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INTRODUCTION

1. ee ruT er LTTLMMMMMMMMMe 106 Injection pump 107 000 TABLE OF CONTENTS Page 3 100 Engine general 104 Piston amp crankshaft Typical engine arrangements 4 Disassembly 56 59 Specification 5 Inspection amp repair 60 69 Cooling system 6 7 ASSembly esessepess eedece base eee 70 74 Water pump amp fan 8 Breaking in engine 75 gli E D 9 Fuel filter amp nozzle 10 Lubrication system 11 105 Starter I SyStelTi zeegt 12 1 SEN Inspection before disassembly 76 77 Troubleshooting 1 14 17 DISASSEMDIY ees 78 83 Trouble Shooting 2 18 20 ASSeImbly esse eini 83 84 Maintenance standard 21 26 Torques on major items 27 28 Maintenance interval 29 106 Alternator 101 Cylinder head amp valves Inspection before disassembly 85 ene general ds c A CMM 30 32 Disassembly Weeer ee 86 ER RER 33 35 The main point of disassembly 87 EE 36 38 Overhaul and inspection 88 90 EEN 39 40 Assembly 90 Valve clearance adjusting 41 102 Flywheel 107
2. 0 04 0 16 0 0016 0 0063 Idler gear injection pump drive gear Checking timing gear backlash 103 TIMING GEAR Page 55 8 Installing oil seal Using an installer install a new oil seal to the timing gear case until it is flush with the end face of the case as shown in the illustration The lip of the seal must be toward the inside of the gear case 9 Installing timing gear case Pm i S 1 a T a Install the oil pump drive gear and idler gear to the gc SA du E Ja 8 timing gear case Install the cover in position E b Install the baffle plate to the crankshaft c Install the timing gear case and gasket to the front face of the crankcase Make sure the locating dowels enter their holes in the case and gasket d Tighten the bolts to the specified torque 1 2 0 1 kgf m Tightening torque 8 70 7 bf ft 12 51 N m 10 Installing crankshaft pulley a Apply engine oil to the oil seal running surface of the pulley Woodruff key b Push the pulley on to the crankshaft in alignment with the keys c Install two lock bolts M12 X 1 25 to the rear end of the crankshaft and insert a bar between the bolts to hold the crankshaft d Tighten the nut with washer to the specified torque Apply engine oil Msi AU Installi kshaft pull Tightening torque 28947 Ibf ft EE 3923 10 N m x CAUTION Use a strong bar to hold the crankshaft 1
3. b The weight of the piston is stamped on the top of the piston 2 Checking pistons and piston rings a Check the clearance between the groove and the piston ring with a feeler gauge as shown in the illustration If the clearance exceeds the service limit replace the piston ring Unit mn in Checking between groove and piston ring Service Item Assembly standard Limit No 1 0 060 0 100 0 200 ring 0 0024 0 0040 0 0079 E eech No 2 0 045 0 085 ring ring 0 0018 0 0032 0 150 SE 0 025 0 065 0 0059 9 0 0010 0 0026 b Install a new piston rings and recheck the clearance If the clearance still exceeds the service limit replace the piston 104 PISTON amp CRANKSHAFT Page 62 3 Checking clearance between ends of piston ring Install the piston ring in a new cylinder or a gauge and measure the clearance between the ends of the ring with a feeler gauge If the clearance exceeds the service limit replace all piston rings Inside diameter of gauges Standard 88 00 Ex mm 190 00 P mm diameter of 0 25 O S 188 25 i mm 190 25 2s mm crankcase 0 50 O S 188 50 T mm 90 50 SS mm NOTE Install the piston ring in the cylinder squarely with a Inside Checking clearance between ends of piston ring iston B Unit mn in Item Assembly Service standard Limit Clearance Ka No 0 20 0 35 between ring 0 0099 0 0158 1 50 SE 0 20 0 40 0 0591 1 Oil DH S diiit
4. Xx NOTE The maximum limit of stock to be removed from the crankcase and cylinder head grinding is 0 2 mm 0 008in in all Tappets 1 Checking for wear Check the cam contact face of each tappet for wear Replace badly worn tappets if any 2 Checking clearance between tappet and bore Measure the diameter of the tappet and the inside diameter of the bore in the crankcase for the tappet as shown in the illustration to check the clearance If the clearance exceeds the service limit replace the tappets If the bores are worn beyond the service limit replace the crankcase Unit mm in Normal Assembly Service Item Size standard limit Inside diameter of 14 000 14 018 14 100 bore for 0 5512 0 5519 0 5551 tappet Clearance between u 0 016 0 052 0 080 tappet and 0 0006 0 0021 0 0032 bore Checking crankcase top face Cam contact face of tappet Checking clearance between tappet and bore 104 PISTON amp CRANKSHAFT Page 69 Assembly Apply engine oil 1 Installing tappets a Apply engine oil to the tappets and install them in the bores in the crankcase b Make sure the tappets rotate smoothly 2 Installing crankshaft a Install the lower halves of the main bearings in the main bearing caps Install the upper halves of the No 5 bearing main bearings in the crankcase with flange x NOTE a Make sure the upper and lower halves of the main bearin
5. 105 ALTERNATOR Page 85 2 Disassembly D bolt bearing retainer 9 regulator 2 pulley 6 front bearing rectifier 3 rotor front bracket D rear bracket 4 rear bearing stator 105 ALTERNATOR Page 86 3 The main point of disassembly 1 Remove the two bolts mounting the front bracket to the stator Using the end of a flat screw driver inserted in the gap between the stator and front bracket pry them apart and remove the front bracket Caution If the screw driver is inserted too deep stator core damage may occur 2 Put a piece of cloth around the rotor and grip in a vice Undo the nut and remove the pulley soldering 3 Removing stator and rectifier Heat the three soldered connections to remove the wire leads Remove stator Caution Use care in removing the soldered connections Excessive heat may cause damage to the components soldering point Remove the nut attached to rectifier and remove rectifier 105 ALTERNATOR Page 87 4 Overhaul and inspection 1 The main point of checking 1 Check of diodes Check whether or not current flows between the lead wire from the diode and the case of the diode Resistance reading should be small in one direction and larger in the other direction Check all diodes and if the resistance reading is the same in both directions replace the rectifier 2 Check of field coil Check for current flow between rings of the sleeve
