06200 Cylinder liner flange protrusion -

Measure
Bolt 37591-06300 Cylinder liner flange protrusion -

Measure
M22 × 2.5 - 115mm
Projection 37598-09201 Depth of counterbore in crabkcase

Plate measurement
3-6

item
Basic engine Piston installer 37191-07100 Piston- Install
Applicable piston diameter: ø89 to
178 mm [3.5 to 7.0 in.]
Crankcase 37591-07010 Depth of counterbore in crabkcase -

Grinder Reface
Cap remover 37791-02100 Main bearing cap - Remove
M27 × 1.5
Connecting rod 37591-01010 Connecting rod bushing - Install/

Bushing installer remove
Connecting rod gauge Sheet thick- Connecting rod end play setting
ness: 0.5 mm
[0.02 in.]
37791-01500
Sheet thick-
ness: 0.6 mm
[0.024 in.]
37791-01600
Fuel Nozzle tester 83091-03301 Fuel injection nozzle opening pressure
system - Measure
Socket 58309-73100 Fuel injection pump gear and water

pump gear - Install/remove
Fuel 37591-06100 Fuel injection pump coupling clear-

Injection pump coupling ance - Adjust
gauge GO : 48.75 mm [1.9192 in.]
NO GO: 49.25 mm [1.9390 in.]
3-7

item
Cooling Water pump pliers 37591-03100 Water pump cover snap ring -Install/
system remove
Applicable size: ø180 to 300 mm
[7.09 to 11.81 in.]
Impeller remover 37591-03200 Impeller of water pump - Remove

M18 × 1.5 mm [0.059 in.]
Ring remover 37791-03400 Water pump unit seal - Remove
Cooling Unit seal 37191-06300 Water pump unit seal - Press-fit

system Installer
Ring installer 37791-03300 water pump unit seal ring - Press-fit
3-8
1. Determining overhaul timing .................................................................................. 4-3
2. Compression pressure - Measure.......................................................................... 4-4
4-1
1. Determining overhaul timing

In most cases, the engine should be overhauled when the compression pressure of the engine becomes low. An increase in
engine oil consumption and blow-by gas should be considered when evaluating engine condition.
Symptoms like a decrease in output, increase in fuel consumption, decrease in oil pressure, difficulty of engine starting and
increase in noise should be considered when evaluating overhaul timing, although those symptoms are often affected by other
causes, and are not always effective to evaluate overhaul timing.
Decreased compression pressure shows a variety of symptoms and engine conditions, thus making it difficult to accurately
determine when the engine needs an overhaul.
The following shows typical problems caused by reduced compression pressure.
(1) Decreased output power
(2) Increased fuel consumption
(3) Increased engine oil consumption
(4) Increased blow-by gas through the breather due to worn cylinder liners and piston rings (Visually check the blow-by
amount)
(5) Increased gas leakage due to poor seating of inlet and exhaust valves
(6) Difficulty in starting
(7) Increased noise from engine parts
(8) Abnormal exhaust color after warm-up operation
The engine can exhibit these conditions in various combinations.
Some of these problems are directly caused by worn engine parts, while others are not.
Phenomena described in items (2) and (6) can result from improper fuel injection volume and timing of the fuel injection pump,
worn plunger, faulty nozzles and also faulty conditions of electrical devices such as battery and starter.
The most valid reason to overhaul an engine is a decrease in compression pressure due to worn cylinder liners and pistons, as
described in item (4), and once this is determined, it is reasonable to take other problems into consideration for making a final
evaluation.
4-3
2. Compression pressure - Measure
Compression gauge
(a) Be sure to measure the compression pressure of P/N:33A91-01700
every cylinder. It is risky to measure the com-
pression pressure of two or three cylinders, and Gauge adapter
to assume that the compression pressure is the P/N:37591-02200
same for all cylinders, as they are independent
cylinders.
(b) Also be sure to check engine speed when mea-
suring the compression pressure, as compres-
sion pressure varies depending on engine Compression pressure - Measure
speed.
(c) Measuring the compression pressure at regular
intervals is important to obtain correct data.
(1) Remove the injection nozzle from the cylinder head
where the compression pressure is to be measured.
(2) Attach the compression gauge adapter to the fuel injec-
tion nozzle mount and connect compression gauge.
(3) Crank the engine with the starter at the no-injection
position (i.e. with the fuel injection pump rack position
being set to zero).
Read the engine speed and compression pressure while
the engine is running at the specified speed.
Note: Check that the battery is fully charged when cranking
the engine with the starter.
If the battery voltage is decreased, sufficient rotational
speed, which is required for compression pressure test,
cannot be obtained.
(4) If the measured value exceeds the limit, overhaul the
engine.
Basic
Item Standard Limit
Rotational speed
1.8 MPa 1.27 MPa
Compression
{18.5 kgf/cm2} {13 kgf/cm2} 120 min-1
pressure
[263 psi] [185 psi]
4-4
1. Cylinder heads and Valve mechanisms - Disassemble and Inspect .................. 5-3
1.1 Fuel inlet connector - Remove.................................................................................................. 5-4
1.2 Nozzle assembly - Remove ...................................................................................................... 5-4
1.3 Valve clearance - Inspect ......................................................................................................... 5-4
1.4 Fuel injection timing - Inspect ................................................................................................... 5-5
1.5 Rocker shaft assembly - Remove............................................................................................. 5-5
1.6 Clearance between the bottom face of valve bridge and the top face of valve rotator - Inspect5-5
1.7 Valve bridge - Remove ............................................................................................................. 5-6
1.8 Rocker case - Remove ............................................................................................................. 5-6
1.9 Cylinder head assembly - Remove........................................................................................... 5-6
1.10 Valve sinkage - Measure .......................................................................................................... 5-6
1.11 Valve and Valve spring - Remove ............................................................................................ 5-7
1.12 Nozzle gland stud bolt and Bridge guide - Remove.................................................................. 5-7
2. Rear equipment - Disassemble and Inspect ......................................................... 5-8
2.1 Flywheel face and radial runouts - Measure............................................................................. 5-9
2.2 Flywheel - Remove ................................................................................................................... 5-9
2.3 Rear idler shaft thrust collar - Remove ..................................................................................... 5-9
2.4 Timing gear case - Remove.................................................................................................... 5-10
2.5 Timing gear backlash - Measure ............................................................................................ 5-10
2.6 Rear idler gear end play - Measure ........................................................................................ 5-10
2.7 Rear idler gear - Remove ....................................................................................................... 5-11
2.8 Accessory drive - Remove...................................................................................................... 5-11
2.9 Camshaft end play - Measure................................................................................................. 5-11
2.10 Camshaft gear - Remove........................................................................................................ 5-11
2.11 Camshaft - Remove................................................................................................................ 5-12
2.12 Rear idler shaft - Remove....................................................................................................... 5-12
2.13 Rear plate - Remove............................................................................................................... 5-12
3. Front equipment - Disassemble and Inspect ...................................................... 5-13
3.1 Damper face and radial runouts - Measure ............................................................................ 5-14
3.2 Damper and Crankshaft pulley - Remove............................................................................... 5-14
3.3 Pump plate (for water pump and oil pump) - Remove ............................................................ 5-14
3.4 Oil pump gear - Remove......................................................................................................... 5-15
3.5 Breather case - Remove......................................................................................................... 5-15
3.6 Front gear case - Remove ...................................................................................................... 5-15
3.7 Water pump bearing cover and Oil pump bearing cover - Remove........................................ 5-15
3.8 Front idler gear backlash - Measure ....................................................................................... 5-16
3.9 Front idler gear end play - Measure........................................................................................ 5-16
3.10 Front idler gear - Remove....................................................................................................... 5-16
3.11 Front idler shaft - Remove ...................................................................................................... 5-16
3.12 Coupling - Remove ................................................................................................................. 5-17
5-1
4. Cylinder liner, Piston and Connecting rod - Disassemble and Inspect............ 5-18
4.1 Piston protrusion - Measure.................................................................................................... 5-19
4.2 Connecting rod end play - Measure........................................................................................ 5-19
4.3 Hard carbon deposits on the upper part of cylinder liner - Remove ....................................... 5-19
4.4 Connecting rod cap - Remove ................................................................................................ 5-19
4.5 Piston - Remove ..................................................................................................................... 5-20
4.6 Piston ring - Remove .............................................................................................................. 5-21
4.7 Piston pin and Piston - Remove ............................................................................................. 5-22
4.8 Cylinder liner inside diameter - Measure ................................................................................ 5-22
4.9 Cylinder liner flange protrusion - Measure.............................................................................. 5-22
4.10 Cylinder liner - Remove .......................................................................................................... 5-22
5. Crankcase, Crankshaft and Main bearing - Disassemble and Inspect ............. 5-23
5.1 Crankcase - Invert .................................................................................................................. 5-24
5.2 Crankshaft end play - Measure............................................................................................... 5-24
5.3 Piston cooling nozzle - Remove ............................................................................................. 5-24
5.4 Main bearing cap - Remove.................................................................................................... 5-24
5.5 Crankshaft - Remove.............................................................................................................. 5-25
5-2
1. Cylinder heads and Valve mechanisms - Disassemble and Inspect

Understanding current condition of the engine before disassembling is very important to investigate the faulty part of engine
and to maintain the engine efficiently.
Depending on the maintenance work or purpose, it is desirable to inspect the following before proceeding with any work.
Valve clearance - Inspect
Fuel injection timing - Inspect
Clearance between the bottom face of valve bridge and the top face of valve rotator - Inspect
Valve sinkage - Measure
1
15
3
Replace
4
Replace
Replace 5
Crack, oil leakage,
2
fatigue
Replace
16 6
17 Wear
Crack, oil leakage,
scale deposit
Replace Crack, carbon deposit Replace
Damage, scale deposit
8
18
Wear,
clogged of oil hole
Damage 19
11 14
Wear 13 Contact, wear
10 29 Wear on both ends,
9 Wear of stem and seat surfaces bend
7 Corrosion, damage,
12 carbon deposit 31
20
20 13 24 Wear of cam and
21 25 circumference contact
22 Fatigue, crack
26
23 27
Inlet side Crack, damage, fatigue Replace
28 30
Exhaust side Crack of rubber
Cylinder heads and Valve mechanisms - Disassemble and Inspect

Disassembling sequence
1 Rocker cover 12 Bridge cap 22 Valve spring
2 Fuel inlet connector 13 Valve bridge 23 Stem seal
3 Washer, nut 14 Push rod 24 Upper rotator
4 Nozzle gland 15 Water outlet connector 25 Inner valve spring
5 Fuel injection nozzle 16 Rocker case 26 Outer valve spring
6 Gasket 17 Cylinder head bolt 27 Lower retainer
7 Adjusting screw 18 Cylinder head 28 Stem seal
8 Bolt (Approx. 35 kg [77.2 lb.]) 29 valve
9 Rocker arm 19 Inlet port packing 30 Cylinder head gasket
10 Spacer 20 Valve cotter 31 Tappet
11 Rocker shaft 21 Valve rotator
5-3
1.1 Fuel inlet connector - Remove

Remove the fuel inlet connector.
Fuel inlet connector
Fuel inlet connector - Remove

1.2 Nozzle assembly - Remove
When removing the nozzle assembly using a nozzle Gasket

remover, be careful not to get caught your fingers
between the nozzle remover weight, bar and the Nozzle gland
plate.
Nozzle remover
P/N:33591-10101
Before removing the nozzle holder, clean the nozzle

assembly to prevent foreign matter from getting into
the cylinder head. Keep the nozzle and the fuel inlet Nozzle assembly - Remove
connector together, and handle the nozzle with care
to avoid damage to the nozzle tip.
(1) Remove the nozzle gland.
(2) Remove the nozzle holder using the nozzle remover.
(3) Remove the gasket remained inside the cylinder head.
1.3 Valve clearance - Inspect
Inspect the valve clearance, and recognize the current condi-
tion.
Valve clearance
For the inspection procedure, refer to "Valve clearance -
Inspect and Adjust" of "ASSEMBLY OF BASIC
ENGINE."
Valve clearance - Inspect
5-4
1.4 Fuel injection timing - Inspect

Inspect the fuel injection timing, and recognize the current
condition. Pointer
For the inspection procedures, refer to "Fuel injection tim-
ing - Check and Adjust" of "ASSEMBLY OF BASIC
ENGINE. "
Stamped line on the flywheel

ࣇࣛ࢖࣍࢖࣮ࣝࡢ้⥺
Fuel injection timing - Inspect
1.5 Rocker shaft assembly - Remove
(1) Loosen the adjusting screw of rocker arm.
Lock nut
(2) Remove the rocker shaft assembly from the rocker
case.
Note: Keep the removed rocker shaft assembly together with
the bolts. Loosen
(3) Remove the push rod.
Adjusting screw
Rocker shaft assembly - Remove

(4) Disassemble the rocker shaft assembly.
Note: Do not remove the rocker bushing unless it is defective
Rocker shaft
or its inside diameter exceeds the limit. Rocker arm
Spacer
Lock nut
Adjusting screw
Rocker shaft assembly - Disassemble

1.6 Clearance between the bottom face of valve bridge and the top face of valve rotator - Inspect
Inspect the clearance between the bottom surface of valve
Hold the top of bridge
bridge and the top surface of valve rotator, and recognize by hand
the current condition. Valve bridge Bridge cap Clearance between
For the inspection procedure, refer to "Clearance between the bottom surface
Valve rotator of valve bridge and
the bottom surface of valve bridge and the top surface of the top surface of
valve rotator
valve rotator - Measure" of "ASSEMBLY OF BASIC
ENGINE. "
Clearance between the bottom face of valve bridge

and the top face of valve rotator - Inspect
5-5
1.7 Valve bridge - Remove

Remove the valve bridge and bridge cap.
Note: Be careful not to drop the bridge cap into the push rod Screw
Bridge cap
hole.
Valve bridge - Remove

1.8 Rocker case - Remove
(1) Remove the snap ring of water outlet connector.
Water outlet connector
(2) Slide the water outlet connector to the snap ring groove Snap ring groove
side, and separate it from the rocker case.
(3) Remove the rocker case from the cylinder head.
Rocker case
Rocker case - Remove

1.9 Cylinder head assembly - Remove
Eye nut
P/N:37591-02400
When removing the cylinder head gasket, be careful
not to damage the cylinder head or crabkcase surface
with a screwdriver or the like.
(1) Remove cylinder head bolts.
(2) Remove the cylinder head by lifting it up using the
sling.
Note: Dowel pins are used to retain the cylinder head in a
fixed position, and therefore, the cylinder head needs
to be removed perpendicular to the mounting surface. Cylinder head assembly - Remove
(3) Remove the cylinder head gasket.
1.10 Valve sinkage - Measure
Measure the valve sinkage, and recognize the current condi-
tion.
For the measurement procedure, refer to "Valve sinkage -
Measure" of "ASSEMBLY OF BASIC ENGINE."
5-6
1.11 Valve and Valve spring - Remove

Using a valve spring pusher, compress the valve spring
Valve spring pusher
evenly and remove the valve cotters.
P/N:33591-04500
Note: If valves are reusable, mark each valve seat and the
mating valve guide for identifying their original posi-
tions. Do not mix valve seats with other valves when
reassembling.
Valve spring - Compress
Exhaust Inlet
Valve cotter
Valve cotter
Upper rotator
Valve rotator
Inner valve
spring Valve spring
Outer valve
spring Stem seal
Lower retainer
Stem seal
Valve and Valve spring - Remove

1.12 Nozzle gland stud bolt and Bridge guide - Remove
Do not remove the nozzle gland stud bolt and the bridge
Nozzle gland
guide from the cylinder head unless they are found to be
stud bolt
defective.
Bridge guide Bridge guide
If they are removed, see "Nozzle gland stud bolt and Bridge
guide - Inspect and Replace" of "INSPECTION AND
REPAIR OF BASIC ENGINE."
Nozzle gland stud bolt and Bridge guide - Remove
5-7
2. Rear equipment - Disassemble and Inspect

Flywheel face and radial runouts - Measure
Timing gear backlash - Measure
Rear idler gear and camshaft end play - Measure
Flaw, wear
Replace Flaw, wear
10
Replace
12
15
13
16 Clogging
11
7 Peeling, wear
9
Replace 11
Crack, 8
14
dowel hole defect
Replace
9
10 8
14
Replace
Clogging, wear
4
Replace
3 Wear, flaw, aging
Replace
6
2
1
5 Flaw
4
Replace 3
Crack, dowel hole defect,

flaw, abnormal wear
Rear equipment - Disassemble and Inspect

1 Pick-up 10 Accessory drive (Approx. 21 kg [46 lb.])
2 Flywheel (Approx. 140 kg [309 lb.]) (Refer to the page of "FUEL SYSTEM" for disassembly,inspection and as-
3 Cover sembly.)
4 Thrust collar 11 Camshaft gear
5 Timing gear case (Approx. 150 kg [331 lb.]) 12 Thrust plate
6 Oil seal 13 Camshaft (Approx. 47 kg [103 lb.])
7 Oil seal slinger 14 Idler shaft
8 Thrust plate 15 Rear plate (Approx. 28.5 kg [62.8 lb.])
9 Idler gear 16 Nozzle plate
5-8
2.1 Flywheel face and radial runouts - Measure

Measure the face and radial runouts of the flywheel, and
recognize the current status.
For the measurement procedure, refer to "Flywheel face and Face runout
measurement
radial runouts - Measure" of "ASSEMBLY OF BASIC
Radial runout
ENGINE." measurement

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

only cause damage to it, but also lead to person-
nel injuries.
(b) Be careful not to cut your hands with the ring gear
when pulling out the flywheel.
Flywheel
Jack bolt
P/N:64362-68500
Be sure to remove the pickups before removing the (M12 x 1.25 mm)
flywheel. Flywheel - Remove
(1) Attach a hoisting tool to the flywheel to prevent it from
falling.
(2) Screw two jack bolts evenly into the jack bolt holes,
and remove the flywheel.
2.3 Rear idler shaft thrust collar - Remove
(1) Remove the cover from the timing gear case.
(2) Install the bolts (M6 x 1.0 mm [0.04 in.]) into the dedi-
cated bolt holes for removal of rear idler shaft thrust
collar, and remove the rear idler shaft thrust collar.
Note: Mark the collars to distinguish between right and left Rear idler shaft
thrust collar
collars so that the same backlash and end play can be
Cover
restored at reassembly.
Put a right
and left identification mark.
Rear idler shaft thrust collar - Remove
5-9
2.4 Timing gear case - Remove
Eyebolt
(a) Be careful not to damage the oil seal when remov- P/N:05930-00200
(M12 × 1.25 mm)
ing timing gear case.
(b) Be careful not to drop or hit the timing gear case.
It can, not only cause damage to it, but also lead
to personnel injuries.
(1) Attach a hoisting tool to the timing gear case to prevent
it from falling. Timing gear case
(2) Raise the timing gear case to disengage the dowel pins
and remove the timing gear case. Timing gear case - Remove
(3) Remove the oil seal from the timing gear case.
2.5 Timing gear backlash - Measure

Measure the timing gear backlash, and recognize the current
condition. Camshaft gear
For the measurement procedure, refer to "Timing gear back- Injection
pump gear
lash - Measure" of "ASSEMBLY OF BASIC ENGINE."
Rear idler gear

Timing gear backlash - Measure
2.6 Rear idler gear end play - Measure
Measure the rear idler gear end play, and recognize the cur-
rent condition.
For the measurement procedure, refer to "Rear idler gear
end play - Measure" of "ASSEMBLY OF BASIC
ENGINE."
Rear idler gear end play - Measure
5-10
2.7 Rear idler gear - Remove

(1) Remove the oil seal slinger from the crankshaft.
(2) Remove the thrust plate.
(3) Remove the rear idler gears (right and left).
Thrust plate
Rear idler gear
Slinger
Rear idler gear - Remove
2.8 Accessory drive - Remove
Remove the accessory drive from the rear plate.
(Refer to the section of "FUEL SYSTEM" for disassembly,
inspection and assembly.)
Note: Remove the rearmost cylinder cam cover on the left
side before removing the left side fuel injection pump
accessory drive case so that bolts do not interfere with
the cover.
Fuel injection pump

accessory drive
Accessory drive - Remove

2.9 Camshaft end play - Measure
Measure the camshaft end play, and recognize the current
condition. Camshaft gear
For the measurement procedure, refer to "Camshaft end
play - Measure" of "ASSEMBLY OF BASIC ENGINE."
Camshaft end play - Measure

2.10 Camshaft gear - Remove
Remove the camshaft gear from the camshaft.
Camshaft gear
Camshaft gear - Remove
5-11
2.11 Camshaft - Remove
Support the camshaft with a bar inserted through the

side cover mounting section when removing the cam-
shaft. Be careful not to bump the camshaft. If you do,
the cam portion and cam shaft bushing get damaged.
(1) Remove the thrust plate.
(2) Support the camshaft from the side cover mounting sec- Camshaft
Thrust plate
tion, remove the camshaft from the crabkcase.
Note: Before removing camshaft, remove the oil seal case,
oil seal and coupling from the cam shaft front end. Camshaft - Remove
2.12 Rear idler shaft - Remove
Install the sliding hammer to the dedicated hole (M22×1.5
mm [0.059 in.]) for removal , and remove the rear idler Rear idler shaft
shaft.
Sliding hammer
Rear idler shaft

Rear idler shaft - Remove
2.13 Rear plate - Remove
(1) Remove the rear plate from the crabkcase.
(2) Remove the nozzle plate from the crabkcase. Nozzle plate
Rear plate
Rear plate - Remove
5-12
3. Front equipment - Disassemble and Inspect

Damper face and radial runouts - Measure
Front idler gear backlash - Measure
Front idler gear end play - Measure
Front equipment - Disassemble and Inspect
5-13
3.1 Damper face and radial runouts - Measure

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

3.2 Damper and Crankshaft pulley - Remove
Lift the crankshaft Crankshaft

pulley with rope pulley
Be careful not to drop or bump the damper. It can,
Jack bolt
not only cause damage to it, but also lead to person-
(M14 × 1.5 - 120 mm)
nel injuries.
(1) Install the guide bolts to the damper mounting holes on
the crankshaft.
(2) Wrap a rope to the groove of crankshaft pulley and lift
the crankshaft pulley. Screw two jack bolts evenly into
the jack bolt holes, and remove the crankshaft pulley.
(3) While raising the damper using a hoist tool, install two Crankshaft pulley - Remove
jack bolts evenly into the jack bolt holes, and remove
Jack bolt
the damper. P/N:64362-68500
Guide bolt (M12 × 1.25 mm)
Damper
Damper - Remove
3.3 Pump plate (for water pump and oil pump) - Remove
Install two jack bolts evenly into the jack bolt holes, and
remove the pump plate.
Jack-bolts
P/N:64362-68500
(M12 × 1.25 mm)
Pump plate (for water pump and oil pump) - Remove
5-14
3.4 Oil pump gear - Remove

Remove the oil pump gear together with the bearing.
Oil pump gear
Oil pump gear - Remove

3.5 Breather case - Remove
Remove the breather case from the front gear case.
Breather case
Packing
Breather case - Remove

3.6 Front gear case - Remove
Eye bolt
05930-00200
When removing the front gear case, be careful not to (M12 × 1.25 mm)
damage the oil seal or not to distort the pointer by
hitting.
(1) Attach a hoisting tool to the front gear case.
(2) Raise the front gear case to disengage the dowel pins,
and remove the front gear case.
(3) Remove the oil seal from the front gear case.
Front gear case
Front gear case - Remove

3.7 Water pump bearing cover and Oil pump bearing cover - Remove
Remove the water pump bearing cover and oil pump bear-
Water pump
ing cover from the front plate.
bearing
cover
Oil pump
bearing cover
Water pump bearing cover and Oil pump bearing
cover - Remove
5-15
3.8 Front idler gear backlash - Measure

Measure the front idler gear backlash, and recognize the
current condition.
For the measurement procedure, refer to "Front idler gear
backlash - Measure" of "ASSEMBLY OF BASIC
ENGINE."
Front
idler gear

3.9 Front idler gear end play - Measure
Measure the end play of front idler gear, and recognize the
current condition. Front
For the measurement procedure, refer to "End play of front idler gear
idler gear - Measure" of "ASSEMBLY OF BASIC

ENGINE."

3.10 Front idler gear - Remove
Remove the thrust plate and front idler gear from the front
idler shaft.
Front
idler gear
Front idler gear - Remove

3.11 Front idler shaft - Remove
Do not remove the front idler shaft unless it is necessary. If
it is necessary to remove the front idler shaft, install two
jack bolts evenly into its dedicated holes, and remove the
front idler shaft.
Jack-bolts
(M101.25 mm)
Front idler shaft - Remove
5-16
3.12 Coupling - Remove

(1) Remove the oil seal case and oil seal from the crab-
kcase.
Oil seal case
Note: Inspect the oil seal. If any defect is found, replace it
with a new one.
O-ring
Oil seal
Oil seal case - Remove

(2) Screw two jack bolts evenly into the jack bolt holes,
and remove the coupling from the camshaft.
Jack bolt
(M12×1.25 mm)
Coupling - Remove
5-17
4. Cylinder liner, Piston and Connecting rod - Disassemble and Inspect

Piston protrusion - Measure
Connecting rod end play - Measure
Cylinder liner inside diameter - Measure
Cylinder liner flange protrusion - Measure
Wear, flaw
5
9
6
7
Scratches on the outer surface, crack,

flaw, wear, carbon deposit
10
8
11 Crack, clogged oil hole
Scratches on the inner surface,
wear, rust on the outer surface
and O-ring groove, cavitation
Wear on the inner surface, 12

flaw, discoloration
Replace
Deformation, wear
Flaw, Seizing,
peeling of inner
and outer surface
4
Wear on the serration, crack 3
1
Flaw
Cylinder liner, Piston and Connecting rod - Disassemble and Inspect

1 Connecting rod cap bolt 7 Oil ring
2 Connecting rod cap 8 Snap ring
3 Lower connecting rod bearing 9 Piston pin
4 Upper connecting rod bearing 10 Piston
5 No. 1 compression ring 11 Connecting rod
6 No. 2 compression ring 12 Cylinder liner (Approx. 16 kg [35 lb.])
5-18
4.1 Piston protrusion - Measure

Measure the piston protrusion, and recognize the current
condition. Piston protrusion
For the measurement procedure, refer to "Piston protrusion -
Measure" of "ASSEMBLY OF BASIC ENGINE."
Piston protrusion - Measure

4.2 Connecting rod end play - Measure
Measure the connecting rod end play, and recognize the cur-
rent condition.
Connecting rod
For the measurement procedure, refer to "Connecting rod
end play - Measure" of "ASSEMBLY OF BASIC
ENGINE."
Connecting rod
end play

4.3 Hard carbon deposits on the upper part of cylinder liner - Remove
Be sure to remove hard carbon deposits from the

upper part of the cylinder liner before removing the pis-
ton. Hard carbon deposits, if not removed, cause dam-
age to the piston and piston rings.
Remove hard carbon deposits from the upper part of cylin-
der liner using a carbon remover.
Note: Be careful not to damage the inner surface of the cyl-
inder liner.
Hard carbon deposits on the upper part of cylinder
liner - Remove
4.4 Connecting rod cap - Remove
Using a socket wrench, remove the connecting rod bolts
through the inspection window on the side of the crabkcase,
and remove the connecting rod cap and connecting rod bear-
ings.
Note:(a) Be careful not to damage the connecting rod bear-
ings by dropping them into the oil pan.
(b) The connecting rod bearings that have been re-
moved should be arranged in the order so that their
location is clearly identified, i.e. their cylinder num-
bers, and whether it is upper or lower bearing.
Connecting rod cap - Remove
5-19
4.5 Piston - Remove
When holding the connecting rod with your hand to prevent it from swinging, be very careful, as you may suffer
hand injuries from accidental movement of the connecting rod.
(a) When pulling out the piston, be careful not to drop the upper connecting rod bearing.
(b) Use care not to damage the cylinder liner by the swing of the connecting rod when pulling out the piston and
connecting rod from the cylinder liner.
(c) When only a few pistons remain in the cylinders, the crankshaft tends to turn by itself. Be sure to hold the crank-
shaft to prevent it from rotating while removing pistons.
(d) Make sure that the connecting rod does not interfere with the piston cooling nozzle when removing the piston.
(e) When pulling the piston out of the cylinder liner, hold the piston by hand so that the piston does not rock. If the
piston rocks the piston skirt will be damaged by the connecting rod.
4.5.1 Removing the piston by raising it with chain Eye bolt

blocks P/N:37591-02500
(M12 × 1.25 mm)
(1) Rotate the crankshaft and bring the piston, of which
connecting rod cap has been removed, to the point of
top dead center.
(2) Install the eye bolt to the threaded hole on the piston
top, and support the piston so that the piston cannot fall
down.
Weight of piston with
(3) Rotate the crankpin slightly to the inspection window connecting rod:
Crank pin approx. 24 kg [53 lb.]
side so that the connecting rod big end does not inter-
Removing the piston by raising it with chain blocks
fere with the cylinder liner.
(4) Gently pull out the piston by making sure that the con-
necting rod big end slides into the cylinder liner.
5-20
4.5.2 Removing the piston by pushing the connecting Eye bolt

rod big end P/N:37591-02500
(M12 × 1.25 mm)
(1) Rotate the crankshaft and bring the piston, of which
connecting rod cap has been removed, to the point of
top dead center.
(2) Install the eye bolt to the threaded hole on the piston
top, and support the piston so that the piston cannot fall
down.
Weight of piston
(3) Rotate the crankshaft gently until the crankpin can be with connecting rod:
Crank pin approx. 24 kg [53 lb.]
removed from the connecting rod and the lower bolt
Crankshaft - Rotate
hole can be visible from the inspection window.
(4) Insert a long rod, and push up the bottom of connecting
rod gently, using the crankpin as a fulcrum.
Note: Protect the crankpin and connecting rod big end with a
cloth or rubber to prevent the damage by the rod.
(5) Push up the connecting rod and piston while adjusting
the supporting point. Wrap a cloth
When the oil ring is slide out of the cylinder liner, gen- Turning bar
tly sit the oil ring on the top face of the cylinder liner.
(6) Raise the piston using the eye bolt on the piston top,
and remove the piston from the cylinder liner. Connecting rod big end - Push up
4.6 Piston ring - Remove
Ring expander
When removing the piston ring, be careful not to get P/N:37191-03200
caught your fingers between the piston and cylinder
wall by rocking movement of the piston.
If the piston is forcibly moved and interfered with the

connecting rod, the piston can be damaged.
Hold the piston and connecting rod in a piston vise, and
remove the piston rings using a ring expander. Piston ring - Remove
5-21
4.7 Piston pin and Piston - Remove

(1) Remove the snap ring using ring pliers.
(2) Place a piece of wood against the end face of piston pin
and lightly tap with a hammer to remove the piston pin,
and separate the piston from the connecting rod.
Note:(a) Do not tap the piston pin directly with a hammer.
(b) If the piston is stubborn, heat the piston with a heat-
er or in hot water.
Piston pin and Piston - Remove

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

4.9 Cylinder liner flange protrusion - Measure
Measure the cylinder liner flange protrusion, and recognize
Bolt Cylinder liner
the current condition. P/N:37591-06300 flange protrusion
For the measurement procedure, refer to "Cylinder liner Tightening
torque
flange protrusion - Measure" of "ASSEMBLY OF BASIC
98 N·m
ENGINE." {10 kgf·m}
[72 lbf·ft]
Liner pusher
P/N:37591-06200
4.10 Cylinder liner - Remove
(1) Install the cylinder liner remover to the cylinder liner.
Note: Take care not to hit the piston cooling nozzle when in-
Cylinder liner
stall the remover plate to the bottom of cylinder liner. remover
(2) Rotate the handle, and remove the cylinder liner. Removing P/N:37591-04100
margin
80 mm
[3.15 in.]
Cylinder liner
Cylinder liner - Remove
5-22
5. Crankcase, Crankshaft and Main bearing - Disassemble and Inspect

Crankshaft end play - Measure
11
Scale deposit, damage, Uneven contact,

crack, clogged oil hole crack on counterbore,
fretting and corrosion
on fitting bore of cylinder liner
2 Damage
Valve operation, Replace
clogged of oil hole 8
Wear
10
Damage on inner
9
and outer surface,
corrosion, flaking
Flaking, wear,
6 uneven contact
Wear, damage, crack 7
4
Wear
5
Crack
Damage
3
1
Crankcase, Crankshaft and Main bearing - Disassemble and Inspect

1 Main bearing cap bolt 4 Lower main bearing 8 Upper thrust plate
2 Side bolt 5 Lower thrust plate 9 Eyebolt
3 Main bearing cap 6 Crankshaft (Approx. 620 kg [1367 lb.]) 10 Piston cooling nozzle
(Approx. 16 kg [35 lb.]) 7 Upper main bearing 11 Crankcase
(Approx. 1850 kg [4079 lb.])
5-23
5.1 Crankcase - Invert

Using a rotating table, invert the crabkcase.When the rotat-
Weight of crankshaft with crankcase:
ing table is not available, tie wire ropes to the crabkcase approx. 2615 kg [5765 lb.]
using batten and cloth pads, and raise the crabkcase using a
hoist and crane and lay it on the wooden block with its side
facing downwards.Then, change the positions of the wire
ropes, and turn over to invert the crabkcase.
Crankcase - Invert
5.2 Crankshaft end play - Measure
Measure the crankshaft end play, and recognize the current
condition.
For the measurement procedure, refer to "Crankshaft end
play - Measure" of "ASSEMBLY OF BASIC ENGINE."

