Mitsubishi Heavy Industries S4S, Service Manual

Page 1: ...Printed in Japan Pub No Pub No SERVICE MANUAL SERVICE MANUAL July 2016 July 2016 99616 101A0 99616 101A0 ...

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Page 3: ...ntenance and also to take necessary measures which involves the disassembly inspection repair and reassembly of the engine and engine parts Read this manual carefully and understand the work procedures fully before disassembling inspecting repairing or reassembling the engine The contents of the manual are based on the engine models that are being produced at the time of publication Due to improve...

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Page 5: ...isassembly 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 identif...

Page 6: ... 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 Units of measurement Measurements are based on the International System of Units SI...

Page 7: ...e crankcase which can cause oil mist to ignite and explode Care about fuel oil and exhaust gas leakage If any fuel oil or exhaust gas leakage is found immedi ately take corrective measures to stop it Such leakages if left uncorrected can cause fuel or engine oil to reach hot engine surfaces or hot exhaust gas to contact flammable materials possibly leading to personal injury and or damage to equip...

Page 8: ...ch parts If any part of the clothing or outfit ting is caught by a rotating part se rious bodily injuries could result Lockout and tagout Be sure to lockout and tagout before starting inspection and maintenance Lockout and tagout are effective methods of cutting off machines and equipment from energy sources To accomplish the lockout tagout remove the starter switch key set the battery switch to O...

Page 9: ... gine running or just after the engine stops If the radia tor cap is not closed tightly steam and hot coolant may gush out and can cause scalds Add coolant only after the coolant tempera ture dropped Do not add coolant immediately after the engine stops Wait until the coolant temperature lowers sufficiently to avoid a risk of burns Be careful of exhaust fume poi soning Operate engine in well venti...

Page 10: ...cified in this manual and handle them carefully Use of any other fuel oil or LLC or improper handling may cause various engine problems and malfunctions Obtain the Material Safety Data Sheets MSDS issued by the fuel oil and LLC suppliers and follow the direc tions in the MSDSs for proper handling Handle LLC long life coolant carefully When handling LLC always wear rubber gloves and protective face...

Page 11: ...t away with plenty of clean fresh 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 When abnormality occurs Stop overheated engine after cooling run Even if the engine comes to overheat do not stop the engine immediately Abrupt stopping of an overheated engine can cause...

Page 12: ...ling speeds for 5 to 10 minutes for warming up Start the work after this operation is completed Warm up operation circulates the lubricant through the engine Therefore individual engine parts are well lu bricated before they are subjected to heavy loads This is very important for longer service life high perfor mance and economical operation Do not conduct warm up operation for a longer time than ...

Page 13: ... of tools optimum for each work Always keep in mind to select most appropriate tools for the work to be performed and use them correctly If tools are damaged replace with new tools Avoidance of prolonged time of starter oper ation Do not operate the starter for more than 10 seconds at a time even if the engine does not start Wait for at least 30 seconds before next engine cranking Continuous opera...

Page 14: ...o 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 fractured 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 War...

Page 15: ...aft Inspecting and repairing piston connecting rod crankshaft and crankcase 6 Reassembly of basic engine Reassembling piston connecting rod crankshaft and crankcase Reassembling timing gear and camshaft Reassembling flywheel Reassembling cylinder head and valve mechanism 7 Fuel system Removing fuel system Disassembling inspecting and reassembling fuel system Installing fuel system 8 Lubrication sy...

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Page 17: ...ction pump direct injection specification 1 7 2 2 Lubrication system flow diagram 1 8 2 2 1 S4S in line fuel injection pump specification 1 8 2 2 2 S4S DT in line fuel injection pump specification 1 8 2 2 3 S4S distributor type fuel injection pump specification 1 9 2 2 4 S4S DT distributor type fuel injection pump specification 1 9 2 3 Cooling system flow diagram 1 10 2 3 1 S4S 1 10 2 3 2 S4S DT 1...

Page 18: ...ht view Front Rear Fuei injection pump Oil filter Flywheel Fuel filter Oil drain plug Fan Oil level gauge Coolant drain plug Water pump coolant inlet Air inlet Fuel feed pump Stop solenoid Governor Crankshaft pulley Fuel inlet Fuel return pipe Front Rear Hanger Oil pan V belt Alternator Thermostat case Coolant outlet Hanger Starter Oil filler Exhaust outlet Flywheel housing ...

Page 19: ... filter Flywheel Fuel filter Oil drain plug Oil level gauge Coolant drain plug Water pump coolant inlet Fuel feed pump Stop solenoid Governor Crankshaft pulley Fuel inlet Fuel leak Front Rear Hanger Air inlet Hanger Oil filler Flywheel housing Starter Oil pan V belt Alternator Thermostat case Coolant outlet Turbocharger exhaust outlet ...

Page 20: ...leak Fan Water pump coolant inlet Fuel injection pump Crankshaft pulley Fuel inlet Oil drain plug Flywheel Oil filter Coolant drain plug Magnetic valve stop solenoid Oil level gauge Air inlet Front Rear Hanger Oil pan V belt Alternator Thermostat case Coolant outlet Hanger Oil filler Exhaust outlet Flywheel housing Starter ...

Page 21: ...t Rear Water pump coolant inlet Fuel injection pump Crankshaft pulley Oil drain plug Flywheel Oil filter Coolant drain cock Stop switch Oil level gauge Hanger Relief valve Fuel outlet Turbocharger exhaust outlet Front Rear Air inlet Flywheel housing Starter Oil pan V belt Alternator Thermostat case Coolant outlet ...

Page 22: ...uel system flow diagram 2 1 2 S4S DT in line fuel injection pump direct injection specification Fuel system flow diagram Fuel filter Fuel inlet Fuel leak off pipe Fuel injection nozzle Fuel injection pump Fuel return pipe Fuel filter Fuel inlet Fuel leak off pipe Fuel injection nozzle Fuel injection pump Fuel return pipe Fuel leak ...

Page 23: ...4S DT distributor type fuel injection pump direct injection specification Fuel system flow diagram Fuel filter Fuel inlet Fuel leak off pipe Fuel injection nozzle Fuel injection pump Fuel return pipe Fuel leak Fuel filter Fuel inlet Fuel leak off pipe Fuel injection nozzle Fuel injection pump Fuel return pipe Fuel leak ...

Page 24: ...Lubrication system flow diagram Pushrod Tappet Camshaft Idler gear Oil pump Piston Valve mechanism Relief valve Oil filter Oil strainer Oil pan Main gallery Crankshaft Fuel injection pump Oil jet Pushrod Tappet Camshaft Idler gear Oil pump Piston Valve mechanism Relief valve Oil filter Oil strainer Oil pan Main gallery Crankshaft Fuel injection pump Turbocharger Oil cooler Safety valve ...

Page 25: ...cification Lubrication system flow diagram Pushrod Tappet Camshaft Idler gear Oil pump Piston Valve mechanism Relief valve Oil filter Oil strainer Oil pan Main gallery Crankshaft Oil jet Pushrod Tappet Camshaft Idler gear Oil pump Piston Valve mechanism Relief valve Oil filter Oil strainer Oil pan Main gallery Crankshaft Turbocharger Oil cooler Safety valve ...

Page 26: ...ooling system flow diagram 2 3 2 S4S DT Cooling system flow diagram Water pump Water jacket Cylinder head Bypass pipe Cooling inlet Cooling outlet Thermostat Water pump Water jacket Cylinder head Bypass pipe Thermostat Oil cooler Cooling outlet Cooling inlet ...

Page 27: ...t and exhaust system flow diagram 2 4 2 Turbocharged engine Inlet and exhaust system flow diagram Inlet Exhaust Exhaust Blow by gas Inlet Air breather pipe blow by gas reduction Inlet Inlet Exhaust Exhaust Exhaust manifold Inlet manifold Discharge Blow by gas Turbocharger Air breather pipe ...

Page 28: ...GENERAL 1 12 3 Engine serial number location The engine serial number is stamped on the right side of crankcase Stamp location of engine serial number Engine serial number ...

Page 29: ... Width 593 mm 23 35 in 593 mm 23 35 in Height 710 mm 27 95 in 821 mm 32 32 in Dry weight 245 kg 540 lb 255 kg 562 lb Basic engine Cylinder Type Dry integral with cylinder block Piston ring Number of rings Compression rings 2 Oil ring w expander 1 Valve timing when warm Inlet valve Open BTDC 30 BTDC 18 Close ABDC 50 ABDC 54 Exhaust valve Open BBDC 74 BBDC 66 Close ATDC 30 ATDC 22 Starting system St...

Page 30: ...ater cooled multi plate Oil filter Type Cartridge type paper element Cooling system Cooling method Water cooled forced circulation Coolant capacity engine water jacket 5 5 L 1 45 U S gal Water pump Type Volute type centrifugal pump Speed ratio to crankshaft 1 3 varies depending on the specification Discharge capacity 160 L 42 27 U S gal min at pump rotation of 3600 min 1 0 75 MPa 7 5 kgf cm 106 67...

Page 31: ...n Speed in use 1000 to 18000 min 1 Rated generating speed 5000 min 1 Permissible speed 22000 min 1 Speed ratio to crankshaft 2 0 varies depending on the specification Glow plug Type Sheathed Rated voltage current 10 5V 9 7A 30 second duration 11V 5 5A 30 second duration Magnetic valve Stop solenoid option ETR type RUN ON Rated voltage 12V Rated thermometer 20 C 68 F Rated absorption current 55A Ra...