6. S z 9z2 le8 o8 9 ZIL o OD c ke Q Se Dl Sle o An elt SC We O D N O Cj We Co Ne Q C eft Be c ole o Ss ol el 9 2 ec 5s E z 9 9se 9z 9 5 9 o CLD o Te O Ss Re O 7 SE fos o o Geh Ls ce al of l lscls52 s cl 2 O O O O o D o o E o 2oc 4 rei 2 olz e C O O Alacla Mla o E o c v GH WH Sac ECH ESCHER SNE ETE Sele Se OG S gz C E o les a c 5 5 x LO O OO O O z c C c C gt O Clow LI LL a LL LL LL ES O U w S ols O J E ott a Se ECH EH ER EH SH NSA ECH ECH SECH ECH EH NSA NEE Correction Heat oil pan starting After starting warm of engine through Retighten and replace gasket if necessary Replace crankcase Check and repair Replace part s if necessary Repair or replace Repair or replace Repair or replace starter if necessary Repair or replace ring gear Replace pinion Recharge or replace battery Heat It if necessary Replace part s Replace copper packing s and if necessary glow plug s Replace alternator if necessary Adjust or replace Connect wires properly o Repair of replace Repair or replace Check and replace bearings with undersize ones if necessary Retighten Reinstall timing gears or adjust valve sinkage Replace part s Readjust valve clearance to 0 25mm 0 0098in Repair Replace gear s or idler gear bushing TROUBLESHOOTING Page 18 Cause
7. Unit mm in 0 25 0 0098 22736 90011 9 emer 77 0 0197 2 2638 900118 A 00177 0 0295 2 2599 9 OOS 2 ecu NOTE a Grind all crankpins to the same undersize b Finish the fillet radius to 3mm 0 12in Undersize of crankpin 2 Checking oil clearance of main bearings a Install the upper and lower halves of the bearings and the cap to the crankcase and tighten the cap nuts to the specified torque Measure the inside diameter of the bearing as shown in the illustration 8 50 5 kgf m 6144 Ibf ft 8845 N m Tightening torque b Measure the diameter of the journal of the crankshaft as shown in the illustration and subtract the diameter of the journal from the inside diameter of the bearing Step a The difference is the oil clearance of the main bearing Unit mm in Normal Assembly Service Item MN Size Standard limit rina 69 840 69 855 i 2 55712 5585 standard Oil o 0 035 0 100 0 200 clearance 0 0014 0 0039 0 0079 c If the oil clearance exceeds the service limit replace the bearing and recheck the oil clearance d If the oil clearance still exceeds the service limit use 0 25mm 0 0098in 0 50mm 0 0197in or 0 75mm 0 029 5in undersize bearings refinish the journals to any of the undersize listed below Unit mm in JL sg dimension 0 0098 2 549270 00058 4 0138 0 0197 2 539470 00058 000138 Undersize of journal
8. 3 When re charging battery always remove from the tractor 4 While running the engine never remove the positive cable from of alternator 5 Never allow the positive cable on terminal B to come in contact with a ground or negative lead 6 When using a steam cleaner use care not to touch the alternator Page 84 3 Checking the voltage of alternator 1 Using a heavy gauge wire connect the positive terminal of the battery to an ammeter Connect the cable from the ammeter to the terminal B of the alternator as shown in the figure above 2 Connect a voltmeter between terminal L and a negative terminal 3 When the starter switch is placed in the OFF position the voltmeter reads 0 V 4 Without starting the engine turn the switch to the ON position and read the voltmeter value Make sure that the voltage reading is below battery voltage 5 Disconnect the amp meter and start the engine After the engine has started reconnect the ammeter 6 The ammeter reading should be below 5A when the engine is at 1800 rpm When the engine is turning at 1800 rpm the alternator is turning at 2500 rpm 7 After starting the engine turn all the lights and electrical accessories off Read the voltmeter The voltage reading is affected by ambient temperature The higher the temperature the lower the voltage reading Se Voltage reading at 20 C 14 7 0 3 V N
9. If the bores exceeds the service limit for diameter out of round and taper increase them for oversize pistons L3AS L3AL Unit mm in Assembly standard service Limit 90 00 0 Standard 3 46 0 00138 0 0 035 Oylinder inner 0 25 90 25 v EE DIE 0 0098 3 47414 000198 40 008 90 50 0 035 0 50 0 0 0197 920429999 Out of round and taper of 0 015 0 00059 bores Maximum m Unit mm in Assembly standard service Limit 88 00 10 035 0 Standard 3 46 0 00138 0 0 035 Cylinder inner 0 25 88 25 Y SEN E 0 0098 3 474477 90138 5 008 88 50 0 035 0 50 0 0 0197 3 4842 0 00138 Out of round and taper of 0 015 0 00059 bores Maximum b Boring and honing 1 Determine an oversize to which the bores are to be increased by boring and honing on the basis of the maximum measurement taken on the bores 2 Bore then finish hone the bores to the oversize determined in Step 1 Measuring diagram Checking crankcase bore Piston pin right angle direction 104 PISTON amp CRANKSHAFT Page 68 2 Checking top face Check the top face warpage using an accurate straight edge and a feeler gauge in three positions lengthwise two crosswise and two widthwise as shown in the illustration If warpage exceeds the repair limit grind the crankcase Unit mm in Assembly Repair Item ww standard Limit Warpage of 0 05 0 0020 0 20 crankcase top face maximum 0 0079
10. T 107 ENGINE STOP Page 90 1 Outline SUT m C y O scio ae i E eet eer ae 12V PW Es Pull coil 50A DA SS Hold eo A 2 Operation When starting the engine high current is supplied to A qol the pull coil of the fuel solenoid through the starter EM Jd E motor opening the fuel valve Once the engine has n started current is supplied to the hold coil through the i eg if l eo J ignition switch continuing to hold the fuel valve open mg Gg P With the switch in off position no current is supplied to i i Glai either of the coils therefore fuel is no longer supplied to the engine Caution If the wire lead from starter motor to pull coil is removed the fuse will be blown due to high current required during starting y L i 3 Assembly of fuel solenoid e S rte MOTOI 1 Remove the tie rod cover 2 Coat the screw threads of fuel solenoid with a sealant 3 After temporarily mounting the fuel solenoid and nut Ee move the speed adjustment lever of the injection pump LASH to the maximum stop position SE NS g Caution1 Take care not to allow any sealant to come Wees ES MS in contact with any working part of solenoid lt r a o ITA Caution2 Be careful when cleaning the solenoid with E ut v Lm cleaner not to infiltrate the