5.3 Piston cooling nozzle - Remove
Remove the piston cooling nozzle from the crabkcase.
5.4 Main bearing cap - Remove
Main bearing cap

When removing the main bearing cap from the crab-
kcase, be careful not to damage the lower main bear-
Eyebolt
ing or the lower thrust plate that are attached to the P/N:37791-02100
cap. Also be careful not to drop those parts from the (M27 × 1.5 mm)
cap, which may damage the crankshaft.
(1) Remove the main bearing cap bolt and side bolt. Side bolt
(2) Install the eye bolts to the outer bolt holes on the main Main bearing cap bolt
bearing cap.
(3) Give a light shake, and remove the main bearing cap by Main bearing cap - Remove
raising gradually.
(4) Remove the lower thrust plate from the rearmost main
bearing cap.
5-24
5.5 Crankshaft - Remove
(a) Before removing the crankshaft, remove the front Crankshaft assembly
side upper thrust plate first so that it will not fall

into the crabkcase.
(b) When placing the crankshaft onto a pallet or other
stands, be careful not to damage the crankshaft.
Once placed on a pallet, the crankshaft should be
locked in place to prevent it from rocking.
(1) Push the mating face of the front upper thrust plate,
remove the thrust plate by rotating. Crankshaft - Remove
(2) Suspend the crankshaft in a horizontal position, and
slowly lift the crankshaft upward.
Note: Do not attach a chain or other hoisting devices directly
onto the crankshaft, as they could damage the crank-
shaft. Place cloth belts or pads in position where a
chain or other hoists are hooked before lifting crank-
shaft.
(3) Remove the upper main bearing from the crabkcase,
paying attention to the lug position, and remove the
upper thrust plate on the rear side.
5-25
1. Cylinder head and Valve mechanism - Inspect and Repair ................................. 6-3
1.1 Rocker bushing inside diameter and Rocker shaft outside diameter - Measure ...................... 6-3
1.2 Rocker bushing - Replace ........................................................................................................ 6-3
1.3 Valve stem outside diameter and Valve guide inside diameter - Measure ............................... 6-4
1.4 Valve guide - Replace............................................................................................................... 6-4
1.5 Valve face - Inspect .................................................................................................................. 6-5
1.6 Valve face - Reface .................................................................................................................. 6-5
1.7 Valve seat - Reface .................................................................................................................. 6-6
1.8 Valve seat - Replace................................................................................................................. 6-6
1.9 Valve and Valve seat - Lap....................................................................................................... 6-8
1.10 Valve bridge, Bridge cap, Valve cotter and Valve rotator - Inspect .......................................... 6-8
1.11 Squareness and free length of valve spring - Measure ............................................................ 6-9
1.12 Tappet - Inspect........................................................................................................................ 6-9
1.13 Push rod runout - Measure ..................................................................................................... 6-10
1.14 Nozzle gland stud bolt and Bridge guide - Inspect and Replace ............................................ 6-10
1.15 Distortion of cylinder head bottom surface - Measure ............................................................ 6-10
2. Rear equipment - Inspect and Repair .................................................................. 6-11
2.1 Rear idler bushing inside diameter and Rear idler shaft outside diameter - Measure ............ 6-11
2.2 Rear idler bushing - Replace .................................................................................................. 6-11
2.3 Cam lift of camshaft - Measure............................................................................................... 6-11
2.4 Camshaft runout - Measure .................................................................................................... 6-12
2.5 Camshaft journal outside diameter - Measure........................................................................ 6-12
2.6 Camshaft bushing - Inspect .................................................................................................... 6-12
2.7 Camshaft bushing - Replace .................................................................................................. 6-13
3. Front equipment - Inspect and Repair ................................................................. 6-14
3.1 Damper - Inspect visually ....................................................................................................... 6-14
3.2 Crankshaft pulley - Inspect ..................................................................................................... 6-14
3.3 Outside diameter and inside diameter of oil pump drive bearing fit - Inspect ......................... 6-14
3.4 Front idler bushing inside diameter and Front idler shaft outside diameter - Measure........... 6-15
3.5 Front idler bushing - Replace.................................................................................................. 6-15
6-1
4. Piston and Connecting rod - Inspect and Repair ............................................... 6-16

4.1 Piston - Inspect visually .......................................................................................................... 6-16
4.2 Piston weight .......................................................................................................................... 6-16
4.3 Piston outside diameter - Measure ......................................................................................... 6-16
4.4 Piston ring groove - Inspect .................................................................................................... 6-16
4.5 Piston pin bore inside diameter - Measure ............................................................................. 6-17
4.6 Piston ring - Inspect visually ................................................................................................... 6-17
4.7 Piston ring end gap - Measure................................................................................................ 6-17
4.8 Piston pin outside diameter - Measure ................................................................................... 6-17
4.9 Connecting rod bushing inside diameter - Measure ............................................................... 6-18
4.10 Connecting rod bushing - Replace ......................................................................................... 6-19
4.11 Connecting rod assembly weight rank.................................................................................... 6-21
4.12 Connecting rod big end bore diameter and roundness - Measure ......................................... 6-21
4.13 Side face of connecting rod big end (width) - Measure .......................................................... 6-22
4.14 Connecting rod big end serration and bolt holes - Inspect ..................................................... 6-22
4.15 Connecting rod bearing - Inspect............................................................................................ 6-22
4.16 Connecting rod bearing thickness - Measure ......................................................................... 6-23
4.17 Connecting rod bend and twist - Inspect ................................................................................ 6-23
5. Crankcase and Crankshaft - Inspect and Repair ................................................ 6-24
5.1 Crankcase top surface distortion - Measure ........................................................................... 6-24
5.2 Inside diameter of main bearing bore - Measure .................................................................... 6-24
5.3 Cylinder liner fitting section of crabkcase - Inspect................................................................. 6-24
5.4 Counterbore in crabkcase - Repair......................................................................................... 6-25
5.5 Crankshaft crankpin and Journal outside diameters - Measure ............................................. 6-26
5.6 Crankpin and Rearmost crank journal width - Measure.......................................................... 6-27
5.7 Crankshaft runout - Measure .................................................................................................. 6-28
5.8 Crankshaft gear - Inspect ....................................................................................................... 6-28
5.9 Crankshaft gear - Replace...................................................................................................... 6-28
5.10 Oil seal slinger - Inspect ......................................................................................................... 6-29
5.11 Oil seal slinger - Replace........................................................................................................ 6-29
5.12 Main bearing - Inspect ............................................................................................................ 6-30
5.13 Thickness of main bearing shell - Measure ............................................................................ 6-31
5.14 Thrust plate - Inspect .............................................................................................................. 6-31
5.15 Thickness of thrust plate - Measure........................................................................................ 6-32
5.16 Piston cooling nozzle - Inspect ............................................................................................... 6-32
6-2
1. Cylinder head and Valve mechanism - Inspect and Repair

1.1 Rocker bushing inside diameter and Rocker shaft outside diameter - Measure
Measure the inside diameter of the rocker bushing and the
Measurement direction Measurement
outside diameter of the rocker shaft.If the measurement direction
exceeds the limit, replace the rocker bushing or rocker shaft
Measurement
with a new one. point
Item Nominal Standard Limit

Rocker bushing ø36 mm 36.000 to 36.040 mm 36.090 mm
inside diameter [1.42 in.] [1.4173 to 1.4189 in.] [1.4209 in.]
Rocker shaft ø36 mm 35.966 to 35.991 mm 35.940 mm
outside diameter [1.42 in.] [1.4160 to 1.4170 in.] [1.4150 in.]
Rocker bushing inside diameter and Rocker shaft

outside diameter - Measure
1.2 Rocker bushing - Replace
(1) Pull out the rocker bushing using the rocker bushing
tool. Removal
Rocker bushing tool

P/N:37591-02600
Rocker arm
Rocker bushing
Rocker bushing - Remove

(2) Install a new rocker bushing using the rocker bushing
Bushing inside surface Turn up
tool. roughness the notch.
With the positioning notch (4 mm [0.16 in.] width) of Ra0.8μm{ ▽▽▽
3.2S }
the rocker bushing facing upward, align the position as Rocker bushing tool
P/N:37591-02600 Press-fit it from
shown in the illustration. Press fit the rocker bushing chamfered side
into the chamfered side of the rocker arm hole. Rocker bushing
[0.59 in.] [0.79 in.]

15 mm 20 mm
(3) Make sure the rocker arm and rocker bushing has the
same oil hole. Press-fit
(4) Measure the inside diameter of the rocker bushing that

Rocker arm
has been installed. If the measurement is out of toler-
Rocker bushing - Insert
ance, ream the bore to the standard.
Rocker bushing
notch Rocker arm
Rocker bushing
matching mark
Rocker bushing
Press-fit the rocker bushing parallel to

rocker bushing notch and screw hole center line.
Rocker bushing - Positioning
6-3
1.3 Valve stem outside diameter and Valve guide inside diameter - Measure
Measure the outside diameter of the valve stem and the
inside diameter of the valve guide at the top and bottom Measuring
ends in orthogonal direction as shown, as the sliding area direction
tends to wear at top and bottom ends. If the measurement
exceeds the limit, replace the valve guide or valve with a
new one.
Note: Lap the valve and valve seat whenever new valve is in- Measuring
points
stalled.

Valve stem out- ø10 mm 9.940 to 9.960 mm 9.910 mm Valve stem outside diameter - Measure
side diameter [0.39 in.] [0.3913 to 0.3921 in.] [0.3902 in.]
Valve guide ø10 mm 10.000 to 10.015 mm 10.060 mm Measurement
inside diameter [0.39 in.] [0.3937 to 0.3943 in.] [0.3961 in.] direction
Measurement
point
Valve guide inside diameter - Measure

1.4 Valve guide - Replace
Valve guide remover

P/N:33591-04300
The valve guide must be inserted to the specified
depth. Be sure to use the guide & seal installer when
press-fitting the valve guide.
(1) Remove the valve guide using the valve guide remover.
Valve guide - Remove

(2) Using the guide & seal installer, install a new valve
guide slowly with a press. Guide & seal installer
P/N:37191-11500
31.5 mm [1.240 in.]
Valve guide
Cylinder head
Valve guide - Press fit
6-4
1.5 Valve face - Inspect

Inspect the valve face after the valve guide is inspected or
replaced.Lap the valve and valve seat whenever the valve is
Seat width
refaced or replaced.
Valve seat
Valve margin
angle
Valve sinkage
Valve face - Inspect

1.5.1 Valve margin - Inspect
Measure the valve margin. If the measured value is less than
the specified limit, repair or replace the valve with a new
one.
1.5.2 Seat width - Inspect
Apply a thin lead-free coloring paste on the valve seat face, Valve lapper
P/N:30091-08800
and hit the valve face against the valve seat using a valve
lapper to check for contact condition. If the contact is not
even, or any defects are found, or if the specified limit is Lead-free
exceeded, reface or replace the valve. coloring paste
Note: Do not rotate the valve when pressing the valve face
coated with lead-free coloring paste against the valve
seat.
Item Nominal Standard Limit Seat width - Inspect

Valve seat
30° - -
angle
Valve
seat 2.21 to 2.42 mm
2.3 mm 2.8 mm
Seat width [0.0870
[0.091 in.] [0.110 in.]
to 0.0953 in.]
2.8 to 3.2 mm
3.0 mm 2.5 mm
Valve margin [0.110
[0.118 in.] [0.098 in.]
to 0.126 in.]
Good Bad
Contact condition between valve seat and valve

1.6 Valve face - Reface
If the valve face is significantly worn out, reface the valve
face using a valve refacer. Valve refacer
Note:(a) Grind the valve face with the valve refacer held at
the specified angle.
(b) The valve margin should not exceed the specified
limit. If the dimensions after refacing does not meet
Grind the valve face
the specified values, replace the valve with a new using the valve refacer
one. at the specified angle.
Valve face - Reface

6-5
1.7 Valve seat - Reface

(1) Use the valve seat cutter or valve seat grinder to reface
the valve seat.After refacing, sand the valve seat lightly
using 400 grit sandpaper, inserting it between the cutter Socket
and valve seat. (Width across flats:
32 mm [1.26 in.])
If the seat width exceeds the standard, grind the valve
seat with a valve seat cutter having different angles. Valve seat cutter
P/N:37591-06400
(2) Lap the valve in the valve seat. 37591-06430
Note:(a) Valve seat refacing should be kept to an absolute
minimum.
(b) If the seat width cannot be repaired to the standard
Valve seat - Reface
value, or valve contact surface slants toward the
outer periphery, replace the valve seat with a new
one.
(c) If the valve sinkage exceeds the specified limit after
refacing, replace the valve seat with a new one.
1.8 Valve seat - Replace
Ensure the proper interference. Improper interference

could cause the valve seat to fall off or the cylinder
head to crack.
Be careful not to damage the machined surface of cylinder
head when removing the valve seat.
1.8.1 Valve seat - Remove (using the valve seat
Valve seat puller
puller) P/N:32591-04200
Remove the valve seat using the valve seat puller.
Valve seat - Remove (using the valve seat puller)

1.8.2 Valve seat - Remove (by welding)
To remove the valve seat, weld a stud to the valve seat as Welding
shown. Then, insert a shaft into the valve guide hole from
Shaft
the top of the cylinder head, and drive the valve seat out
with the shaft. Valve seat
Note: Be careful not to allow spatters to adhere to the ma-
chined surface of the cylinder head during welding.
Stud
Valve seat - Remove (by welding)
6-6
1.8.3 Valve seat - Install

Unit: mm [in.]
]
(1) Before installing the valve seat, measure the inside
11.6 0 +0.004
[0.457 0
+0.1
diameter of the valve seat fit of cylinder head and the Cylinder head
[0.32]
outside diameter of the valve seat to make sure that the
8
interference is within the range of standard value. If the
[0.142]
3.6
measured value exceeds the standard value, use an
60°
oversize valve seat. If the inside diameter of valve seat Valve seat fitting
bore inside diameter
fitting portion of cylinder head exceeds the limit,
Valve seat outside diameter
replace the cylinder head with a new one.
Same in size on inlet and exhaust sides.
Note: Oversized valve seats are available in 0.03 and 0.06
Valve seat fitting bore
mm [0.0012, 0.0024 in.] sizes.
Rema
Item Standard Limit
rks
Valve seat
Inside diameter of 60.000 to 60.030 mm 60.120 mm Valve seat
-
valve seat fitting [2.3622 to 2.3634 in] [2.3669 in.]
portion Valve seat installer
assembly
60.100 to 60.130 mm 2 lines,
Standard - P/N:37591-04010
[2.3661 to 2.3673 in] brown
Valve
seat 0.03 mm 60.130 to 60.160 mm 3 lines,
-
outside [0.0012 in.] [2.3673 to 2.3685 in] brown
diameter
0.06 mm 60.160 to 60.190 mm 4 lines,
-
[0.0024 in.] [2.3685 to 2.3697 in] brown
Valve seat - Install
Valve seat 0.070 to 0.130 mm
- -
interference [0.0028 to 0.0051 in]
(2) Cool the valve seat at least for 4 minutes in liquid nitro-
gen before fitting it into the cylinder head cooled to
room temperature.
(3) Install the valve seat into the cylinder head using a
valve seat caulking tool.
6-7
1.9 Valve and Valve seat - Lap

Lap the valve against the valve seat whenever the valve seat
is refaced or the valve is replaced.
(1) Apply a thin coat of lapping compound evenly to the
valve face.
Note:(a) Do not allow the compound to adhere on the valve
stem.
(b) Compound spreads more evenly if it is mixed with Compound
a small amount of engine oil.
(c) Use medium-grain compound (125 to 150 mesh)
for initial lapping, then use fine-grain compound
Compound - Apply
(200 mesh) for finishing.
(2) Use a valve lapper for lapping. Valve lapper
Push the valve against the valve seat while rotating the P/N:30091-08800
valve little by little.
(3) Wash off the compound using diesel oil.
(4) Apply engine oil to the contact surface of the valve, and
perform a finish lapping.
(5) Check valve face contact condition.
Valve and Valve seat - Lap

1.10 Valve bridge, Bridge cap, Valve cotter and Valve rotator - Inspect
(1) Inspect the contact surface between valve bridge and
valve stem, and the sliding surface between valve Valve bridge
Bridge cap
bridge and bridge guide. If they are significantly worn Valve cotter
or there is any evidence of uneven contact, replace Bridge guide
Valve stem
them with new ones.
Valve
(2) Check the bridge cap for wear. If it is significantly worn rotator
out, replace the bridge cap with a new one.
(3) Check the valve rotator for rotation. If any defect is
found, replace the valve rotator with a new one.
(4) Inspect the contact surface between valve bridge and
Valve bridge, Bridge cap, Valve cotter and Valve
valve stem, and valve cotter and valve rotator. If there is
rotator - Inspect
any evidence of uneven contact or dent, replace them
with new ones.
6-8
1.11 Squareness and free length of valve spring - Measure

Measure the squareness and free length of valve spring. The
free length or squareness exceed the specified limit, replace Squareness of the spring
a valve spring with a new one.
Free length
Squareness and free length of spring - Measure

Nominal Standard Limit
Free length 73 mm [2.87 in.] 71 mm [2.80 in.]
A
A=1.5° or less B B = 2.2 mm [0.087 in.] over
Squareness B=1.9 mm [0.0748 in.] or less
Inlet valve spring Lf entire length
Lf=73 mm [2.87 in.]
66.0 mm [2.60 in.]/ 289 to 319 N

Installed length/load -
{29.45 to 32.55 kgf} [64.97 to 71.71 lbf]
Free length 90.6 mm [3.567 in.] 88.12 mm [3.4693 in.]
A
Inner spring Lf entire length
Lf=90.6 mm [3.567 in.]
Installed length/ 56.0 mm [2.20 in.] / 137 to 152 N

-
load {14 to 15.5 kgf} [30.80 to 34.17 lbf]
Exhaust valve spring
Free length 96.57 mm [3.8020 in.] 93.92 mm [3.6976 in.]
A
Outer spring Lf entire length
Lf=96.57 mm [3.8020 in.]
Installed length/ 62.0 mm [2.44 in.]/496 to 549 N

-
load {50.6 to 56.0 kgf} [111.5 to 123.4 lbf]
1.12 Tappet - Inspect

Inspect the tappet at the tappet/cam contact for wear. If
worn or damaged, replace the tappet with a new one.
Flaw, local wear Flaw, local wear
Good Bad Bad
Tappet at tappet/cam contact - Inspect
6-9
1.13 Push rod runout - Measure

Measure the runout of push rod by TIR.If the runout
exceeds the standard, replace the push rod with a new one.
Item Standard Remarks

Push rod runout 0.50 mm [0.0197 in.] or less TIR V-block
Push rod
1/2 1/2
Surface plate
Push rod runout - Measure

1.14 Nozzle gland stud bolt and Bridge guide - Inspect and Replace
Inspect the nozzle gland stud bolt for bending or damage at
threaded portion. Nozzle gland stud bolt
91 mm
Inspect the bridge guide for uneven wear and damage on the Bridge guide [3.58 in.]
sliding surface. 34 mm
[1.34 in.]
1.14.1 Nozzle gland (studs) - Install
Install the nozzle gland stud bolt so that the bolt is at the
52 mm
specified dimension. [2.06 in.]
1.14.2 Bridge guide - Install

Press-fit the bridge guide so that the guide is at the specified
dimension.
Nozzle gland stud bolt and Bridge guide - Install
1.15 Distortion of cylinder head bottom surface - Measure
Refacing of cylinder head should be kept to an abso-

lute minimum.Excessive grinding of the cylinder head
may result in defects such as contact between piston
and valve.
With a straight edge placed on the bottom face of the cylin-
der head, measure the bottom face distortion using a thick- Cylinder head
ness gauge.If the specified limit is exceeded, replace with a
new one, or grind/repair.
Distortion of cylinder head bottom surface - Measure
When grinding, record the amount that has been ground.
Note that total grinding amount, which includes the grind- 154.9 to 155.1 mm Cylinder head top surface
ing amount of the top of crabkcase, must be 0.50 mm [6.10 to 6.11 in.] roughness Ra1.6Ǵm{ٖٖٖ}
[0.020 in.] or less.
Item Standard Limit

Distortion of cylinder head 0.03 mm [0.0012 in.] 0.07 mm
bottom surface or less [0.0028 in.]
The height of cylinder head 154.9 to 155.1 mm
-
(reference) [6.098 to 6.106 in.]
Height of cylinder head - Measure
6-10
2. Rear equipment - Inspect and Repair

2.1 Rear idler bushing inside diameter and Rear idler shaft outside diameter - Measure
Measure the rear idler bushing inside diameter and the rear
idler shaft outside diameter. If the specified limit is Measuring
direction
exceeded, replace the rear idler bushing or rear idler shaft
Measuring
with a new one.
points

Rear idler bushing ø65 mm 65.000 to 65.030 mm 65.060 mm
Rear idler shaft ø65 mm 64.951 to 64.970 mm 64.900 mm
Rear idler bushing inside diameter and Rear idler shaft

outside diameter - Measure
2.2 Rear idler bushing - Replace
(1) Using the removal side of the idler bushing puller,
Bushing installer
remove the rear idler bushing. P/N:37791-02500 1 mm
[0.04 in.]
(2) Orient the oil groove of rear idler bushing as shown in Lower the rear idler bushing
from the end of gear boss
the illustration, and using the bushing installer install- by 1 mm [0.04 in.].
ing side, insert the rear idler bushing from the large $
gear side. ً
(3) Ream the bore of rear idler bushing that has been
ً
#
installed to bring it to the dimensions shown.
Note: Reaming after press-fit is necessary, as the rear idler Rear idler bushing
bushings are supplied in a semi-finished condition. Rear idler gear
Ra0.8μm
]_
ٖٖٖ
٧ Φ0.05 S A
3.2S
Φ0.1 S B
Φ65H7(+0.030
0 )mm [2.56( +0.0012
0 )in.]
Rear idler bushing - Replace
2.3 Cam lift of camshaft - Measure
Measure the major axis and minor axis of cam to determine
cam lift.If the specified limit is exceeded, replace the cam-
shaft with a new one.
Major axis
Item Standard Limit
Cam lift of camshaft 9.260 to 9.340 mm 8.45 mm
(major axis - minor axis) [0.3646 to 0.3677 in.] [0.3327 in.]
Minor
axis
Cam lift of camshaft - Measure
6-11
2.4 Camshaft runout - Measure

Measure the runout of camshaft by TIR. If the specified
limit is exceeded, correct the camshaft using a press, or
V-block
replace the camshaft with a new one.
Note: With a dial gauge set on the camshaft, rotate the cam-
shaft one turn and read the gauge indication.
Item Standard Limit Remarks 1/2 Surface plate 1/2

0.05 mm 0.08 mm
Camshaft runout TIR
[0.0020 in.] or less [0.0031 in.]
Camshaft runout - Measure

2.5 Camshaft journal outside diameter - Measure
Measure the diameter of each camshaft journal in two direc-
tion at right angles to each other.If the specified limit is
exceeded, replace the camshaft with a new one.