Page 32: ...51 lb Basic engine Cylinder Type Dry integral with cylinder block Piston ring Number of rings Compression rings 2 Oil ring w expander 1 Valve timing when warm Inlet valve Open BTDC 30 BTDC 18 Close ABDC 50 ABDC 54 Exhaust valve Open BBDC 74 BBDC 66 Close ATDC 30 ATDC 22 Internal EGR valve timing Inlet valve Open BBDC 10 varies depending on the specification Close ABDC 90 varies depending on the sp...

Page 33: ...9 78 7 11 psi Safety valve Opening pressure 1 1 MPa 11 kgf cm 157 psi Oil cooler Type Water cooled multi plate Oil filter Type Cartridge type paper element Cooling system Cooling method Water cooled forced circulation Coolant capacity engine water jacket 5 5 L 1 45 U S gal 5 5 L 1 45 U S gal Water pump Type Volute type centrifugal pump Speed ratio to crankshaft 1 3 varies depending on the specific...

Page 34: ...in 1 Rated generating speed 5000 min 1 Permissible speed 22000 min 1 Speed ratio to crankshaft 2 0 Glow plug Type Sheathed Rated voltage current 10 5V 9 7A 30 second duration 11V 5 5A 30 second duration Magnetic valve Stop solenoid ETR type RUN ON Rated voltage 12V Power consumption 20W Starting voltage 6 3V or below Return voltage 2 5V or more Coil resistance 8 Ω Table 1 2 Main specifications S4S...

Page 35: ...t losing them 4 Pay attention to assembling marks Put your marks on the parts if necessary to ensure correct reassembling 5 Carefully check each part for defects during disassembling or cleaning Do not miss symptoms which can not be detected after disassembling or cleaning 6 When lifting or carrying heavy parts exercise utmost caution to ensure safety Pay attention to balance of heavy parts when h...

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Page 37: ...m 2 8 2 Tightening torque table 2 9 2 1 Major bolt tightening torque 2 9 2 1 1 Basic engine 2 9 2 1 2 Fuel system 2 9 2 1 3 Lubrication system 2 10 2 1 4 Cooling system 2 10 2 1 5 Inlet and exhaust systems 2 10 2 1 6 Electrical system 2 10 2 2 Standard bolt and nut tightening torque 2 11 2 2 1 Metric automobile screw thread 2 11 2 2 2 Metric course screw thread 2 11 2 3 Standard stud tightening to...

Page 38: ...8 MPa 29 kgf cm 412 psi When oil and water temperatures at 20 to 30 C 68 to 86 F Direct injection 2 9 MPa 30 kgf cm 421 psi 2 6 MPa 27 kgf cm 377 psi Lubricating oil pressure Rotated speed at 1500 min 1 0 3 to 0 5 MPa 3 to 5 kgf cm 43 to 71 psi 0 15 MPa 1 5 kgf cm 21 psi Oil temperature at 70 to 90 C 158 to 194 F Idling speed 0 10 MPa 1 0 kgf cm 14 psi or more 0 05 MPa 0 5 kgf cm 7 psi Valve clear...

Page 39: ...3 9 to 14 1 0 547 to 0 555 Valve seat and valve Valve seat angle 30 Valve sinkage Inlet 0 4 0 016 0 3 to 0 5 0 012 to 0 020 1 0 0 039 Exhaust 0 5 0 020 0 4 to 0 6 0 016 to 0 024 1 0 0 039 Seat width 1 4 0 055 1 26 to 1 54 0 0496 to 0 0606 1 8 0 071 Valve margin 2 13 0 0839 Refacing permissible up to 1 83 0 0720 Valve spring Free length 48 85 1 9232 47 60 1 8740 Perpendicularity θ 1 5 or less Δ 1 3...

Page 40: ...045 to 0 085 0 0018 to 0 0033 0 150 0 0059 Oil ring 4 0 0 157 0 020 to 0 060 0 0008 to 0 0024 0 150 0 0059 Closed gap of ring No 1 compression ring 0 30 to 0 50 0 0118 to 0 0197 1 50 0 0591 No 2 compression ring 0 50 to 0 70 0 0197 to 0 0276 1 50 0 0591 Oil ring 0 30 to 0 50 0 0118 to 0 0197 1 50 0 0591 Piston pin Outside diameter ø 30 1 18 29 994 to 30 000 1 1809 to 1 1811 Clearance between pisto...

Page 41: ...2 1220 No 3 ø 53 2 09 52 94 to 52 96 2 0842 to 2 0850 52 90 2 0827 Clearance between camshaft journal and camshaft bushing 0 040 to 0 090 0 0016 to 0 0035 0 15 0 0059 Replace bushing if limit is exceeded Reaming if necessary End play 0 10 to 0 25 0 0039 to 0 0098 0 30 0 0118 Replace thrust plate Idler Clearance between bushing and shaft 0 009 to 0 050 0 0004 to 0 0020 0 100 0 0039 Idler gear end p...

Page 42: ...104 0 300 0 0118 Replace thrust plates before limit is reached If limit is exceeded use one of follow ing oversize thrust plates 0 15 0 0059 0 30 0 0118 Main bearing Clearance between main bearing and crank shaft journal 0 050 to 0 110 0 0020 to 0 0043 0 200 0 0079 crank journal outside diameter ø 78 3 0709 0 9 0 0354 Replace bearings before limit is reached Regrind crank journal and use next unde...

Page 43: ...tandard Limit Remark Oil pump Clearance between outer rotor and case 0 20 to 0 30 0 0079 to 0 0118 0 50 0 0197 Replace pump assembly Main shaft outside diameter between case ø 16 0 63 15 985 to 16 000 0 6293 to 0 6299 Main shaft outside diameter between oil pump bushing ø 14 0 55 13 957 to 13 975 0 5495 to 0 5502 Clearance between main shaft and pump case 0 032 to 0 074 0 0013 to 0 0029 0 150 0 00...

Page 44: ... 15 N 1 5 kgf Replace Pinion gap 0 5 to 2 0 Adjust by packing Nonload char acteristics Voltage 11V 23V Inspect Armature current 130A or below Rotational speed 3800 min 1 Alter nator 12V 50A Output charac teristics when hot Rotational speed min 1 1500 or less Inspect 2500 or less 33A or more 5000 or less 47A or more IC regulator controlled voltage 14 7 0 3V at 20 C 68 F Brush length 18 5 5 0 Replac...

Page 45: ...8 3 1 1 Front plate 8 1 25 11 3 1 5 1 15 0 15 8 3 1 1 Timing gear case cover 8 1 25 18 1 1 5 1 85 0 15 13 4 1 1 Crankshaft pulley 30 1 5 490 10 50 1 361 7 3 Idler thrust plate 10 1 25 34 5 3 5 0 5 25 3 6 Rocker adjusting nut 8 1 25 20 2 2 0 2 15 1 4 Table 2 9 Tightening torque table Fuel system Description Threads Dia Pitch mm Torque Remark N m kgf m lbf ft Fuel injection nozzle Swirl chamber 20 1...

Page 46: ...plug 1 4 18NPTF 39 2 3 9 4 0 4 28 9 2 8 Water pump mounting bolt 8 1 25 Tightening with water pump case cover 9 8 1 1 0 1 7 2 0 7 8 1 25 18 6 2 9 1 9 0 3 13 7 2 1 Water pump plug R3 8 32 4 2 3 3 0 2 23 9 1 4 Table 2 12 Tightening torque table Inlet and exhaust systems Description Threads Dia Pitch mm Torque Remark N m kgf m lbf ft Exhaust manifold bolt only 8 1 25 30 4 2 9 3 1 0 3 22 4 2 1 Exhaust...

Page 47: ...gth classification 4T 7T 10 9 N m kgf m lbf ft N m kgf m lbf ft N m kgf m lbf ft M6 1 0 10 0 39 3 9 0 4 2 9 8 8 0 9 6 5 12 7 1 3 9 4 M8 1 25 12 0 47 11 8 1 2 8 7 18 1 9 13 30 3 1 22 M10 1 25 14 0 55 21 1 2 15 16 35 3 6 26 60 6 1 44 M12 1 25 17 0 67 35 3 3 6 26 64 6 5 47 108 11 0 80 4 7 10 Table 2 15 Metric course screw thread Threads Dia Pitch mm Width across flats mm in Strength classification 7T...

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Page 49: ...3 1 SERVICE TOOLS 1 Special tool 3 2 ...

Page 50: ... Gauge adapter swirl chamber 30691 21100 Engine compression pressure measuring Gauge adapter direct injection 32A91 01100 Engine compression pressure measuring Socket 58309 73100 Engine turning Valve spring pusher 30691 04500 Valve spring removal installation Valve guide remover 32A91 00300 Valve guide removal Valve sheet insert caulking tool Inlet 36791 00200 Exhaust 34491 03020 Valve seat instal...

Page 51: ...ller 32A91 00100 Valve guide installation Camshaft bushing installer set 30691 00010 Camshaft bushing removal installation Idler bushing installer 30091 07300 Idler bushing removal installation Idler shaft puller MH061077 Idler shaft removal Piston ring pliers 31391 12900 Piston ring removal installation Table 3 1 Special tool list 2 3 Tool name Part No Shape Use ...

Page 52: ... installation Oil seal sleeve installer guide set 30691 13010 Oil seal sleeve installation of crankshaft rear side Piston installer 34491 00200 Piston installation Oil pump bushing installer 32A91 00400 Oil pump bushing installation Table 3 1 Special tool list 3 3 Tool name Part No Shape Use ...