11. Valve stem s stickin s e Readjust valve clearance to 0 25mm 0 0098in Rocker arm s not lifting valve s l Cylinder s piston s or piston ring s worn l Poor compression l l NOM Repair or replace Piston ring s sticking l i l Repair or replace Exhaust gas leak in cylinder head gasket l l Retighten Replace gasket if necessary Valve spring s broken l j Repair or replace Not enough torque of starter at starting l Repair or replace Overheating Add coolant to correct level Leak in unit seal of water pump Repair or replace Not enough coolant l Cracks in crankcase water jacket Replace crankcase Leak in other part s Repair or replace TROUBLESHOOTING Page 20 Cause Correction Air in cooling system Bleed air by loosening air bleed plug drain plug or hose clamp Radiator not Rust or scale deposits in radiator Flush dissipating heat properly Dust and dirt build up on radiator Flush Fan belt slipping Adjust belt tension Thermostat defective stuck closed Replace Atmospheric temperature low Cover radiator Edere pang Radiator uncovered heat excessively Thermostat defective stuck open Replace l i ES Repair or replace Cylinder s piston s or piston ring s sticking Running part s Main or connecting rod bearing s sticking l seized Mo Repair or replace Idler gear bushing sticking Repair or replace MAINTENANCE STANDARDS 1 MAINTENANCE STANDARDS Pa
12. After installing the bushing insert the piston pin into position and make sure it rotates smoothly Crankshaft 1 Checking oil clearance of connecting rod bearings a Install the upper and lower halves of the bearings and the cap to the connecting rod and tighten the cap nuts to the specified torque Measure the inside diameter of the bearing as shown in the illustration 5 50 5 kgf m Tightening torque A024 Ibi s ft 54 5 N m b Measure the diameter of the crankpin of the crankshaft as shown in the illustration and subtract the diameter of the crankpin from the inside diameter of the bearing Step a The difference is the oil clearance of the connecting rod bearing Unit mm in Normal Assembly oervice Item m size standard limit GR 57 955 57 970 EE 2 2817 2 2823 i standard l l Oil o 0 03 0 09 0 20 clearance 0 0012 0 0035 0 0079 c If the oil clearance exceeds the repair limit replace the bearing and recheck the oil clearance d If the oil clearance still exceeds the repair limit use 0 25mm 0 0098in 0 50mm 0 0197in or 0 75mm 0 02 95in undersize bearings When using undersize bearings refinish the crankpins to any of the undersize listed below Weight mark side Oil holes cun Ends of bushing Installing connecting rod Measuring Measuring direction part Measuring Measuring direction part Measuring crankpin 104 PISTON amp CRANKSHAFT
13. Engine stop DISasselmDly sksm 42 Inspection amp repair 43 Engine stop circuit 91 ASSeImbly eegen 44 uM 108 Injection pump 103 Timing gear Disassembly 45 48 SE 92 Inspection amp repair 49 52 Fuel system 93 94 Assembly 52 55 Timing BTDC setting 95 96 100 ENGINE GENERAL Page 4 Typical engine arrangements Exhaust manifold Engine Number Oil filter Water pump Water temperature sensor Crankshaft pulley Water outlet X Cooling fan mec Ge rte TIL II asl eL IC M Oil filler tl M e Coe Fuel filter Injection pump Oil gauge iz L 1 Moh Flywheel mE reegt Bees Oil drain plug DU Right side NOTE Rotation of c
14. Fan belt worn or torn out gt replace Fan plate deformed or torn out replace D Cooling fan 2 Spacer 3 Water pump pulley 4 Fan belt 5 Water pump assembly 6 Gasket D Plate Cover Thermostat Thermostat housing 0 By pass hose Thermostat testing e Remove the thermostat from the engine e Hang the thermostat in the pan of water as shown in the illustration The thermostat must be below the surface of the water and it must be away from the side of the pan x i e Heat the water uniformly in the pan and measure a temperature at which the valve starts opening and a temperature at which the valve lift distance is more than 8mm 0 3in If the valve does not start opening at the WB correct temperature or if it does not open to the correct lift T Si Pe Temperature replace the thermostat a Valve opening 76 515 90 T Valve opens at 76 541 5C Valve opens 90 C more than 8mm 100 ENGINE GENERAL Page 9 Construction of fuel system Fuel system consists of fuel tank filter injection pump high pressure pipe and injection nozzle Injection nozzle Fuel supply pipe Fuel return pipe um Air vent on fuel system Uncap the air vent plug on the pump and block it using a cloth Then push the head of the filter several times Tighten the cap when the fuel is coming out of the plug T Gi d Air vent plug without any air bubbles S p i Notices in air vent Pressu
15. Remove the pulley from the crankshaft x WARNING Make sure the bar will not come off when removing the pulley M12X1 25 Removing crankshaft pulley 2 Removing timing gear case Remove the timing gear case with the oil pump drive gear and idler gear from the crankcase Pull the case straight off the locating dowels x CAUTION The front plate is bolted inside the gear case Do not attempt to remove the plate with the case by tapping 3 Removing timing gear case Measure the backlash between the gears and make a record of the measurements to be referred to at the time of assembly If the backlash exceeds the service limit replace the gears Unit mm in Assembly ervice Item standard limit Backlash between crankshaft 0 05 to 0 15 gear and idler gear 0 0020 to Backlash between idler gear and camshaft gear EE Bee Backlash between injection d dubi pump drive gear and idler gear 0 0016 to 0 0063 4 Checking end play of idler gear Uh ZE Checking timing gear backlash Check the end play with a feeler gauge or a dial indicator If the end play exceeds the service limit replace the thrust plate Unit mm in Assembly Service Item e standard limit 0 05 to 0 20 0 35 p ay ol g 0 0020 to 0 0079 0 0138 Checking end play of idler gear 103 TIMING GEAR Page 47 5b Removing idler gear Unscrew the bolt and washer and remove the idler gear 6 Check
16. 344 6 844 o No 1 and No 2 54 53 94 to 53 96 53 90 9 o O dq ctc O3 plates Clearance between shaft 0 025 to 0 075 0 100 Replace and bushing bushing End play 0 05 to 0 20 as P PACES plates Fit interference of shaft in crankcase bore Crankshaft gear and idler gear 0 038 to 0 076 Timing gears 0 05 toD T9 Idler gear and camshaft gear 0 25 Replace gears Injection pump drive gear 0 04 to 0 16 and idler gear Clearance between rotors 0 04 to 0 09 0 15 and cover Clearance between outer rotor 0 200 to 0 275 0 500 and case Shaft diameter CO 12 985 to 13 000 Lubrication system Oil pump Clearance between shaft and case 0 032 to 0 074 Relief valve opening pressure 3 0 to 4 0 50 43 to 57 kgf cm psi kpa 343 294 to 392 MAINTENANCE STANDARDS Page 26 Unit mm Normal Assembly standard Trad limit Service limit size Standard clearance Clearance Clearance Fit interference of bearing 0 026 0 064 ti unit in case T t which val starts opening Temp at which valve lifts EC more than 8 0 3 150 160 m Seat shall hold a test pressure Group Item Remarks Cooling system Water Thermostat ioe Valve opening pressure kgf cm psi kpa Test by means of hand tester using diesel fuel at 20 C 68 F If discharge pattern is bad even after nozzle is washed in clean diesel fuel replace nozzle tip Fuel system Injection no