Camshaft journal ø84 mm 83.92 to 83.94 mm 83.87 mm
outside diameter [3.31 in.] [3.3039 to 3.3047 in.] [3.3020 in.] Measuring
direction
Camshaft journal outside diameter - Measure

2.6 Camshaft bushing - Inspect
(1) Check the inside surface of each bushing for damage,
corrosion, flaking and other abnormalities. If any defect
is found, replace the camshaft bushing with a new one. Measuring
direction
(2) Measure the camshaft bushing inside diameter with the
bushing installed in the crabkcase. If the specified limit
is exceeded, replace the camshaft bushing with a new
one.
Note: Be careful not to damage the inner surface of camshaft
bushing when measuring the inside diameter.
Item Nominal Standard Limit Camshaft bushing inside diameter - Measure

Camshaft bushing ø84 mm 84.000 to 84.035 mm 84.100 mm
6-12
2.7 Camshaft bushing - Replace
No. 1 to 8 journals No. 9 journal

(right and left) (right and left)
Before tightening the set bolt, be sure to check that
the set bolt is in alignment with the set bolt hole in the
Front Rear
camshaft bushing. of engine of engine
Make sure that the oil hole in the camshaft bushing is
in alignment with the oil hole from the oil gallery.
Camshaft Camshaft
(1) Remove the set screws from the side of the crabkcase bushing bushing
and remove the camshaft bushings. Sealing washer Sealing washer
Set bolt
(2) Install the camshaft bushing by aligning the set bolt
hole of crabkcase with the set bolt hole of camshaft Camshaft bushing - Install
bushing, and secure the camshaft bushing with the set
bolt.
Note: Make sure that the oil hole of the camshaft bushing is
in alignment with the oil hole of the crabkcase.
6-13
3. Front equipment - Inspect and Repair

3.1 Damper - Inspect visually
Check the damper for cracks around the outer periphery,
swelling in the end plate, silicone oil leakage and discolor-
ation and separation of coating due to overheating. If any
defect is found, replace the damper with a new one.
Damper - Inspect visually

3.2 Crankshaft pulley - Inspect
Check the belt groove of the pulley for wear.
(1) Check the sinkage of the belt.
(2) Fit a new belt in the pulley groove so that belt becomes
taut.
(3) Replace the pulley with a new one if the belt sinks more 1.6 mm [0.063 in.]
or less
than 1.6 mm [0.063 in.] below the pulley rim.
Belt pulley - Inspect for wear

3.3 Outside diameter and inside diameter of oil pump drive bearing fit - Inspect
Rotate the bearing and if the rotation is not smooth, replace
the bearing with a new one. Bearing
Inspect the fit between the oil pump bearing cover and the
bearing. If significant wear is found, replace them with new
ones.
Inspect the fit between the pump plate and the bearing. If Oil pump bearing
significant wear is found, replace them with new ones. cover
Inspect the fit between oil pump gear and bearings. If signif- Oil pump gear
icant wear is found, replace them with new ones. Pump plate
Item Nominal Standard Oil pump drive bearing fit - Inspect

Inside diameter of bearing fit
ø110 mm 110.000 to 110.035 mm
in the oil pump bearing
[4.33 in.] [4.3307 to 4.3321 in.]
cover
Inside diameter of bearing fit ø110 mm 109.987 to 110.022 mm
in the pump plate [4.33 in.] [4.3302 to 4.3316 in.]
ø110 mm 109.985 to 110.000 mm
Outside diameter
[4.33 in.] [4.3301 to 4.3307 in.]
Bearing
ø50 mm 49.988 to 50.000 mm
Inside diameter
[1.97 in.] [1.9680 to 1.9685 in.]
Outside diameter of bearing ø50 mm 49.993 to 50.013 mm
fit in the oil pump gear [1.97 in.] [1.9682 to 1.9690 in.]
6-14
3.4 Front idler bushing inside diameter and Front idler shaft outside diameter - Measure
Measure the front idler bushing inside diameter and the
front idler shaft outside diameter. If the specified limit is Measuring
direction
exceeded, replace the front idler bushing or front idler shaft
with a new one. Measuring
points
Front idler bushing ø50 mm 50.000 to 50.025 mm 50.060 mm
Front idler shaft ø50 mm 49.950 to 49.975 mm 49.900 mm
Front idler bushing inside diameter and Front idler

shaft outside diameter - Measure
3.5 Front idler bushing - Replace
(1) Using the removal side of the idler bushing puller, Lower the rear idler bushing
remove the front idler bushing. from the end of gear boss
by 1 mm [0.04 in.].
(2) Using the installation side of the idler bushing puller,
install the front idler bushing from the 1mm [0.04 in.] Idler bushing puller
[0.04 in.]
C1 P/N:32591-02500
1 mm
chamfered side until the its end face becomes flush with [0.04 in.]
the gear boss end face. Furthermore, using the removal Front idler bushing
side of the idler bushing puller, lower the idler bushing
end face from the end face of gear boss by 1 mm [0.04
A
▲
in.]. (5 mm) ▲
[0.20 in.] C3
(3) Ream the bore of front idler bushing that has been [0.12 in.] Front idler gear
B
Ra0.8μm
installed to bring it to the dimensions shown.
{ 3.2S }
▽▽▽
◎ Φ0.05 S A
Note: Reaming after press-fit is necessary, as the front idler Φ0.1 S B
bushings are supplied in a semi-finished condition.
Φ50H7(+0.025
0 )mm [1.97( +0.0010
0 )in.]
Front idler bushing - Replace
6-15
4. Piston and Connecting rod - Inspect and Repair

4.1 Piston - Inspect visually
Check the combustion surface, piston pin bore, ring groove,
sliding surface and bottom surface of the piston. If any
defect are found, replace the piston with a new one.
Piston - Inspect visually

4.2 Piston weight
Check the piston weight stamped on the top face of piston.
When replacing pistions, be sure that the weight difference
per engine is within the permissible range. Parts number
Last 5 digits
punch mark
Weight difference per ±10 g
- -
engine [0.35 oz.]
CAM
Direction mark Piston weight
Piston weight punch mark location

4.3 Piston outside diameter - Measure
Measure the piston outside diameter of the piston skirt at
[1.57 in.]
40 mm
right angles to the piston pin.If the specified limit is
exceeded, replace the piston with a new one.
Measuring
points
Piston outside ø170 mm 169.765 to 169.805 mm 169.66 mm
diameter [6.69 in.] [6.6835 to 6.6850 in.] [6.6795 in.]
Piston outside diameter - Measure

4.4 Piston ring groove - Inspect
Remove carbon deposits from pistons and inspect the

entire circumference of the piston. Ring carrier
No.1 compression ring
(1) Remove all deposits such as carbon from each ring groove
groove.
No.2 compression ring
(2) Visually check each ring groove for wear or damage. If
groove
faulty, replace the piston with a new one. Conduct dye Oil ring groove
penetration test to inspect the ring carrier of No. 1 com-
pression ring groove for cracks and flaking.
Piston ring groove - Inspect
6-16
4.5 Piston pin bore inside diameter - Measure

Measure the piston pin bore inside diameter. If the specified
limit is exceeded, replace the piston with a new one.

Piston pin bore ø70 mm 70.002 to 70.015 mm 70.040 mm
inside diameter [2.76 in.] [2.7560 to 2.7565 in.] [2.7575 in.] Measuring
directions Measuring
points
Piston pin bore inside diameter - Measure

4.6 Piston ring - Inspect visually
Check the sliding surface and the top and bottom surfaces
for seizing, abnormal wear, foreign substance biting and
plating delamination. If any such traces are found, replace
the piston rings with new ones.
4.7 Piston ring end gap - Measure
Place the piston rings in a gauge or a new cylinder liner, and
measure the end gap. If the specified limit is exceeded,
replace piston rings with a new set of rings.
Note: Using a piston, push the piston ring squarely into the Thickness
gauge
gauge or the cylinder liner.
Item Standard Limit

No.1 0.6 to 0.8 mm
compression [0.024 to 0.032 in.]
Piston ring No.2 0.6 to 0.8 mm 2.0 mm End gap
end gap compression [0.024 to 0.032 in.] [0.078 in.] Gauge bore diameter: 170 ± 0 mm [6.69 ± 0 in.]
0.3 to 0.45 mm Piston ring end gap - Measure
Oil
[0.012 to 0.0177 in.]
4.8 Piston pin outside diameter - Measure

Measure the piston pin outside diameter.
If the specified limit is exceeded, replace the piston pin with
a new one.
Measuring
Item Nominal Standard Limit direction
Piston pin outside ø70 mm 69.987 to 70.000 mm 69.970 mm
diameter [2.76 in.] [2.7554 to 2.7559 in.] [2.7547 in.]
Measuring
points
Piston pin outside diameter - Measure
6-17
4.9 Connecting rod bushing inside diameter - Measure

Measure the inside diameter of the connecting rod bushing.
If the specified limit is exceeded, replace the connecting rod Measuring
directions
bushing with a new one.
Measuring
Item Nominal Standard Limit points
Inside diameter of
ø70 mm 70.020 to 70.040 mm 70.070 mm
the connecting rod
[2.76 in.] [2.7567 to 2.7575 in.] [2.7587 in.]
bushing
Connecting rod bushing inside diameter - Measure
6-18
4.10 Connecting rod bushing - Replace

Using the connecting rod bushing installer, replace the con-
necting rod bushings.
4.10.1 Installer base and Connecting rod - Fix
Matching mark on the base Matching mark
(1) Align the match mark on the base with the match mark on the base
(red scribed line)
(red ø4 mm [0.16 in.])
on the plate, and install the plate.
Plate
Base Matching mark
on the plate
Connecting rod bushing installer
(red ø4 mm [0.16 in.])
P/N:37591-01010
Connecting rod bushing installer - Use (1)
(2) With the connecting rod bearing disengaged from the
connecting rod, install the connecting rod cap to the Oil hole of
connecting rod Bolt Plate
plate.
(3) Align the match mark, and install the connecting rod to
the plate.
(4) Tighten the connecting rod bolts to the specified torque.
(5) Secure the connecting rod in place with the bracket.
Matching mark Bracket Matching mark

(red scribed line) on the plate
4.10.2 Connecting rod bushing - Remove Applying pressure by
(1) Apply engine oil to the inner surface of connecting rod a pressing machine
bushing.
(2) Attach the collar A to the mandrel and insert the assem- Mandrel
bly into the connecting rod bushing while aligning the

Collar A
match mark (red line) on the collar A with that on the
base.
(3) Using a pressing machine, apply pressure gradually on
the head of the mandrel to pull out the connecting rod
bushing. Bushing to
be pulled out
Bracket
Matching
mark
Removing direction
6-19
4.10.3 Connecting rod bushing - Press-fit
(a) Make sure that the match marks (red lines) on col- Oil hole of
connecting rod bushing
lars A and B are in alignment.
(b) Make sure that the oil hole of the connecting rod
bushing is in alignment with the match mark (red Matching mark on collar A
(red ø4 mm [0.16 in.])
ø4 mm [0.16 in.]) on collar A.
(1) Align the oil hole with the match mark on collar A (ø4
mm [0.16 in.] red), and install a new connecting rod
bushing on collar A. Connecting rod bushing installer - Use (4)
(2) Install the combination of collar A and collar B to the Applying pressure by a
mandrel, and secure them with the nut. pressing machine
Mandrel
Matching mark
(red scribed Collar A
lines)
Bushing to
be pressed
Collar B
Nut
Matching mark
(red scribed
lines)
Removing direction
(3) Apply engine oil to the outer periphery of the connect-
Matching mark on collar A
ing rod bushing. Align the match mark (red line) on the (red ø4 mm [0.16 in.])
Oil hole of connecting rod
collar A with that of collar B so that the oil hole of con-
necting rod bushing is aligned with the oil hole of the
connecting rod, and then install the bushing into the
connecting rod using a pressing machine.
Oil hole of connecting rod
6-20
(4) Measure the inside diameter of the connecting rod

Bushing inner surface
bushing. Inside diameter of
roughness
If the measurement is out of tolerance, ream the bore to 1.6S
Ra0.4ȣm ^`
‫ۃۃۃ‬
connecting rod
bushing
the standard.
Connecting rod
bushing
Item Standard
70.020 to 70.040 mm
Inside diameter of the connecting rod bushing
[2.7567 to 2.7575 in.]
Connecting rod
Connecting rod bushing inside diameter - Measure

4.11 Connecting rod assembly weight rank
When replacing a connecting rod, be sure to check the
weight rank of the connecting rod. In one engine, all the
connecting rods must be of the same weight rank.
Weight rank list

Allowable
Part No. Weight rank Weight
value
37719-32020 M 15420 g [543 oz.]
±30 g
37719-60040 C 14050 g [495 oz.]
[±1.05 oz.]
37719-60050 D 14200 g [500 oz.] Weight rank mark location
Note: The weight rank of the connecting rod assembly Connecting rod weight rank mark location
mounted on the engine is also stamped on the caution
plate.
4.12 Connecting rod big end bore diameter and roundness - Measure
Measure the connecting rod bore diameter at the front and
rear ends respectively in the directions A, B and C as shown
in the illustration. The out-of-roundness is determined by A
B
subtracting the minimum value from the maximum value
among the measurements of A, B and C. C Front Rear
If the specified limit is exceeded, replace it with a new one.

Measuring Measuring
Round- points
Item Nominal Standard Limit directions
ness limit
Minimum:
131.000 to 130.950 mm
Connecting
rod big end
ø131 mm 131.025 mm [5.1555 in.] 0.100 mm Connecting rod big end bore diameter - Measure
[5.16 in.] [5.1575 to Maximum: [0.0039 in.]
bore diameter
5.1585 in.] 131.050 mm
[5.1594 in.]
6-21
4.13 Side face of connecting rod big end (width) - Measure

(1) Inspect the side face of connecting rod big end visually.
If there are any defects such as wear or damage, replace
the connecting rod with a new one. Side of connecting rod big end (width)
(2) Measure the side face of connecting rod big end
(width). If the measured value differs from the specified
standard value, replace it with a new one.
Item Standard
Side face of connecting rod big end 59.7 to 59.8 mm
(width) [2.3504 to 2.3543 in.]
Side face of connecting rod big end (width) - Measure

4.14 Connecting rod big end serration and bolt holes - Inspect
Inspect the connecting rod big end serration and bolt holes
with magnetic particle method. If there are any defects such
as cracks, fretting and foreign substance biting, replace it
with a new one.
4.15 Connecting rod bearing - Inspect
Inspect the sliding surface, back surface and end surface of
connecting rod bearing. If there are any defects such as poor
contact, sliding scratches, corrosion and foreign substance
biting, replace it with a new one.
Flaking Scratches
Adhesion
End face
Connecting rod bearing - Inspect
6-22
4.16 Connecting rod bearing thickness - Measure

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

3.000 mm 2.957 to 2.970 mm 2.930 mm
Standard
[0.1181 in.] [0.1164 to 0.1169 in.] [0.1154 in.]
0.25 mm 3.125 mm 3.082 to 3.095 mm 3.055 mm
[0.0098 in.] [0.1230 in.] [0.1213 to 0.1219 in.] [0.1203 in.]
Connecting rod 0.50 mm 3.250 mm 3.207 to 3.220 mm 3.180 mm
bearing thickness at center [0.0197 in.] [0.1280 in.] [0.1263 to 0.1268 in.] [0.1252 in.]
Undersize
0.75 mm 3.375 mm 3.332 to 3.345 mm 3.305 mm
[0.0295 in.] [0.1329 in.] [0.1312 to 0.1317 in.] [0.1301 in.]
1.00 mm 3.500 mm 3.457 to 3.470 mm 3.430 mm
[0.0394 in.] [0.1378 in.] [0.1361 to 0.1366 in.] [0.1350 in.]
4.17 Connecting rod bend and twist - Inspect

(1) Measure the dimensions of C and L as shown in the
C Unit: mm [in.]
illustration to check the bend and twist of the connect-
C 0.05 0.0020
L [ ]
ing rod.Straighten the connecting rod with a press so L 100 3.94
that the measurement value meets the standard. Piston C 0.05 0.0020 L
pin [ ]
L 100 3.94
If the measured value differs from the specified stan- C
dard value, replace it with a new one.
Connecting rod bend Connecting rod twist
Note: Before checking bend and twist, tighten the connecting
Tightening torque
rod cap to the specified torque. ○Bolt mark “AL” ,“AU”
637 ± 31.9 N·m {65 ± 3.25 kgf·m}
(2) To inspect the connecting rod with the piston installed, [470 ± 24 lbf·ft]
turn the piston upside down and place it on a surface 2-step tightening [wet]
Connecting rod bend and twist - Inspect
plate. Insert a round bar having the same diameter as
the crankpin into the big-end bore, and measure the D
height of the bar using a dial gauge.
C
Item Standard
0.05/100 mm
Connecting rod bend and twist (C/L, C/D) C 0.05 [ 0.0020 ]
[0.0020/3.94 in.] or less
D 100 3.94
Surface plate Unit: mm [in.]

Deflection of connecting rod - Measure
6-23
5. Crankcase and Crankshaft - Inspect and Repair

5.1 Crankcase top surface distortion - Measure
Straight edge
Refacing of crabkcase should be kept to an absolute
minimum.
Excessive grinding of the crabkcase may result in
defects such as defective combustion and contact
between piston and valve.
Apply a straight edge to the top surface of the crabkcase and
measure its distortion using a thickness gauge.If the speci-
fied limit is exceeded, replace with a new one, or grind/ Thickness gauge
repair. Crankcase top surface distortion - Measure
When grinding, record the amount that has been ground.
Crankcase top surface roughness
Note that the total grinding amount, which includes the Ra1.6 μ m [0.024 μ in.] {ٖٖٖ}
grinding amount of the bottom surface of the cylinder head,
must be 0.50 mm [0.020 in.] or less.
Item Standard Limit

Crankcase top surface distor- 0.2 mm
0.1 mm [0.004] or less 549.45 VQ 549.55 mm
tion [0.008 in.]
[21.6313 to 21.6353 in.]
The height from the center of
crank journal to the top of 549.45 to 549.55 mm
-
crabkcase [21.6318 to 21.6358 in.]
(reference)
The height from the center of crank journal to the top
of crabkcase
5.2 Inside diameter of main bearing bore - Measure
(1) Assemble the main bearing cap in the crabkcase in
accordance with the specified method. 588 ± 29.4 N·m
{60 ± 3.0 kgf·m}
(2) Measure the housing diameter in vertical and two diag- [434 ± 22 lbf·ft] [wet]
onal directions.

Inside diameter of
ø179 mm 179.000 to 179.025 mm 179.045 mm
main bearing fit-
[7.05 in.] [7.0472 to 7.0482 in.] [7.0490 in.]
ting bore
392 ± 19.6 N·m
{40 ± 2.0 kgf·m}
[289 ± 14 lbf·ft] [wet]
Inside diameter of main bearing bore - Measure

5.3 Cylinder liner fitting section of crabkcase - Inspect
(1) Inspect the counterbore in crabkcase. Check for the
cracks in edges, uneven contact between the counter- Fitting bore of cylinder liner Counterbore in crankcase
in crankcase
bore and the bottom of cylinder liner flange protrusion.
If any defects are found, reface the counterbore in crab-
kcase.
(2) Inspect the cylinder liner fit in crabkcase. Check that
there are no defects such as the fretting and corrosion.
Cylinder liner fitting section of crabkcase - Inspect
6-24
5.4 Counterbore in crabkcase - Repair

If there is uneven contact in the counterbore in crabkcase,
File
grind and repair. Grind the counterbore using the crabkcase
grinder such that the difference in depth at the circumfer-
ence is less than 0.05 mm [0.0020 in.].
After the grinding of the counterbore in crabkcase is com-
pleted, measure the cylinder liner flange protrusion at each
cylinder. Counterbore
in crankcase
Crankcase grinder
P/N:37591-07010
Counterbore in crabkcase - Repair
6-25
5.5 Crankshaft crankpin and Journal outside diameters - Measure

(1) Measure the outside diameter of the crankpins and
crank journals.
Measuring Measuring
If the specified limit is exceeded, use the undersize directions points
bearing, and grind the crankshaft to fit the undersize
bearing.
If the specified limit is exceeded even if the -1.00 mm
[-0.0394 in.] undersize bearing is used, replace the
crankshaft with a new one.
(2) Determine the out-of-roundness and the out-of-cylin-
dricity (taper) based on the outside diameters that have
been measured.
5.5.1 Crankpin and Crank journal - Grind
Measuring Measuring
When using the undersize bearing, grind to the standard directions points
value corresponding to the undersize bearing to be used.
Do not change the fillet radius and the width of shaft when
grinding. If the hardness is decreased, quench the crankshaft
again and inspect it with magnetic particle method.
After grinding, measure the width of crankpin and crank
journal.
Crank journal outside diameter - Measure
Item Nominal Size Standard Limit

Standard 124.930 to 124.950 mm [4.9185 to 4.9193 in.] 124.890 mm [4.9169 in.]
0.25 mm [0.0098 in.] 124.680 to 124.700 mm [4.9087 to 4.9094 in.] 124.640 mm [4.9071 in.]
ø125 mm
Crankpin outside diameter 0.50 mm [0.0197 in.] 124.430 to 124.450 mm [4.8988 to 4.8996 in.] 124.390 mm [4.8972 in.]
[4.92 in.] Under
size 0.75 mm [0.0295 in.] 124.180 to 124.200 mm [4.8890 to 4.8898 in.] 124.140 mm [4.8874 in.]
Standard 169.920 to 169.940 mm [6.6898 to 6.6905 in.] 169.880 mm [6.6882 in.]
Crankshaft journal outside ø170 mm
diameter [6.69 in.] Under
size 0.75 mm [0.0295 in.] 169.170 to 169.190 mm [6.6602 to 6.6610 in.] 169.130 mm [6.6586 in.]
- Deviation of 0.01 mm [0.0004 in.] or
Parallelism - 0.03 mm [0.0012 in.]
less over entire pin length
- Diameter difference 0.01 mm
Roundness - 0.03 mm [0.0012 in.]
[0.0004 in.] or less
- Diameter difference 0.01 mm
Cylindricity - 0.03 mm [0.0012 in.]
Pin and [0.0004 in.] or less
journal
Pin R7 [0.28] - 6.8 to 7.0 mm [0.268 to 0.276 in.] -
Fillet
radius R8.5 -
Journal 8.3 to 8.5 mm [0.327 to 0.335 in.] -
[0.335]
Hardness - - Hv > 590 -
Surface roughness - - Ra 0.2 μm [0.008 µin.] -
Angular deviation between -
- ±20' -
pins
6-26
5.6 Crankpin and Rearmost crank journal width - Measure

(1) Inspect the end of crankshaft for harmful scratch and
wear.
(2) Measure the crankpin and rearmost crank journal Rearmost crank
Crankpin width journal width
width.
When using undersize thrust plate due to wear of rear-
most crank journal width, grind the crankshaft for the
use with the undersize thrust plate.
5.6.1 Rearmost crank journal width - Grind

When using the undersize thrust plate, grind the rearmost
Crankpin and Rearmost crank journal width - Measure
crank journal width for the use with the undersize thrust
plate.
Do not change the fillet radius when grinding. Quench the
crankshaft if its surface hardness has been significantly
decreased, and after quenching perform a magnetic-particle
test.Ensure that the finishing accuracy after grinding shall
not exceed the standard value.
Note: The difference of thickness between front and rear
thrust plates must be 0.25 mm [0.0098 in.] or less.
Item Nominal Size Standard

120 mm
Crankpin width - 120.20 to 120.30 mm [4.7323 to 4.7362 in.]
[4.72 in.]
Standard 67.00 to 67.03 mm [2.6378 to 2.6390 in.]
0.25 mm One side 67.25 to 67.28 mm [2.6476 to 2.6488 in.]

[0.0098 in.] Both sides 67.50 to 67.53 mm [2.6575 to 2.6587 in.]
67 mm
Rearmost crank journal width 0.50 mm One side 67.50 to 67.53 mm [2.6575 to 2.6587 in.]
[2.64 in.] Undersize
0.75 mm One side 67.75 to 67.78 mm [2.6673 to 2.6685 in.]

6-27
5.7 Crankshaft runout - Measure

Support the crankshaft at the front and rear journals with V-
blocks, and measure the crankshaft runout at the center jour- V-block
nal using a dial gauge.If the runout deviates slightly from
the standard, grind the crankshaft. If the runout exceeds the
standard considerably, straighten the crankshaft using a
press.
If the specified limit is exceeded, replace the crankshaft
Surface plate
with a new one. 1/2 1/2
If the crankshaft has been repaired by grinding or pressing,
inspect the crankshaft for cracks and other harmful damage
Crankshaft runout - Measure
using a magnetic particle method.
Item Standard Limit Remarks

0.04 mm [0.0016 in.] 0.10 mm
Crankshaft runout TIR
or less [0.0039 in.]
5.8 Crankshaft gear - Inspect

If there are any defects on the crankshaft gear tooth, such as
flaking, wear, or uneven contact, replace the crankshaft gear
with a new one.
5.9 Crankshaft gear - Replace
Use protective gloves when you touch hot parts. Crankshaft gear
Touching hot parts with bare hands can result in
burns.
5.9.1 Crankshaft gear - Remove

Using a gear puller, remove the gear from the crankshaft.
Note: When removing the crankshaft gear by heating, the
heating temperature should be 180°C [356 °F] or less.
Crankshaft gear - Remove
6-28
5.9.2 Crankshaft gear - Install

Align dowel pin
and notch
(a) Make sure the correction installation direction and
position of crankshaft gear.
(b) When the crankshaft gear is shrinkage-fit to
crankshaft, heat the crankshaft gear evenly with
the specified temperature.
(1) Measure the outside diameter of crankshaft and inside

diameter of crankshaft gear, and check the interference.
(2) Heat the crankshaft gear evenly with the specified tem- Crankshaft gear - Install
perature. After the confirmation of gear direction and Temperature for shrink fitted: Fitting direction
position, install the crankshaft gear. 180 to 200 °C [356 to 392 °F] or less
Fitting direction
Standard value Standard value

of interference of interference
0.106 to 0.171 mm 0.274 to 0.358 mm
[0.0042 to 0.0067 in.] [0.0108 to 0.0141 in.]
Front Rear
Installation directions
5.10 Oil seal slinger - Inspect
If any defect such as dent, damage, wear and backlash that
Front Rear
can lead to oil leakage are found, replace the oil seal slinger
with a new one. Timing
gear case
Front
gear case
Oil seal Oil seal

slinger slinger
Oil seal Oil seal
Oil seal slinger - Inspect
5.11 Oil seal slinger - Replace
Use protective gloves when you touch hot parts. Oil seal slinger
Touching hot parts with bare hands can result in
burns.
5.11.1 Oil seal slinger - Remove

Using a gear puller, pull out the oil seal slinger from the
crankshaft.
Note: When removing the oil seal slinger by heating, the
Oil seal slinger - Remove
heating temperature should be 100°C [212°F] or less.
6-29
5.11.2 Oil seal slinger - Install

Identification mark Identification mark
(1) Measure the outside diameter of crankshaft and inside (37425-08201) (37411-04200)
diameter of oil seal slinger, and check the interference.
(2) Heat the oil seal slinger evenly with temperature of
110ºC [230 °F]. After the conformation of direction and
position, install the slinger.
Contact to the gear. Contact to the gear.
Standard value Standard value
of interference: of interference:
0.064 to 0.163 mm 0.210 to 0.294 mm
[0.0025 to 0.0064 in.] [0.0083 to 0.0116 in.]
Front Rear
Oil seal slinger - Install
Oil seal slinger
Rear side installing tool

Slinger installer
P/N:37491-02100
Installer
Installer guide
P/N:37491-02200
Rear oil seal slinger - Install

5.12 Main bearing - Inspect
main bearing. If any defect such as poor contact, sliding
scratches, corrosion and foreign substance biting is found, Damage, corrosion,
flaking
replace the main bearing with a new one.
End face
Main bearing - Inspect
6-30
5.13 Thickness of main bearing shell - Measure

Measure the thickness of each main bearing shell at its cen-
ter.
If the measurement exceeds the limit, replace both upper
and lower main bearing shells with new ones as a set.
When the crankshaft is ground due to wear of crank journal, Measure at
the center of bearing
use the undersize bearing.
For the crankshaft grinding procedure, refer to "Crankpin
and Crank journal - Grind" of "INSPECTION AND
Note: Replacement shells for undersized main bearing are
available in sizes of -0.25, -0.50, -0.75 and -1.00 mm
Thickness of main bearing shell - Measure
[-0.0098, -0.0197, -0.0295 and -0.0394 in.].

4.500 mm 4.467 to 4.480 mm 4.425 mm
Standard
[0.1772 in.] [0.1759 to 0.1764 in.] [0.1742 in.]
0.25 mm 4.625 mm 4.592 to 4.605 mm 4.550 mm
[0.0098 in.] [0.1821 in.] [0.1808 to 0.1813 in.] [0.1791 in.]
Main bearing thickness 0.50 mm 4.750 mm 4.717 to 4.730 mm 4.675 mm
at center [0.0197 in.] [0.1870 in.] [0.1857 to 0.1862 in.] [0.1841 in.]
Undersize
0.75 mm 4.875 mm 4.842 to 4.855 mm 4.800 mm
[0.0295 in.] [0.1919 in.] [0.1906 to 0.1911 in.] [0.1890 in.]
1.00 mm 5.000 mm 4.967 to 4.980 mm 4.925 mm
[0.0394 in.] [0.1969 in.] [0.1956 to 0.1961 in.] [0.1939 in.]
5.14 Thrust plate - Inspect

thrust plate. If any defect such as poor contact, sliding
scratches, corrosion and foreign substance biting is found, End face
replace the thrust plate with a new one.
Damage, corrosion,
flaking
Thrust plate - Inspect
6-31
5.15 Thickness of thrust plate - Measure

Measure the thickness of thrust plate.
If the specified limit is exceeded, replace the thrust plate
with a new one. When the crankshaft is ground due to wear
of crankshaft, use the undersize thrust plate.
For the crankshaft grinding procedure, refer to "Rearmost
crank journal width - Grind" of "INSPECTION AND
Note:(a) Replacement thrust plates are available in three un-
dersizes: 0.25, 0.50, 0.75 mm [0.0098, 0.0197,
0.0295 in.].
Thickness of thrust plate - Measure
(b) Because the undersize thrust plate can be used in
only one side (a set of upper and lower), the end
play can be adjusted with a minimum crankshaft
grinding.