Page 53: ...4 1 DETERMINATION OF OVERHAUL 1 Determining overhaul timing 4 2 2 Testing compression pressure 4 3 ...

Page 54: ...ressure 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 operati...

Page 55: ...inder head where the compression pressure is to be measured 2 Attach the compression gauge adapter to the glow plug mount and connect compression gauge 3 Crank the engine with the starter then read the compression gauge indication while the engine is running at the specified speed 4 If the compression pressure is lower than the limit overhaul the engine For direct injection type 1 Remove the injec...

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Page 57: ...8 3 4 Measuring timing gear backlash 5 9 3 5 Measuring idler gear and camshaft gear end play 5 9 3 6 Removing fuel injection pump 5 9 3 7 Removing oil pan 5 10 3 8 Removing oil strainer 5 10 3 9 Removing oil pump gear 5 10 3 10 Removing idler gear 5 11 3 11 Removing camshaft 5 11 3 12 Separating camshaft gear 5 11 3 13 Installing camshaft gear and thrust plate5 12 3 14 Removing front plate 5 12 3 ...

Page 58: ...20 Valve stem seal 7 Rocker arm IN 14 Cylinder head 21 Cylinder head gasket 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 21 19 20 Wear Check for cracks or carbon or scale deposits Check end faces for wear Check for bend Check for pitted or fracture coils Test force and length Check for wear Check oil hole for clogging Check threads for stripping Check surface that makes contact with valve push rod...

Page 59: ...ft Note a Be sure to arrange the parts of rocker shaft assembly in the order of disassembly Reassemble the rocker shaft assembly in the reverse order of disassembly by making sure of the original combination of rocker arm and shaft assembly so that the same clearance between the rocker shaft and arms is restored when reassembling b Do not remove the rocker bush when it is not faulty and its inside...

Page 60: ... gasket from the cylinder head Note If there is a cylinder head problem check the bolts for tightness with a torque wrench before removing the cylinder head bolts Removing cylinder head assembly 1 5 Removing valve and valve spring Using a valve spring pusher compress the valve spring evenly and remove the valve cotters Note If valves are reusable mark each valve seat and the mating valve for ident...

Page 61: ...lywheel Disassembling and inspecting flywheel Disassembling sequence 1 Flywheel 2 Flywheel housing Remove parts 2 and 3 as a unit 3 Oil seal 4 Gasket 4 2 3 1 Replace Damaged threads Lip wear damage or aging Crack knock hole defect gear damage Crack knock hole defect ...

Page 62: ...e of the bolt that has been removed 3 Remove remaining bolts from the flywheel 4 Remove the lock washer 5 Hold the flywheel firmly with both hands and by moving it back and forth pull it out straight Removing flywheel 2 2 Removing flywheel housing 87 21 Be careful not to damage the oil seal 1 Remove bolts from the flywheel housing 2 Screw a guide bolt into the threaded hole of the bolt that has be...

Page 63: ...f oil hole wear Wear damage Wear damage Lip wear damage or aging Clogged oil hole Crack abnormality of knock hole Worn belt groove Flaking uneven contact damage key groove defect abnormal wear bushings Flaking uneven contact damage key groove defect abnormal wear bushings 1 Crankshaft pulley 6 Oil strainer 11 Camshaft gear 2 Cover 7 Oil pump gear 12 Thrust plate 3 Timing gear case 8 Thrust plate 1...

Page 64: ... cover Unscrew the cover mounting bolts and dismount the cover Removing cover 3 3 Removing timing gear case 87 21 The front plate is bolted to the crankcase from inside the gear case Do not attempt to remove the front plate together with the gear case by tapping 1 Remove bolts from the timing gear case 2 Remove the timing gear case Note Bolts have different lengths Pay attention to the positions o...

Page 65: ...suring backlash timing gear 3 5 Measuring idler gear and camshaft gear end play Using a feeler gauge or dial gauge measure the end play of idler gear and camshaft gear If the measured value exceeds the limit replace the idler gear with the new gear Measuring idler gear and camshaft gear end play 3 6 Removing fuel injection pump 1 Remove the pump bracket mounting bolts 2 Unscrew the mounting bolts ...

Page 66: ...2 Remove bolts from the oil pan 3 To remove oil pan tap bottom corners of the oil pan with a plastic hammer Removing oil pan 3 8 Removing oil strainer 1 Remove the oil strainer mounting bolts 2 Remove the oil strainer from the crankcase Removing oil strainer 3 9 Removing oil pump gear 1 Remove the oil pump gear tightening nuts 2 Remove the oil pump gear Removing oil pump gear Bolt Oil pan Oil stra...

Page 67: ...rankcase 2 Remove the thrust plate bolt 3 Remove the camshaft from the crankcase 4 Remove the tappet Removing camshaft 3 12 Separating camshaft gear Using hydraulic press remove the camshaft gear and thrust plate from the camshaft Note Do not remove the camshaft gear from the camshaft unless the camshaft gear or the thrust plate is defective Separating gear from camshaft Idler gear Camshaft gear P...

Page 68: ... 302 F 3 Press fit the camshaft gear with press Installing camshaft gear and thrust plate 3 14 Removing front plate 1 Remove the front plate bolts 2 Remove the front plate from the crankcase Note If it is difficult to remove the front plate lightly tap it with a plastic hammer Removing front plate 3 15 Removing oil pump 1 Remove the oil pump mounting bolts 2 Remove the oil pump Removing oil pump P...

Page 69: ...19 Crankcase 6 Oil ring 13 Side seal 7 Snap ring 14 Thrust plate 1 2 3 10 11 14 13 12 14 15 14 17 19 16 18 4 5 6 8 7 9 Scratches on inside and outside surfaces seizing flaking Damaged threads Damaged threads Cracks Flaking uneven contact Scratches cracks dent clogged oil holes wear Wear Wear Wear damage Fatigue Wear clogged oil holes Cracks clogged oil holes Serration for cracks wear Surface scrat...

Page 70: ...of cylinder 87 21 Be sure to remove carbon deposits from the upper part of the cylinder before removing the piston as they could cause damage to the piston and piston ring Remove carbon deposits from the upper part of cylinder using a cloth or oil paper Note Be careful not to damage the inner surface of the cylinder Removing carbon deposits from the upper part of cylinder 4 3 Pulling out piston 1 ...

Page 71: ...arate the piston from the connecting rod Note a Do not tap the piston pin directly with a mallet b If the piston is stubborn heat the piston with a piston heater or in hot water Removing piston pin 4 6 Removing main bearing cap 1 Unscrew the main bearing cap bolts 2 Remove the main bearing cap Note a Be careful not to damage the main bearings b Mark the bearings for their cylinder numbers Removing...

Page 72: ...ir original positions are restored when reassembling Note a When raising the crankshaft do not allow wire chain to come into contact with the crankshaft To avoid damage to the crankshaft when raising use a cloth belt or pad b Mark the bearings for their cylinder numbers 4 8 Removing tappet Remove the tappets using a magnetic Note Be sure to arrange the removed tappets for reassembling to the same ...

Page 73: ...ler shaft 6 14 3 10 Measuring clearance between tappet and tappet guide hole 6 14 3 11 Inspecting tappet 6 14 3 11 1 Contact surface of camshaft 6 14 3 11 2 Contact surface of pushrod 6 14 3 12 Inspecting V belt groove wear 6 15 4 Inspecting and repairing piston connecting rod crankshaft and crankcase 6 16 4 1 Measuring crankcase top surface distortion 6 16 4 2 Measuring cylinder inside diameter 6...

Page 74: ...ne Measuring valve stem outside diameter Measuring valve guide inside diameter Item Nominal Standard Limit Rocker bushing inside diameter ø 19 mm 0 75 in 19 010 to 19 030 mm 0 7484 to 0 7492 in Rocker shaft outside diameter ø 19 mm 0 75 in 18 980 to 19 000 mm 0 7472 to 0 7480 in Clearance between rocker bushing and shaft 0 010 to 0 050 mm 0 0004 to 0 0020 in 0 070 mm 0 0028 in Measuring direction ...

Page 75: ...lve guide installer 1 To remove valve guides use a valve guide remover 2 To press fit valve guides use a valve guide installer 3 Check contacts between valves and valve seats after replacing valve guides Pulling out valve guide Press fitting valve guide Valve guide remover P N 32A91 00300 Valve guide installer P N 32A91 00100 14 0 1 mm 0 55 0 004 in Press ...

Page 76: ...ns of valve seat and valve 1 5 Refacing valve face If the valve face is significantly worn out reface the valve face using a valve refacer Note a Grind the valve face using the valve refacer at the specified angle b Secure the valve margin width equal to or greater than the limit If the dimensions after refacing does not meet the specified values replace the valve with a new one Refacing valve fac...

Page 77: ...rit sandpaper inserting it between the cutter and valve seat 2 Lap the valve in the valve seat Note a Valve seat refacing should be kept to an absolute minimum b If the valve seat width exceeds the limit due to wear or refacing replace the valve seat with a new one c If the valve sinkage exceeds the limit after refacing replace the valve seat with a new one Refacing valve seat Valve seat cutter ...

Page 78: ... diameter and valve seat outside diameter to make sure the interference meets the specified value 3 Cool the valve seat at least for four minutes in liquid nitrogen before fitting it into the cylinder head that is kept at room temperature 4 Fit the cold valve seat into the cylinder head using a insert caulking tool Replacing valve seat Valve seat fitting bore Driving in valve seat Valve seat Weld ...