17. Assembly Maximum standard limit undercut segment D Hoi 7 Check for current flow between each terminal and body of the armature or coil Replace the armature assembly if current flows a 8 Check for a short circuit between each of the terminals If current does not flow the coil of the armature is short circuited and needs to be replaced 105 STARTER Page 82 9 Check for a short circuit between coil and yoke assembly If current flows between them the yoke assembly needs to be replaced 3 Check of over running clutch 1 If the bearing does not rotate smoothly or it is noisy replacement with a new one is necessary 2 Hold the outside of the over running clutch by hand Looking into the shaft end turn the shaft clockwise Only the shaft should rotate Turn the shaft counter clockwise The shaft and over running clutch should rotate together Caution Do not clean over running clutch with oil 4 Reduction gear Replace if worn or defective 3 Assembly Assemble by reversing the disassembly procedure Be sure to grease the starter motor assembly by applying grease to the area noted by arrows in the drawing below 1 Lubrication points Grease multi purpose grease Caution Do not allow grease to come in contact with the brushes or armature coat grease on mounting surface 105 STARTER Page 83 2 Assembly of stop ring Install stop ring in the ring groove of pinion shaft P
18. Bis 0 0118 0 0197 4 Checking clearance between piston pin and bore Measure the inside diameter of the pin bore of the piston and the diameter of the pin as shown in the illustration to check the clearance If the clearance exceeds the service limit replace the parts Unit mm in Normal Assembly Service Item un Size standard limit E 7 994 28 000 i pin 1 1021 1 10234 Clearance between u 0 000 0 016 0 050 piston pin 0 0000 0 0006 0 0020 and bore 5 Checking clearance between connecting rod bushing and piston pin Measure the inside diameter of the connecting rod bushing bore and the diameter of the piston pin as shown in the illustration to check the clearance If the clearance exceeds the service limit replace the parts k Measuring direction HE l zy Unit mm in m LES E kem NONO Assembly SSES sd E S Measure size standard limit av Inside diameter 28 28 020 28 045 i of bushing 1 10 1 1032 1 1041 Wd H ee Ge M i ti d bushi _ easuring connecting rod bushing and piston pin 0 0008 0 0020 0 0032 104 PISTON amp CRANKSHAFT Page 63 6 Replacing connecting rod bushings a Use a connecting rod bushing puller to replace the replace the connecting rod bushings b When installing a new bushing align the oil holes in the bushing and connecting rod Position the ends of the bushing at the location shown in the illustration c
19. If SR va ae no current flow replace the rotor assembly lee eee pes ou S Bes 29 n Si i S t m ag i y E H o E LI AE LEAU z d fi J A s A em ip Check for current flow between sleeve rings and body To 7 V If no current flow replace the rotor assembly E a I d EY 105 ALTERNATOR Page 88 Check for current flow between sleeve rings and body If no current flow replace the rotor assembly 3 Check of stator core eae d Y T l i Check for current flow between each of the lead wires ES Pads ch of the stator core If no current flow replace the stator Na SA core i ON Check for current flow between each of the lead wires and stator core If no current flow replace the stator core 4 Check of brush Replace the brushes if they are worn to shorter than 7 mm 105 ALTERNATOR Page 89 The brush and spring can be removed if the connection is unsoldered When replacing the brushes push them into the holder and solder connections 5 Assembly Assemble opposite of the disassembly procedure paying special attention to the following 1 When pressing the rear bearing to the rotor shaft heat the bearing and press on the shaft 2 When attaching the rotor to the rear bracket use a small stiff wire inserted through the small hole in the rear of bracket to hold the brushes in place during assembly P M i SSE ass JU St
20. Installing oil pan a Install a new gasket on the oil pan Apply three bond 1207C or 1211 or equivalent to the seats formed of the crankcase for the No 1 and No 5 main bearing caps just enough to be forced out of the seats slightly when the U seals are installed b Install the U seals to the bottom of the crankcase by fitting them into the grooves in the main bearing caps while forcing their ends into the seats to which three bond was applied in step a as shown in the illustration 5 Turn the crankcase upside down for the steps that follow Turning crankcase upside down 103 TIMING GEAR Page 54 6 Installing idler gear T HYD pum AUPE Van BE Save JEA Idler gear Camshaft Idler gear puo drive gear Crankshaft gear a Apply engine oil to the idler gear shaft b Install the idler gear with its marks in alignment with the marks on the injection pump drive gear camshaft gear and crankshaft gear as shown in the illustration c Put the thrust plate on the idler gear and tighten the bolt with washer to the specified torque d Move the idler gear back and forth in the axial direction to make sure it has correct end play 7 Checking timing gear backlash After installing the timing gear check them for backlash as shown in the illustration Unit mm in Assembly standard SEMIS Limit Crankshaft gear idler gear TEE Idler gear 0 0020 0 0059 camshaft gear
21. NOTE a Grind all crankpins to the same undersize b Finish the fillet radius to 3mm 0 12in 0 0295 EE ee Page 64 Measuring diagram T 1 XK d e j e H Z i i d E h Measuring journal Fillet radius 104 PISTON amp CRANKSHAFT Page 65 3 Checking oil seal running surface Check the oil seal running surface of the balancer shaft drive gear for wear at the rear end of the crankshaft If the drive gear is badly worn replace the oil seal with replacement oil seal and oil seal sleeve HU SE LE ree a Rd i nii Oil seal running surface Checking oil seal running surface a Installing oil seal sleeve Heat an oil seal sleeve in an oven to a temperature of 100C to 150C 212 F to 302 F and install it by tapping uniformly with a hammer Oil seal sleeve When the oil seal sleeve is worn after the engine has been operated replace both oil seal and oil seal sleeve Oil seal Me H Oil seal sleeve q Oil seal running surface b Removing oil seal sleeve Hold a flat cold chisel at right angles to the sleeve and cut the sleeve at three places to loosen it as shown in the illustration If it is impossible to remove the sleeve in this method hold the chisel in the axial direction and lightly tap the sleeve to loosen it CAUTION Be extra careful not to cause damage to the drive gear when removing the sleeve Removing oil seal sleeve