5.00 mm 4.83 to 4.90 mm 4.76 mm
Standard
[0.1969 in.] [0.1902 to 0.1929 in.] [0.1874 in.]
0.25 mm 5.25 mm 5.08 to 5.15 mm 5.01 mm
[0.0098 in.] [0.2067 in.] [0.2000 to 0.2028 in.] [0.1972 in.]
Thickness of thrust plate
0.50 mm 5.55 mm 5.38 to 5.45 mm 5.31 mm
Undersize
[0.0197 in.] [0.2185 in.] [0.2118 to 0.2146 in.] [0.2090 in.]
0.75 mm 5.75 mm 5.58 to 5.65 mm 5.51 mm
[0.0295 in.] [0.2264 in.] [0.2197 to 0.2224 in.] [0.2169 in.]
5.16 Piston cooling nozzle - Inspect

Inspect the piston cooling nozzle.
Spray holes
If there are any defects such as valve malfunctions and oil
hole clogging, replace the piston cooling nozzle with a new
one.
Item Standard
Piston cooling nozzle 0.10 to 0.15 MPa
Valve opening pressure {1.0 to 1.5 kgf/cm2} [14 to 21 psi]
Oil hole
Valve
Piston cooling nozzle - Inspect
6-32
1. Crankshaft and Main bearing - Install.................................................................... 7-3
1.1 Crankcase - Invert .................................................................................................................... 7-3
1.2 Piston cooling nozzle - Install ................................................................................................... 7-3
1.3 Upper main bearing - Install...................................................................................................... 7-4
1.4 Rear upper thrust plate - Install ................................................................................................ 7-4
1.5 Crankshaft - Install.................................................................................................................... 7-5
1.6 Front upper thrust plate - Install................................................................................................ 7-5
1.7 Lower main bearing shell and Lower thrust plate - Install......................................................... 7-6
1.8 Main bearing cap - Install.......................................................................................................... 7-7
1.9 Crankshaft end play - Measure................................................................................................. 7-8
1.10 Crankcase - Invert .................................................................................................................... 7-8
2. Cylinder liner, Piston and Connecting rod - Assemble........................................ 7-9
2.1 Cylinder liner top ridge height - Measure.................................................................................. 7-9
2.2 Cylinder liner flange protrusion - Calculate (in cylinder liner removed condition) ..................... 7-9
2.3 Cylinder liner - Install .............................................................................................................. 7-10
2.4 Cylinder liner flange protrusion - Measure (in cylinder liner installed condition)..................... 7-11
2.5 Cylinder liner inside diameter - Measure ................................................................................ 7-11
2.6 Piston and Connecting rod - Assemble .................................................................................. 7-12
2.7 Piston ring - Install .................................................................................................................. 7-12
2.8 Crankshaft - Rotate................................................................................................................. 7-13
2.9 Piston installation - Prepare.................................................................................................... 7-13
2.10 Upper connecting rod bearing - Install.................................................................................... 7-13
2.11 Piston - Install ......................................................................................................................... 7-14
2.12 Connecting rod cap - Install .................................................................................................... 7-16
2.13 Connecting rod end play - Measure........................................................................................ 7-17
2.14 Piston protrusion - Measure.................................................................................................... 7-18
3. Front equipment - Assemble ................................................................................ 7-19
3.1 Coupling - Install ..................................................................................................................... 7-19
3.2 Front plate - Install .................................................................................................................. 7-19
3.3 Front idler shaft - Install .......................................................................................................... 7-19
3.4 Front idler gear - Install........................................................................................................... 7-19
3.5 Front idler gear backlash - Measure ....................................................................................... 7-20
3.6 Front idler gear end play - Measure........................................................................................ 7-20
3.7 Water pump bearing cover and Oil pump bearing cover - Install............................................ 7-20
3.8 Water coupling - Install ........................................................................................................... 7-20
3.9 Front gear case - Install .......................................................................................................... 7-21
3.10 Front oil seal - Install............................................................................................................... 7-21
3.11 Oil pump gear and Pump plate (for water pump and oil pump) - Install ................................. 7-21
3.12 Breather case - Install............................................................................................................. 7-22
3.13 Damper and Crankshaft pulley - Install................................................................................... 7-22
3.14 Damper face and radial runouts - Measure ............................................................................ 7-22
3.15 Pointer - Install and Adjust...................................................................................................... 7-23
7-1
4. Rear equipment - Assemble ................................................................................. 7-24

4.1 Rear plate - Install................................................................................................................... 7-24
4.2 Rear idler shaft - Install........................................................................................................... 7-24
4.3 Camshaft - Install.................................................................................................................... 7-24
4.4 Camshaft gear - Install............................................................................................................ 7-25
4.5 Camshaft end play - Measure................................................................................................. 7-25
4.6 Fuel injection pump accessory drive - Install .......................................................................... 7-25
4.7 Rear idler gear - Install ........................................................................................................... 7-26
4.8 Rear idler gear end play - Measure ........................................................................................ 7-26
4.9 Timing gear backlash - Measure ............................................................................................ 7-26
4.10 Timing gear case - Install........................................................................................................ 7-27
4.11 Rear idler shaft thrust collar - Install ....................................................................................... 7-27
4.12 Rear oil seal - Install ............................................................................................................... 7-28
4.13 Flywheel - Install ..................................................................................................................... 7-28
4.14 Flywheel face and radial runouts - Measure........................................................................... 7-28
4.15 Pickup - Install ........................................................................................................................ 7-29
5. Cylinder head and Valve mechanism - Assemble .............................................. 7-30
5.1 Cylinder head - Assemble....................................................................................................... 7-30
5.2 Valve sinkage - Measure ........................................................................................................ 7-31
5.3 Tappet - Install ........................................................................................................................ 7-31
5.4 Liquid gasket - Apply .............................................................................................................. 7-31
5.5 Cylinder head gasket - Install ................................................................................................. 7-32
5.6 Cylinder head assembly - Install............................................................................................. 7-32
5.7 Cylinder head bolt - Tighten.................................................................................................... 7-32
5.8 Rocker case - Install ............................................................................................................... 7-33
5.9 Bridges and Bridge cap - Install.............................................................................................. 7-33
5.10 Valve bridge and Adjusting screw - Adjust ............................................................................. 7-33
5.11 Clearance between the bottom face of valve bridge and the top face
of valve rotator - Inspect ......................................................................................................... 7-34
5.12 Rocker shaft assembly - Install............................................................................................... 7-34
5.13 Valve clearance - Check and Adjust....................................................................................... 7-35
5.14 Fuel injection timing - Check and Adjust................................................................................. 7-35
5.15 Valve timing - Inspect ............................................................................................................. 7-37
5.16 Fuel injection nozzle assembly - Install .................................................................................. 7-38
7-2
1. Crankshaft and Main bearing - Install


facing downwards.Then, change the positions of the wire
ropes, and turn over to invert the crabkcase.
Crankcase - Invert
1.2 Piston cooling nozzle - Install
Be sure to tighten the piston cooling nozzle to the 34 ± 1.7 N·m {3.5 ± 0.18 kgf·m} Eye bolt
[25 ± 1.2 lbf·ft]
specified torque using a torque wrench. If it is exces-
sively tightened, it could cause the check valve to mal-
function, possibly leading to piston seizure.
Install the piston cooling nozzle onto the crabkcase and
tighten the eye bolts to the specified torque.
Piston cooling nozzle
Piston cooling nozzle - Install
7-3
1.3 Upper main bearing - Install
(a) Do not apply engine oil to the back faces of the main bearing shells and main bearing fitting bores in the crank-
case when installing the main bearings.Install the main bearings only after cleaning off foreign matters, oil and
grease from these surfaces using cleaning solvent.
(b) When installing main bearings, be careful not to confuse upper shells with lower shells.
The upper main bearing shells are identified by machined oil holes. The lower main bearing shells have no oil
holes or grooves. If main bearing shells are installed incorrectly, it can cause the seizure of crankshaft and
main bearings.
(c) Be careful not to damage the bearings when installing.
(1) Clean the main bearing fitting bores and main bearing
cap mating surfaces using cleaning solvent, and make
sure that these surfaces are free from any foreign sub-
stances.
(2) Make sure that the main bearings are neither damaged Lug groove
nor contaminated.
(3) Fit the upper main bearing shell in the crabkcase bore
while aligning the notch on the shell with the lug of the Oil hole
crabkcase.
Upper main bearing
Note:(a) Make the main bearing end protrusion from the
Upper main bearing - Install
crankcase bore even at both ends.
(b) The oil hole in the upper main bearing shell will be
aligned with the oil hole in the crabkcase by align-
ing the notch of upper shells with the lug of the
crabkcase.
(4) Apply an even coat of clean engine oil to the sliding
surface of upper main bearing shells.
1.4 Rear upper thrust plate - Install
Be careful not to damage the thrust plate when

installing.
(1) With the oil grooves facing the engine rear side, install
the rear upper thrust plate to the dowel pins on the
crankcase rearmost.
(2) Apply engine oil evenly to the sliding surface.
Note: Front upper thrust plate should be installed after the Oil
grooves
crankshaft is installed.
Rear upper thrust plate - Install
7-4
1.5 Crankshaft - Install

(1) Make sure that the sliding surfaces of the upper main
bearing shells, which have just been installed in the
crabkcase, are evenly coated with clean engine oil.
(2) Thoroughly wash the crankshaft with cleaning oil, and
clean the crankshaft using compressed air. Then, apply
an even coat of clean engine oil to the crankshaft jour- After cleaning,
apply engine oil
nals. to crank journals.
Note: When washing crankshaft, be sure to thoroughly wash After cleaning,
the crank journals, crankpins, and oil holes so that they dry with
compressed air.
are free from foreign substances, dust and dirt.Make
Crankshaft - Clean
sure that oil holes are free from any burrs.
(3) Keeping the crankshaft in a horizontal position, slowly
install into the crabkcase. Crankshaft assembly
Note: When hoisting the crankshaft, use cloth belts or pads
so that the crankshaft does not get damaged.
(4) Gently rotate the crankshaft to check for smooth rota-
tion of the crankshaft.
Crankshaft - Install
1.6 Front upper thrust plate - Install
Be careful not to damage the front upper thrust plate Front upper thrust
plate
when installing.
(1) Push the crankshaft, which has been installed, towards
the engine front so that the rear upper thrust plate,
which already installed, comes into slight contact with
the crank journal end face.
Insert it between
(2) With the oil grooves on the front upper thrust plate fac- the crankshaft and
ing toward engine front, insert the front upper thrust crankcase.
plate into the clearance between the crankshaft and Front upper thrust plate - Install
crabkcase.
(3) Move the crankshaft back and forth to make sure there
is proper end play.
7-5
1.7 Lower main bearing shell and Lower thrust plate - Install
(1) Install the lower main bearing shell, aligning with the
Lower main
lug of the main bearing cap. bearing
Note: Make a protrusion amount of bearings even.
Lower thrust
(2) Apply an even coat of clean engine oil to the sliding plate
surface of lower main bearing shells. Lug groove
(3) Install the lower thrust plate to the dowel pin on the
Lower thrust
rearmost main bearing cap. plate
Note: Install the lower thrust plate so that its oil grooves face
outward. Main bearing cap
Oil groove Dowel pin
Lower main bearing shell and Lower thrust plate -
Install
7-6
1.8 Main bearing cap - Install
Be sure to observe the specified tightening sequence

when installing the main bearing cap bolts and side
bolts.
(1) Make sure that the main bearings and thrust plates,
"FRONT" mark
which have been installed to main bearing caps, are
evenly coated with clean engine oil.
(2) Install the main bearing caps so that their stamp num-
bers are arranged in numerical order from engine front
Main bearing caps
to rear, and that the embossed mark of "FRONT" faces
toward the engine front (so that all lugs are aligned on
the same side.)
(3) Tentatively install the main bearing cap bolts and wash-
ers after applying engine oil to them.
Main bearing cap - Install
(4) Tap the main bearing caps with a soft-head hammer
evenly to install them in position.
(5) Tentatively install the side bolts and O-rings after
applying engine oil to them.
(6) Tentatively tighten the main bearing cap bolts and side First
bolts except the rearmost ones, to the half of specified Main bolt: 294 ± 15 N·m
{30 ± 1.5 kgf·m} [217 ± 11 lbf·ft]
torque in the specified tightening sequence as shown in Tighten to the specified Side bolt: 196 ±10 N·m
torque in the numerical {20 ± 1 kgf·m} [144.66 ± 7.23 lbf·ft]
Second
the illustration. order in two steps.
Main bolt: 588 ± 29.4 N·m
[Wet]
(7) Tighten the main bearing cap bolts and side bolts {60 ± 3.0 kgf·m} [434 ± 22 lbf·ft]
Side bolt: 392 ±19.6 N·m
except the rearmost ones to the specified torque in the {40 ± 2.0 kgf·m} [289 ± 14 lbf·ft]
31 24 41 32
specified sequence shown in the illustration.
(8) Tentatively tighten the rearmost cap bolts and side bolts 5 6 5 6
so that the rearmost main bearing cap is lightly seated. or

Measure the crankshaft end play in this condition.
Tightening sequence of main bearing cap bolts
588 ± 29.4 N·m

392 ± 19.6 N·m {60 ± 3.0 kgf·m}
{40 ± 2.0 kgf·m} [434 ± 22 lbf·ft]
[289 ± 14 lbf·ft] [Wet]
[Wet]
Main bearing cap bolt - Install
7-7
1.9 Crankshaft end play - Measure

(1) Make sure that the crankshaft rotates smoothly.
(2) Attach a dial gauge to the rear end face of crankshaft.
(3) Using a bar, move the crankshaft fully to the front and
rear sides, and measure the clearance at front and rear
sides respectively. The end play is the difference
between front and rear clearances.
If the end play exceeds the standard value, inspect the
thrust plates and the crankshaft.
If the end play is less or equal to the standard value,
move the crankshaft back and forth in loose rearmost
main bearing cap bolt condition, and measure the end
play once again.
Note: In general, the rear thrust plate wears faster than the
front thrust plate. Therefore, in most cases, the correc-
tion is achieved by replacing the rear thrust plate with
the next oversize one.
(4) After the final tightening of the rearmost main bearing
cap is completed, measure the end play again for con-
firmation.
(5) Again, make sure that the crankshaft rotates smoothly.
(6) Double-check all main bearing cap bolts and side bolts
to make sure they have been tightened properly.
Item Standard Limit

0.200 to 0.400 mm 0.500 mm
Crankshaft end play
[0.0079 to 0.0157 in.] [0.0197 in.]

facing downwards.Then, rehang the wire ropes. Invert the
crabkcase on the wooden blocks and turn it to the normal
position.
Crankcase - Invert
7-8
2. Cylinder liner, Piston and Connecting rod - Assemble

2.1 Cylinder liner top ridge height - Measure
(1) Place the dial gauge on the top surface of the cylinder
Ridge height
liner flange, and zero the dial gauge.
(2) Measure the height of the annular top ridge of the cylin-
der liner at four locations.
(3) If the measured value does not meet the standard, or if Cylinder liner top
the ridge is lacked, replace the cylinder liner with a new
one.
Item Standard
0.16 to 0.24 mm
Cylinder liner top ridge height
[0.0063 to 0.0094 in.]
Cylinder liner top ridge height - Measure
2.2 Cylinder liner flange protrusion - Calculate (in cylinder liner removed condition)
If the amount of protrusion is insufficient, the cylinder

head gasket will fail to seal hermetically, resulting in
gas or water leakage.
(1) Inspect the cylinder liner contact surface on the crab-
kcase. If there is any evidence of uneven contact, reface
the counterbore using the crabkcase grinder such that
the difference in depth at the circumference is less than Projection plate
0.05 mm [0.0020 in.]. P/N:37598-09201
For repair procedure, refer to "Counterbore in crab-

Counterbore depth
kcase - Repair" of "INSPECTION AND REPAIR OF
BASIC ENGINE."
(2) Make sure that the top and bottom of cylinder liner
flange, the top surface of crabkcase and the contact sur-
face of cylinder liner are clean before measurement.
(3) Measure the depth of counterbore in crabkcase. Depth of counterbore in crabkcase - Measure
Item Standard
14.00 to 14.05 mm
Depth of counterbore in crabkcase
[0.5512 to 0.5531 in.]
(4) Measure the thickness of cylinder liner flange.
Item Standard
14.16 to 14.20 mm
Thickness of cylinder liner flange
[0.5575 to 0.5591 in.]
Cylinder liner
Thickness of cylinder liner flange
7-9
(5) Calculate the cylinder liner flange protrusion by sub-

tracting the depth of counterbore in crabkcase from the Crankcase
Shim
thickness of the cylinder liner flange. Cylinder liner
If the measured value exceeds the standard value, insert
a shim under the cylinder liner flange. Select a shim
which makes the cylinder liner flange projection the
largest within the tolerance of the standard.
Note:(a) Shims are available in 3 thicknesses: 0.05, 0.10 and
0.15 mm [0.0020, 0.0039 and 0.0059 in.].
(b) Do not double the shims.
Shim - Insert
Item Standard
0.11 to 0.20 mm
Cylinder liner flange protrusion
[0.0043 to 0.0079 in.]
Shim thickness Part No.

0.05 mm [0.0020 in.] 37507-12510
0.10 mm [0.0039 in.] 37507-12500
0.15 mm [0.0059 in.] 37507-12520
2.3 Cylinder liner - Install
Apply engine oil to the mounting surface of the O-rings

to prevent O-rings from twisting.
(1) Install the O-rings to the cylinder liner.
(2) Insert the shim to the cylinder which requires the
adjustment of the cylinder liner flange protrusion.
Apply
engine oil
Cylinder liner O-rings - Install

(3) Slowly insert the cylinder liner into the bore in the crab-
kcase. Using the appropriate cylinder liner installer,
lightly tap the cylinder liner until its flange rests snugly
on the seating surface of the crabkcase. Then, give sev-
eral light taps on the liner to settle. Installer
Note: To check that the O-rings have been installed properly, Cylinder liner
make sure that the roundness of inside cylinder liner

(especially O-ring installing position) is normal by
measuring.
Cylinder liner - Install
7-10
2.4 Cylinder liner flange protrusion - Measure (in cylinder liner installed condition)
(1) Remove the dust and dirt from the crabkcase top face
Bolt Cylinder liner
and the cylinder liner top end face at which measure- P/N:37591-06300 flange protrusion
ment is to be taken. Tightening
torque
(2) Attach the liner holders on equally spaced 4 locations
98 N·m
of the cylinder liner upper rim and tighten the bolts of {10 kgf·m}
[72 lbf·ft]
the holders evenly so that the cylinder liner comes into
close contact with the crabkcase.
(3) Apply the dial gauge plunger to the top face of the crab-
kcase, and zero the dial gauge. Liner pusher
P/N:37591-06200
(4) Measure the flange protrusion at four locations on the
top of the cylinder liner, and obtain the mean value.
(5) If the mean value of the protrusion is smaller than the
standard, insert a shim under the cylinder liner flange.
For shim and standard value, refer to "Cylinder liner
flange protrusion - Calculate (in cylinder liner removed
condition)" of "ASSEMBLY OF BASIC ENGINE."
2.5 Cylinder liner inside diameter - Measure

Measure the inside diameter of the cylinder liner at three
levels, i.e., upper (position of No.1 compression ring when
Cylinder liner
piston is at top dead center), middle, and O-ring insertion
portion, in both directions parallel to and perpendicular to
the piston pin direction of the inside cylinder liner.
If the measured value exceeds the specified limit, replace
the cylinder liner with a new one, or repair the deformation.

ø170 mm 170.000 to 170.040 mm 170.500 mm
Inside diameter
[6.69 in.] 6.6929 to 6.6945 in.] [6.7126 in.]
0.02 mm
Roundness - -
Pin right angle
0.02 mm
Cylindricity - - Pin direction
[1.18 in.]
[3.94 in.]
30 mm
100 mm
[9.84 in.]
250 mm
Cylinder liner dimension measuring position
7-11
2.6 Piston and Connecting rod - Assemble

(1) Apply engine oil to the piston pin, and assemble the
A
piston and the connecting rod. The orientation of piston View A
and connecting rod is shown in the illustration. Piston weight
Note: The piston and piston pin are assembled with each oth-
er by a clearance fit. However, the piston pin is more Camshaft
easily inserted into the piston if the piston is warmed
&$0
Matching
up with a heater or with hot water. marks
(2) Install the snap ring with ring pliers.Make sure the snap Direction mark
ring is fully inserted into the ring groove. (CAMЎ)
Part No.
Piston and Connecting rod - Assembling orientation
Piston and Connecting rod - Assemble

2.7 Piston ring - Install
Ring expander
P/N:37191-03200
Every piston ring has a top mark near the end gap.
Install piston rings with this mark facing upward. Top mark
No.1
If the rings are installed upside down, it could cause
compression ring
malfunctions such as excessive oil consumption or
No.2
engine seizing. compression ring
(1) Install the piston rings to the piston with a ring Oil ring
expander.
Coil spring
(2) Install the oil ring with its end gap 180° away from the
joint of the coil spring, as shown in the illustration. Piston and Piston ring - Install
Coil spring joint
180°
Oil ring ends
Oil ring end gap and coil spring joint - Orientation
7-12
2.8 Crankshaft - Rotate

(1) Install two bolts in the flywheel mounting holes of the
crankshaft.
(2) Using the bolts, rotate the crankshaft with a bar.
M22 × 1.5 mm
Crankshaft
Crankshaft - Rotate
2.9 Piston installation - Prepare
(1) Rotate the crankshaft to a position at which the con-
necting rod big end does not hit the crankpin when the
piston is installed.
Crankpin Position that the connecting

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

2.10 Upper connecting rod bearing - Install
Upper connecting
rod bearing
Do not apply engine oil to the back face of the upper Lug groove
connecting rod bearings.
Install the upper connecting rod bearing into the connecting
rod big end while aligning its lug with the lug groove, and
apply engine oil to the sliding surface.Make sure that the oil
hole of the connecting rod and the oil hole of the bearing are
aligned. Oil hole
Upper connecting rod bearing - Install
7-13
2.11 Piston - Install

Piston top face stamp
「CAM↓」
When installing the piston, install the eye bolt to the Eye bolt
threaded hole on the piston top, and raise the piston P/N:37591-02500
(M10 × 1.25 mm)
with chain block. When the installation work is carried
CAM
out by hand, be sure to take preventive measures so
that piston does not falling down, and be very careful
Camshaft side
not to hurt hands and fingers or not to damage the
parts.
Avoid contact.
Camshaft
Piston and Connecting rod - Install
(a) Make sure that the punch mark on the piston top
faces the camshaft side. No.1
Coil spring joint compression
(b) Checking through the inspection window on the ring ends
side of crabkcase, make sure that the connecting
rod does not come into contact with the piston
Piston pin
cooling nozzle when installing piston.
(c) To protect the oil ring from damage due to shock,
gently insert the piston. No.2
(1) Insert the connecting rod into the cylinder liner, being compression Oil ring ends
ring ends
careful not to damage the cylinder liner, and slowly
lower the piston to the upper surface of the crabkcase. Piston ring end gaps - Orientation
(2) Apply engine oil to the piston rings.

Place the end gaps equally spaced each other, avoiding
thrust and anti-thrust direction, and pin direction.
(3) Hold the compression rings of the piston with your Compression ring
hands, and gently insert the piston skirt into the cylin-
der liner.
Piston- Install
(4) Double-check the position of piston rings to make sure
that piston rings end gaps have been arranged correctly.
Apply engine oil to the piston rings.
Apply engine oil to the inner surface of piston installer.
Make sure that the oil ring is fully seated in the groove.
Then, compress the piston rings with the piston
Piston installer
installer. P/N:37191-07100
Note: For piston ring orientation, see above (2).
Piston ring - Compress
7-14
(5) Install piston into cylinder liner by tapping the piston

head with a soft-head hammer.
Note: Make sure that the piston is not caught in the cylinder
liner, or the connecting rod big end does not hit the
crank pin.
Use a soft hammer
handle
Piston- Install
(6) Make sure that the upper connecting rod bearing shell is
properly seated through the inspection window on the Check bearing position.
side of the crabkcase. If the bearing shell is not seated

properly, push the bearing upward with your hand to
correct the position.
Piston - Install (6)

(7) If the upper connecting rod bearing is off the connect-
ing rod big end, rotate the crankshaft to make a space
between the connecting rod big end and crankpin.
Then, insert the connecting rod bearing, sliding it along
the crankpin, and making sure that the lug in the bear-
ing shell is fully seated in the groove of the rod.
Upper connecting
rod bearing
Piston - Install (7)
7-15
2.12 Connecting rod cap - Install
Lower connecting
(a) Make sure that the matching numbers on the con- Connecting rod bolt rod bearing
necting rod and the connecting rod cap are on the Lug groove
same side and in alignment. Thread
(b) Check the identification mark to make sure the
mounting position of the connecting rod bolts.
Serration
(c) When installing the connecting rod caps, make
sure that dust, metal particles, etc. are not caught Connecting rod
Bolt seating
in the serrations, bolt seating surfaces and the bolt cap
surface
threads. Connecting rod cap - Install (1)
(1) Install the lower connecting rod bearing, aligning its
lug with the lug groove of the connecting rod bearing
cap.
(2) Apply engine oil to the connecting rod bolt threads and
seating surface, and the sliding surface of the lower
connecting rod bearing shell.
(3) Install the connecting rod caps to the connecting rods so

Identification mark
that that the matching numbers on the connecting rod “AU”: Top (short)
caps and the connecting rods are on the same side and
AU
in alignment.
(4) Tentatively tighten the connecting rod bolts.
Note: Bolt identification mark
AL
"AU": Upper (short) (Part number: 37519-21300)
"AL": Lower (long) (Part number: 37519-11400)
Identification mark
"2": No differentiation between upper and lower (Part “AL”: Bottom (long)
number: 37519-20301)
Connecting rod cap - Install (2)
(5) The joint between the connecting rod cap and rod
should be flush to ensure the end play.
Note: To adjust the end play, the connecting rod gauge may
be inserted between the two connecting rods for the
minimum end play.
Ensure the end play

with a connecting
rod gauge
P/N :37791-01500 (Thickness 0.5 mm [0.020 in.])

:37791-01600 (Thickness 0.6 mm [0.024 in.])
7-16
(6) Measure the connecting rod end play, and adjust the
Tightening torque
end play to the range of the standard value. ○Bolt identification mark “AL”“AU”
(7) Tighten the connecting rod bolts to the specified torque. 637 ± 31.9 N·m {65 ± 3.25 kgf·m}
[470 ± 24 lbf·ft]
Tightening procedure: loosen the bolts completely after 2-step tightening method (Wet)
○Bolt identification mark “2”
tightening to the specified torque, and retighten to the 539 ± 27 N·m {55 ± 2.75 kgf·m}
specified torque. [398 ± 20 lbf·ft]
2-step tightening method (Wet)
Measure the end play again.
Note: To tighten the connecting rod bolts using the angle
method, follow the steps below.
(a)Tighten the bolts with snug torque.
Bolt identi-
Bolt loca-
fication Snug torque Part No.
tion
mark
245 ± 12.3 N·m
Upper AU {25 ± 1.25 kgf·m} 37519-21300
[180 ± 9 lbf·ft]
294 ± 14.7 N·m
Lower AL {30 ± 1.5 kgf·m} 37519-11400
[217 ± 11 lbf·ft]
245 ± 12.3 N·m
- 2 {25 ± 12.5 kgf·m} 37519-20301
[180 ± 9 lbf·ft]
(b)Further rotate the bolt 60±3 degrees.

(c)Loosen all bolts, and then tighten them to the
specified angle again.(2-time tightening method)
2.13 Connecting rod end play - Measure

Measure the end play of the connecting rod.
If the specified limit is exceeded, find the causal parts, and
Connecting rod
replace them with new ones.
Item Standard Limit

0.6 to 0.9 mm 1.4 mm
Connecting rod end play
[0.024 to 0.035 in.] [0.055 in.]
Connecting rod
end play
7-17
2.14 Piston protrusion - Measure
Piston protrusion
Piston protrusion must always meet the standard, as
the amount of protrusion not only influences engine
performance, but it also prevents valve interference.
Measure the protrusion of each piston, following the
instructions below. If the measured value does not meet the
standard, inspect the clearances between various parts
involved.
(1) Bring the piston to top dead center.
(2) Apply the dial gauge plunger to the top surface of the Piston protrusion - Measure
crabkcase, and zero the dial gauge. Top clearance
(3) Move the dial gauge to the top face of piston, measure Cylinder head Piston protrusion
the maximum protrusion by rotating around top dead gasket thickness Cylinder head
center.
Note: The crankshaft position that indicates the maximum Cylinder liner
protrusion is defined as the correct top dead center.
Crank
(4) Measure the protrusion at four points on the piston Cylinder liner Piston
case
head, and calculate the mean value. flange protrusion
Note: The top clearance (clearance between the piston top
and cylinder head) can be determined by the piston
Top clearance
protrusion, cylinder liner flange protrusion and cylin-
der head gasket thickness.
Top clearance = cylinder head gasket thickness + cyl-
inder liner flange protrusion - piston protrusion
Item Standard
0.03 to 0.63 mm
Piston protrusion
[0.0012 to 0.0248 in.]
0.11 to 0.20 mm
Cylinder liner flange protrusion
[0.0043 to 0.0079 in.]
1.77 to 1.83 mm
Thickness of cylinder head gasket
[0.0697 to 0.0720 in.]
1.25 to 2.00 mm
Top clearance
[0.0492 to 0.0787 in.]
7-18
3. Front equipment - Assemble

3.1 Coupling - Install
(1) Install the coupling with aligning the dowel pin on the
camshaft front end, and tighten the bolt.
(2) Install the oil seal and O-ring to the oil seal case, and
tighten the bolt. Oil seal
case
Note:(a) Apply the grease to the oil seal lip and the entire cir-
cumference of the O-ring.
(b) Before installing the coupling, oil seal and oil seal
case, install the camshaft.
Coupling
Oil seal
Coupling - Install
3.2 Front plate - Install
(1) Apply sealant (ThreeBond 1211) to the front plate
packing mounting surface of the crabkcase, and install
Front plate
the packing.
(2) Apply the same sealant (ThreeBond 1211) to the pack-
ing, and then install the front plate.
(3) Tighten the bolt with the specified torque.
(4) Make sure that the lower end of the front plate is flush 59 ± 5.9 N·m
with the bottom surface of the crabkcase. Cut off any {6 ± 0.6 kgf·m}
[43 ± 4.3 lbf·ft]
excess packing neatly.
Front plate - Install

3.3 Front idler shaft - Install
(1) Install the front idler shaft to the crabkcase.
108 ± 10.8 N·m

{11 ± 1.1 kgf·m}
[80 ± 8 lbf·ft]
Front idler shaft
Front idler shaft - Install

3.4 Front idler gear - Install
(1) Apply engine oil to the front idler gear shaft.
(2) Install the front idler gear.
Front idler gear
(3) Install the thrust plate and tighten bolts to the specified
torque.
Thrust
plate
60 ± 3.0 N·m
{6.1 ± 0.31 kgf·m} [44 ± 2.2 lbf·ft]
Front idler gear - Install
7-19
3.5 Front idler gear backlash - Measure

Measure the backlash of the front idler gears by using either
of the following methods; measure the gear play with the
dial gauge applied to a tooth flank on the pitch circle at a
right angle to the tooth axis, or measure the clearance
between gears by inserting a thickness gauge between the
gears at the tooth-to-tooth contacting area. If the specified
limit is exceeded, replace the gears with new ones. Front
idler gear
Item Standard Limit
0.12 to 0.28 mm 0.50 mm
Front idler gear backlash
[0.0047 to 0.0110 in.] [0.0197 in.]
3.6 Front idler gear end play - Measure
Measure the end play of the front idler gear. If the measure-
ment exceeds the limit, replace the thrust plate or rear idler Front
gear with a new one. idler gear
Item Standard Limit

Front idler gear 0.20 to 0.40 mm 0.6 mm
end play [0.0079 to 0.0157 in.] [0.024 in.]