Page 79: ...ittle by little 3 Wash off the compound using diesel fuel 4 Coat the contact surface of the valve with engine oil then lap the valve again 5 Check valve to seat contact Coating valve with lapping Lapping valve and valve seat 1 9 Measuring perpendicularity and free length of valve spring Measure the perpendicularity and free length of the valve spring If the limit is exceeded replace the valve spri...

Page 80: ...ng a feeler gauge If the measurement exceeds the limit grind the bottom face using a surface grinder Note Do not grind the surfaces more than 0 2 mm 0 008 in in total cylinder head bottom surface plus crankcase top surface Measuring distortion of the bottom surface of the cylinder head 1 11 Measuring pushrod runout Measure the runout of each pushrod Replace if the limit is exceeded Measuring pushr...

Page 81: ...0 24 in into glow plug hole and tap the combustion jet inner face perimeter lightly to pull out the combustion jet 2 When installing the combustion jet align the positioning hole and jet nozzle with the center of cylinder press fit with tapping by plastic hammer Removing combustion jet Press fitting combustion jet Round rod Combustion jet Combustion jet Jet nozzle ...

Page 82: ...r for a missing tooth or worn teeth and if defects are found replace the ring gear 2 4 Replacing ring gear 2 4 1 Removing ring gear 1 Heat the ring gear evenly using an acetylene torch or other appropriate heat source 2 With a rod placed on the periphery of ring gear tap the rod with a hammer evenly around the ring gear and remove the ring gear 2 4 2 Installing ring gear 1 Heat the ring gear evenl...

Page 83: ...he measured value exceeds the limit replace the idler gear with the new gear Measuring idler gear and camshaft gear end play 3 3 Measuring cam lift Measure the minor and major axes of cam to determine cam lobe lift If the lift is less than the limit replace the camshaft with a new one Measuring cam lift Item Standard Limit Timing gear backlash 0 05 to 0 15 mm 0 0020 to 0 0059 in 0 25 mm 0 0098 in ...

Page 84: ...e inside diameters of camshaft hole camshaft bushing if installed using a cylinder gauge If the limit is exceeds drive in the camshaft bushing If the camshaft bushing has already been installed replace the camshaft bushing with a new one Measuring camshaft hole bushing inside diameter Item Standard Limit Remark Camshaft runout 0 04 mm 0 0016 in or less 0 10 mm 0 0039 in TIR Item Standard Limit Cam...

Page 85: ...aller set so that the oil hole in the bushing aligns with the oil hole to the oil gallery Installing camshaft bushing 3 8 Measuring idler bushing inside diameter and idler shaft outside diameter Measure the idler bushing inside diameter and the idler shaft outside diameter If the inside diameter of idler gear bushing exceeds the limit replace the idler gear assembly with a new one If the outside d...

Page 86: ...n or damaged Contact surface of camshaft 3 11 2 Contact surface of pushrod 1 Apply Shinmyoutan or equivalent lead free coloring paste on the pushrod and check the contacts 2 Check that the pushrod contacts the tappet concentrically If it does replace the tappet and pushrod with new one Contact surface of pushrod Item Nominal Standard Interference between shaft and crankcase hole ø 35 mm 1 38 in 0 ...

Page 87: ...nd measure the sinkage of V belt If the wear appears excessive and the belt top surface sinks 1 6mm 0 06 in or more down from the top edge of groove replace the pulley with a new one If the pulley has two or more grooves for belt and the difference of the wear amount between grooves is significant replace the pulley with a new one Inspecting V belt groove wear 1 6 mm 0 06 in or more ...

Page 88: ...piston and valve Apply a straight edge to the top surface of the crankcase and measure its distortion using a feeler gauge If the distortion exceeds the limit grind the cylinder head using a surface grinder Note Do not overgrind the cylinder head as the piston protrusion deviates from the standard value Note Do not grind the surfaces more than 0 2 mm 0 0079 in in total cylinder head bottom surface...

Page 89: ...s worn unevenly select an oversize that ensures complete cylindericity when the cylinder is re bored to the maximum All cylinders must be re bored to the same oversize if one cylinder is re bored 5 If the cylinder has a slight wear and is reused after replacing only the piston rings remove the steps in worn portion in the upper part of the cylinder using a ridge reamer Hone it as necessary Measuri...

Page 90: ...imit is exceeded replace all the rings as a set Note Use a piston to push the piston ring squarely into the gauge or the sleeve Measuring piston ring end gap Item Nominal Standard Limit Piston outside diameter at piston skirt STD ø 94 mm 3 70 in 93 955 to 93 985 mm 3 6990 to 3 7002 in 93 770 mm 3 6917 in 0 25 mm 0 0098 in OS 94 205 to 94 235 mm 3 7089 to 3 7100 in 94 020 mm 3 7016 in 0 50 mm 0 019...

Page 91: ...is exceeded then replace the piston with a new one Measuring clearance between piston ring groove and piston ring 4 6 Measuring piston pin bore diameter and piston pin outside diameter Measure the piston pin bore diameter and piston pin outside diameter Replace if the limit is exceeded Measuring piston pin bore diameter and piston pin outside diameter Item Standard Limit Clearance between piston r...

Page 92: ...he top dead center 2 Apply the dial gauge plunger to the top surface of the crankcase and zero the dial gauge 3 Measure the protrusion at four points on the piston head and calculate the mean value Note Subtract the mean value from the thickness of the gasket compressed by tightening the cylinder head and the clearance between the piston top and cylinder head will be determined Measuring piston pr...

Page 93: ... If an undersize bearing is used grind the crankpin to the specified undersize Measuring connecting rod bearing inside diameter Measuring crankpin diameter 4 9 Measuring clearance between connecting rod bushing and piston pin Measure the inside diameter of the connecting rod bushing and the outside diameter of the piston pin Replace if the limit is exceeded Measuring connecting rod bushing inside ...

Page 94: ...place the connecting rod with a new one 2 In general a connecting rod aligner is used to check bend and twist Note Before checking bend tighten the connecting rod cap to the specified torque 3 To inspect the connecting rod with the piston installed turn the piston upside down and place it on a surface plate Insert a round bar having the same diameter as the crankpin into the big end bore and measu...

Page 95: ...e limit is exceeded replace the connecting rod with a new one Measuring connecting rod end play 4 14 Weight difference of connecting rod assembly in one engine 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 difference in connecting rod assembly Flaking Scratches Fusion Item Standard...

Page 96: ...nt value is below the limit grind the journal to fit the undersize bearing If the measurement value is below the service limit replace the crankshaft with a new one Measuring crankpin diameter Item Nominal Standard Limit Outside diameter ø 78 mm 3 07 in 77 955 to 77 970 mm 3 0691 to 3 0697 in 77 850 mm 3 0650 in Repair 77 100 mm 3 0354 in Replace Roundness 0 01 mm 0 0004 in or less 0 03 mm 0 0012 ...

Page 97: ... been reduced considerably re harden the crankshaft and check for flaws by means of magnetic particle inspection Ensure that the surface finish accuracy of the crankpins and journals is kept within the standard even after the correction by grinding Finished dimension of fillet R Item Undersize Finished size Crank journal 0 25 mm 0 0098 in 77 705 to 77 720 mm 3 0592 to 3 0598 in 0 50 mm 0 0197 in 7...

Page 98: ...th V blocks and measure the crankshaft runout at the center journal using a dial gauge If the runout deviates from the standard only slightly grind the crankshaft to repair If the runout exceeds the standard considerably straighten the crankshaft using a press If the limit is exceeded replace the crankshaft If the crankshaft has been repaired by grinding or pressing inspect the crankshaft for crac...

Page 99: ...the key on the crankshaft 2 Press fit the gear fully in alignment with the key Installing crankshaft gear 4 21 Inspecting oil seal contact surface Inspect the oil seal contact surface located on the crankshaft rear part If the crankshaft wears due to the oil seal replace the oil seal and the oil seal sleeve with new spare parts Inspecting oil seal contact surface 1 Crankshaft gear Puller P N MH061...

Page 100: ... 23 Removing oil seal sleeve 87 21 When making a cut in the sleeve be very careful not to damage the crankshaft with the chisel Make a cut at three locations on the periphery of the oil seal sleeve to reduce its tension To do so hold a chisel against the sleeve periphery in the radial direction and strike it with a hammer When the sleeve is loosened remove the sleeve If the sleeve can not be remov...

Page 101: ...rank journal 5 Calculate the clearance between the inside diameter of the main bearing and outside diameter of the crank journal 6 Replace the main bearing if the clearance exceeds the limit 7 Measure the clearance between the main bearing cap and the crank journal again Use the undersize bearing if the limit is exceeded 8 If an undersize bearing is used grind the crank journal to the specified un...

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Page 103: ...pump gear 7 10 2 7 Installing fuel injection pump 7 10 2 8 Inspecting and adjusting timing gear after installation 7 10 2 8 1 Inspecting backlash and end play 7 10 2 9 Installing front oil seal 7 11 2 10 Installing timing gear case 7 11 2 11 Installing oil strainer 7 11 2 12 Installing oil pan 7 12 2 13 Installing cover 7 13 2 14 Installing crankshaft pulley 7 13 3 Reassembling flywheel 7 14 3 1 I...

Page 104: ... the wood ruff key on the crankshaft 2 Make sure that the main bearing upper shells that are installed in the crankcase bores have their inner periphery the surface comes into contact with the journal lubricated with an even coat of fresh engine oil 3 Wash the crankshaft thoroughly with cleaning oil and dry it completely by blowing compressed air Then apply an even coat of fresh engine oil to the ...