22. arranged uniformly around the circumference of the cam disk The cam disk s face cams are always in contact with the roller holder assembly s rollers because the cam disk and the plunger are pressed against the roller holder assembly by the set force of the two plunger springs Because of this the plunger can follow cam disk movement Therefore as the cam disk is rotated on the roller holder assembly by the drive shaft simultaneous plunger rotation and reciprocating movement is possible The roller holder assembly construction is such that it can only rotate in a certain angle range in accordance with timer operation Because the plunger rotates and reciprocates simultaneously suction of the fuel oil into the pressure chamber pressurization in the pressure chamber delivery into the engine cylinder are possible Speed Governing The governor is located in the upper part of the injection pump chamber Four flyweights and a governor sleeve are held in the flyweight holder which is mounted on the governor shaft The flyweight holder is rotated and accelerated by the drive shaft gear through rubber dampers The governor lever assembly is supported by pivot bolts in the pump housing and the ball joint at the bottom of the lever assembly is inserted into the control sleeve which slides over the outside surface of the plunger The top of the lever assembly the tension lever is connected to the governor spring by a retaining pin whi
23. drive shaft is turned by the engine s timing gear and fuel is drawn by the injection pump s feed pump through the sedimentor and fuel filter to the injection pumps s fuel inlet The fuel filter acts to filter the fuel and the sedimentor is located in the lower portion of the fuel filter to remove moisture from the fuel system With drive shaft rotation the fuel oil sucked into the feed pump is pressurized by the feed pump and fills the injection pump chamber The fuel oil pressure is proportional to drive shaft speed and when it exceeds a specified pressure excess fuel again returns to the inlet side through a regulating valve located at the feed pump s fuel oil outlet The fuel oil in the injection pump chamber flows through the distributor head inlet into the pressure chamber where plunger rotation and reciprocating motion increase its pressure The fuel oil is then delivered through the injection pipe to the nozzle and nozzle holder An overflow valve located at the top of the injection pump functions to maintain a constant fuel oil temperature in the pump chamber by returning excess fuel oil to the fuel tank 107 INJECTION PUMP Fuel Delivery The drive shaft rotated by the engine s timing belt or gear rotates the cam disk through a cross coupling The cam disk s press fitted pin fits into a groove in the plunger to rotate the plunger To reciprocate the plunger the cam disk is also equipped with raised face cams
24. jets when they are cracked or otherwise faulty a To remove the combustion jet tap the jet off the cylinder head with a 6mm 0 24 in diameter round bar inserted through the glow plug hole as shown in the illustration b To install a replacement jet position the jet so that the orifice is toward the center of the cylinder and drive it into position with a plastic hammer Caulking tool M T ERSA Installing valve seat Round bar o6 Combustion Jets Combustion Jet Orifice Center of cylinder 101 CYLINDER HEAD amp valves Page 39 3 Assembly 1 Installing valve stem seals a Apply engine oil to the valve stem and put the valve in the valve guide b Put a new stem seal on the valve guide c Using stem seal installer 21c81 10400 install the stem seal to the valve guide making use of the valve stem as a guide 2 Installing valves and valve springs Valve spring e Put the valve spring and retainer on the valve guide Using valve spring pusher 30691 04500 compress the valve spring and install the valve cotters to the valve Xx CAUTION Compressing the valve spring excessively will cause the retainer to make contact with and damage the stem seal b Tap the top of the valve with a soft faced hammer several times to make sure the valve spring and valve cotters are properly installed 3 Installing cylinder head gasket a Make sure the machined surface of
25. loose Interference between valve s and piston s Valve spring s broken Excessive valve clearance Foreign material in cylinder s Excessive gear backlash Hard starting Engine will No exhaust smoke turn Little exhaust smoke Excessive exhaust smoke Cranking speed low Engine Engine can be cranked manually will not turn Engine cannot be cranked manually Glow plug indicator does not glow red power Excessive white exhaust smoke Not enough Excessive black exhaust smoke Exhaust smoke abnormal During operation During idling Engine hunts Engine runs rough CH ie CH c uc 5 O Engine knocks excessively Engine noisy O O q O e D q O O mE EM E E O e O q O O O C O During operation TROUBLESHOOTING Page 17 Coolant S Lubrication tempera Alternator 7 system defective ture defective abnormal 9 o t Ka c s 32 s S9 Ee CO oO ra gt be Q n D ER Ce o O O O gt z Q a O E e e Wal D CO Bes Zn CH 4 Cc O Q O O D D x 0 2 Ke E c Ola 5 2 gjo O O D Fa D Ola oO o x sl 2 8 s e O18 Ze Sls 3 2 v5 Bes O Cc oO O O o el S e
26. may cause a serious damage on the engine Valve push rod bech kee s lt F e Valve mechanism Pressure relief valve Main gallery Oil filter with built in bypass valve 100 ENGINE GENERAL Page 12 Cil system Oil pump 1 Clearance between outer rotor and inner rotor Check the clearance with a feeler gauge as shown in the illustration If the clearance exceeds the service limit replace the pump assembly Unit liens Assembly Service standard limit Clearance between 0 13 0 15 0 20 outer and inner rotor 2 Clearance between rotors and cover Check the clearance with a feeler gauge and straight edge as shown in the illustration If the clearance exceeds the service limit replace the pump assembly Unit tem Assembly Service standard limit Clearance between 0 04 0 09 0 15 rotors and cover 3 Clearance between outer rotor and case e Check the clearance with a feeler gauge as shown in the illustration If the clearance exceeds the service limit replace the pump assembly Unit tem Assembly Service standard limit Clearance between 0 20 0 275 0 50 Outer rotor and case Notices in assembling e Be sure to mach the mark both on the upper case and low case of the oil pump when assembling 100 ENGINE GENERAL Page 13 Cil filter Replace at every 300 hours Packing nna TN Relief valve i i Pressure relief valve Inspection Tightening