3.7 Water pump bearing cover and Oil pump bearing cover - Install
(1) Install the oil seal to the water pump bearing cover.
Water pump
(2) Install the water pump bearing cover and oil pump bearing cover
bearing cover to the front plate.
108 ± 10.8 N·m
{11 ± 1.1 kgf·m}
[80 ± 8.0 lbf·ft]
Oil seal
Oil pump
bearing cover
Water pump bearing cover and Oil pump bearing
cover - Install
3.8 Water coupling - Install
(1) Apply the grease to the O-ring and O-ring groove.
(2) Install the water couplings of crabkcase and gear case
Apply grease
to the crabkcase, taking care not to damage the O-rings.
Apply grease
Water coupling - Install
7-20
3.9 Front gear case - Install

(1) Apply sealant (ThreeBond 1211) to the front gear case
Eye bolt
packing mounting surface of the crabkcase, and install 05930-00200
the packing. Apply the same sealant (ThreeBond 1211) (M12 × 1.25 mm)
to the packing, and then install the front gear case.
(2) Tighten the bolts evenly to the specified torque.
(3) Make sure that the lower end of the front gear case is
flush with the bottom surface of the crabkcase. Cut off
M12 : 59 ± 3.0 N·m
any excess packing neatly. {6 ± 0.3 kgf·m}
[43 ± 2.2 lbf·ft]
M16 : 255 ± 12.8 N·m
{26 ± 1.3 kgf·m}
[188 ± 9.4 lbf·ft]
Front gear case - Install
3.10 Front oil seal - Install
Using the front seal installer assembly, install the front oil
Insert bolt
seal.
Guide flange
(1) Apply clean engine oil evenly to the oil seal lip.
Insert
Note: Pay attention to the mounting direction of oil seal, and
be careful not to damage the oil seal. Socket bolt
(2) Install the guide flange to the stud on the front end of Bolt
the crankshaft, insert the spacer, and secure them with
the nut. Front seal installer
(3) Set the oil seal to the insert and install it to the guide assembly
Swing washer P/N:37591-05010
flange.
Front oil seal - Install (1)
(4) Tighten the bolt that has been installed to the guide
flange to insert the oil seal into the front cover. 15.5 mm 17.5 mm
(5) Remove the installer assembly. [0.610 in.] [0.689 in.]
Slinger
Front seal installer

assembly
P/N:37591-05010
Oil seal
Front oil seal - Install (2)

3.11 Oil pump gear and Pump plate (for water pump and oil pump) - Install
(1) Install the bearing to the oil pump gear.
(2) Insert the oil pump gear. 59 ± 5.9 N·m Oil pump
gear
(3) Install the pump plate to the front case. {6 ± 0.6 kgf·m}
[43 ± 4.3 lbf·ft]
Pump plate
Oil pump gear and Pump plate (for water pump and oil
pump) - Install
7-21
3.12 Breather case - Install

Install the breather case to the front gear case.
Breather case
Breather case - Install

3.13 Damper and Crankshaft pulley - Install
(1) Install the guide bolts to the damper mounting holes on
the crankshaft. Guide bolt Dowel pin
(2) Aligning with the dowel pins, install the spacer, back Crankshaft pulley
damper, spacer, front damper, and crankshaft pulley, in
490 ± 24.5 N·m
that order, through the guide bolt. {50 ± 2.5 kgf·m}
(3) Tighten the bolt with the specified torque. [361 ± 18 lbf·ft]
Note: Make sure the correct installation position and direc-
tion of damper.
Damper and Crankshaft pulley - Install
With punch mark Without punch mark
Front damper Rear damper
Spacer
Damper - Installation position and orientation

3.14 Damper face and radial runouts - Measure
Measure the face and radial runouts of the damper.
If the measured value extremely deviates from the standard,
check the assembling condition such as bolts looseness or
accumulation of foreign substances on the mounting face.
Note: Avoid measuring at stamp position.
Item Standard
Face runout (reference) 0.5 mm [0.020 in.] or less
Face runout
Radial runout (reference) 0.5 mm [0.020 in.] or less
Radial runout
7-22
3.15 Pointer - Install and Adjust

(1) Install the pointer to the front gear case.
(2) Rotate the crankshaft to bring top dead center of No. 1
cylinder. Align the stamped line of top dead center of
No. 1 cylinder on the periphery of damper with the Timing gear
case
pointer.
(3) Rotate the flywheel so that its punch mark is positioned
at the same distance from the two punch marks stamped Flywheel
on the timing gear case. This position is considered to
be top dead center of No. 1 cylinder.
Note: For checking procedure of top dead center by the pis-
Top dead center of punch mark - Check
ton movement, refer to "Piston protrusion - Measure"
of "ASSEMBLY OF BASIC ENGINE."
7-23
4. Rear equipment - Assemble

4.1 Rear plate - Install
(1) Install the nozzle plate.
Nozzle plate
(2) Apply sealant (ThreeBond 1211) to the rear plate pack-
ing mounting surface of the crabkcase, and install the
packing.
(3) Apply the same sealant (ThreeBond 1211) to the pack-
ing, and then install the rear plate.
Torque
(4) Tighten the bolt with the specified torque. M12 : 108 ± 5.4 N·m
{11 ± 0.55 kgf·m}
(5) Make sure that the lower end of the rear plate is flush [80 ± 3.98 lbf·ft]
M16 : 255 ± 12.8 N·m
with the bottom surface of the crabkcase. Cut off any {26 ± 1.3 kgf·m}
excess packing neatly. [188 ± 9.4 lbf·ft]
Rear plate - Install
4.2 Rear idler shaft - Install
Install the O-rings to the rear idler shaft and apply grease to
the O-rings. Rear plate
Align the rear idler shaft to the dowel pin, and install the
Apply grease to O-ring
rear idler shaft to the crabkcase.
Rear idler shaft

Dowel pin
Rear idler shaft - Install
4.3 Camshaft - Install
Camshaft
Install the camshaft through the crabkcase window,
supporting it with a protective pad. Be careful not to
Thrust plate
bump the camshaft. If you do, the cam portion and
cam shaft bushing get damaged. 59 ± 5.9 N·m
{6 ± 0.6 kgf·m}
(1) Apply engine oil to the inner surface of camshaft bush- [43 ± 4.3 lbf·ft]
ing.
(2) Apply the engine oil to the camshaft oil gallery and
journal and cam portions.
(3) Support the camshaft with a protector, and insert the Camshaft - Install
camshaft gently to the crabkcase.
(4) Install the thrust plate, and tighten the bolts to the spec-
ified torque.
(5) Make sure that the camshaft rotates smoothly.
7-24
4.4 Camshaft gear - Install

(1) Install the camshaft gear by aligning its hole with the
dowel pin on the camshaft. Camshaft gear
(3) Make sure that the camshaft rotates smoothly.
127 ± 6.4 N·m

{13 ± 0.65 kgf·m}
[94 ± 5 lbf·ft]
Camshaft gear
Camshaft gear - Install
4.5 Camshaft end play - Measure
Measure the camshaft end play.If the specified limit is
exceeded, find the causal parts, and replace them with new Camshaft gear
ones.
Item Standard Limit

0.10 to 0.25 mm 0.40 mm
Camshaft end play
[0.0039 to 0.0098 in.] [0.0157 in.]
Camshaft end play - Measure

4.6 Fuel injection pump accessory drive - Install
(1) Install the O-ring to the mounting surface of the fuel
injection pump accessory drive case. Apply a thin coat 108 ± 5.4 N·m {11 ± 0.55 kgf·m}
[80 ± 4.0 lbf·ft]
of ThreeBond 1212 to the flange.
(2) Install the fuel injection pump accessory drive to the
rear plate.
Fuel injection pump

accessory drive
Fuel injection pump accessory drive - Install
7-25
4.7 Rear idler gear - Install

(1) Rotate the crankshaft to bring the No. 1 at top dead cen-
ter. Camshaft gear
(2) Apply engine oil to the idler shaft. Rear idler gear
(3) Install the idler gear, aligning it with the match marks.

(4) Install the thrust plate to the idler shaft.


/

5

(6) Ensure that the match marks on the timing gears are
aligned as shown in the illustration.
Injection pump gear Injection pump gear
Crankshaft gear
Timing gear train
Thrust plate
392 ± 19.6 N·m
{40 ± 2.0 kgf·m}
[289 ± 14 lbf·ft]
Apply Molykote to threads.
Dowel pin
Apply Molykote on the
inner surface of rear
idler bushing
(whole surface).
Rear idler gear
Slinger
Rear idler gear - Install
4.8 Rear idler gear end play - Measure
Measure the end play of the rear idler gear. If the measure-
ment exceeds the limit, replace the thrust plate or rear idler
gear with a new one.
Item Standard Limit

0.3 to 0.5 mm 1.0 mm
Rear idler gear end play
[0.0118 to 0.0197 in.] [0.040 in.]
Rear idler gear end play - Measure

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

Backlash between crank gear 0.12 to 0.28 mm 0.50 mm Rear idler gear
and rear idler gear [0.0047 to 0.0110 in.] [0.0197 in.]
Rear idler gear end play and Timing gear backlash -
Backlash between idler gear 0.12 to 0.18 mm 0.50 mm Measure
and camshaft gear [0.0047 to 0.0071 in.] [0.0197 in.]
Backlash between idler gear 0.12 to 0.18 mm 0.50 mm
and injection pump gear [0.0047 to 0.0071 in.] [0.0197 in.]
7-26
4.10 Timing gear case - Install
Eye bolt
Be careful not to drop or hit the timing gear case. P/N:05930-00200
(M12 × 1.25 mm)
Doing so may damage the timing gear case and also
could lead to personnel injuries.
(1) Apply sealant (ThreeBond 1211) to the packing mount-
255 ± 12.8 N·m
ing surface of the rear plate, and install the packing. {26 ± 1.3 kgf·m}
(2) Apply sealant (ThreeBond 1211) to the timing gear [188 ± 9.4 lbf·ft]
case mounting surface of the packing. Timing gear case
(3) Attach a hoisting tool to the timing gear case, align it
with the dowel pin, and install the timing gear case. Timing gear case - Install
(5) Cut off neatly any excess packing from the bottom of
crabkcase.
4.11 Rear idler shaft thrust collar - Install

(1) Apply grease to the rear idler thrust collars, and insert
the thrust collars to the timing gear case.
Be sure that the position matching mark "TOP" is ori-
Rear idler
ented on the top side. Also the rear idler shaft thrust
shaft thrust collar
collar should be installed in according to the identifica-
tion marks made during removal. Cover
(2) Tighten the nut to the specified torque.
196 ± 9.8 N·m
(3) Install the cover to the timing gear case.
{20 ± 1.0 kgf·m}
[145 ± 7 lbf·ft]
Rear idler shaft thrust collar - Install
7-27
4.12 Rear oil seal - Install

Use the rear seal installer assembly to install the rear oil
seal. Insert bolt
(1) Apply clean engine oil evenly to the oil seal lip. Guide flange
Insert
Note: Pay attention to the mounting direction of oil seal, and Swing washer
be careful not to damage the oil seal.
Socket bolt
(2) Install the guide flange to the crankshaft rear end face, Rear seal installer
assembly
and secure it with the insert bolts. P/N:37791-06010 Bolt
(3) Set the oil seal to the insert and install it to the guide
flange.
(4) Tighten the bolt that has been mounted on the guide
Rear oil seal - Install (1)
flange to insert the oil seal into the timing gear case.
(5) Remove the installer assembly. 17.5 mm [0.6890 in.]
Timing 21.5 mm [0.8465 in.]
Gear case
Oil seal
Rear seal installer

assembly
Slinger P/N:37791-06010
Rear oil seal - Install (2)

4.13 Flywheel - Install
Be careful not to drop or hit the flywheel.Doing so may Flywheel

damage to the flywheel and lead to personnel injuries.
(1) Check the mounting surfaces of flywheel and crank-
shaft to make sure that they are free from any foreign
substances or scars. 588 ± 29.4 N·m
{60 ± 3.0 kgf·m}
(2) Attach a hoisting tool to the flywheel. [434 ± 22 lbf·ft]
(3) Install the flywheel by aligning its holes with the dowel [Wet]
pins on the crankshaft.
(4) Apply engine oil to the bolt threads and bolt seat sur- Flywheel - Install
faces, then tighten the bolts to the specified torque.
4.14 Flywheel face and radial runouts - Measure

Measure the face and radial runouts of the flywheel.
If the measured value extremely deviates from the standard,
check the assembling condition such as bolts looseness or Face runout
measurement
accumulation of foreign substances on the mounting face.
Radial runout
measurement
Item Standard
Face runout (reference) 0.336 mm [0.0132 in.] or less
Radial runout (reference) 0.130 mm [0.0051 in.] or less
7-28
4.15 Pickup - Install

(1) Rotate the crankshaft so that the ring gear tooth tip is
Timing gear case 5/8-18UNF
positioned at the center of the pickup mounting hole.
(2) Insert the pickup into the hole slowly and carefully by
hand.
(3) When the tip of pickup comes into contact with the ring
gear tooth tip, loosen the pickup so that the clearance to Lock nut
the ring gear meets the standard. Return 1 rotation 1.4 m
after bringing
(4) Fix with the lock nut of the pickup. into contact [0.05 m
5 in.
]
Ring gear
Pickup - Install
7-29
5. Cylinder head and Valve mechanism - Assemble

5.1 Cylinder head - Assemble
Guide & seal installer Guide & seal installer
P/N:37191-11500 P/N:37591-12300
(a) Be careful when inserting the stem seal through Valve stem
the valve, as the edge of the valve can cause
Stem seal
damage to the lip of stem seal.
33.6 mm [1.323 in.]

34.3 mm [1.350 in.]
(b) Do not apply oil or liquid sealant to the fitting por- Valve guide
tion between the stem seal and the valve guide.

(c) Always replace the stem seal with a new one once Lower retainer
it has been removed. Cylinder head

(1) Apply engine oil to the valve stem, and insert the valve Inlet side Exhaust side
onto the valve guide. Stem seal - Install
(2) Install the lower retainer to the valve guide on the Exhaust Inlet
exhaust side.
Valve cotter
(3) Insert the stem seal to the valve guide using the guide & Valve cotter
Upper rotator
seal installer. Valve rotator
Inner valve
Note: Before the installation of stem seal, the valve should be spring Valve spring
installed so that valve stem seal is centered on the Outer valve
valve stem upon installation. spring Stem seal
(4) Apply engine oil to the lip of stem seal. Lower retainer
(5) Install the retainer, valve spring and rotator to the valve Stem seal
guide, and install the valve cotter using the valve spring
Valve and valve spring - Install
pusher.
Note: Components are different between inlet side and ex- Valve spring pusher
haust side, thus, do not mistake inlet parts for exhaust P/N:33591-04500
parts, or vise versa.
Apply engine oil.

Valve cotter - Install
(6) Tap the top of valve stem lightly several times with a
soft-head hammer to ensure that the valve spring and Valve stem head
valve cotters are properly installed and seated firmly.
Valve - Install
7-30
5.2 Valve sinkage - Measure

Measure the valve sinkage.
If the measurement exceeds the limit, replace the valve or
Seat width
valve seat with a new one.Lap the valve and valve seat
whenever the valve or valve seat has been refaced or
replaced.
Item Standard Limit

Valve seat
-0.1 to 0.1 mm Valve margin
Valve sinkage 1.0 mm [0.040 in.] angle
[-0.004 to 0.004 in.] Valve sinkage
Valve sinkage - Measure

5.3 Tappet - Install
Coat the periphery of tappets with engine oil, insert them
into the tappet holes and place them gently on the cam-
shafts.
Apply engine oil.
Tappet - Install
5.4 Liquid gasket - Apply
(a) Do not apply liquid gasket more than necessary.

Doing so may cause deformation of O-rings. 10 mm
Do not apply
[0.39 in.]
When applying gasket to portions A and B, in par- liquid gasket
on this area.
ticular, take utmost care since there is little clear-
A
ance to the O-rings. 5 to 8 mm
[0.20 to 0.32 in.]
(b) Do not apply liquid gasket around the periphery of Liquid gasket:
ThreeBond 1211
bore. Doing so may cause gas leakage. P/N:37594-01300
(1) Wipe off oil, grease and other contamination from the Liquid gasket coating area
cylinder head gascket, the cylinder head bottom surface Liquid gasket - Range of application (head side)
and the crabkcase upper surface.
(2) Apply a thin coat of liquid gasket to both sides of the 10 mm
[0.39 in.]
cylinder head gasket around the tappet holes and oil
passages. Beads of liquid gasket should be 5 to 8 mm Do not apply liquid gasket
[0.20 to 0.32 in.] from the cylinder head gasket outer on this area.
edge with a thickness of 0.2 to 0.5 mm [0.008 to 0.020

in.]. The range of application is shown on the right. B
Liquid gasket:
Note: After the application of liquid gasket to the cylinder ThreeBond 1211
P/N:37594-01300
head gasket is completed, install the cylinder head be-
Liquid gasket coating area
fore the liquid gasket dries.
Liquid gasket - Range of application (crabkcase side)
7-31
5.5 Cylinder head gasket - Install

(1) Wipe off oil, grease and other contamination from the
cylinder head bottom surface and the crabkcase top sur-
face.
(2) Install the cylinder head gasket that has been coated
with liquid gasket onto the crankcase with the dowel
pin and the hole in alignment.
Dowel pins
Cylinder head gasket - Install
5.6 Cylinder head assembly - Install
(1) Apply engine oil to the cylinder head bolt threads, bolt
Eye nut
seats and washer surfaces. P/N:37591-02400 Apply engine oil.
Note: Do not apply excessive amount of engine oil. An ap-
propriate amount of oil should be applied.
(2) Install the eye nut to the stud bolt, and lift the cylinder
head assembly.
(3) Slowly lower the cylinder head, and install the cylinder
head while aligning down pins with holes. After mak-
ing sure that the dowel pins have been properly inserted
in the holes, tentatively tighten the cylinder head bolts.
Cylinder head assembly - Install
5.7 Cylinder head bolt - Tighten
There are two methods used to tighten the cylinder head
Torque for 2-time tightening method:
bolts, i.e., torque method and angle tightening method. 539 ± 27 N·m {55 ± 2.75 kgf·m}
[398 ± 20 lbf·ft] [Wet] 2
5.7.1 Torque tightening method Snug torque for 4
(1) Tighten the cylinder head bolts progressively in the angle tightening
method:
sequence shown in the illustration. 294 ± 14.7 N·m
(2) Loosen all bolts, then retighten them according to this {30 ± 1.5 kg f·m} 5
[217 ± 11 lbf·ft] 6
torque method. (2-time tightening method)
5.7.2 Angle tightening method
(1) Tighten the cylinder head bolts to the specified snug 3
1
torque in the sequence shown in the illustration.
Cylinder head bolts - Tightening sequence
(2) Place the head bolt plate on the top of cylinder head.
(3) Put the mark to the cylinder head bolt.
Head bolt plate
(4) Tighten bolts by turning 65±3°in the specified
P/N:37598-08900
sequence.
(5) Loosen all bolts, and then tighten them to the specified
angle again.(2-time tightening method) Apply engine oil.
Cylinder head bolt - Angle tightening method
7-32
5.8 Rocker case - Install

(1) Apply grease to a new O-ring and install the O-ring to
Connector
water outlet connector. mounting hole Connector
Snap ring groove
(2) Install the snap ring groove of water outlet connector to (deeper hole) mounting hole
the deeper connector mounting hole of rocker case, and
insert the water outlet connector fully.
Water outlet
(3) Install the rocker case by aligning its holes with the connector
dowel pins.
(5) Slide the water outlet connector into the adjacent con- O-rings
Apply grease. Rocker case
nector mounting hole of the rocker case.
Water outlet connector - Install
(6) Install the snap ring to the snap ring groove on the
water outlet connector. Slide the water outlet
connector to the next
connector hole.
108 ± 5.4 N·m

Water outlet Snap ring {11 ± 0.55 kgf·m}
スナップ
connector groove
リング溝 [80 ± 4 lbf·ft]
Rocker case - Install
5.9 Bridges and Bridge cap - Install
(1) Apply engine oil to the bridge guide.
(2) Install the bridge onto the bridge guide so that the Bridge cap
screw-fitted end of the bridge is positioned on the
exhaust manifold side.
(3) Apply engine oil to the bridge contact area of bridge
cap, and install the bridge cap. When install bridge
caps, be careful not to drop the cap inside the crabkcase
Apply engine
through the push rod hole.
oil.
Bridges and Bridge cap - Install

5.10 Valve bridge and Adjusting screw - Adjust
Adjust the contact condition of valve steam top face so that
Hold the top of
the bridge and bridge guide evenly push the both valves. bridge by hand 55 ± 2.8 N·m
(1) Loosen the adjusting screw so that its top face protrudes {5.6 ± 0.28 kgf·m}
Tighten 10° [40.5 ± 2.07 lbf·ft]
from top face of nut by 6 to 7 mm [0.23 to 0.27 in.].
(2) Hold the top of bridge by hands so that the top face of
Contact
valve stem on the other side of adjusting screw comes surface of
in close contact with the bridge end face. valve
bridge and
(3) Turn the adjusting screw slowly until the screw con- valve
tacts the top face of valve stem. Then, turn the screw
further, at angle of 10° from the position, and tighten
Valve bridge and Adjusting screw - Adjust
the lock nut to the specified torque.
7-33
5.11 Clearance between the bottom face of valve bridge and the top face of valve rotator - Inspect
Hold the top of bridge

by hand
Be sure to secure the standard clearance between Valve bridge Bridge cap Clearance between
valve bridge and valve rotator. If the clearance is the bottom surface
smaller than the standard, the valve cotter may Valve rotator of valve bridge and
the top surface of
come off or get damaged. valve rotator
Hold the valve bridge by hand to make close contact of the

top end face of valve stem. Then, inspect the clearance
between the bottom surface of valve bridge and the top sur-
face of valve rotator. If the measured clearance deviates
from the standard, find the causal parts, and replace them Clearance between the bottom face of valve bridge
and the top face of valve rotator - Inspect
with new ones.
Item Standard
Clearance between the bottom face
of valve bridge and the top face of 2.1 mm [0.083 in.]
valve rotator
5.12 Rocker shaft assembly - Install

(1) Install the spacer to the rocker shaft, and mount the
147 ± 7.4 N·m Spacer
rocker arms on both sides. {15 ± 0.75 kgf·m}
Oil passage
[108 ± 5.46 lbf·ft]
(2) Align the pin hole of the rocker shaft with the position-
Positioning
ing pin, and install the rocker shaft assembly to the pin
rocker case.
Rocker shaft
Rocker case Oil passage (clearance)
Rocker shaft assembly - Install
7-34
5.13 Valve clearance - Check and Adjust

Adjust the valve clearance. The valve clearance should be
adjusted when the engine is cold.
Note:(a) The inlet valves are on the left side and the exhaust
valves are on the right side when the cylinder head VALVE CLEARANCE (COLD)
is viewed from the camshaft gear side. INLET

0.6 mm EXHAUST 0.8 mm
F I R I N G O R D E R
(b) The valve clearance standard value is indicated on 1-9-6-14-2-10-4-12-8-16-3-11-7-15-5-13
FUEL INJECTION TIMING °
BTDC
the caution plate on the No. 1 cylinder rocker cover. CON-ROD RANK
Item Standard
Inlet 0.6 mm [0.024 in.]
Valve clearance
Exhaust 0.8 mm [0.032 in.] Valve clearance - Indication location
(1) Inspection should be performed in firing order

sequence at TDC of compression stroke by rotating the
1 8
crankshaft in the normal direction.
(2) On each cylinder, it is assumed that the piston is at top
dead center on compression stroke when the corre-
sponding cylinder number stamped on the damper is
Check for compression
aligned with the pointer, and neither the inlet valve nor top dead center
the exhaust valve are lifted off its seat by the push rod.
Firing order
(3) Insert a thickness gauge between the rocker arm and the Cylinder number:1-9-6-14-2-10-4-12-8-16-3-11-7-15-5-13
bridge cap, and while measuring clearance, adjust the No. 1 cylinder compression top dead center - Check
clearance by either tightening or loosening the screw so
that the movement of the thickness gauge becomes
slightly constricted.
(4) After adjustment is completed, tighten the lock nut
firmly to the specified torque. Then, check the clear-
ance again.
64 ± 3.2 N·m
{6.5 ± 0.33 kgf·m}
[47 ± 2.4 lbf·ft]
Valve clearance - Adjust
5.14 Fuel injection timing - Check and Adjust
5.14.1 Specified value of fuel injection timing - Check
The fuel injection timing varies depending on the engine
output, speed and fuel gas specifications. Be sure to check
out the plate on the No. 1 rocker cover for the fuel injection VALVE CLEARANCE (COLD)
timing. INLET
0.6 mm EXHAUST 0.8 mm
F I R I N G O R D E R
1-9-6-14-2-10-4-12-8-16-3-11-7-15-5-13
FUEL INJECTION TIMING °
BTDC
CON-ROD RANK
Specified value of fuel injection timing - Check
7-35
5.14.2 Fuel injection timing - Check

(1) Rotate the crankshaft in the normal direction, and stop
rotating when the No. 1 cylinder is positioned at 1 8
approx. 30 degrees before top dead center (TDC) on
compression stroke.
(2) Check that the valve clearance of both inlet and exhaust
of No. 1 cylinder meets the standard value, and that the Check for compression
valves are not pressed down. Then this position is top dead center
determined as the top dead center on compression
stroke.
No. 1 cylinder compression top dead center - Check
Check that the "0" stamped line of fuel injection pump
flywheel indicates near the pointer.
(3) While rotating the crankshaft to the normal direction Pointer
progressively, align the line mark with the pointer of
the engine for specified fuel injection timing.
If the "0" line mark of fuel injection pump flywheel
aligns with the pointer, the fuel injection timing has
been adjusted to the specified timing.
If the "0" line mark does not align with the pointer, the
fuel injection timing should be adjusted to the specified Stamped line on the flywheel
ࣇࣛ࢖࣍࢖࣮ࣝࡢ้⥺
timing. Fuel injection timing - Check
Note: For the left fuel injection pump, rotate the crankshaft
so that No. 9 piston is at top dead center (TDC) on
compression, then follow the procedure described
above.
5.14.3 Fuel injection timing - Adjust

Line mark
(1) While rotating the crankshaft to the normal direction
on the flywheel
progressively, align the line mark with the pointer of
the engine for specified fuel injection timing.
(2) Loosen the bolt (long) of driving coupling, and rotate
Pointer
the fuel injection pump only. Adjust the "0" line mark
to the pointer, then tighten the bolt (long).
Bolt (long)
(3) From the specified fuel injection timing, rotate the
108 ± 5 N·m
crankshaft in the reverse direction by approx. 10° {11 ± 0.5 kgf·m}
(4) By turning the crankshaft to the normal direction pro- [129.5 ± 3.6 lbf·ft]
Fuel injection timing - Adjust
gressively again, align the line mark for fuel injection
timing with the pointer.
Then make sure that the "0" line mark of fuel injection
pump flywheel aligns with the pointer.
Repeat the step (2) if not aligned correctly.
7-36
5.15 Valve timing - Inspect

The specified valve timing is automatically achieved, pro-
vided that the gears are assembled by aligning match marks
and that the valve clearance is adjusted to the specified
value. For confirmation, check the valve timing as follows:
5.15.1 Valve timing when valve clearance is 0 mm
Top dead center
(1) Check that the valve clearance is adjusted to the stan- 45㺽 63㺽
dard. Exhaust Inlet valve
valve close open
(2) Insert the thickness gauge, which has the same distance
Rotational
as the standard valve clearance, between bridge cap direction
and rocker arm. (valve clearance 0 mm)
(3) Rotate the crankshaft in the normal direction little by
little, and find the position at which the thickness gauge Exhaust
valve open 53㺽 35㺽 Inlet valve
is tightly wedged (valve open position) and the position close
at which the thickness gauge starts to move (valve Bottom dead center
Valve timing when valve clearance is 0 mm
closed position).
(4) Check that the obtained angle meets the angle shown in Rocker arm
the illustration.
Standard value
of valve clearance
Bridge cap Thickness gauge

Valve clearance 0 mm
5.15.2 Valve timing when valve clearance is 2 mm
Top dead center
[0.08 in.] 25㺽 Inlet valve
Exhaust 7㺽
For reliable inspection at position where the valve motion open
valve close
changes rapidly, adjust the clearance to 2.5 mm [0.098 in.].
Rotational
(1) Insert a 0.5 mm [0.020 in.] thickness gauge between direction
the bridge cap and the rocker arm. (Valve clearance 2
mm [0.08 in.])
(2) Rotate the crankshaft in the normal direction little by Exhaust Inlet valve
valve open 21㺽 3㺽
little, and find the position at which the thickness gauge close
is tightly wedged (valve open position) and the position Bottom dead center
Valve timing when valve clearance is 2 mm [0.08 in.]
at which the thickness gauge starts to move (valve
closed position). Rocker arm
(3) Check that the obtained angle meets the angle shown in
the illustration.
Valve clearance
(4) Readjust valve clearance to normal values. 2 mm [0.08 in.]
0.5 mm
[0.020 in.]
Bridge cap Thickness gauge

Valve clearance 2 mm [0.08 in.]
7-37
5.16 Fuel injection nozzle assembly - Install