Page 105: ...en bolts Installing main bearing cap 1 6 Inserting side seal 1 Apply a sealant to the outer periphery of new side seals 2 With the round section of the side seals facing outward press them partway into the front and rear caps using hands 3 When the side seals are installed partway into caps use a tool with flat surface such as to install completely taking care not to bend them Note Make sure that ...

Page 106: ...connecting rod shown in the illustration Note The pistons and piston pins are assembled to each other in clearance fit However the piston pins are more easily inserted into the pistons if the pistons are warmed up with a heater or in hot water 2 Using ring pliers install the snap ring Check the snap ring for its tension and make sure the ring fits snugly in the groove Note Install all the snap rin...

Page 107: ...he piston with a ring expander Piston piston ring orientation 2 Install the oil ring with its end gap 180 away from the joint of the coil spring as shown in the illustration Reassembling oil ring 1 11 Preparation for installing pistons 1 Lay the engine along its side 2 Clean the cylinder inner surface and the crank pin with a cloth and apply engine oil Cleaning cylinder inner surface and applying ...

Page 108: ...ons 87 21 Do not forcefully insert the piston as it may cause damage to the piston rings and crank pin 1 Apply engine oil to the circumference of the piston and piston rings 2 Orient the ring end gaps diagonally opposite each other avoiding the piston pin direction and its right angle direction 3 Turn the crankshaft to bring the crank pin of the cylinder to the bottom dead center 4 Orient the fron...

Page 109: ...ark facing on the same side as the match mark on the connecting rod 2 Tighten the connecting rod cap nuts evenly and progressively to the specified torque 3 Inspect end play of the connecting rod If end play is small loosen and retighten the cap nuts Installing connecting rod cap 54 5 N m 5 5 0 5 kgf m 40 3 6 lbf ft ...

Page 110: ...plate 1 Clean the mounting surface of the gasket 2 Apply sealant to the gasket to prevent it from falling 3 With aligning to the dowel pin install the gasket and the front plate 4 Secure the front plate with mounting bolts 5 Cut the gasket protruding from crankcase bottom side with cutter Installing front plate 1 Installing front plate 2 Oil pump O ring 11 3 1 5 N m 1 15 0 15 kgf m 8 3 1 1 lbf ft ...

Page 111: ...e specified torque 4 Make sure that the camshaft rotates lightly Move the camshaft gear back and forth and make sure there is end play Installing camshaft 2 5 Installing idler gear 1 Apply engine oil to the idler gear shaft 2 Install the idler gear with its match marks aligned with the marks on the crankshaft gear and camshaft gear 3 Attach the thrust plate to the idler gear and tighten the mounti...

Page 112: ...2 Tighten the fuel injection pump mounting bolts evenly Installing fuel injection pump 2 8 Inspecting and adjusting timing gear after installation Be sure to inspect and adjust the timing gear when the timing gear has been reassembled 2 8 1 Inspecting backlash and end play After installing the timing gears be sure to inspect and adjust the backlash and end play between gears Measuring idler gear e...

Page 113: ...wel pins install the gasket to the crankcase 2 Apply engine oil to the oil seal lip 3 Install the timing gear case and tighten the bolts 4 Cut the gasket protruding from crankcase bottom side with cutter Installing timing gear case 2 11 Installing oil strainer Set a new O ring to the oil strainer and install the oil strainer to the crankcase Installing oil strainer Installer Gasket 18 1 1 5 N m 1 ...

Page 114: ... oil pan to the crankcase within five minutes of applying the liquid gasket 4 Tighten the mounting bolts to the specified torque Note Cut the nozzle tip of the liquid gasket tube at the position shown on the right when squeezing the liquid gasket in a 4 mm 0 16 in diameter bead Liquid gasket application position Installing oil pan 1 Installing oil pan 2 Apply ThreeBond 1207C to all around oil pan ...

Page 115: ...ew two guide bolts into the threaded holes at the rear end of the crankshaft Place a bar across the two guide bolts so that the crankshaft does not turn 2 Install the crankshaft pulley and tighten the nuts to the specified torque Installing crankshaft pulley Cover Crankshaft pulley 490 10 N m 50 1 kgf m 361 4 7 3 lbf ft Guide bolt M12 1 25mm Front Rear The bar that prevnets crankshaft rotation ...

Page 116: ... when the flywheel housing is replaced replace the dowel pins with new ones Installing flywheel housing 3 3 Installing flywheel 87 21 The person who holds the pulley must be very careful to assure safety by communicating with the person who is installing the flywheel 1 One person must firmly hold the pulley with a wrench to prevent the crankshaft from turning 2 Screw the guide bolt into the rear e...

Page 117: ...ntact with the valve guide 1 Apply engine oil to the lip of new valve stem seal 2 Push the shoulder of the valve stem seal and fit the valve stem steal into the valve guide 3 Insert the valve stem seal into the valve guide using the valve stem seal installer Installing valve stem seal 4 3 Installing valve and valve spring 1 Install the valve spring and retainer on the valve guide Install the valve...

Page 118: ...the dowel pins on the crankcase top surface with guide Note a Be careful not to displace the cylinder head gasket when installing b Do not lift up cylinder head by one person Use crane or lift up by two persons Installing cylinder head assembly 4 6 Tightening cylinder head bolts In the numerical order as shown in the illustration tighten cylinder head bolts progressively to the specified torque Ti...

Page 119: ...t installed as it was the clearance becomes different and it may result in a defect such as wear increase 3 After reassembling make sure the rocker arm and oil pipe move freely Reassembling rocker shaft assembly 4 9 Installing rocker shaft assembly 1 Install the valve caps to the valve heads 2 Tighten the long bolts of the rocker bracket to the specified torque 3 Tighten the short bolts of the roc...

Page 120: ... the engine 3 Stop turing the crankshaft when 0 notch mark stamped on the crankshaft pulley is aligned with the pointer 4 At this position move the rocker arms of the inlet and exhaust valves for the No 1 cylinder up and down and make sure there is clearance that is the pushrods are not pushing the inlet and exhaust valves off their seats Determining top dead center of No 1 cylinder compression st...

Page 121: ... 4 12 Installing rocker cover 1 Make sure that the gasket is firmly installed into the rocker cover 2 Tighten the rocker cover mounting nuts to the specified torque Installing rocker cover 11 5 1 5 N m 1 15 0 15 kgf m 8 5 1 1 lbf ft ...

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Page 123: ...8 11 2 7 Inspecting fuel spray pattern of fuel injection nozzle 8 11 2 8 Cleaning and inspecting nozzle tip 8 12 2 9 Reassembling fuel injection nozzle swirl chamber type 8 13 2 10 Reassembling fuel injection nozzle direct injection type 8 14 2 11 Inspecting and cleaning gauze filter of distribute type fuel injection pump Bosch 8 15 3 Installing fuel system 8 16 3 1 Installing fuel injection pump ...

Page 124: ...r and injection pipe to prevent dust from entering the fuel system 1 1 Removing fuel filter and fuel pipe Removing fuel filter and fuel pipe Removing sequence 3 3 1 1 2 Filter for in line type fuel injection pump Filter for distributor type fuel injection pump 1 Fuel hose 2 Fuel filter bracket 3 Fuel filter ...

Page 125: ...uel leak off pipe and fuel injection nozzle in line type fuel injection pump Removing sequence 1 Fuel return pipe 5 No 4 fuel injection pipe 2 No 1 fuel injection pipe 6 Fuel leak off pipe swirl chamber specification Fuel hose direct injection specification 3 No 2 fuel injection pipe 4 No 3 fuel injection pipe 7 Fuel injection nozzle 1 1 2 3 4 5 2 3 4 5 6 6 7 7 Direct injection specification Swirl...

Page 126: ...zzle distributor type fuel injection pump Removing sequence 1 Fuel return pipe 5 No 4 fuel injection pipe 2 No 1 fuel injection pipe 6 Fuel leak off pipe swirl chamber specification Fuel hose direct injection specification 3 No 2 fuel injection pipe 4 No 3 fuel injection pipe 7 Fuel injection nozzle 1 2 3 4 5 6 7 1 2 3 4 5 6 7 Direct injection specification Swirl chamber specification Replace Repl...

Page 127: ...Removing fuel injection pump Removing fuel injection pump Removing sequence 1 Bracket 2 Fuel injection pump flange 3 Bracket 1 1 3 2 2 Distributor type fuel injection pump In line type fuel injection pump Replace Crankcase ...

Page 128: ... 1 Disassembling and inspecting fuel filter in line type fuel injection pump Disassembling and inspecting fuel filter in line type fuel injection pump Disassembling sequence 1 Filter element 2 Filter bracket 2 1 Crack and damaged threads Clogged cracks Replace Every 500 hrs ...

Page 129: ...assembling and inspecting fuel filter Disassembling and inspecting fuel filter Disassembling sequence 1 Level sensor 2 Filter element 3 Body 1 2 3 Crack and damaged threads Clogged cracks Replace Every 500 hrs Replace Replace ...

Page 130: ...e sure that the gasket is properly seated on the groove 51 1 Do not use the filter of which case has dents as it may be damaged during operation and cause fuel leakage that becomes fire hazard 9 Install the fuel filter element to the filter body 87 21 Be careful not to dent or damage the fuel filter case 10 Using new O ring install the level sensor to the fuel filter element 11 After completion of...