27. o9 wes po eem ver wee p ox eem one se M M10 x 1 25 NR jie Jang M4 x 0 7 OTST DX E NE LX 39 1 3 a 43 t4 Gk au 39 r4 49 T5 L2 SE SC 92 Ol BE Tl E d IEE Tig a GE 49 T5 39 T4 29 dE TORQUES ON MAJOR ITEMS Page 28 2 2 Standard bolts Thread dia x pitch 7T and larger re m 2 3 Standard studs Thread dia x pitch For driving in ferrous materials m e f o e oe ee 2 4 Standard plugs Thread dia x pitch For driving in ferrous materials De Lee 3 THREAD SEALANTS Applied to Mating parts Remarks Cylinder head coolant hole plug Cylinder head Three Bond 1386D Apply to hole and install plug Crankcase coolant hole plug Three Bond 1386D Apply to hole and install plug Crankcase oil gallery plug Three Bond 1386D Apply to hole and install plug Crankcase oil return pipe Three Bond 1344 Apply to pipe and tighten Crankcase No 1 and No 5 bearing cap grooves Balancer shaft drive gear Crankshaft Three Bond 1215 RAM to the inside of gar and Oil pan gasket and U seal Three Bond 1207C or 1211 See pages 49 and 50 MAINTENANCE INTERVAL Page 29 4 MAINTENANCE SCHEDULE 1 Use the service meter to determine servicing intervals 2 The servicing intervals in the schedule are for an average operating conditions Service the engine earlier than the scheduled intervals if necessary The intervals depends on application operating conditions and fuel oil and lube oil used
28. standard limit Angle 30 o l D Width 1 18 1 04 1 32 1 6 2 0 0465 0 0409 0 052 0 063 Q 0 Valve Valve 0 8 0 7 0 9 Re margin sinkage 0 031 0 028 0 035 0 051 Valve margin 1 70 1 20 Valve seat angle Valve sinkage 0 0669 0 0472 1 Replacing valve seats a Weld a stud to the valve seat Insert a bar through the the valve guide from the upper side of the cylinder head to put its end on the stud as shown in the illustration Then drive the seat off the head Xx NOTE When welding the stud to the valve seat avoid contact of any spatter with the machined surf ace of the cylinder head b Before installing a replacement valve seat measure the bores in the cylinder head for the valve seats to mark sure they are correct in dimension i om gp 1 1 F 1 1 a IK Inlet Exhaust Valve seat bore dimensions 101 CYLINDER HEAD amp valves Page 38 c Chill the valve seat in liquid nitrogen of 170 C 274 F for more than 4 minutes with the cylinder head kept at normal temperature or heat the cylinder head up to 80 C to 100 C 176 F to 212 F with the valve seat chilled in ether or alcohol containing dry ice d Using a caulking tool drive the seat into MEC Part number Caulking tool for inlet valve seat 30691 02700 Caulking too l for exhaust valve seat 30691 02800 Combustion jets e Replacing Replace the combustion
29. the crankcase and the top of the pistons are clean b Put a new gasket on the crankcase with UP mark side up Make sure the locating dowels enter their holes in the gasket i w SC m y x CAUTION Do not use any sealant s a 2E UP Mark A Installing cylinder head gasket 101 CYLINDER HEAD amp valves Page 40 4 Installing cylinder head Put the cylinder head on the crankcase Make sure the locating dowels enter their holes in the cylinder head 5 Tightening cylinder head bolts Tighten the cylinder head bolts to the specified torque in two or three steps in the sequence shown in the illustration 120 5 kgf m Tightening torque 87 4 Ibf ft 118155 N m Sa e A a y vi Weg arr RS M S 6 K rear ep ati pF sin aat at n La rt Q wt d a abad Les 2 vs d 4 vi 47 Bi D HN A 5s D Kai KE Al Gen KE Cas Mg s erts gt uit wes 2 x ag Cylinder head bolt tightening sequence 6 Assembling rocker arms and rocker shafts When installing the rocker arms to the rocker shaft position the arms with their assembly marks pointing forward After installing the arms make sure they move smoothly 7 Installing valve push rods a Insert the push rod into position through the push rod hole in the cylinder head b Make sure the ball end of the push rod is in the socket formed of the tappet Assembling rocker arms and rocker shaft 8 Install
30. 04 PISTON amp CRANKSHAFT Page 56 Disassembly 1 Connecting rod cap 2 Connecting rod bearing lower half 3 Main bearing cap 4 Main bearing lower half 5 Crankshaft 6 Main bearing upper half 7 Connecting rod 8 Connecting rod bearing upper half 9 Snap ring 10 Piston pin 11 Piston 12 No 1 ring 13 No 2 ring 14 Oil ring 15 Tappet 16 Crankcase 17 Drive gear x NOTE When replacing the crankcase carefully remove the parts such as the relief valve etc from the crankcase to reuse them at the time of assembly 104 PISTON amp CRANKSHAFT Page 57 1 Checking thrust clearance of connecting rod big end a Carefully lay the crankcase on its side b Check the clearance between the connecting rod big end and the crankpin with a feeler gauge as shown in the illustration c If the thrust clearance exceeds the service limit replace the connecting rod Unit mm in Rote Assemble oervice standard Limit Thrust clearance db 5 0 50 of connecting rod big end 0 0059 0 0138 0 0197 2 Maximum permissible difference between average weight of all connecting rod assemblies in one engine When replacing the connecting rods select new connecting rods having the same weight rank marks so that the difference between average weight of all connecting rod assemblies in one engine does not exceeds the maximum permissible limit Matching marks Maximum permissible d
31. 104 PISTON amp CRANKSHAFT Page 66 4 Checking run out Support the crankshaft on its front and rear journals in V blocks With the dial indicator set at 0 00mm 0 0000in at the center journal turn the camshaft full one revolution and read the indicator as shown in the illustration If run out is out of the assembly standard but does not exceeds the repair limit repair the crankshaft by grinding If run out exceeds the repair limit repair the crankshaft by cold working Replace the crankshaft of run out exceeds the repair limit excessively Checking crankshaft run out Unit mm in Assembly standard Item Repair limit Crankshaft 0 02 0 0008 0 05 run out Maximum 0 0020 5 Removing crankshaft gear Remove the crankshaft gear with a gear puller as shown in the illustration 3X NOTE Do not remove the gear unless it requires replacement 6 Installing crankshaft gear a Heat the gear in an oven to a temperature of 100 C to 150 C 212 F to 302 F b Install the key to the crankshaft c Install the gear by fitting the key into the keyway in the gear Installing crankshaft gear 104 PISTON amp CRANKSHAFT Page 67 Crankcase 1 Checking bores a Measure the engine bore with a cylinder bore gauge having a dial indicator Take measurements as A B and C positions in the bore on axes 90 apart as shown in the illustration to check the diameter out of round and taper