(1) Remove the fuel inlet connector from fuel injection
98 ± 4.9 N·m Spherical side down
nozzle assembly. {10 ± 0.5 kgf·m}
[72 ± 3.6 lbf·ft]
(2) Install three O-rings to the fuel injection nozzle, and
apply grease to the surface. Nozzle gland
O-ring
(apply grease)
(3) Apply a thin coat of grease to the gasket and install it to
the fuel injection nozzle. Gasket
(apply grease)
(4) Aligning the fuel inlet connector mounting hole of the
69 ± 5 N·m
cylinder head with that of the fuel injection nozzle, {7 ± 0.5 kgf·m}
install the fuel injection nozzle assembly into the cylin- [50 ± 3.6 lbf·ft]
Fuel inlet connector
der head, and tentatively tighten the assembly.
Fuel injection nozzle - Install
(5) Tighten the nut to the specified torque to secure the
nozzle gland.
(6) Install the sleeve to the clearance between inlet connec-
tor and cylinder head hole.
(7) Tighten the fuel inlet connector to the specified torque.
(8) Install the sleeve securely, and fix it with band.
Note: Do not forget to install the gasket when installing the
fuel injection nozzle assembly.
7-38
1. Fuel system - Remove and Inspect........................................................................ 8-3
1.1 Fuel injection pipe and Fuel leak-off pipe - Remove and Inspect ............................................. 8-3
1.2 Fuel filter and Fuel pipe - Remove and Inspect ........................................................................ 8-4
1.3 Stop solenoid - Remove and Inspect........................................................................................ 8-5
1.4 Fuel control link - Remove and Inspect .................................................................................... 8-6
1.5 Governor actuator - Remove and Inspect................................................................................. 8-7
1.6 Fuel injection pump - Remove and Inspect .............................................................................. 8-8
2. Fuel system - Disassemble and Inspect................................................................ 8-9
2.1 Fuel filter (paper element) - Disassemble and Inspect ............................................................. 8-9
2.2 Fuel injection nozzle - Disassemble and Inspect.................................................................... 8-11
2.3 Fuel injection nozzle - Inspect and Adjust .............................................................................. 8-12
2.4 Fuel injection nozzle - Assemble ............................................................................................ 8-15
2.5 Fuel injection pump accessory drive - Disassemble and Inspect ........................................... 8-16
2.6 Outside diameter and inside diameter of accessory drive bearing fit - Inspect ...................... 8-17
2.7 Fuel injection pump accessory drive - Assemble.................................................................... 8-18
3. Fuel system - Install .............................................................................................. 8-19
3.1 Fuel injection pump - Install .................................................................................................... 8-19
3.2 Governor actuator - Install ...................................................................................................... 8-23
3.3 Fuel control link - Install .......................................................................................................... 8-24
3.4 Stop solenoid - Install ............................................................................................................. 8-28
3.5 Fuel filter and Fuel pipe - Install.............................................................................................. 8-30
3.6 Fuel injection pipe and Fuel leak-off pipe - Install................................................................... 8-31
8-1
1. Fuel system - Remove and Inspect

1.1 Fuel injection pipe and Fuel leak-off pipe - Remove and Inspect
Replace
Replace
4
3 A
Right fuel injection pump
A
1
2
Replace
Replace B
2
6
Left cylinder head
Replace
Right cylinder head 7 Replace
7
Front
5
Left fuel injection
pump
Replace
B
8
9
Fuel injection pipe and Fuel leak-off pipe - Remove and Inspect
Removing sequence
1 Right leak-off pipe 5 Left leak-off pipe
2 Right leak-off pipe 6 Left leak-off pipe
3 Clamp 7 Left leak-off pipe
4 No.1 to 8 fuel injection pipe 8 Clamp
9 No.9 to 16 fuel injection pipe
Cover the openings on the fuel injection pipe, nozzle inlet connector and fuel injection pipe to prevent dust from
entering the fuel system.
8-3
1.2 Fuel filter and Fuel pipe - Remove and Inspect
11 Replace Replace
14
13
Front
11 15
12
Replace 16 6
7 5
Replace
Replace
Left 2
8
10
9 3 2
Right
4
1
Fuel filter and Fuel pipe - Remove and Inspect

Removing sequence
1 Fuel pipe 7 Pipe stay 12 Left fuel pipe
2 Clamp 8 Left fuel pipe 13 Left fuel pipe
3 Right fuel pipe 9 Left fuel pipe 14 Fuel filter assembly
4 Right fuel pipe 10 Connector 15 Fuel filter bracket
5 Fuel filter assembly 11 Clamp 16 Pipe stay
6 Fuel filter bracket
8-4
1.3 Stop solenoid - Remove and Inspect
Replace
4 Replace
Stop solenoid - Remove and Inspect

Removing sequence
1 Follower 3 Plate
2 Stop solenoid 4 Bracket
8-5
1.4 Fuel control link - Remove and Inspect
Looseness,
wear
4
A
5 Fatigue, deformation
7 Replace Looseness,
wear
12
To governor 6 A
lever 1
13
14
Looseness, wear
Looseness, wear
11 10
8
Looseness, wear
9
Fuel control link - Remove and Inspect

Removing sequence
1 Left link 6 Governor lever 11 Control link lever
2 Left link 7 Bearing cover 12 Bearing cover
3 Left link 8 Right link 13 Control shaft
4 Left lever 9 Right link 14 Pipe
5 Stop lever 10 Right lever
8-6
1.5 Governor actuator - Remove and Inspect
8-7
1.6 Fuel injection pump - Remove and Inspect
3
4
Fuel injection pump - Remove and Inspect

Removing sequence
1 Coupling cover 4 Fuel injection pump (Approx. 68 kg [149 lb.])
2 Cover stay 5 Shim (check the installing position)
3 Stay 6 Bracket
8-8
2. Fuel system - Disassemble and Inspect

2.1 Fuel filter (paper element) - Disassemble and Inspect
Air vent plug

9 ± 1 N·m
{0.9 ± 0.1 kgf·m}
[6.5 ± 0.7 lbf·ft]
Replace
Crack, flaw
Fuel filter bracket
Fuel filter Filter wrench:

cartridge Use the filter wrench to
Dent dismount the fuel filter.
(Use only when dismounting)
Fuel filter - Disassemble, Inspect and Assemble
8-9
2.1.1 Fuel filter cartridge - Install
(a) Make sure that there is no flame around the area before handling fuel.
(b) Wipe any split fuel to prevent a fire.
(c) Do not use the fuel filter cartridge that has a dent in the case. If the case is dented, it can cause damage to
the fuel filter cartridge, leading to fuel leaks during operation, and result in a fire.
(a) When installing the fuel filter cartridge, do not use a filter wrench. Tighten it with your hand.
(b) Be careful not to dent or damage the surface of the fuel filter cartridge.
(1) Clean the mounting surface of the fuel filter cartridge.
(2) Apply clean fuel on the fuel filter gasket.
(3) After the fuel filter gasket comes into contact with the base, tighten the cartridge by 3/4 to 1 turn by hand.
Note: After the installation is completed, bleed air from the fuel system.
(4) Run the engine, and make sure that there is no fuel leaks.
8-10
2.2 Fuel injection nozzle - Disassemble and Inspect

Fuel injection start pressure - Inspect
Fuel injection nozzle spray - Inspect
Replace
10 2
Replace Replace
9
3
Fatigue, damage
Wear of needle valve and contact surface
7
Carbon deposit
Nozzle hole clogged, needle valve fixing
6
5
Replace
4
Fuel injection nozzle - Disassemble and Inspect

1 Set screw, sealing washer 6 Nozzle tip
2 Cap nut, sealing washer 7 Spacer
3 Adjusting screw 8 Push rod, nozzle spring, spring seat
4 O-ring 9 O-ring
5 Retaining nut 10 Nozzle holder
Note: Nozzle tip, spacer, and nozzle spring must be replaced with new ones as a set.
8-11
2.3 Fuel injection nozzle - Inspect and Adjust

2.3.1 Fuel injection start pressure - Inspect and
Adjust
Nozzle tester
Never touch the fuel injection nozzle tip during nozzle P/N:83091-03301
injection test.
(1) Install the fuel injection nozzle onto the nozzle tester.
(2) Push down the handle at a speed of once a second and
measure the pressure when injection starts.If it is out of
the standard, adjust it to the standard.
(3) To adjust the injection start pressure, remove the set Fuel injection start pressure - Inspect
screw on the nozzle holder, loosen the cap nut and turn
the adjusting screw with a screwdriver. Set screw
(4) After adjustment, tighten the cap nut and set screw to 39 ± 5 N·m
{4 ± 0.5 kgf·m}
the specified torque. [28 ± 3.6 lbf·ft]
(5) After tightening the set screw, inspect the injection start
Large
pressure against to make sure it is within the standard. Small pressure
pressure
Item Nominal Standard Cap nut
34.32 to 34.81 MPa 73.5 ± 4.5 N·m
34.32 MPa {7.5 ± 0.5 kgf·m}
Fuel injection {350 to 355 kgf/cm2}
{350 kgf/cm2} [54 ± 3.3 lbf·ft]
starting pressure [4978 to 5049 psi]
[4978 psi]
(the value when it is new) Fuel injection start pressure - Adjust
2.3.2 Fuel injection nozzle spray - Inspect
When adjusting for nozzle opening pressure using the noz-
zle tester, inspect for nozzle hole condition and fuel spray Good Defective spray patterns
pattern.If spray condition is faulty, clean or replace the noz-
zle tip.
Checking points of fuel spray are as follows:
· Fuel is injected straight.
· Fuel is injected in a spray of fine droplets. Large After Inter- Whirling
angle dribble mittent spray
· Fuel is injected without after-dribbling.
spray spray
Fuel injection nozzle spray - Inspect
8-12
2.3.3 Nozzle tip - Clean and Replace
(a) Be careful not to hit the nozzle tip.

(b) The needle valve and body are precision parts.
Handle them carefully, and do not change the
original valve and body combination.
(1) Remove the retaining nut.
(2) Remove the nozzle tip.
Nozzle tip
Retaining nut
Nozzle tip - Remove

(3) Clean the needle valve and body of the nozzle tip.
When cleaning the needle valve and nozzle tip body,
use clean wash oil. Assemble the needle valve and body
in clean diesel fuel after cleaning.
(4) Tighten the nozzle tip tightening retainer nut to the
specified torque. Body
(5) If the spray pattern is still faulty after cleaning and
Needle
adjusting, change the nozzle tip with a new one. valve
New nozzle tips are coated with anti-corrosive agent,
therefore, it is necessary to wash the nozzle tips before
Nozzle tip - Clean
use. First wash it in wash oil, and wash it again with
clean diesel fuel before installation.
2.3.4 Squareness, free length, and parallelism of noz-

zle spring - Measure
Squareness
Measure the squareness, free length and parallelism for top
and bottom surface of nozzle spring. Square
Item Standard
Free length 30 mm [1.18 in.]
Squareness 0.6 mm [0.024 in.] or less Free length
Parallelism for top and bottom surface 0.1 mm [0.004] or less
Note: Nozzle tip, spacer, and nozzle spring must be replaced

Squareness, free length, and parallelism of nozzle
with new ones as a set.
spring - Measure
8-13
2.3.5 Push rod - Inspect

Inspect the push rod visually. If its spring seat wears Check for spring seat
uneven wears
unevenly, or its needle valve contact surface wears remark-
ably, or the cavitation occurs on its tapered parts, replace the
push rod with a new one.
Needle valve contact

surface wears Check for cavitation
Push rod - Inspect

2.3.6 Spacer - Inspect
High pressure
Inspect the spacer visually. If its needle valve contact sur-
seal surface
face and high pressure seal surface wear remarkably, replace
the spacer with a new one.
Note: Nozzle tip, spacer, and nozzle spring must be replaced
with new ones as a set.
High pressure
seal surface
Needle valve contact surface
Ǿ6 mm [0.24 in.]
Spacer - Inspect
8-14
2.4 Fuel injection nozzle - Assemble
39 ± 5 N·m Never hit with a hammer when

{4 ± 0.5 kgf·m} mounting onto the cylinder head.
[28 ± 3.6 lbf·ft]
73.5 ± 4.5 N·m Apply engine oil on the upper and

{7.5 ± 0.5 kgf·m} lower surfaces of the sealing washer.
[54 ± 3.6 lbf·ft]
186.5 ± 9.5 N·m

{19 ± 1 kgf·m}
[137 ± 7 lbf·ft]
Fuel injection nozzle - Assemble
Be sure to tighten the retaining nut to the specified torque.Excessive tightening torque on the retaining nut can hin-
der smooth movement of the needle valve and could result in abnormal exhaust smoke or needle sticking.
Note: When coupling the nozzle tip into the nozzle holder, make sure to align the nozzle tip knock pin with the nozzle holder
hole.
8-15
2.5 Fuel injection pump accessory drive - Disassemble and Inspect
Deformation, wear on the lip
Wear, damage
Rotation
9
Wear, damage
Rotation 8
6
Flaking, wear
5
7
4
2 3
1
Fuel injection pump accessory drive - Disassemble and Inspect

1 Nut 4 Snap ring 7 Bearing
2 Washer 5 Drive shaft 8 Bearing
3 Fuel injection pump gear 6 Drive case 9 Oil seal
8-16
2.6 Outside diameter and inside diameter of accessory drive bearing fit - Inspect
(1) Rotate the bearing and if the rotation is not smooth,
replace the bearing with a new one. Fuel injection pump gear
(2) Inspect the fit of drive shaft and bearing. If significant
wear is found, replace them with new ones.
(3) Inspect the fit of drive case and bearing. If significant
wear is found, replace them with new ones. Socket
(4) Inspect the drive shaft and oil seal, and if any defect is P/N:58309-73100
found, replace them with new one.
Item Nominal Standard

ø90 mm 89.987 to 90.022 mm Fuel injection pump gear - Remove
Inside diameter of case to [3.54 in.] [3.5428 to 3.5442 in.]
bearing fit ø100 mm 99.987 to 100.022 mm
[3.94 in.] [3.9365 to 3.9379 in.]
ø90 mm 89.985 to 90.000 mm
Small
Outside [3.54 in.] [3.5427 to 3.5433 in.]
diameter ø100 mm 99.985 to 100.000 mm
Large
[3.94 in.] [3.9364 to 3.9370 in.]
Bearing
ø45 mm 44.988 to 45.000 mm
Small
Inside [1.77 in.] [1.7712 to 1.7717 in.]
diameter ø50 mm 49.988 to 50.000 mm
Large
[1.97 in.] [1.9680 to 1.9685 in.]
ø45 mm 45.002 to 45.013 mm
Outside diameter of drive shaft [1.77 in.] [1.7717 to 1.7722 in.]
[1.97 in.] [1.9686 to 1.9690 in.]
8-17
2.7 Fuel injection pump accessory drive - Assemble
490 ± 24.5 N·m

{50 ± 2.5 kgf·m}
[361 ± 18 lbf·ft]
Apply engine oil on the lip
Apply engine oil
Fuel injection pump accessory drive - Assemble
8-18
3. Fuel system - Install

3.1 Fuel injection pump - Install
108 ± 5.4 N·m

{11±0.55 kgf·m}
[80±4 lbf·ft]
108 ± 5 N·m
{11 ± 0.5 kgf·m}
[80 ± 4 lbf·ft]
108 ± 5.4 N·m

{11±0.55 kgf·m}
[80±4 lbf·ft]
108 ± 5.4 N·m

{11±0.55 kgf·m}
[80±4 lbf·ft]
Fuel injection pump - Install
8-19
3.1.1 Checking before installing fuel injection pump

Pointer
Make sure the mounting location of drive coupling. If it “0” mark line
is installed 180 degrees out of position, the fuel injec- on the flywheel.
tion timing cannot be adjusted.
(1) Turn the crankshaft. Align with the No.1 compression

top dead center when installing right bank fuel injection
pump, and align with the No. 9 compression top dead
center when installing left bank fuel injection pump.
(2) Remove the tentatively installed the drive coupling and Pointer and line mark - Align
the laminated plate set on the drive coupling side from
the fuel injection pump assembly, and install the drive
Fuel injection pump accessory drive
coupling and laminated plate set to the accessory drive
shaft through the woodruff key. The drive coupling
Driving coupling
should be inserted to the accessory drive case side as
much as possible, with the tightening bolts loosened.
(3) Align the line mark with "0" on the fuel injection pump Shaft tightening bolt
flywheel with the pointer. (the injection start timing of
cylinder No. 1 and No. 9)
/DPLQDWHGSODWHVHW
Laminated plate set
Drive coupling - Install
(4) Make sure that the camshaft stamped letter and the cou-
pling key groove are oriented as shown in the illustra- PS8: 50.7°
tion. PS8A: 49.9°
Coupling key
groove
Stamped characters
for camshaft
Fuel injection pump camshaft and Driving coupling -

Orientation
(As viewed from the rear (driving side))
8-20
3.1.2 Fuel injection pump - Install
(a) Install and assemble new shim of the same thickness (t=0.25 mm [0.0098 in.]) as removed shim on the fuel
injection pump installing surface of right bank bracket. (No shims at the left bank bracket.)
(b) First, tighten the bolt (long) to connect the drive coupling and laminated plate to the specified torque, and then
loosen it. Then, tighten it to the specified torque. (2-time tightening method)
(c) Wash the bolt, bushing and washer before using. The foreign materials on the contact surface of drive coupling
and laminated plate can cause a slipping or damages.
(d) After the tightening of couplings is completed, check the laminated plates for distortion, and retighten the cou-
pling if distorted.
(1) Install a new shim having the same thickness (t=0.25
Washer Nut
Bushing
mm [0.0098 in.]) as the shim, which has been removed,
(Do not apply oil.) 108 ± 5 N·m
to the fuel injection pump mounting face of right bank {11 ± 0.5 kgf·m}
[80 ± 3.7 lbf·ft]
bracket. 2-time tightening
Note: The left bank bracket has no shim. method
(2) Raise the fuel injection pump. Slowly lower the fuel Bolt (long)
injection pump, and install it while aligning with the

Washer
dowel pin of bracket. (Do not apply oil.)
Note: Before installing bolts, make sure that the shim has
been installed firmly. Laminated plate
(3) Connect the laminated plate and drive coupling, and

tentatively tighten the bolt.
Check that the "0" stamped line of fuel injection pump Drive coupling
flywheel with the No. 1 and 9 compression top dead
center indicates near the pointer.
Note: When installing coupling connecting bolts, be careful
not to forget bushings and washers, and also pay atten- Bolt (short)
tion to the mounting direction. 108 ± 5 N·m
{11 ± 0.5 kgf·m}
(4) Adjust the clearance between the drive coupling and [80 ± 3.7 lbf·ft]
flywheel to the standard. Drive coupling and Laminated plate - Connect
For the adjusting procedures, refer to "Clearance
Inserting points for shim (6 points)
between fuel injection pump flywheel and driving cou-
pling - Adjust" of "FUEL SYSTEM."
(5) Tighten all bolts and nuts that are tentatively installed
to couplings to the specified torque.
(6) Recheck the clearance between couplings and the tight-
ening condition of bolts and nuts.
108 ± 5.4 N·m

(View from the top of bracket) {11 ± 0.55 kgf·m}
[80 ± 4 lbf·ft]
Shim - Insert position
8-21
(7) Install the stay between the fuel injection pump case
and crabkcase.
(8) Refill engine oil through the oil drain pipe mounting
hole of cam chamber.
(9) Install the oil pipe and fuel pipe.
Refill the engine oil to the

intake hole on the oil drain pipe.
Engine oil - Refill
3.1.3 Clearance between fuel injection pump flywheel
Clearance
and drive coupling - Adjust 49 ± 0.25 mm 172 ± 5 N·m
[1.93 ± 0.0098 in.] {17.5 ± 0.5 kgf·m}
Adjust the clearance between the fuel injection pump fly- [126.6 ± 3.6 lbf·ft]
wheel and the drive coupling using the fuel injection pump
coupling gauge as follows:
(1) Insert the GO side of the gauge into the clearance
between the fuel injection pump flywheel and the drive
coupling. GO
Fuel injection pump
(2) Tighten the bolt with the specified torque. coupling gauge
P/N:37591-06100
(3) Make sure that the NO GO side of the gauge cannot be
NO GO
Clearance between fuel injection pump flywheel and

inserted in the clearance while the GO side can be
drive coupling - Adjust
inserted. In this state, the clearance between the fuel
injection pump flywheel and the drive coupling should
be the set value.
(4) If the set value cannot be achieved by inserting the
gauge, loosen the bolt, and set the clearance all over
again.
8-22
3.2 Governor actuator - Install
PROACT
Replace
Replace
Replace
Governor actuator - Install
8-23
3.3 Fuel control link - Install
Looseness, wear
A
Fatigue, deformation
Replace Looseness, wear
A
To governor lever
Looseness, wear
Looseness, wear
Looseness, wear
Fuel control link - Install
8-24
3.3.1 Control shaft - Install
If the bearings at both ends of control shaft are not properly installed, or if the bearings do not rotate smoothly, it
could result in a hunting or other malfunctions.
Cover Control shaft
㧻-ring
Stopper lever
Pipe
Left of engine Right of engine
Control shaft - Install
(1) Insert the pipe with O-ring to the timing gear case.
(2) Insert the control shaft to the pipe.
(3) Press-fit the bearing to the both ends of control shaft, and install the bearing cover.
(4) Using a plastic mallet, tap on the both ends of control shaft alternately for snug fit.
(5) Rotate the control shaft by hand, and make sure that it rotates smoothly.
3.3.2 Control link lever - Install
(1) Install the link lever of both banks (stamped mark: L and R) together with ball bearing, snap ring and end plate to the stay.
(2) Tentatively install the link lever having a serration hole to the right end of control shaft.
(3) Tentatively install the link lever that is connected to the governor actuator, together with the ball bearing, snap ring and end
plate to the left end of control shaft.
(4) When the governor actuator output shaft is at "0" position (fuel decrease side), install the serration with the throttle lever
positioned at 55°. (Top surface of throttle lever becomes nearly horizontal.)
8-25
3.3.3 Fuel control rink - Install and adjust
Fixed length (239 mm [9.41 in.]) control rlink

B-1
Control link
Control link lever
lever
Control shaft lever
65 ± 0.7 mm [2.56 ± 0.028 in.]
Distance from the end of

fuel injection pump to the
end of rack: 68 ± 0.5 mm
[2.68 ± 0.019 in.]
Rack "0":
Rack "0": 65
65 mm
mm [2.60
[2.60 in.]
in.]
Play: approx.
Play: approx. 33 mm
mm [0.12
[0.12 in.]
in.]
Right-bank linkage - Overall view
Distance from the end of Stop lever

fuel injection pump to the Flexible length
end of rack: 68 ± 0.5 mm control link C
[2.68 ± 0.019 in.] Flexible length control link
Governor lever
Rack "0": B-2
65 mm [2.60 in.]
Play:
approx. 3 mm [0.12 in.]
Almost horizontal
239 ± 1.5 mm [9.41 ± 0.059 in.]
PROACT
Rack control lever

Fuel injection
pump rack A
65 ± 0.7 mm [2.56 ± 0.028 in.]
Left-bank linkage - Overall view
8-26
If the play of fuel injection pump rack is too large, engine overrun may occur.
(1) Set the length of the link A between the fuel injection
pump rack and the rack control lever (for both right and
left banks) to 65±0.7 mm [2.56±0.03 in.], and install
the link A to the right and left banks respectively.
Fixed length control link for the right bank
(2) Install the right-bank fixed length control link B-1 (239
mm [9.41 in.]) in between the control link lever and
control shaft lever.
(3) Set the left-bank variable-length control link B-2 to Welding
239 mm [9.41 in.] and tentatively fix the link B-2 to the Extendable control link for the left bank Right-hand
Left-hand thread thread
stop lever having a serration hole.
Check that the fuel injection pump rack of both banks
are at the no-injection position, then install the stop
Make the screw engagement margin even.
lever togeterh with the spacer and cancel spring to the
Right and left-bank control links
serrations on the control shaft.
Note: Screw the reverse threaded portions in, right and left,
equally.
(4) Fine adjust the left-bank variable-length control link C
so that both right and left-bank fuel injection pump
racks move the same distance.
(5) Install to the output shaft serrated portion of the gover-

nor actuator so that the governor lever "A" face 0
becomes nearly horizontal.
(6) Install the variable-length control link between the con- 10
trol shaft lever and the governor lever.

Scale 0
Fine adjust the distance from the end of fuel injection
pump to the end of rack to be 68 mm [2.68 in.] when
the angle scale of the governor output shaft reads 0 (no
injection position).
Note: Screw the reverse threaded portions of the variable-
Governor actuator output shaft - Angle scale
length control link, right and left equally, so that the
length of thread engagement becomes 8 mm [0.32 in.]
or more.
(7) Check that the distance between the end of fuel injec-
°
tion pump and fuel injection pump rack is 65 mm [2.56 Stopper bolt 55
in.] and the play is 3 mm [0.12 in.] when the stop lever
A
is fully pulled to the stop side.
(8) Install the stopeer bolt to the plate. Nearly horizontal
When the governor actuator output shaft angle scale position
reads "0" degree, install the stopper bolt until it comes Proact plate
into contact with the top face of the governor lever.
Throttle lever
Governor lever stopper - Adjust
8-27
3.4 Stop solenoid - Install
Control shaft
Replace
Replace
Stop solenoid - Install
8-28
3.4.1 Stop solenoid (RUN ON) - Adjust
OFF Stop solenoid
Adapter
Follower
Clearance:
0 mm (contact)
Engine stop Engine stop
condition condition
Tightening
position
adjustment
Bracket
Stop solenoid
OFF: 68 to 69 mm
[2.68 to 2.72 in.]
Play: approx. 2 to 3 mm
[0.08 to 0.12 in.]
Stop solenoid (RUN ON) - Adjust

(1) Turn the stop solenoid off (engine stop).
(2) Adjust the mounting position of stop solenoid using the elongate hole of bracket so that the clearance between the follower
and the adaptor becomes 0 mm [0 in.] (bring it into contact).
Note: When the power of governor actuator is OFF, the fuel injection pump rack is at the no injection (engine stop) position. In
this state, the distance between the fuel injection pump case end face and the fuel injection pump rack end is 68 to 69 mm
[2.68 to 2.72 in.].
3.4.2 Stop solenoid operation - Check
(during engine running condition)
(1) Turn the stop solenoid ON (the engine running condition).
(2) Run the engine at idle speed.
(3) Turn the stop solenoid off (the engine stop condition).
(4) Check that the engine is stopped completely and the distance from the end of fuel injection pump to front of control rack is
68 to 69 mm [2.68 to 2.72 in.].
Note:(a) If the distance between the end of fuel injection pump and the end of control rack is 70 mm [2.76 in.] (the play is 4 mm
[0.16 in.]) or more, the engine may not be stopped.
(b) If the distance between the end face of fuel injection pump and the tip of control rack is 65 mm [2.56 in.] (rack "0" =
the stopper contact state), the stopper of the fuel injection pump rack may be damaged. Be sure to ensure proper play
(2 to 3 mm [0.08 to 0.12 in.]
8-29
3.5 Fuel filter and Fuel pipe - Install
Replace Replace
Front
Replace
Replace
Replace
Left
Right
Fuel filter and Fuel pipe - Install
8-30
1. Lubrication system - Remove and Inspect............................................................ 9-3
1.1 Oil pipe and Right oil cooler - Remove and Inspect.................................................................. 9-3
1.2 Oil pump, Oil filter, Oil pan and Left oil cooler - Remove and Inspect ...................................... 9-4
1.3 Breather and Oil filler - Remove and Inspect............................................................................ 9-5
2. Lubrication system - Disassemble, Inspect and Assemble................................. 9-6
2.1 Oil pump and Safety valve - Disassemble and Inspect ............................................................ 9-6
2.2 Oil pump and Safety valve - Inspect ......................................................................................... 9-7
2.3 Oil pump and Safety valve - Assemble..................................................................................... 9-9
2.4 Oil filter, Oil filter alarm, Relief valve and Left oil cooler - Disassemble and Inspect .............. 9-10
2.5 Oil filter - Inspect..................................................................................................................... 9-11
2.6 Oil filter alarm - Inspect........................................................................................................... 9-11
2.7 Relief valve - Inspect .............................................................................................................. 9-11
2.8 Oil cooler - Inspect.................................................................................................................. 9-12
2.9 Oil thermostat - Inspect........................................................................................................... 9-12
2.10 Oil filter, Oil filter alarm, Relief valve, and Left oil cooler - Assemble ..................................... 9-13
2.11 Oil filter cartridge - Install ........................................................................................................ 9-13
2.12 Right oil cooler - Disassemble and Inspect............................................................................. 9-14
2.13 Right oil cooler - Inspect ......................................................................................................... 9-14
2.14 Right oil cooler - Assemble ..................................................................................................... 9-14
3. Lubrication system - Install .................................................................................. 9-15
3.1 Breather and Oil filler - Install ................................................................................................. 9-15
3.2 Oil pump, Oil filter, Oil pan and Left oil cooler - Install............................................................ 9-16
3.3 Oil pipe and Right oil cooler - Install ....................................................................................... 9-17
9-1
1. Lubrication system - Remove and Inspect

1.1 Oil pipe and Right oil cooler - Remove and Inspect
4
Replace: O-ring
Oil filter Packing
Sealing washer
Accessory drive Front

3
Crankcase
A
7
B
6
7
Oil cooler
9
A Oil pan
11 8
Crankcase
10 2
5
B 5
11 1
10 Accessory
drive
Oil pipe and Right oil cooler - Remove and Inspect

Removing sequence
1 Right drain pipe 5 Oil pipe 9 Left oil pipe
2 Right oil pipe 6 Right oil cooler (approx. 21 kg [46.3 lb.]) 10 Oil drain connector
3 Left drain pipe 7 Oil pipe 11 Turbocharger bracket
4 Left oil pipe 8 Right oil pipe
9-3
1.2 Oil pump, Oil filter, Oil pan and Left oil cooler - Remove and Inspect
Replace
Replace 8
10
Replace 9
Replace
7
Clogged
Replace 12
Replace
Replace Replace 5
6
Replace
Replace 3
Replace 1
Damage, crack
11 Replace
Replace
Oil pump, Oil filter, Oil pan and Left oil cooler - Remove and Inspect
Removing sequence
1 Bypass drain pipe 5 Oil pipe 9 Connector
2 Connector 6 Oil filter assembly, left oil cooler 10 Oil pump (Approx. 26 kg [57 lb.])
3 Oil pipe (Approx. 40 kg [88 lb.]) 11 Oil pump (Approx. 190 kg [418 lb.])
4 Oil pipe 7 Stay 12 Oil strainer assembly
8 Oil pipe
9-4
1.3 Breather and Oil filler - Remove and Inspect
1 2
1
Replace
4
Replace
Replace
Replace
5
Replace
6
7
Replace
Breather and Oil filler - Remove and Inspect

Removing sequence
1 Breather hose 4 No. 5 side cover breather 7 Oil filler cap
2 Rear breather 5 Oil level gauge 8 Oil filler
3 Breather pipe 6 Level gauge guide
9-5
2. Lubrication system - Disassemble, Inspect and Assemble

2.1 Oil pump and Safety valve - Disassemble and Inspect
Replace
Fatigue, damage, wear
Damage, crack
Replace
Replace
Damage on the spline, wear
2
Damage, wear
5
Contact, flaking,
wear
3
3
Damage, wear
Replace
Replace
1
Damage, crack
Oil pump and Safety valve - Disassemble and Inspect

1 Oil pump cover 3 Driven gear 5 Oil pump case
2 Drive gear 4 Safety valve assembly
9-6
2.2 Oil pump and Safety valve - Inspect

2.2.1 Drive gear and driven gear backlash - Measure
Measure the drive gear and driven gear backlash. If the
specified limit is exceeded, replace the gears with new ones.
Item Standard Limit

Drive gear and driven 0.100 to 0.200 mm 0.400 mm
gear backlash [0.0039 to 0.0079 in.] [0.0157 in.]
2.2.2 Clearance between gears and case - Measure

Measure the clearance between gear teeth and case bore. If
the limit is exceeded, replace gears or case with a new one.
Item Standard Limit

Clearance between gear 0.100 to 0.148 mm 0.350 mm
teeth and case bore [0.0039 to 0.0058 in.] [0.0138 in.]
Clearance between gears and case - Measure

2.2.3 End clearance between gears and case - Mea-
sure
Measure the end clearance between gear width and case
depth. If the limit is exceeded, replace gears or case with a
new one.
Item Standard Limit

Clearance between gear 0.040 to 0.116 mm 0.210 mm
width and case depth [0.0016 to 0.0046 in.] [0.0083 in.]
End clearance between gears and case - Measure

2.2.4 Drive and driven gear shaft outside diameters
and Bushing inside diameter - Measure
(1) Inspect the gear teeth. If any defects are found, replace
the gear with a new one.
(2) Measure the drive and driven gear shaft outside diame-
ters and the bushing inside diameter. If any of the gear
and bushing combination exceeds the limit, replace it
with the new set of such parts.