Page 131: ...g and inspecting fuel injection nozzle swirl chamber type Disassembling sequence 1 Nozzle retaining nut 4 Pressure pin 7 Nozzle holder 2 Nozzle tip assembly 5 Pressure spring 8 Gasket 3 Distance piece 6 Washer 4 5 6 7 8 1 2 3 Settling breakage Wear damage Carbon deposit nozzle hole clogging Wear Replace ...

Page 132: ...embling and inspecting fuel injection nozzle direct injection type Disassembling sequence 1 Nozzle retaining nut 4 Straight pin 7 Shim 2 Nozzle tip assembly 5 Pressure pin 8 Nozzle body 3 Tip packing 6 Pressure spring 4 5 6 7 8 1 2 3 Wear damage Carbon deposit clogged spay holes Wear Fatigue breakage ...

Page 133: ...esults in a change in the fuel injection pressure by 1 0 MPa 10kgf cm 142 psi There are ten kinds of shim from 1 25 to 1 70 mm 0 0492 to 0 0669 in Inspecting fuel injection nozzle with nozzle tester 2 7 Inspecting fuel spray pattern of fuel injec tion nozzle 1 When adjusting the nozzle opening pressure using the nozzle tester check for nozzle hole condition and fuel spray pattern 2 Checking points...

Page 134: ...em carefully and do not change the combination of the valve and body 3 Tighten the nozzle tip tightening retainer nut to the specified torque 4 If the spray pattern is still faulty after cleaning and adjusting change the nozzle tip with a new one Note New nozzle tips are coated with vaseline to prevent from rusting Wash if off in a clean gas oil before installation Replacing fuel injection nozzle ...

Page 135: ...YSTEM 8 13 2 9 Reassembling fuel injection nozzle swirl chamber type Reassembling fuel injection nozzle swirl chamber type 36 7 2 5 N m 3 75 0 25 kgf m 27 1 1 8 lbf ft 58 9 5 9 N m 6 0 6 kgf m 43 4 4 3 lbf ft ...

Page 136: ...FUEL SYSTEM 8 14 2 10 Reassembling fuel injection nozzle direct injection type Reassembling fuel injection nozzle direct injection type 29 4 5 N m 3 0 5 kgf m 21 7 3 6 lbf ft ...

Page 137: ...he fuel in the injection pump and remove the fuel hose and fuel pipe 3 Remove the spring with a tweezer 4 Remove the gauze filter with a tweezer Note When removing the gauze filter be careful not to damage the metal mesh of the gauze filter 5 Remove the dirt and dust from the gauze filter cleaning with compressed air or diesel fuel When damage is found or when the gauze filter is still dirty after...

Page 138: ...UEL SYSTEM 8 16 3 Installing fuel system 3 1 Installing fuel injection pump Installing fuel injection pump Distributor type fuel injection pump In line type fuel injection pump Replace Replace Crankcase ...

Page 139: ...check the top dead center Remove the delivery valve holder delivery valve spring and stopper from the No 1 cylinder of the fuel injection pump and reinstall the delivery valve holder only 2 Install a spare injection pipe to the No 1 plunger of the fuel injection pump Face the other end of the injection pipe to downward so that the fuel flow out condition can be seen clearly 3 Rotate the crankshaft...

Page 140: ...ssion stroke Make sure that the marks on the flange plate and the fuel injection pump body are aligned 1 Remove the gear case cover Removing gear case cover 2 Attach the turning socket to the pulley nut and turn the crankshaft in the normal direction clockwise as viewed from the front end Turning engine 3 Stop turning the crankshaft when the marks of the fuel injection pump gear and idler gear are...

Page 141: ...a When changing parts be sure to use our desig nated parts Unless our designated parts are used the exhaust emission regulations cannot be met b Take care that the parts may be partly modified due to improvement for example c Work related to the exhaust emission regulations can be conducted only at our designated service factories However do not change the adjustment by cutting and removing the ta...

Page 142: ...e nut 11 Install the support bracket A onto the fuel injection pump 12 Install the support bracket B onto the support bracket A and temporary tighten with through bolt and nut Alignment mark of fuel injection pump 13 By aligning the timing marks of the fuel injection pump gear and the idler gear install the fuel injection pump to the front plate Match mark of gears 14 Install the gear case cover 1...

Page 143: ... fuel leak off pipe and fuel injection nozzle in line type fuel injection pump Installing fuel injection pipe fuel leak off pipe and fuel injection nozzle in line type fuel injection pump Direct injection specification Swirl chamber specification Replace Replace 58 9 5 9 N m 6 0 6 kgf m 22 6 2 N m 2 3 0 2 kgf m 22 1 N m 2 2 0 2 kgf m ...

Page 144: ...e distributor type fuel injection pump Installing fuel injection pipe fuel leak off pipe and fuel injection nozzle distributor type fuel injection pump Direct injection specification Swirl chamber specification Replace Replace 58 9 5 9 N m 6 0 6 kgf m 22 6 2 N m 2 3 0 2 kgf m 22 1 N m 2 2 0 2 kgf m ...

Page 145: ...FUEL SYSTEM 8 23 3 5 Installing fuel filter and fuel pipe Installing fuel filter and fuel pipe Filter for in line type fuel injection pump Filter for distributor type fuel injection pump ...

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Page 147: ...or and pump case9 6 2 2 3 Measuring clearance between outer rotor and pump case 9 6 2 2 4 Measuring clearance between main shaft and pump case 9 7 2 2 5 Measuring clearance between main shaft and bushing 9 7 2 2 6 Installing oil pump bushing 9 7 2 3 Reassembling oil pump 9 8 2 4 Disassembling and inspecting oil cooler 9 9 2 5 Inspecting oil filter 9 10 2 6 Inspecting relief valve 9 11 2 7 Inspecti...

Page 148: ...LUBRICATION SYSTEM 9 2 1 Removing lubrication system 1 1 Removing oil filter and relief valve Removing oil filter and relief valve Removing sequence 1 Oil filter 2 Relief valve 2 1 Replace Replace ...

Page 149: ...LUBRICATION SYSTEM 9 3 1 2 Removing oil cooler Removing oil cooler Removing sequence 1 Oil cooler assembly 2 Oil cooler gasket 1 2 Replace Replace ...

Page 150: ...YSTEM 9 4 1 3 Removing oil pump oil pan and oil strainer Removing oil pump oil pan and oil strainer Removing sequence 1 Oil pump 2 Oil pan 3 Oil strainer 4 Safety valve for the engine with oil cooler 1 2 3 4 Replace ...

Page 151: ... 5 2 Disassembling inspecting and reassembling lubrication system 2 1 Disassembling and inspecting oil pump Disassembling oil pump Disassembling sequence 1 O ring 2 Shaft assembly 3 Outer rotor 4 Pump case 1 2 3 4 Replace ...

Page 152: ... play of rotor and pump case 2 2 3 Measuring clearance between outer rotor and pump case Measure the clearance between the outer rotor and the pump case If measured value exceeds the limit replace the oil pump with new one Measuring clearance between outer rotor and pump case Item Standard Limit Clearance between outer rotor and inner rotor 0 13 to 0 15 mm 0 0051 to 0 0059 in 0 20 mm 0 0079 in Thi...

Page 153: ...ling oil pump bushing 87 21 Install the oil pump bushing in the crankcase so that it is even with the front face of the crankcase Install the oil pump bushing by using the oil pump bushing installer Installing oil pump bushing Item Standard Limit Main shaft outside diameter between case 15 985 to 16 000 mm 0 6293 to 0 6299 in Clearance between main shaft and pump case 0 032 to 0 074 mm 0 0013 to 0...

Page 154: ...LUBRICATION SYSTEM 9 8 2 3 Reassembling oil pump Reassembling oil pump Flush Flush ...

Page 155: ...N SYSTEM 9 9 2 4 Disassembling and inspecting oil cooler Disassembling and inspecting oil cooler Disassembling sequence 1 Oil cooler case 2 Oil cooler element 2 1 Crack deformation Replace Clogging crack Replace ...

Page 156: ...LUBRICATION SYSTEM 9 10 2 5 Inspecting oil filter Inspecting oil filter Apply engine oil to the gasket when installing Clogged cracks Replace Every 250 hrs ...

Page 157: ...ing safety valve for the engine with oil cooler 1 Check the safety valve and its seat for contact Check the spring for fatigue and damage If faulty or damaged replace the part 2 Measure the safety valve opening pressure If the pressure does not fall within the standard range replace the spring with a new one Inspecting safety valve Item Standard Relief valve opening pressure 0 35 0 05 MPa 3 5 0 5 ...

Page 158: ... lubrication system 3 1 Installing oil pump oil pan and oil strainer Installing oil pump oil pan and oil strainer Replace 11 3 1 5 N m 1 15 0 15 kgf m 8 3 1 1 lbf ft 69 5 N m 7 0 5 kgf m 50 6 3 6 lbf ft 39 5 N m 4 0 5 kgf m 29 3 7 lbf ft ...

Page 159: ...LUBRICATION SYSTEM 9 13 3 2 Installing oil cooler Installing oil cooler Replace Replace ...

Page 160: ...LUBRICATION SYSTEM 9 14 3 3 Installing oil filter and relief valve Installing oil filter and relief valve Replace Replace 49 5 N m 5 0 5 kgf m 36 1 3 6 lbf ft ...

Page 161: ... 4 2 Disassembling inspecting and reassembling cooling system 10 5 2 1 Disassembling and inspecting thermostat10 5 2 2 Inspecting thermostat 10 6 2 3 Disassembling water pump 10 7 2 4 Inspecting water pump 10 7 3 Installing cooling system 10 8 3 1 Installing water pump 10 8 3 2 Installing thermostat 10 9 3 3 Installing cooling fan fan pulley and V belt 10 10 ...