32. 4 Inspection after break in e Check under and around the engine for loose bolts or nuts e Check and adjust the valve clearance Check the adjust the injection timing Adjustment Adjustment and inspection should be carried out at both the low idle soeed and maximum speed with no load Notices in adjustments This adjustments must be carried out at the authorized service network by LS Mtron However this service can be available when the seal on the injection pump keep its condition as same as the beginning from the factory Make a same seal on the pump after adjustment of the governor This seal can be using an evidence of warrantable e Adjustment should be carried when engine oil reaches at or over 70 C 105 STARTER Page 75 1 Inspection before disassembly Before disassembling starter motor check the following articles 1 Test without load Connect ammeter voltmeter tachometer and battery as shown in figure above to check the values listed below When switch is ON the pinion is projected and the starter motor is rotated If the speed measured is equal to or over the prescribed speed it is normal However if not disassemble the starter motor and overhaul Model name of starter motor Characteristics Rating power without load Terminal voltage Caution Use a heavy gauge wire and thoroughly ti
33. Correction Fuel injection pump not delivering fuel properly Greater variance of fuel Injection quantity Not enough fuel injection quantity injection pump Too much fuel injection quantity Fuel injection nozzle s defective Fuel injection timing advanced Fuel tank supply valve closed No fuel in tank Fuel lines restricted Air in fuel system Leak in fuel lines or connections Fuel filter clogged Air in fuel system Fuel injection pump plunger s jammed Fuel injection pump plunger s worn Bearing s worn Fuel injection pump plunger spring s broken Fuel injection pump plunger pinion s loose Delivery valve s defective Delivery valve spring s broken Governor stop lever link binding Control rack sticking Fuel injection pump plunger s jammed Fuel injection pump plunger s worn Bearing s worn Fuel injection pump plunger pinion s loose Full load setting of governor improper Stop lever sticking in increase position Full load setting of governor improper Fuel injection pump plunger pinion s loose Needle valve in nozzle tip s sticking Nozzle tip seat s defective Nozzle spring s broken Fuel injection pressure low Carbon on packing at nozzle tip s Fuel injection pump improperly installed Timing gears incorrectly installed Open the valve Refuel Repair or clean fuel pipes with air Retighten connections or replace fuel pipes Retighten connections Clean or re
34. INTRODUCTION Page 1 This service manual has instructions and procedures for the subject on the front cover The information specifications and illustrations this manual are on the basis of the information that was current at the time this issue was written Correct servicing test and repair procedures will give the engine a long service life Before starting a test repair or rebuild job the serviceman must read the respective sections of this manual to know all the components he will work on Continuing improvement of product design may have caused changes to your engine which are not included in this manual Whenever a question arises regarding your engine or this manual consult your dealer or distributor for the latest available information 000 TABLE OF CONTENTS Page 2 Table of contents mmm MTM 000 Engine general u TLLMMMMM 100 Cylinder head amp valves 101 Flywheel erue LT TTLMMMMMMMewe 102 Timing gear camshaft amp oil pan 103 Piston amp crankshaft eL 104 Start motor T nee TT TMT MTM m 105 Alternator
35. Make sure the engine oil air cleaner starter and battery are normal Compreesion b Start the engine and allow it to warm up thoroughly _ Gauge adaptor ee 1 Move the control lever to the stop position 2 Remove the glow plugs from all cylinders Connect compression gauge 33391 02100 to the cylinder on which the compression is to be measured with compression gauge adaptor 30691 21100 3 Crank the engine with the starter and after the gauge pointer stops moving take a pressure reading from the gauge 4 If the reading on the gauge is lower than the repair limit overhaul the engine Xx CAUTION a Be sure to measure the compression on all cylinders b The compression pressure may vary depending on engine rpm This makes it necessary to check the engine rpm when measuring the compression 101 CYLINDER HEAD amp VALVES Page 31 Unit kgf cm psi kpa Assembly standard Repair limit Compression x NOTE Measure the compression with the engine running at 150 to 200 rpm XX CAUTION a Measure the compression at regular intervals to obtain the data on the gradual change of compression b The compression would be slightly higher than the assembly standard in a new or overhaul engine but it will drop after break in period 3 Precautions for disassembly and assembly This section outlines basic recommended procedures some of which require special tools devices or work methods and contains basic safet
36. Page 51 Unit mm in Normal Assembly Service Item SIZE Standard Limit No 1 53 94 53 96 53 90 2 SES ang i E 2 1236 2 1244 2 1220 of No 2 Pup ogg 52 94 52 96 52 90 2 0842 2 0850 2 0827 5 Clearance between camshaft journal COO T3 and bore in crank l 0 0028 0 0043 case or bushing for camshaft 5 Measuring bore in crankcase bushing for camshaft 4 3 Inside diameter 54 03 54 05 2 EEN uc 2 1272 2 1280 Inside 2 54 03 54 05 diameter SES Ge 2 1272 2 1280 of bore for 53 03 53 05 2 l camshaft No 3 5342 09 Ir 0878 2 0886 3 Checking bend Support the camshaft on its front and rear journals in V blocks With the dial indicator set at 0 00mm 0 0000 in at the center journal turn the camshaft full one revolution and read the indicator as shown in the illustration 1 2 of the reading on the indicator is bend of the camshaft If the reading exceeds the repair limit straighten the camshaft by cold working or replace it Unit mm in standard 0 02 0 0008 0 05 EES EEN maximum 0 0020 4 Removing camshaft gear To remove the camshaft gear use a hydraulic press Thrust plate Xx NOTE Do not remove the camshaft thrust place or gear unless it requires replacement Removing camshaft gear 103 TIMING GEAR Page 52 5 Installing camshaft gear and thrust plate a Install the key and thrust plate to the camshaft b Heat t