Drive shaft out- 29.887 to 29.900 mm 29.840 mm
side diameter [1.1767 to 1.1772 in.] [1.1748 in.]
Driven shaft out- ø30 mm 29.947 to 29.960 mm 29.920 mm
side diameter [1.18 in.] [1.1790 to 1.1795 in.] [1.1780 in.]
Bushing inside 30.000 to 30.021 mm 30.055 mm
diameter [1.1811 to 1.1819 in.] [1.1833 in.]
9-7
2.2.5 Oil pump safety valve - Inspect

Stopper Valve
Valve spring
Item Standard
1.3 ± 0.13 MPa
Safety valve opening pressure
{13 ± 1.3 kgf/cm2} [189 ± 19 psi]
(1) Inspect the oil pump safety valve spring, and if any
O-ring
deformation, wear, or damage is found, or if the speci-
fied limit is exceeded, replace it with a new one.
Item Standard Limit

Safety valve 65.8 mm [2.591 in.]/ 65.8 mm [2.591 in.]/ Safety valve - Inspect
Spring installed 359 N 314 N
length/load {36.6 kgf} [80.7 lbf] {32.0 kgf} [70.6 lbf]
Safety valve
78 mm [3.07 in.] -
Spring free length
(2) Inspect the valve and stopper. If significant wear or

malfunction of sliding part are found, replace them with
new ones.
9-8
2.3 Oil pump and Safety valve - Assemble
33 ± 3.3 N·m 88 ± 10 N·m

{3.4 ± 0.34 kgf·m} {9 ± 1.0 kgf·m}
[25 ± 2.5 lbf·ft] [65 ± 7.4 lbf·ft]
Apply engine oil

to O-ring.
74 ± 10 N·m
{7.5 ± 1.0 kgf·m}
[54 ± 7.4 lbf·ft]
Apply ThreeBond No.1215 to the

cover and case.
Oil pump and Safety valve - Assemble
9-9
2.4 Oil filter, Oil filter alarm, Relief valve and Left oil cooler - Disassemble and Inspect
10
Clogged, crack
Replace
11
Replace Replace 5
Crack, deformation 12
Replace
1
Crack, deformation 12
6
Replace
Replace
Replace
5 1
1
Replace
Fatigue, damage,
4 wear
8 Aging, wear, crack
2 Wear, crack
Replace
Oil filter, Oil filter alarm, Relief valve and Left oil cooler - Disassemble and Inspect
1 Full-flow oil filter 5 Adapter assembly 9 Thermostat seal
2 Bypass oil filter 6 Relief valve assembly 10 Oil cooler element
3 Oil filter alarm 7 Connector 11 Plate
4 Bracket 8 Oil thermostat 12 Oil filter bracket
(Approx. 15 kg [33 lb.])
9-10
2.5 Oil filter - Inspect

When replacing the oil filter, sample the oil (500 ml [0.13
U.S. gal.]) and check for metal and other particles. If metal
or other particles are found, cut and unfold the element, and
inspect the color and shape of metal particles trapped in the
element to identify the cause.
Oil filter - Inspect

2.6 Oil filter alarm - Inspect
(1) Use a tester to check the alarm for insulation and conti-
nuity. If the alarm is found to be defective, disassemble
and repair. If the bakelite or rubber insulations are dete-
riorated or damaged, replace the alarm.
(2) If the filter alarm lamp lighting pressure exceeds the
standard, replace the alarm with a new one.
Item Standard
Oil filter alarm 0.15 to 0.18 MPa ǡ
Differential pressure for activa- {1.5 to 1.8 kgf/cm2}
tion of alarm [21 to 26 psi]
Oil filter alarm - Inspect
2.7 Relief valve - Inspect
(1) Inspect the relief valve spring, and if any deformation,
wear or damage is found, replace the spring with a new Valve
one.
Spring
Item Standard
Relief valve
188 mm [7.40 in.]
Spring free length
(2) Inspect the valve, and if any wear, flaw, or slide mal-
functions are found, replace the valve with a new one.
Relief valve - Inspect
9-11
2.8 Oil cooler - Inspect

Check oil passages of the element for flaws or cracks by
Air
blowing compressed air of 1.5 MPa {15 kgf/cm2} [217 psi]. Check for leakage,
damage, crack
If any leakage or damage is found, replace the element with
a new one.
Oil cooler - Inspect

2.9 Oil thermostat - Inspect
2.9.1 Oil thermostat seal - Inspect
(1) Inspect the oil thermostat seal for deterioration and Thermostat seal
cracks. If defects are found, replace the seal with a new
one. Installing direction
(2) Refer to the illustration for the correct direction of seal

installation.
Thermostat
Oil thermostat seal - Install

2.9.2 Oil thermostat operation - Inspect
Water (stir with bar)

Be very careful of hot water and flames.
Otherwise, you may get burned or end up causing a
fire.
(1) Immerse the oil thermostat in a container filled with

water.
(2) Heat the water while measuring the water temperature.
Record the temperature at which the valve start to open,
and at which valve lift becomes the standard value. Oil thermostat operation - Inspect
Replace the thermostat if a deviation from standard
temperature is significant.
Note:(a) Stir the water to maintain uniform temperatures
during the test.
(b) At assembly, be sure to check the valve opening
temperature stamped on the side of thermostat
valve.
Item Standard
80 to 84°C
[176 to 183.2°F]
95°C[203°F]
11 mm [0.43 in.] or more
9-12
2.10 Oil filter, Oil filter alarm, Relief valve, and Left oil cooler - Assemble
To assemble, follow the disassembly sequence in reverse.
Thoroughly clean oil passages using an oil wash, and dry
the cleaned parts with compressed air.
2.11 Oil filter cartridge - Install
(a) To install the oil filter cartridge, tighten the oil fil-
ter cartridge by hand. Do not use filter wrenches.
(b) Be careful not to dent or scratch the surface of
the oil filter cartridge.
(1) Clean the mounting surface of the oil filter cartridge.
(2) Apply clean engine oil on the oil filter gasket.
(3) When the oil filter gasket comes contact with the base
surface, tighten the cartridge by 3/4 to 1 turn by hand.
(4) Run the engine, and make sure that there is no fuel
leaks.
9-13
2.12 Right oil cooler - Disassemble and Inspect
4
Aging, wear, crack
Clogged, rupture,
crack
Replace 5
2
Replace Replace
Replace
Wear, crack
Replace
1
Replace
3
Crack, deformation
Replace
Replace
Right oil cooler - Disassemble and Inspect

1 Connector 3 Oil cooler cover 5 Thermostat seal
2 Oil thermostat 4 Oil cooler element
2.13 Right oil cooler - Inspect
Inspect in the same manner as the left side inspection.
Replace defective parts if any.
2.14 Right oil cooler - Assemble
To assemble, follow the disassembly sequence in reverse.
Thoroughly clean oil passages using an oil wash, and dry the cleaned parts with compressed air.
9-14
3. Lubrication system - Install

3.1 Breather and Oil filler - Install
Replace
Replace
Replace
Replace
Replace
Replace
Breather and Oil filler - Install
9-15
3.2 Oil pump, Oil filter, Oil pan and Left oil cooler - Install
Replace
Replace
Replace
Replace
108 ± 10.8 N·m
{11 ± 1.1 kgf·m} Clogged
[80 ± 8.0 lbf·ft]
Replace
Replace
Replace
Apply sealant (Heldite) Replace
to both surfaces of the
oil pan packing along
its parting line.
Replace
Replace
Replace
59 ± 5.9 N·m
{6 ± 0.6 kgf·m}
[43 ± 4.3 lbf·ft]
Replace
Damage, crack Replace
Oil pump, Oil filter, Oil pan and Left oil cooler - Install
9-16
3.3 Oil pipe and Right oil cooler - Install
Replace: O-ring
Oil filter ࠉࠉࠉ Packing
Sealing washer
Front
Accessory drive
Crankcase
Oil cooler
A Oil pan
Crankcase
Accessory
drive
Oil pipe and Right oil cooler - Install
9-17
1. Cooling system - Remove and Inspect................................................................ 10-3
1.1 Water pipe - Remove and Inspect .......................................................................................... 10-3
1.2 Thermostat case and Water pipe - Remove and Inspect ....................................................... 10-4
1.3 Water pump - Remove............................................................................................................ 10-5
2. Cooling system - Disassemble, Inspect and Assemble..................................... 10-6
2.1 Thermostat - Disassemble and Inspect .................................................................................. 10-6
2.2 Thermostat - Inspect............................................................................................................... 10-7
2.3 Water pump - Disassemble and Inspect................................................................................. 10-8
2.4 Water pump - Inspect ........................................................................................................... 10-10
2.5 Water pump - Assemble ....................................................................................................... 10-11
3. Cooling system - Install ...................................................................................... 10-14
3.1 Water pipe - Install................................................................................................................ 10-14
3.2 Thermostat case and Water pipe - Install ............................................................................. 10-15
3.3 Water pump - Install.............................................................................................................. 10-15
10-1
1. Cooling system - Remove and Inspect

1.1 Water pipe - Remove and Inspect
Replace 6 6
4 Crack, aging
5 Crack, aging 5
Crack, B
aging
3 E
C
2
7 7
1
Crack, aging
Crack, aging
8 8
C Replace Replace
A
E
Crack, aging
Water pipe - Remove and Inspect

Removing sequence
1 Rubber hose 4 Water pipe 7 Rubber hose
2 Water pipe 5 Rubber hose 8 Water pipe
3 Rubber hose 6 Water pipe
10-3
1.2 Thermostat case and Water pipe - Remove and Inspect
Replace
Replace
5 6
Replace
4
2
Replace 7
1
3
Replace
10
8
11
Thermostat case and Water pipe - Remove and Inspect

Removing sequence
1 Coupling 6 Bracket
2 Bypass water pipe 7 Bracket
3 Bypass water pipe 8 Nut
4 Left thermostat case 9 Pulley (for alternator driving)
5 Right thermostat case 10 Key
11 Water pump (approx. 40 kg [88 lb.])
10-4
1.3 Water pump - Remove

Remove the nuts using the socket.
Socket
P/N:58309-73100
Water pump - Remove
10-5
2. Cooling system - Disassemble, Inspect and Assemble

2.1 Thermostat - Disassemble and Inspect
2
3
Aging, wear, crack
4
Replace
Wear, crack
Thermostat - Disassemble and Inspect

1 Thermostat cover 3 Thermostat 5 Thermostat case
2 Snap ring 4 Thermostat seal
10-6
2.2 Thermostat - Inspect

2.2.1 Thermostat seal - Inspect
(1) Inspect the thermostat seal for deterioration and cracks. Thermostat seal
If defects are found, replace the seal with a new one.
(2) Refer to the illustration for the correct direction of seal
Installing direction
installation.
Thermostat
Thermostat seal - Install

2.2.2 Thermostat operation - Inspect
Water (stir with bar)

Be very careful of hot water and flames.
Otherwise, you may get burned or end up causing a
fire.
(1) Immerse the thermostat in a container filled with water.

(2) Heat the water while measuring the water temperature.
Record the temperature at which the valve start to open,
and at which valve lift becomes the standard value.
Replace the thermostat if a deviation from standard Thermostat operation - Inspect
temperature is significant.
Note:(a) Stir the water to maintain uniform temperatures
during the test.
(b) At assembly, be sure to check the valve opening
temperature stamped on the side of thermostat
valve.
Item Standard
69 to 73°C
[156.2 to 163.4°F]
85°C[185°F]
9 mm [0.35 in.] or more
10-7
2.3 Water pump - Disassemble and Inspect
14
15
Rotation
16
10
Replace
11
Flaking, wear
8 1
2
9
3
6
Replace 4
7
5 12
13
Rotation
17 Replace
Corrosion, flaw
Replace
18 Replace
Corrosion, crack, flaw
Replace
Water pump - Disassemble and Inspect

1 Snap ring 7 O-ring 13 Unit seal
2 Cover 8 Water pump gear 14 Oil seal
3 O-ring 9 Bearing 15 Snap ring
4 Impeller 10 Snap ring 16 Bearing
5 Nut 11 Water pump shaft 17 Oil pump (Approx. 21 kg [46 lb.])
6 Oil seal sleeve 12 Ring 18 O-ring
10-8
2.3.1 Water pump mounted on engine - Inspect

With fingers, touch the drain port at the center of the water
pump case bottom. If water is oozing out, the unit seal is
defective, and if oil is oozing out, the oil seal is defective.
Water pump mounted on engine - Inspect

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

(2) Remove the impeller with the impeller remover.
Impeller remover P/N:37591-03200
(Remover plate) Impeller
(Jack-bolt)
Shaft
Impeller - Remove
10-9
2.3.3 Water pump shaft - Remove

(1) Remove the oil seal sleeve. Gear puller
(2) Remove the gear and ball bearing together using the
gear puller.
(3) Remove the snap ring from the water pump impeller
ball bearing.
(4) Insert the two half rings of the ring remover between
the unit seal ring and the water pump case as shown in
the illustration.
(5) Install the outer ring on the outer side, taking care not to
Water pump gear - Remove
drop the half ring.
(6) Push the impeller end face of water pump shaft with a
Ring remover Press
hand press, remove the unit seal ring and shaft. P/N:37791-03400 Unit seal ring
(Half ring)
(Outer ring)
Water pump
case
Water pump shaft - Remove

2.4 Water pump - Inspect
Measure the inside diameter of the fit between the water
pump case and bearing, and the outside diameter of fit
between the shaft and bearing, and the inside and outside
diameter of bearings.If any of the measurements is out of
the standard, replace the part with a new one.
Item Nominal Standard

Bearing ø120 mm 119.987 to 120.022 mm
Pump case
Inside [4.72 in.] [4.7239 to 4.7253 in.]
diameter of
cover bear- Bearing cover ø110 mm 110.005 to 110.040 mm
ing fit [4.33 in.] [4.3309 to 4.3323 in.]
Outside ø120 mm 119.985 to 120.000 mm

diameter [4.72 in.] [4.7238 to 4.7244 in.]
Large
Inside ø55 mm 54.985 to 55.000 mm
diameter [2.17 in.] [2.1648 to 2.1654 in.]
Bearing
Outside ø110 mm 109.985 to 110.000 mm
diameter [4.33 in.] [4.3301 to 4.3307 in.]
Small
Inside ø50 mm 49.988 to 50.000 mm
diameter [1.97 in.] [1.9680 to 1.9685 in.]
ø55 mm 55.011 to 55.024 mm
Outside diameter of shaft to [2.17 in.] [2.1658 to 2.1663 in.]
[1.97 in.] [1.9686 to 1.9694 in.]
1.04 mm 0.58 to 1.50 mm
Impeller front clearance
[0.0409 in.] [0.0228 to 0.0591 in.]
10-10
2.5 Water pump - Assemble
Replace
Front plate
Bearing case
Oil seal
392 ± 19.6 N·m
{40 ± 2.0 kgf·m}
[289 ± 14 lbf·ft]
Replace Install the oil seal sleeve

to turn the chamfered
side of oil seal sleeve
at the pulley.
Replace
Apply LLC to the outer circumference

of floating seat and sliding surface when
press-fitting the unit seal (rotating side)
Apply LLC. to the ring.
Apply sealant (ThreeBond 1102) to the
outer circumference of unit seal
(fixing side)
Unit seal (rotating side) Apply engine oil to the oil seal lip,
and fit it with the end of case face.
Unit seal (fixing side)
Apply sealant.
Water pump - Assemble
10-11
2.5.1 Oil seal - Install

(1) Using installer, install the oil seal, making sure that oil
seal surface is flush with the water pump case face.
(2) Apply engine oil to the oil seal lip.
Apply engine oil.
Oil seal - Install

2.5.2 Unit seal (stationary side) - Install
Unit seal installer
(1) Apply sealant (ThreeBond 1102) to the outer circum- P/N:37191-06300
ference of the unit seal (stationary side).
(2) Insert the unit seal into the water pump case using a unit
seal installer.
Apply sealant.
Unit seal (stationary side) - Install
2.5.3 Water pump shaft - Install
Water pump shaft

When installing the water pump shaft, be careful not with ball bearing
to damage the oil seal and unit seal (fixing side)
inside the pump case.
(1) Press-fit the impeller ball bearing to the water pump

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

Press-fit
Install
(1) Install the unit seal (rotating side) to the unit seal ring. Shaft
(2) Apply LLC to the unit seal (rotating side). 80 ± 0.15 mm

(3) Using the ring installer and press, slowly install the unit [3.1496 ± 0.0059 in.] Ring installer
seal ring to the specified position. P/N:37791-03300
Unit seal ring

Unit seal
(rotating side)
Unit seal ring and Unit seal (rotating side) - Install
10-12
2.5.5 Pulley side ball bearing - Install

(1) Insert the gear into the shaft through the key.
(2) Press-fit the ball bearing on the pulley nut side with a
press.
Press-fit
Pulley side ball bearing - Install

2.5.6 water pump impeller - Press-fit
Flush
Press-fit the water pump impeller with a press. The boss end
face of the water pump impeller should be flush with end Impeller
face of pump shaft when the water pump impeller is Press-fit
installed. Shaft
water pump impeller - Press-fit

2.5.7 Oil seal sleeve - Install
(1) Insert the O-ring to the oil seal sleeve.
(2) With the chamfered portion on the outer periphery of Chamfering
sleeve facing outward (pulley side), install the oil seal O-ring
sleeve into the pump shaft.
Oil seal sleeve
Oil seal sleeve - Install
10-13
3. Cooling system - Install

3.1 Water pipe - Install
Replace
Crack, aging
Crack, aging
Crack, B
aging
C E
Crack, aging
Crack, aging
Replace Replace
C
A
Crack, aging E
Water pipe - Install
10-14
3.2 Thermostat case and Water pipe - Install
Replace
Replace
Replace
Replace
Replace
392 ± 19.6 N·m

{40 ± 2.0 kgf·m}
[289 ± 14 lbf·ft]
108 ± 10.8 N·m

{11 ± 1.1 kgf·m}
[80 ± 8 lbf·ft]
Thermostat case and Water pipe - Install
3.3 Water pump - Install

Tighten the nut to the specified torque using a socket
wrench.
Socket
P/N:58309-73100
Water pump - Install
10-15
1. Inlet and exhaust systems - Remove and Inspect.............................................. 11-3
1.1 Air duct (between radiator and turbocharger) - Remove and Inspect..................................... 11-3
1.2 Air duct (between radiator and crabkcase) - Remove and Inspect......................................... 11-4
1.3 Insulator - Remove and Inspect.............................................................................................. 11-5
1.4 Exhaust pipe - Remove and Inspect....................................................................................... 11-6
1.5 Exhaust manifold - Remove and Inspect ................................................................................ 11-7
2. Inlet and exhaust systems - Install ...................................................................... 11-8
2.1 Exhaust manifold - Install........................................................................................................ 11-8
2.2 Exhaust pipe - Install ............................................................................................................ 11-10
2.3 Insulator - Install ................................................................................................................... 11-11
2.4 Air duct (between radiator and crabkcase) - Install .............................................................. 11-12
2.5 Air duct (between radiator and turbocharger) - Install .......................................................... 11-13
11-1
1. Inlet and exhaust systems - Remove and Inspect

1.1 Air duct (between radiator and turbocharger) - Remove and Inspect
Crack, damage, deformation 2 Replace

Crack, damage, deformation
Crack, damage, Replace
deformation Turbocharger 1
Crack, damage
3 Turbocharger
6 3 Crack, damage, deformation

7
Replace Crack, damage,
4 4 5 deformation
3
6 Turbocharger
A
1 Replace
7 Crack, damage 13
2
Crack, damage, deformation Turbocharger
B
12 D 3
C C
D Crack, damage,
14 deformation
12 Replace 9 Crack, damage,
12 Replace B
deformation
Crack, damage,
11 Crack, damage,
deformation 8
12 deformation
A 8
Replace
10 10
Replace Replace
9
Replace
Crack, damage, deformation 14
Replace
11
Air duct (between radiator and turbocharger) - Remove and Inspect

Removing sequence
1 Air duct 6 Clamp 11 Air duct
2 Air duct 7 Air duct 12 Air duct stay
3 Connector 8 Flexible joint 13 Air duct stay
4 Rubber hose 9 Clamp 14 Air duct stay
5 Air duct 10 Air duct
11-3
1.2 Air duct (between radiator and crabkcase) - Remove and Inspect

11
9 10
Crack, damage
Replace
4 Crack, damage, deformation

Crack, damage
B
Replace 15 Crack, damage
3 8 B
Crack, damage, 14
deformation 7
12
2 Crack, damage
6
Crack, damage Crack, damage,
A A deformation
1
13
Replace
5
Replace Crack, damage, deformation
Air duct (between radiator and crabkcase) - Remove and Inspect

Removing sequence
1 Air duct 6 Rubber hose 11 Air box
2 Rubber hose 7 Air duct 12 Air duct stay
3 Air duct 8 Rubber hose 13 Air duct stay
4 Rubber hose 9 Rubber hose 14 Air duct stay
5 Air duct 10 Air box 15 Air duct stay
11-4
1.3 Insulator - Remove and Inspect
Check for the deformation and damage of insulator.

5
A
6 A
8
2
4
3
3
1 3 2
3 2
1
Insulator - Remove and Inspect
Removing sequence
1 Insulator cover 5 Rear turbo insulator
2 Outer insulator 6 Front turbo insulator
3 Inner insulator 7 Stay
4 Insulator 8 Stay
11-5
1.4 Exhaust pipe - Remove and Inspect
Crack, damage,
3
deformation
Replace

Replace 1
5 Replace
2
1
4 2
Replace
Replace 3
1
4 1
Replace
deformation
2
Crack, damage,
Replace
6 deformation
Exhaust pipe - Remove and Inspect

Removing sequence
1 V clamp 3 Exhaust joint 5 Exhaust pipe (Approx. 50 kg [110 lb.])
2 Turbocharger (Approx. 29 kg [64 lb.]) 4 Exhaust joint 6 Exhaust pipe bracket
11-6
1.5 Exhaust manifold - Remove and Inspect
3
1
Crack, damage,
deformation 2
Replace: gasket
Exhaust manifold - Remove and Inspect

Removing sequence
1 V clamp 2 Flexible joint 3 Exhaust manifold
11-7
2. Inlet and exhaust systems - Install

2.1 Exhaust manifold - Install
Crack, damage,
deformation
108 ± 5.4 N·m

11 ± 0.55 kgf·m
[80 ± 3.98 lbf·ft]
Tightening torque for V-clamp

98 ± 4.9 N·m :20 ± 1.0 N·m {2 ± 0.1 kgf·m} [14.47 ± 0.72 lbf·ft]
10 ± 0.5 kgf·m
[72.33 ± 3.62lbf·ft] Replace: gasket
Exhaust manifold - Install
11-8
2.1.1 Cautions during installation of exhaust manifold

Attach the exhaust gasket so that the side having
Make sure that the centers of exhaust manifold and cou- letters stamped is orientated to the exhaust manifold.
pling are aligned when installing. The misalignment of
exhaust manifold and coupling causes gas leakage. MANIFOLD
Attach the exhaust gasket such that the side having

stamped letters is orientated to the exhaust manifold.
When assembling the exhaust manifold, always replace all
pieces of the exhaust gasket with new ones.
Cautions during installation of exhaust manifold

2.1.2 V clamp - Tighten
Bolt Nut
20 ± 1.0 N·m
Do not distort the circumference of V clamp and {2±0.1 kgf·m}
groove. [14.47±0.72 lbf·ft]
(1) Tentatively and evenly tighten two bolts and nuts.

(2) Apply slight vibration to the circumference of V clamp
so that the mating surface of the exhaust manifold
V-groove
comes into close contact with the tapered face of V
clamp.
(3) Tighten the nut to the specified torque. V clamp - Tighten
(4) Once again lightly vibrate to check the tightening
torque.
11-9
2.2 Exhaust pipe - Install

Replace

Replace
Replace
Replace
Replace

deformation Replace
Crack, damage,
Replace
deformation
V-clamp tightening torque:

9 ± 0.45 N·m
{0.9 ± 0.045 kgf·m} [6.5 ± 0.33 lbf·ft]
Exhaust pipe - Install
Check that the centers of bracket, exhaust pipe and exhaust joint are aligned when installing. The misalignment of bracket,
exhaust pipe and exhaust joint causes gas leakage.
11-10
2.3 Insulator - Install
Check for the deformation and damage of insulator.
A
A
Insulator - Install
11-11
2.4 Air duct (between radiator and crabkcase) - Install
Crack, damage
Replace

Crack, damage
B
Replace Crack, damage
Crack, damage,
deformation
Crack, damage
Crack, damage Crack, damage,

A A deformation
Replace
Replace Crack, damage, deformation
Air duct (between radiator and crabkcase) - Install
11-12
2.5 Air duct (between radiator and turbocharger) - Install
Crack, damage, deformation Replace

deformation Turbocharger
Crack, damage
Turbocharger

deformation
Turbocharger
A
Replace
Crack, damage
Turbocharger
B Crack, damage, deformation
D C
C D Crack, damage,
deformation
Replace B
deformation Crack, damage,
deformation
A Replace
Replace Replace
Replace
Replace
Air duct (between radiator and turbocharger) - Install
11-13
1. Electrical system - Remove and Inspect ............................................................. 12-3
1.1 Starter - Remove and Inspect................................................................................................. 12-3
1.2 Inspection before removal of alternator .................................................................................. 12-3
1.3 Alternator - Remove and Inspect ............................................................................................ 12-4
2. Electrical system - Disassemble, Inspect and Assemble .................................. 12-5
2.1 Starter - Disassemble and Inspect.......................................................................................... 12-5
2.2 Starter - Inspect and Repair.................................................................................................... 12-8
2.3 Starter - Assemble ................................................................................................................ 12-13
2.4 Alternator - Disassemble and Inspect................................................................................... 12-18
2.5 Alternator - Inspect and Repair............................................................................................. 12-21
2.6 Alternator - Assemble ........................................................................................................... 12-24
3. Electrical system - Install.................................................................................... 12-27
3.1 Alternator - Install.................................................................................................................. 12-27
3.2 Starter - Install ...................................................................................................................... 12-27
12-1
1. Electrical system - Remove and Inspect

1.1 Starter - Remove and Inspect

(1) Disconnect the harness.
(2) Remove the starter.
Starter
(Approx. 19 kg [42 lb.])
Starter - Remove and Inspect
1.2 Inspection before removal of alternator
1.2.1 Alternator operation - Inspect
Locate the cause of faulty charging from the malfunctions
described below. Do not remove the alternator for inspec-
tion and repair unless inspection cannot be performed with
the alternator installed on the engine.
Adjusted value of voltage regulator is high.