Page 162: ...NG SYSTEM 10 2 1 Removing cooling system 1 1 Removing cooling fan fan pulley and V belt Removing cooling fan fan pulley and V belt Removing sequence 1 Plate 3 V belt 2 Cooling fan 4 Water pump pulley 1 2 3 4 ...

Page 163: ...COOLING SYSTEM 10 3 1 2 Removing thermostat Removing thermostat Removing sequence 1 Hose 2 Thermostat assembly 3 Gasket 1 2 3 Replace Crack water leakage damage Crack deterioration damage ...

Page 164: ...COOLING SYSTEM 10 4 1 3 Removing water pump Removing water pump Removing sequence 1 Water pump assembly 2 Gasket 1 2 Replace Crack deformation damage ...

Page 165: ...ssembling inspecting and reassembling cooling system 2 1 Disassembling and inspecting thermostat Disassembling thermostat Disassembling sequence 1 Thermostat cover 2 Gasket 3 Thermostat 4 Thermostat case 1 2 3 4 Replace Replace ...

Page 166: ...the table below If the temperatures are not within the standard range replace the thermostat Note a Stir the water in the container with a stick to ensure uniform temperature distribution b Before installing the thermostat be sure to check the valve opening temperature stamped on the thermostat valve side face Inspecting thermostat Item Standard Temperature at which valve starts opening 76 5 1 5 C...

Page 167: ...nspecting water pump Check to make sure that the impeller and shaft of water pump rotate smoothly without noise and irregularities If faulty replace the assembly 1 Water pump cover 2 Gasket 3 Water pump 1 2 3 Replace Crack water leakage damage impeller and shaft rotation Crack water leakage deformation ...

Page 168: ...r pump Installing water pump 32 4 2 N m 3 3 0 2 kgf m 23 9 1 4 lbf ft Water pump and crankcase fixing bolts 5 18 6 2 9 N m 1 9 0 3 kgf m 13 7 2 1 lbf ft Water pump and water pump cover fixing bolts 3 9 8 1 N m 1 0 1 kgf m 7 2 0 7 lbf ft Replace Crack deformation damage ...

Page 169: ...COOLING SYSTEM 10 9 3 2 Installing thermostat Installing thermostat 18 1 1 5 N m 1 85 0 15 kgf m 13 4 1 1 lbf ft Replace Crack water leakage damage Crack deterioration damage ...

Page 170: ...lling cooling fan fan pulley and V belt Installing cooling fan fan pulley and V belt 87 21 Inspect and adjust the V belt within 200 hours opera tion Depending on the operating condition inspecting and adjusting interval may shorten ...

Page 171: ...et manifold 11 3 1 3 Removing exhaust manifold 11 4 2 Disassembling inspecting and reassembling inlet and exhaust systems 11 5 2 1 Measuring exhaust manifold distortion 11 5 3 Installing turbocharger inlet and exhaust systems 11 6 3 1 Installing exhaust manifold 11 6 3 2 Installing inlet manifold 11 7 3 3 Installing turbocharger 11 8 ...

Page 172: ... 11 2 1 Removing turbocharger inlet and exhaust systems 1 1 Removing turbocharger Removing turbocharger Removing sequence 1 2 3 5 4 A A Replace Replace Replace Replace 1 Oil pipe 3 Air hose 5 Turbocharger 2 Oil pipe 4 Air pipe ...

Page 173: ...INLET AND EXHAUST SYSTEMS 11 3 1 2 Removing inlet manifold Removing inlet manifold Removing sequence 1 2 Replace Replace 1 Air inlet elbow 2 Inlet manifold ...

Page 174: ...INLET AND EXHAUST SYSTEMS 11 4 1 3 Removing exhaust manifold Removing exhaust manifold Removing sequence 1 Replace 1 Exhaust manifold ...

Page 175: ... 1 Measuring exhaust manifold distortion 1 Check the flange for crack 2 Check the flange surface for distortion If the distortion exceeds the standard retouch the surface Measuring exhaust manifold distortion Item Standard Exhaust manifold distortion 0 2 mm 0 008 in or less Straight edge Thickness gauge ...

Page 176: ... 6 3 Installing turbocharger inlet and exhaust systems 3 1 Installing exhaust manifold Installing exhaust manifold Replace 30 4 2 9 N m 3 1 0 3 kgf m 22 4 2 1 lbf ft bolt only 18 5 3 5 N m 1 9 0 3 kgf m 13 6 2 5 lbf ft with spacer ...

Page 177: ...INLET AND EXHAUST SYSTEMS 11 7 3 2 Installing inlet manifold Installing inlet manifold Replace Replace ...

Page 178: ...INLET AND EXHAUST SYSTEMS 11 8 3 3 Installing turbocharger Installing turbocharger Replace Replace Replace Replace A A 16 2 2 4 N m 1 6 0 2 kgf m 11 9 1 7 lbf ft 4 1 N m 0 4 0 1 kgf m 3 0 7 lbf ft ...

Page 179: ...Inspecting magnetic switch 12 15 2 4 Reassembling starter 12 16 2 4 1 Installing gear shaft 12 16 2 5 Disassembling and inspecting alternator12 17 2 5 1 Separating front bracket from stator 12 18 2 5 2 Removing pulley 12 18 2 5 3 Removing rear bearing 12 18 2 5 4 Removing front bearing 12 18 2 5 5 Removing stator 12 19 2 5 6 Removing regulator assembly 12 19 2 5 7 Removing rectifier assembly 12 19...

Page 180: ...ELECTRICAL SYSTEM 12 2 1 Removing electrical system 1 1 Removing starter Removing starter Removing sequence 1 3 2 1 Harness 2 Nut 3 Starter ...

Page 181: ...d E terminal is negative 2 Do not use any high voltage tester such as 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 For a built in IC regulator type 6 When a steam cleaner is used do not allow the ...

Page 182: ...ELECTRICAL SYSTEM 12 4 1 3 Removing alternator 12V 50A Removing alternator 12V 50A Removing sequence 1 Alternator 2 Adjusting plate 3 bracket 2 1 3 ...

Page 183: ...ELECTRICAL SYSTEM 12 5 1 4 Removing alternator 12V 75A option Removing alternator 12V 75A option Removing sequence 1 Alternator 2 Adjusting plate 3 bracket 2 1 3 ...

Page 184: ...ELECTRICAL SYSTEM 12 6 1 5 Removing glow plug Removing glow plug Removing sequence 1 2 3 1 2 3 Direct injection specification Swirl chamber specification 1 Nut 2 Connection plate 3 Glow plug ...

Page 185: ...n in the illustration The magnetic switch is normal if the pinion springs out when the switch is turned ON Pull in test 3 Holding test Connect the starter to the circuit as shown in the illustration Pull out the pinion fully by hand The magnetic switch is normal if the pinion does not return when it is released Holding test 4 Return test Connect the starter to the circuit as shown in the illustrat...

Page 186: ...t during operation 1 Connect the starter to the circuit as shown in the illustration 2 In normal condition the pinion pops out when the switch is turned ON and the starter rotates at more than the specified rotation speed If the terminal voltage current or rotation speed does not meet the standard disassemble inspect and repair the starter Test at no load Ammeter Battery Volt meter Switch A V 24V ...

Page 187: ...10 Gear 16 Front bracket 5 Yoke assembly 11 Lever assembly 17 Bearing 6 Armature 12 Washer set 18 Oil seal Replace Replace 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Check gear for worn or damaged teeth Pole and coil installation conditions Check for slippage or seisure Accumulation of brush dust uneven wear or sticking in holder Surface clearness of commutator seizure wear worn or damaged gear ...

Page 188: ...e rotation of the armature and the pinion 3 Place an appropriate tube on the pinion stopper Tap the tube with a hammer to drop the pinion stopper to the clutch side This will expose the stopper ring 4 Remove the stopper ring with pliers and remove the pinion Note Do not reuse the stopper ring for reassembly Connection to move the pinion forward Removing pinion SW1 SW2 Battery 12V Disconnect lead w...

Page 189: ...from the internal gear 3 Remove the packing and plate on the lever support 4 Remove the ball from the internal gear 5 Remove the planetary gears Disassembling starter 1 Disassembling starter 2 2 2 5 Removing overrunning clutch Pull out the internal gear gear shaft overrunning clutch and lever as an assembly from the front bracket and remove the lever Disassembling starter 3 Magnetic switch Rear br...

Page 190: ...If continuity is observed replace the whole brush holder assembly Check the brush holders for looseness 2 3 4 Measuring commutator radial runout 1 Inspect the commutator surface If the surface is rough polish it using a 400 to 600 grit sandpaper 2 Measure the commutator radial runout with a dial gauge If the measured value exceeds the limit replace the armature with a new one Inspecting brushes fo...

Page 191: ... Checking armature coil 1 Inspect the armature coil using a growler Hold a piece of iron plate against the armature core If the iron plate vibrates replace the armature with a new one Inspecting armature coil for short circuit 2 Check that there is no continuity between the commutator and the shaft core If any continuity is observed replace the armature with a new one Inspecting insulation between...

Page 192: ...is defective replace the yoke with a new one Inspecting field coil 2 3 9 Inspecting rear bracket Replace the rear bracket if the bearing is worn 2 3 10 Inspecting overrunning clutch 87 21 Do not clean the overrunning clutch 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 Inspecting overrunning clutch...