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

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

Removing sequence
1 Connector 4 Adjusting rod 6 Alternator
2 Rear belt cover 5 Belt 7 Alternator bracket
3 Front belt cover
12-4
2. Electrical system - Disassemble, Inspect and Assemble

2.1 Starter - Disassemble and Inspect
8 2
Brush powder accumulation,

Gear wear local wear, brush movement
1 inside the holder
10
11
Gear wear, flaw Rotation

7 5 4 3
Rotation
Commutator surface roughness,
Gear wear, flaw seizure, stepped wear
Breaking, ground
Starter - Disassemble and Inspect

1 Safety relay 5 Yoke assembly 9 Front bracket
2 Magnetic switch assembly 6 Armature assembly 10 Pinion case
3 Rear bracket 7 Center bracket 11 Pinion clutch assembly
4 Brush holder assembly 8 Lever assembly
12-5
2.1.1 Safety relay and Magnetic switch - Remove

Magnetic switch
(1) Remove a safety relay.
assembly
(2) Disconnect the lead wire, and remove the magnetic
switch.
Lead wire
Safety relay and Magnetic switch - Remove

2.1.2 Rear bracket - Remove
(1) Remove the through bolts and brush holder screws.
(2) Remove the rear bracket. Rear bracket
Rear bracket - Remove

2.1.3 Armature and Yoke assembly - Remove
(1) Remove the brush from the brush holder assembly.
(2) Remove the yoke from the center bracket.
Armature
Yoke assembly
Brush and Yoke assembly - Remove

(3) Remove the armature assembly.
Armature assembly
Armature assembly - Remove
12-6
2.1.4 Center bracket - Remove

Remove the center bracket. Center bracket
Hexagonal wrench
Center bracket - Remove

2.1.5 Lever assembly - Remove
Remove the lever pin, the inner housing, and the shift lever Lever assembly mounting
bolt, nut
from the pinion case.
Lever assembly - Remove

2.1.6 Pinion set - Remove
Unit: mm [in.]
(1) Remove the pinion stopper with a tool. Pipe
(2) Remove the overrunning clutch from the pinion shaft. ø 24
Pinion shaft [0.94]
(3) Measure the diameter of pinion shaft at bearing fitting
ø 19.1
face. If the limit is exceeded, replace the faulty pinion [0.752]
shaft with a new one. Pinion shaft

Rear shaft out- ø30 mm 30.002 to 30.011 mm Pinion
- Overrunning clutch
side diameter [1.18 in.] [1.1812 to 1.1815 in.] stopper
Front shaft out- ø19 mm 18.90 to 18.94 mm
- Overrunning clutch - Remove
side diameter [0.75 in.] [0.7441 to 0.7457 in.]
ø19 mm 19.000 to 19.033 mm
Front bearing - Bolt 20 mm [0.79 in.]
[0.75 in.] [0.7480 to 0.7493 in.] Press
M5 × 0.8 t = 7 mm
ø19 mm 19.000 to 19.033 mm
Pinion - - 40 mm [0.28 in.]
[0.75 in.] [0.7480 to 0.7493 in.]
37 mm [1.46 in.]
Clearance 10 mm
0.25 mm [0.39 in.]
between bearing - -
120 mm [4.72 in.]
[0.0098 in.]
and shaft
Note: To replace the pinion shaft bearing, the use of a bear-

ing puller tool shown in the illustration is recommend-
M5 × 0.8
ed.
Bearer
Pinion shaft bearing puller
12-7
2.2 Starter - Inspect and Repair

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

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

(3) Make sure there is no continuity between the M termi-
nal and the B terminal.If there is continuity, replace the Terminal M
magnetic switch with a new one.
Tester
Terminal B
Isolation between M terminal and B terminal - Inspect
2.2.2 Continuity between magnetic switch coil, M ter-
Tester
minal and B terminal (with the contact point
inside closed) - Inspect
(1) Push the plunger so as to bring the contact point inside Terminal M Plunger
to the closed position.
(2) Check that there is continuity between the M terminal
and the B terminal. If there is no continuity, replace the
magnetic switch with a new one.
Terminal B
Continuity between M terminal and B terminal (with the

contact point inside closed) - Inspect
12-8
2.2.3 Magnetic switch contact points - Inspect

Contact point
(a) Never conduct an operation test with a dis-
mounted magnetic switch unit.
(b) Always turn the starter switch to ON before mea-
suring the voltage, then turn it to OFF after mea-
suring. If the starter switch is turned to OFF during
voltage measurement, the battery voltage is
directly applied to the voltmeter, and this can dam- Measure voltage drop between terminals B and M.
age the voltmeter.
Magnetic switch contact points - Inspect
Measure the load current of starter. If the voltage drop
between terminals B and M exceeds the limit, repair or
replace the contact point.
Item Limit
Voltage drop between terminals B and M
0.3 V
(under load current of 100 A)
2.2.4 Brush - Inspect for wear

Measure the length of the brushes.
If it is less than the limit, replace the brush holder assembly
and brush assembly with new ones.
Limit
Item Standard Limit Standard
21 to 22 mm
Brush length 13 mm [0.51 in.]
[0.83 to 0.87 in.]
Brush - Inspect for wear

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

Brush spring load 44.1 N 40.2 N
(With brush installed) {4.5 kgf} [9.9 lbf] {4.1 kgf} [9.0 lbf]
2.2.6 Continuity of yoke assembly - Inspect

(1) Check that there is continuity between the M terminal Brush lead wire
Terminal M
of the field coil and the lead wire for the brush. If there
is no continuity, replace the yoke assembly with a new Yoke
one.
(2) Check that there is no continuity between field coil and
yoke. If there is continuity, replace the yoke assembly
coil with a new one.
(3) Check that there is no continuity between the yoke
body and the brush. If there is continuity, replace the
Continuity of yoke assembly - Inspect
yoke assembly with a new one.
12-9
2.2.7 Bearing - Inspect

Rotate the bearing outer race by hand, and make sure it Bearing
rotates smoothly.
Bearing - Inspect
2.2.8 Armature shaft runout - Measure
Using a dial gauge, measure the shaft runout. If the runout
exceeds the standard, repair or replace the armature. Armature shaft
Item Standard Remarks

0.05 mm
Armature shaft runout TIR
[0.0020 in.]
Armature shaft runout - Measure

2.2.9 Commutator outside diameter - Measure
Measure the commutator outside diameter.If the measured
value is less than the limit, replace the armature with a new Ou
tsi
one. de
dia
m
et
Item Nominal Limit er
Commutator outside diameter ø43 mm [1.69 in.] 42 mm [1.65 in.]
Commutator outside diameter - Measure

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

0.06 mm 0.1 mm
Commutator runout TIR
[0.0024 in.] [0.004 in.]
Commutator surface - Polish
12-10
2.2.11 Undercut depth - Measure

Measure the depth of undercutting between the commutator
segments.If the measured value is less than the limit, repair Insufficient recutting
or replace the commutator. Defective
(need recutting) Good
Item Standard Limit
0.7 to 0.9 mm
0.7 to 0.9 mm
Undercut depth 0.2 mm [0.008 in.] [0.028 to 0.035 in.]
[0.028 to 0.035 in.]
Undercut depth - Measure

2.2.12 Front bracket - Inspect
If ball bearing does not turn smoothly or the abnormal noise
is generated, replace the front bracket with a new one.
2.2.13 Armature coil - Inspect

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

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

(3) Check that there is continuity between each segment. If
there is no continuity, replace the armature with a new
one.
Continuity between segments - Inspect
12-11
2.2.14 Overrunning clutch operation - Inspect
The overrunning clutch is coated with grease, thus, do Check that pinion freely rotates.
not wash it in wash oil.
Make sure that, when attempting to turn the overrunning

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

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

Inspect each starter gear. If it is worn or damaged, replace
the gear with a new one.
2.2.17 Safety relay - Inspect
(a) Pay special attention to ensure the battery's polar- Switch1

B S
ities for connection. R Switch2
(+)
(b) Do not crank starter motor for more than 10 sec- Constant-
Battery
voltage
onds at a time. Cranking the starter continuously battery
(-) (+)
could result in a flat battery and a starter burning (-)
out. Connected to the
Terminal for safety starter body
relay earth (E)
Connect the safety relay as shown, and check the starter and
safety relay operations. Safety relay - Inspect
(1) Turn on the switch 1 and make sure that the starter
operates (rotates).
(2) Then make sure that the starter stops when the switch 2
is turned on, and the setting voltage (11 to 13V) is
applied to the R terminal.
12-12
2.3 Starter - Assemble
Apply SAE 20W grease

combined with 5%
molybdenum disulfide.
Apply grease.
Starter - Assemble
Note: Be sure to use proper harness.

If the harness is modified, the starter will not function properly.
12-13
2.3.1 Pinion shaft - Assemble

Assemble the center bracket, pinion clutch assembly and
pinion stopper to the pinion shaft, and insert the shaft in
position by tapping it with a plastic hammer.
Pinion shaft - Assemble

2.3.2 Lever and Pinion shaft - Assemble
(1) Install the shift lever and pinion shaft to the front Pinion shaft
bracket while aligning the mark on the shift lever with Shift lever
the mark on the bracket.
(2) Thoroughly coat the internal gear of the pinion shaft
with Nikko Grease R. Pinion case
Lever and Pinion shaft - Assemble
12-14
2.3.3 Armature, Yoke, Brush and Brush holder -

Install
(1) Align the knock pin with the center bracket and assem-
ble the armature to the yoke. Armature
Yoke assembly
Armature and Yoke - Install

(2) Install the brush holder and brushes.
Brush holder
Brush holder and Brush - Install

Note: Install the positive (+) and negative (-) brushes as
shown in the illustration on the right.
Positive (+) brush Negative (-) brush
Positive (+) and negative (-) brushes - Assemble

2.3.4 Armature end play
Measure the end play of the armature. If the measurement is
out of standard, adjust the end play on rear side.
Item Standard
0.15 to 0.75 mm
Armature end play
[0.0059 to 0.0295 in.]
Armature end play
12-15
2.3.5 Rear bracket - Install

Install the rear bracket to the yoke assembly by aligning Rear bracket
match marks, tighten the brush holder with bolts, and fix the
rear bracket with the through bolts.
Rear bracket - Install

2.3.6 Pinion shaft end play
Measure the pinion shaft end play. If the measurement is out
of standard, adjust the end play on the internal gear side.
Item Standard
Pinion shaft end play 0.2 to 0.8 mm [0.008 to 0.032 in.]
Pinion shaft end play
Insert washer to
adjust end play
End play
Pinion shaft end play - Adjust

2.3.7 Magnetic switch - Install
Magnetic switch
(1) Install the magnetic switch and tighten the screws.
assembly
(2) Connect the lead to the terminal M and tighten it with
the fixing nut.
Lead wire
Magnetic switch - Install

2.3.8 Safety relay - Install
(1) Tighten the lead wire.
(2) Install the safety relay.
12-16
2.3.9 Pinion gear retraction length - Measure

Apply a voltage of 24 V between terminals B and C. Con-
2.5 to 5.5 mm
nect the lead wire and apply a current between terminals B
[0.098 to 0.217 in.]
and M (for 1 second or less). After the pinion is moved,
push the pinion gear and measure the pinion gear retraction
length. If the measured value is not within the standard
range, adjust the length using the adjust screw of the mag-
netic switch.
Pinion gear retraction length - Measure
Adjust the length of adjusting screw

for pinion gear retraction length
adjustment
Pinion gear retraction length - Adjust
12-17
2.4 Alternator - Disassemble and Inspect
Slip ring contamination, flaw, 5

seizure, coil resistance 4 Rotation
Rotation
6
8 Crack, flaw
1 7
Deformation, flaw
3
12
11 Short or open circuit
10
Brush sliding condition, wear
Alternator - Disassemble and Inspect

1 Through bolt 5 Rear bearing 9 Stator
2 Nut 6 Bearing retainer 10 Regulator assembly
3 Pulley 7 Front bearing 11 Rectifier assembly
4 Rotor 8 Front bracket 12 Rear bracket
12-18
2.4.1 Stator and Front bracket - Separate

Rear bracket
(a) Disassembly of alternator should be conducted

only when repair is necessary.
(b) Use care not to insert the screwdriver too deep.
Otherwise its tip may damage the stator.
(1) Remove the through bolts.

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

2.4.2 Pulley - Remove
Pulley
When clamping the rotor in a vice, be sure to hold at Front bracket

the base of claw with a vice. Holding the tip of claw
can cause damage.
(1) Wrap the rotor in cloth and clamp it in the vise.

(2) Remove the pulley nut, and then pull out the pulley.
Rotor
Pulley - Remove
2.4.3 Rear bearing - Remove
Using the bearing puller, remove the rear bearing from the Rotor
rotor.
Rear bearing
Rear bearing - Remove

2.4.4 Front bearing - Remove
Remove screws, and then remove the bearing retainer and
Front
front bearing from front bracket. Screw bracket
Front bearing Bearing retainer
Front bearing - Remove
12-19
2.4.5 Stator - Remove
The solder must be removed in a short time. If the

heat is applied for a long time, the diode will be dam-
aged.
Ｎ
Melt the solder of stator and rectifier, and remove the stator
Stator core
from the rectifier.
Rectifier
Soldering
Stator - Remove
2.4.6 Regulator assembly - Remove
Screw
(1) Remove the screws from the regulator assembly.
(2) Remove the regulator assembly.
Regulator
assembly
Regulator assembly - Remove

2.4.7 Rectifier assembly - Remove
(1) Remove the screws and nuts from the rectifier.
(2) Remove the rectifier assembly. Nut
Screw
Rear bracket
Rectifier assembly
Rectifier assembly - Remove
12-20
2.5 Alternator - Inspect and Repair

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

(2) Isolation between lead wire and core - Inspect
Check that there is no continuity between stator lead
wires and the stator core. If there is continuity, replace
the stator with a new one.
Isolation between lead wire and core - Inspect

2.5.2 Rectifier - Inspect
D F
Check continuity or isolation between diodes using an ana-
D
log tester. Ｎ
Diode (+)
If inspected result does not match the table below, replace
A
the rectifier with a new one. C
A B B F
C
Polarity of tester
Condition
Negative (-) Positive (+) Diode (-)
E Conducted E
A,B,C
D Isolated E
E Isolated
A,B,C Rectifier - Inspect
D Conducted
F A,B,C Isolated
A,B,C F Conducted
Note: A,B,C:Stator coil lead wire connection portion

D,E:Heatsink portion
F: Regulator connection portion
12-21
2.5.3 Rotor - Inspect

(1) Measure the resistance between the slip rings (rotor
coil).If the measured value does not meet the standard,
replace the rotor with a new one.
Item Standard
Resistance between slip rings Approx. 9 to 10.5 ohms
Resistance between slip rings (rotor coil) - Measure

(2) Check that the slip ring and the shaft (or core) are iso-
lated.If there is continuity, replace the rotor with a new
one.
Isolation between slip rings and shaft - Inspect
12-22
2.5.4 Brush - Inspect for wear

Measure the length of the brushes.If the specified limit is
exceeded, replace the brush with a new one.
Item Standard Limit

Brush length 21.5 mm [0.846 in.] 8 mm [0.31 in.]
Wear limit line
Brush - Inspect for wear

2.5.5 Brushes - Replace
(1) To remove the brush and the spring, unsolder the brush Brush holder
lead.
Soldering
Brushes - Replace
(2) To install a new brush, push the brush into the brush
holder as shown in the illustration, and then solder the
Brush
lead to the brush.
Note: Pay attention to the brush insertion direction when in-
stalling.
Brush - Install
12-23
2.6 Alternator - Assemble
147 ± 15 N・m
{15 ± 1.5 kgf・m}
[108 ± 11 lbf・ft]
Alternator - Assemble
Note: Be sure to use proper harness.

If the harness is modified, the alternator will not function properly.
12-24
2.6.1 Rectifier assemble and

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

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

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

2.6.4 Rear bearing - Install
Install the rear bearing to the rotor. Rotor
Rear bearing
Rear bearing - Install
12-25
2.6.5 Pulley - Install

Pulley
(1) Insert the rotor to the front bracket.
(2) Wrap the rotor in cloth and clamp it in the vise. Front bracket
(3) Install spacer and pulley, and fix them with nut. 147 ± 15 N㨯m
{15 ± 1.5 kgf㨯m}
[108 ± 11 lbf㨯ft]
Rotor
Pulley - Install
2.6.6 Rear bracket assembly and Front bracket
assembly - Assemble Rear bracket
(1) Insert a piece of wire to the hole of brush through the
Brush
small hole provided in the bracket, and raise the Wire
brushes. Install the rotor to the rear bracket, and remove
the wire.
Brush - Fix
(2) Assemble the front bracket, stator, and rear bracket, and
secure them with the through bolt.
Through bolt
Rear bracket
assembly
Stator core
Front bracket assembly
Rear bracket assembly and Front bracket assembly -

Assemble
12-26
3. Electrical system - Install

3.1 Alternator - Install
Front
46 ± 8 N·m
{4.7 ± 0.8 kgf·ft}
[34 ± 5 lbf·ft]
Rotation
Deterioration Front gear case
Alternator - Install
3.2 Starter - Install

(1) While engaging the flywheel ring gear with the pinion
gear, install the starter to the timing gear case.
(2) Tighten the starter mounting bolts to the specified
torque.
(3) Install the harness.
59 ± 5.9 N·m
{6 ± 0.6 kgf·m}
[43 ± 4.3 lbf·ft]
Starter
Starter - Install
12-27
1. Engine - Adjust ...................................................................................................... 13-3
1.1 Turning gear - Use.................................................................................................................. 13-3
1.2 Valve bridge and Adjusting screw - Check ............................................................................. 13-4
1.3 Valve clearance - Check......................................................................................................... 13-4
1.4 Fuel injection timing - Check................................................................................................... 13-4
1.5 Fuel system - Bleed air ........................................................................................................... 13-4
1.6 Belt and belt tension - Inspect and Adjust .............................................................................. 13-6
2. Break-in operation ................................................................................................. 13-7
2.1 Preparation before engine starting ......................................................................................... 13-7
2.2 Engine start-up ....................................................................................................................... 13-7
2.3 Break-in operation .................................................................................................................. 13-7
3. Engine Test and Adjustment ................................................................................ 13-9
3.1 Engine performance test......................................................................................................... 13-9
3.2 Emission test .......................................................................................................................... 13-9
3.3 Governor performance test..................................................................................................... 13-9
3.4 Alarm action and emergency stop tests.................................................................................. 13-9
3.5 Maximum fuel injection volume - Set ...................................................................................... 13-9
3.6 Seal ...................................................................................................................................... 13-10
13-1
1. Engine - Adjust
1.1 Turning gear - Use
Before starting the engine, make sure that the turning gear is in the pulled-out position.If the engine is started while
the turning gear is engaged (pushed-in position), it will cause not only damage to the ring gear but also could result
in personal injuries.
(1) Loosen two bolts, and remove the plate from the slot of
the shaft.
Shaft
Bolt
Bolt Plate
Turning gear - Use (for operation)

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

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

shaft.
Ratchet handle
Turning gear - Use (turning)
13-3
1.2 Valve bridge and Adjusting screw - Check

Check the adjustment of the valve bridge and adjusting
screw.If it is unadjusted, adjust it to the standard value.
For the adjusting procedure, refer to "Valve bridge and
Adjusting screw - Adjust" of "ASSEMBLY OF BASIC
ENGINE."
1.3 Valve clearance - Check
Check the valve clearance.
If it is unadjusted, adjust it to the standard value.
For the adjusting procedures, refer to
"Valve clearance - Inspect and Adjust" of "ASSEMBLY OF
BASIC ENGINE. "
1.4 Fuel injection timing - Check
Check the fuel injection timing.
If it is unadjusted, adjust the timing to the specified value.
For the adjusting procedures, refer to
"Fuel injection timing - Check and Adjust" of "ASSEMBLY
OF BASIC ENGINE. "
1.5 Fuel system - Bleed air
(a) Wipe off fuel spilled from the air vent plug thor- [Unlock] [Priming] [Lock]
oughly.Spilled fuel can cause fires.
Turn left Move up
(b) After bleeding of air is completed, be sure to lock and down Hold and
the priming pump cap. If locking is insufficient, it turn right
could cause damage to the priming pump and

result in fuel leaks and fires.
To bleed air from the fuel system, start the air bleeding at
the place nearest to the fuel tank, i.e. water separator, fuel
filter and injection pump (in that order), while feeding fuel Priming pump - Operate
with the priming pump.
1.5.1 Fuel filter (paper element) - Bleed air
Air vent plug
9 ± 1 N·m
If the air vent plugs, thread portion of bracket or seal- {0.9 ± 0.1 kgf·m}
ing washers are damaged, replace them with new [6.5 ± 0.7 lbf·ft]
ones.
(1) Loosen the air vent plugs of the fuel filter by approx.
1.5 turns.
(2) Feed fuel by moving the priming pump up and down.
(3) When fuel flowing from the vent holes no longer con-
tains air bubbles, tighten the air vent plugs to the speci- Fuel filter (paper element) - Bleed air
fied torque.
13-4
1.5.2 Fuel injection pump - Bleed air

(1) Loosen the air vent plugs of the fuel injection pump by
approx. 1.5 turns.
(2) Feed fuel by moving the priming pump up and down.
Air vent plug
(3) When fuel flowing from the vent holes no longer con- 15 ± 2 N·m

tains air bubbles, the air vent plugs should be tightened. {1.5 ± 0.2 kgf·m}
[11 ± 1.4 lbf·ft]
However, before tightening the last air vent plug, lock
the priming pump by turning the cap clockwise while
Priming pump
pushing it down. cap
Note:(a) If all the vent plugs are tightened before the priming
Fuel injection pump - Bleed air
pump cap is locked, fuel pressure acts on the feed
pump, making it hard to press the pump. However,
the check valve operation condition can be checked
because the pressure is stabilized at the check valve
opening pressure.
(b) Wipe off fuel spilled from the air vent plug thor-
oughly.
1.5.3 Priming pump cap - Lock

Position where 90 ± 10°
hand-tightening
If the priming pump cap is not locked sufficiently, the becomes suddenly Priming pump
heavy
screw inside wears due to engine vibration, which may
cause the priming pump cap to pop off and fuel to leak.
If it is over-tightened, the head of the priming pump
can be damaged. Make sure to tighten at the correct
angle.
Check the head packing of the priming pump for defor- Priming pump cap - Lock
mation and damage. If there is any deformation or
damage, replace the priming pump with a new one.
Head packing
(1) Tighten the priming pump cap fully by hand, and mark
this position.
(2) Using a wrench, further tighten the priming pump cap
by 90 ± 10°from the mark position.
(3) Check the mounting condition of head packing. If any
defects such as deformation or dent are found, replace
the priming pump with a new one.
Priming pump cap packing
13-5
1.6 Belt and belt tension - Inspect and Adjust
If any defects such as cuts or surface separations are found during inspection, replace the belt with a new one.
Keep oil and grease off the belt. Oil or grease on the belt causes the belt to slip and shorten the service life.
Excessive belt tension can cause rapid wear of the alternator bearing and shorten the service life of the belt. Adjust
the belt tension accurately by following the procedures below:
1.6.1 Belt - Inspect

(1) Inspect the belt visually for separation or damage.If any defects are found, replace the belt with a new one.
(2) Inspect the deflection of V-belt.
Inspect the V-belt deflection by pressing it with approx. 98 to 147 N {10 to 15 kgf} [22 to 33 lbf] force at the center of its
span. The belt deflection should be 10 to 15 mm [0.39 to 0.59 in.].
If the deflection is out of standard, adjust the belt tension.
1.6.2 Belt tension (alternator) - Adjust
10 to 15 mm
(1) Remove the belt cover. [0.39 to 0.59 in]
(2) Loosen all the fixing bolts of alternator.

(3) Turn the adjusting rod to adjust the belt tension.
(4) Tighten all the fixing bolts of alternator.
(5) Install the belt cover.
Lock nut (Left-hand
thread)
Adjusting bolt
Mounting Lock nut (Left-hand
bolt thread)
Belt tension (alternator) - Adjust
13-6
2. Break-in operation
2.1 Preparation before engine starting
Check the levels of fuel, engine oil, and coolant, and also bleed air from the fuel system and cooling system.
Inspect the link between the governor output lever and the fuel injection pump rack. Check that the fuel control rack is in the
no-injection position when the engine is stopped. Check that the control rack is in the "0" position when the stop lever is
pulled.
Check the wiring of the electrical system (sensor, meter alarm panel, starter, alternator, stop solenoid, and battery), and check
that there is no abnormality when the controller main switch is turned ON.
Set the governor speed lever so that the engine runs at a low idle speed after the start-up.
Operate the stop solenoid, and check that the fuel injection pump rack moves to the no injection position.
Install the pressure gauge, thermometer and flowmeter as required.
2.2 Engine start-up

(1) With the stop lever pulled in the no injection position, rotate the crankshaft for approx. 10 seconds using the starter to allow
the engine oil circulation around the engine. Repeat this 2 or 3 times with one minute rest between them.
Check that there are no defect such as abnormal noise or rotational fluctuation.
(2) Start the engine in the normal way.
Make sure the engine can run at a low idle speed after start-up.
(3) Make sure that the oil pressure increases immediately and the coolant circulates.
(4) Make sure there is no leakage of oil, coolant, fuel and gas (air), and there is no abnormal noise and abnormal vibration.
(5) After making sure that the engine can run at a low idle speed without any problem, turn the key switch to OFF position,
and make sure that the engine has stopped.
2.3 Break-in operation
To be prepared for unforeseeable circumstances during engine operation, make sure that an emergency stop is
available.
2.3.1 Break-in operation load and operation time

The load during break-in operation should be increased progressively as shown in the table.
Note that the time shown in the table is the minimum time required to check the engine in a stable condition.
Break-in operation
Time
Rotation speed (min-1) Load (PS)
(min)
1 Low rotation speed 600 to 900 No-load 20
Medium rotation
2 1000 to 1200 No-load 10
speed
3 High rotation speed 1400 to rated speed No-load 10
4 25 % 20
5 50 % 20
Rated speed
6 75 % 30
7 100 % 20
13-7
2.3.2 Inspection while the engine is running

During the break-in operation, pay attention to followings and make sure there are no abnormalities.
Oil pressure and oil temperature Exhaust temperature
Coolant level and water level Differences between right and left banks
Any leakage of oil, coolant fuel, and gas (air) Blow-by gas (amount and color)
Noise and vibration Rotational fluctuation
Intake air pressure and intake air temperature Face and radial runouts of rotating parts
Exhaust color and odor Indication and operation of meter and alarm
2.3.3 Inspection and adjustment after break-in opera-
tion
Valve clearance Belt tension
Fuel injection timing Inspection of defects such as oil leakage, and repair
Bolts and nuts around the engine - Retighten
13-8
3. Engine Test and Adjustment
(a) Engine test, adjustment and seal should be performed at the appointed maintenance shop only.
When the seal of engine is performed at a service shop other than the appointed shops, ask an appointed
shop for the presence of qualified person for test, adjustment and seal.
(b) Performance check and adjustment of the engine shall be conducted when the water and oil temperatures
become stable after sufficient warm-up operation.
After the break-in operation is completed, and the engine runs normally, check the performance and functions of the engine.
Record the test results by referring the engine data at the time of delivery.
3.1 Engine performance test
Fuel consumption rate, various temperatures and pressures,
and exhaust density
3.2 Emission test
Exhaust analyses
3.3 Governor performance test
Minimum speed at no-load (low idle speed) - Set
Maximum speed at no load (high idle speed) - Set
Load application and load dump tests
Governor regulation, hunting, and rotational fluctuation - Check
Setting conditions of governor controller and others - Check
3.4 Alarm action and emergency stop tests
Oil pressure decrease, water temperature increase, and over-
speed
3.5 Maximum fuel injection volume - Set
(1) With the rack set cap at the end of the fuel injection
Spring case
pump rack (front side) removed, apply rated (maxi-
mum) load. Increase fuel injection volume
(2) Secure the nut at the position that the double nut at the
rack end comes into contact with the spring case end
face.
Maximum fuel injection point
No fuel injection point
Maximum fuel injection volume - Set
13-9
3.6 Seal
After all performance tests and adjustments are completed, stop the engine, and seal the specified portion between governor
actuator and fuel injection pump rack.
3.6.1 Tamper proof - Remove
Tamper proof nut is composed of double structure, and can- Inner nut
not be removed by rotating.
To remove, cut the outer cylinder nut and remove the inner
nut.
Self-locking nut Outer cylinder nut
Tamper proof - Remove

3.6.2 Tamper proof - Install
Tighten the tamper proof nut to the specified torque, and
make sure that the inner nut has been separated.
Tamper proof nut
20±1.0 N㨯m
{2.04±0.1kgf㨯m㨩
[14.8±0.7 lbf㨯ft]
Self-locking nut
17±1.7 N㨯m
{1.73±0.17kgf㨯m㨩
[12.5±1.25 lbf㨯ft]
Tamper proof - Install
13-10
Printed in Japan Pub. No. 99406-14100

99406-14100 - Service Manual S16R-PTAA2 - March 2012

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SERVICE MANUAL

How to use this manual

Terms used in this manual

Stay away from rotating and moving parts

Install protective covers on rotating parts Lockout and tagout

Be careful of exhaust fume poi- Be careful of falling down

Do not climb onto the engine

Always prepare stable scaffold

Be careful when handling fuel, en- Be careful of burns

Service battery When abnormality occurs

Never modify engine Never break the seals

Break-in the engine

Avoidance of prolonged time of starter Ventilation of engine room

Maintenance of warning labels

Tips on disassembling and assem- Tips on assembling

Chapter 2 SERVICE DATA

Chapter 3 SERVICE TOOLS

Chapter 4 OVERHAUL INSTRUCTIONS

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

Chapter 7 ASSEMBLY OF BASIC ENGINE

Chapter 8 FUEL SYSTEM

Chapter 9 Lubrication system

Chapter 10 Cooling system

Chapter 11 INLET AND EXHAUST SYSTEMS

Chapter 12 ELECTRICAL SYSTEM

Chapter 13 ADJUSTMENT AND OPERATION

Engine coolant outlet (To radiator)

Air outlet (To radiator)

Engine coolant inlet

Oil drain port Air inlet (From radiator)

Air inlet Air inlet

Oil drain port

Fuel filter Rear hanger

Front hanger Exhaust pipe,

Oil cooler Stop lever

Fuel injection pump

Fuel injection pump

Coolant drain cock

Fuel feed pump

Breather Fuel filter

Engine right view

2. System flow diagrams

Fuel leak-off pipe

Fuel injection nozzle

Fuel injection pump

Fuel feed pump

Fuel injection pipe To the right side of engine

From the right side of engine

Outline of fuel system

2.2 Outline of lubrication system

Oil thermostat Fuel injection pump

Safety valve Crankshaft

Outline of lubrication system

2.3 Outline of cooling system

Water pump Oil cooler Water jacket

Water outlet pipe

Bypass pipe Oil cooler Water jacket

Outline of cooling system

2.4 Outline of inlet and exhaust system

Exhaust Exhaust pipe

From pre-cleaner From pre-cleaner

Outline of inlet and exhaust system

Displacement Rear Front