Page 193: ...oil Check the continuity between terminal S and terminal M also check the continuity between terminal S and ground If continuity is not exist the coil is open circuit 2 Adhesion of contactor Check that there is no continuity between terminal B and terminal M If continuity is exist the contactor are welded closed Inspecting magnetic switch Terminal B Terminal M Terminal S ...

Page 194: ... the gear shaft into the overrunning clutch Installing gear shaft Pinion shaft gear Pinion Oil seal Armature shaft gear Reduction gear 9 8 2 0 N m 1 0 2 0 kgf m 7 1 5 0 lbf ft Pinion shaft bearing Armature rear side bearing Apply small amount of grease be sure not to allow entering grease into commutator Magnetic switch lever thrust part Gear shaft Driven gear Internal gear Overrunning clutch ...

Page 195: ...tifier assembly 2 Pulley spacer 6 Stator 10 Nut set 3 Screw 7 Rear bracket 4 Front bracket assembly 8 Regulator assembly 1 2 3 4 6 9 7 8 10 5 Crack damage Rotation Deformation and damage Broken wire and ground of coil Rotation Crack damage Sliding state and wear of brushes Dirt damage and seizure of slip ring and coil resistance Short circuit and open circuit ...

Page 196: ...a vise be sure to hold the base of the rotor claw Do not hold the rotor claw as it causes damage to the claw 1 Apply a cloth to the rotor and set it in a vise 2 Remove the pulley nut and then pull out the pulley Removing pulley 2 5 3 Removing rear bearing Remove the rear bearing from the rotor using a bearing puller Removing rear bearing 2 5 4 Removing front bearing Remove the screw and then remov...

Page 197: ...ectifier Removing stator 2 5 6 Removing regulator assembly Remove the screws of the regulator assembly and then remove the regulator assembly Removing regulator assembly 2 5 7 Removing rectifier assembly 1 Remove the screw and nut from the rectifier 2 Remove the rectifier assembly Removing rectifier assembly Soldering Rectifier Stator core Screws Regulator assembly Screw Rectifier assembly Rear br...

Page 198: ...nificantly lower than the current that normally flows in the rectifier by which the accurate resistance may not be measured using a tester and this tendency is noticeable if the measuring range is small Inspecting rectifier 2 6 2 Inspecting rotor assembly 1 Measure the resistance between the slip rings rotor coil If measured value is out of standard replace the rotor assembly with a new one 2 Chec...

Page 199: ...here is no continuity between each lead wire and the stator core If continuity is observed replace the stator Note The core cannot be replaced as a single item Checking for continuity between leads Checking for grounding between the leads and the core 2 6 4 Inspecting brushes for wear Measure the length of the brushes If the measured value is less than the limit replace both the brush holder assem...

Page 200: ...hes 1 To remove the brush and the spring unsolder the brush lead 2 To install a new brush push the brush into the brush holder as shown in the illustration and then solder the lead to the brush Replacing brushes Installing brushes Soldering Brush ...

Page 201: ...tor Reassembling alternator 2 7 1 Installing rectifier assembly and regulator assembly Install the rectifier assembly and regulator assembly on the rear bracket Removing rectifier assembly and regulator assembly Regulator assembly Regulator assembly ...

Page 202: ...ont bracket and secure the bearing retainer with a screw Installing front bearing 2 7 4 Installing rear bearing Press fit the rear bearing to the rotor Installing rear bearing 2 7 5 Installing pulley 1 Insert the rotor into the front bracket Apply a cloth to the rotor and set it in a vise 2 Install the spacer and pulley and secure the pulley with a nut Installing pulley Soldering Rectifier Stator ...

Page 203: ...t the brushes with a piece of wire inserted through the small hole in the bracket After installation remove the wire 2 Assemble the front bracket stator and rear bracket and secure them with through bolts Securing brushes Installing stator and front bracket Wire Rear bracket Brush Through bolt Stator core Front bracket ...

Page 204: ...ake sure the current flow stops when the starter switch is turned to the ON or OFF position 2 Make sure the indicator becomes red hot in 34 to 44 seconds after the starter switch is turned to HEAT position If the indicator becomes red hot too fast or does not heat check the indicator and air heater for shorting and an open circuit using a tester Inspecting air heater Item Rated voltage Armature cu...

Page 205: ... magnetic valve 2 10 2 Inspecting magnetic valve stop solenoid operation Check visually for rubber strips of the tip of the armature and damages Also check the armature moves smoothly by rotating with a hand Inspecting magnetic valve operation 2 11 Installing magnetic valve stop solenoid Install the magnetic valve assembly to the distributor with the specified torque Installing magnetic valve Item...

Page 206: ...gize the stop solenoid and move the stop lever to the operating position Adjust the length of the rod to make the clearance between the stop lever and the operating position stopper screw to 1 5 1 mm and secure it by the nut 4 After installing the stop solenoid energize the stop solenoid again to check that the stop solenoid operates normally Installing stop solenoid 1 Installing stop solenoid 2 S...

Page 207: ...ling glow plug Installing glow plug Direct injection specification Swirl chamber specification 25 5 N m 2 5 0 5 kgf m 18 3 6 lbf ft 1 3 0 3 N m 0 13 0 03 kgf m 0 96 0 22 lbf ft 17 2 2 5 N m 1 75 0 25 kgf m 12 7 1 8 lbf ft 1 3 0 3 N m 0 13 0 03 kgf m 0 96 0 22 lbf ft ...

Page 208: ...ELECTRICAL SYSTEM 12 30 3 2 Installing alternator 12V 50A Installing alternator 12V 50A ...

Page 209: ...ELECTRICAL SYSTEM 12 31 3 3 Installing alternator 12V 75A option Installing alternator 12V 75A option ...

Page 210: ...ELECTRICAL SYSTEM 12 32 3 4 Installing starter Installing starter Terminal B 9 8 2 0 N m 1 0 2 0 kgf n 7 1 5 0 lbf ft ...

Page 211: ...ump 13 5 1 4 Inspecting V belt and adjusting V belt tension 13 6 1 5 Inspecting V belt 13 6 1 6 Adjusting V belt tension 13 6 2 Break in operation 13 7 2 1 Starting up 13 7 2 2 Inspecting engine condition after starting up 13 7 2 3 Break in operation time 13 7 2 4 Inspection and adjustment after break in operation 13 7 3 Performance test JIS standard 13 8 3 1 Engine equipment condition 13 8 3 2 Te...

Page 212: ...n the timing gear case and neither the inlet valve nor the exhaust valve is not lifted off its seat by the push rod 3 Insert a thickness gauge between the rocker arm and valve cap to inspect the clearance Turning engine Determining top dead center of No 1 cylinder compression stroke 1 1 2 Adjusting valve clearance 1 Insert the feeler gauge of the specified thickness between the rocker arm and valv...

Page 213: ...f the fuel filter exceeds the specified level the water may enter into the fuel system Bleed the fuel filter of water in the following procedures 1 2 1 Draining fuel filter 1 Loosen the drain plug on the bottom of the fuel filter 2 Water is easily drained by pressing the manual feed pump repeatedly approx 7 times to feed the fuel 3 Tighten the drain plug securely after draining the water 4 Bleed t...

Page 214: ...in line fuel injection pump 1 Loosen the air vent plugs for the injection pumps approx 1 5 turns 2 Move the cap up and down repeatedly 3 When fuel flowing from the vent holes no longer contains air bubbles tighten the air vent plugs Before tightening the last air vent plug lock the priming pump cap by turning it clockwise while pushing it down 4 Follow the same procedure for the fuel injection pum...

Page 215: ...l filter with a wrench 2 Repeatedly press the priming pump with the cloth applied to the air vent plug 3 When fuel with air bubbles no longer comes out tighten the air vent plug securely Bleeding fuel filter distributor type fuel injection pump 1 Bleeding fuel filter distributor type fuel injection pump 2 Air vent plug Priming pump ...

Page 216: ...ually for separation or damage If any abnormality is found replace the V belt with a new one 2 Inspect V belt tension deflection When pressing the V belt strongly at the center of its span the deflection should be 8 mm 0 31 in Force on the V belt Approx 98 N 10 kgf 22 lbf If the deflection of V belt is not within the standard adjust the V belt tension 1 6 Adjusting V belt tension 1 Loosen all reta...

Page 217: ...nd take appropriate measures 1 The oil pressure must be within the specified value 2 The coolant temperature must be within the specified value 3 The engine must be free from any leakages such as oil coolant and fuel Pay special attention to oil leakage from the fitting face of turbocharger lube oil pipe 4 Check for an abnormal noise Note Knocking noise will disappear as the coolant temperature ri...

Page 218: ... conditions 3 2 2 Continuous load test Operate the engine continuously for 10 hours at 90 load continuous load application of nominal net brake power while the engine speed is maintained at revolutions corresponding to the nominal brake power In this test evaluate the fuel consumption rate and operating condition and confirm that the engine is capable of continuous operation 3 2 3 Low idle test Co...

Page 219: ...rection equation use ޓ 6JG TCPIG QH EQTTGEVKQP HCEVQT ǩ c KU CU HQNNQYU 0 9 ǩ c 1 1 Natural aspiration engine and engine with mechanically driven air charger Turbocharged engine without air cooler or with air to air cooler Turbocharged engine with air to liquid cooler f a 㨯 99 Pd T 298 f a 㨯 99 Pd T 298 f a 㨯 99 Pd T 298 Calculation of correction factor fa Calculation of engine factor fm fm 0 036q...

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