37. Removing cylinder head Remove the bolts that hold the cylinder head Lift off the cylinder head from the crankcase Xx NOTE If any parts of the cylinder head are faulty check the cylinder head bolts for torque with a torque wrench before removing them 4 Removing valves and springs Compress the valve spring with valve spring pusher 30691 Valve spring pusher 04500 and remove the valve cotters x NOTE If the existing valves are to be reused put a mark on each valve for its location Removing valves and valve springs 5 Removing valve stem seals Hemove the stem seals with a pliers as shown in the illustration Xx NOTE Do not reuse the stem seals 101 CYLINDER HEAD amp valves Page 35 6 Cleaning cylinder head Clean the machined surface of the cylinder head that makes contact with the gasket Xx NOTE Remove the gasket with a scraper then clean the machined surface with an oil stone and engine oil 405437 7 Measuring piston projection a Determine the top dead center of the piston with a dial indicator b Install a dial indicator on the crankcase with its point on the top of the piston Set the indicator to read Omm 0 0000 in c Check the piston projection at three points on the top of the piston as shown in the illustration and average the three measurements to determine the projection Subtract the projection from the compressed thickness of the gasket to determine the clearance betw
38. This test is also for break in of the major running parts of the engine Start up procedure Check the fluid levels in the radiator oil pan and fuel tank Bleed the fuel and cooling system e Crank the engine with the starter for 15 seconds to permit lube oil to circulate through the engine For this cranking do not supply fuel to the engine e Slightly move the speed control lever in the direction of increasing the injection quantity and turn the starter switch to the START position Do not move the speed control lever to the full injection position After the engine starts allow it to idle by operating the speed control lever Inspection after starting the engine After starting the engine check the following items Upon discovery of any faulty condition immediately stop the engine and investigate for this cause e Lube oil pressure should be 2 to 4kgf c when the engine is running at the rated speed It should be 1 kgf cm when the engine is running at low idle speed e Coolant temperature should be 75 C to 85 C e Lube oil temperature Should be 70 C to 90 Oil coolant or fuel leaks e Knocking Should die away as the coolant temperature increases No other defects should be noted e Abnormal exhaust smoke and smell Test condition Follow the table shown below Load PS Time min 30 1000 30 1500 10 Rated varies 10 according to 30 specifications 20 Speed rom Page
39. al and crankpin Taper of journal and crankpin Fillet radius of journal and crankpin CO 0 01 Maximum Unit mm Gicu rem Normal Assembly standard Repair limit Service limit Eisen S size Standard clearance Clearance Clearance Free length m 48 85 mM 47 60 Squareness Le Squareness of e dis onion TM S ends with respect EE o center line Q o ab 2 E Assembled load 18 to 20 15 kgf Ibf IN 40 to 44 33 T 177 to 196 147 CH E z d Inside diameter e 19 010 to 19 030 3 rocker arm bushing 19 9 Diameter of rocker shaft 18 980 to 19 00 oc Clearance between rocker arm 0 010 to 0 050 and shaft 0 00039 to 0 00197 Wal E 0 3 Dial indicator o c Bending l 20 Maximum reading be 2 gt Q Maximum Diameter of journal 69 840 to 69 855 ae Diameter of crankpin 57 955 to 57 970 BEEN i EE 48 5 48 46 to 48 54 Es journal to center of crankpin a Pe D Es E 9 Runout S x Parallelism between journal e x and crankpin d 3 O Maximum End play 0 100 to 0 204 0 300 MAINTENANCE STANDARDS Page 24 Unit mm RU Bag Normal Assembly standard Repair limit Service limit RR p size Standard clearance Clearance Clearance 5 Standard 89 970 89 955 to 89 985 89 770 L3BL 87 970 E 0 25 o 90 220 90 205 to 90 235 90 020 L3BL 88 220 2 Oversize o di 5 0 50 i 5 O i 90 470 90 455 to 90 485 90 270 L3BL 88 470 T Oversize E clearance Maximum permi
40. anked manually turn Engine cannot be cranked manually Glow plug indicator does not glow red Glow plug indicator glows red Not enough Little exhaust smoke power Excessive white exhaust smoke Excessive black exhaust smoke During idling Exhaust smoke abnormal During operatio n White Black Engine knocks excessively Engine noisy Engine runs rough Engine hunts During idling During operation TROUBLESHOOTING Page 15 Engine vibrates excessively Coolant Los Alternat Lubrication tempera m system ture defectiv defective abnorm al Q O 9 Wal Wal 9 5 O We oO Cc O w B o o o o be c o Q ic o e Q 0 Q 0 o E o c o E O Z Oo Oo Oo o RV LC o o Z Oo O D O o o Correction o Q A D Se d Fa 2 a D o S c O is D 5 Q ER T p o o hn c o x o wn CH c O N e O O O OQ E D T O c o o c uw Q Oo CR e N E c A E Oo P c c o o o o Oo ME O x3 e Oo c O O O O O o be 2 O Oo Si SI zl 2 15 2 ESlo al o Eo 5 SECHER ER ER ERAN Sol tl cys 28 z Es o 2 C o c 0 Oo o E SE Oo A D o D o O C 9 P EE Ze D oe a e I8 l 5 s s1 5 o a o gt Or e wej D 2 2 C 2 D D Lo o Oo D zm e 2 z i Ww T O 2 DEA e o 9S
41. c uj T soj O 3 s o o Check and replace part s if necessary o o o Replace nozzle tip s o o o Use fuel for cold weather Q Use good quality oil Use oil of proper viscosity Use oil of proper viscosity o Retighten and replace packing s if necessary D e Change element and oil N Change element and oil ol Jo o e O O o O O Adjust full load setting of governor TROUBLESHOOTING Page 16 Cooling system Electrical system Mechanical system Complaint Engine not warm Radiator dissipating heat excessively Not enough coolant Radiator not dissipating heat properly Oylinder head gasket leaks Cranks in crankcase water jacket Starter switch defective Starter magnetic switch defective Starter defective Starter free wheel defective Flywheel ring gear and pinion defective Battery voltage low Glow plus s or indicator Open circuited Glow plus s short circuited Alternator defective Relay defective Wiring defective Running parts seized Cylinder s piston s or piston ring s worn Piston ring s worn Excessive oil clearance Connecting rod cap bolts
42. degree gt Firstly remove a gauge bolt on the rear side of the pump then install dial gauge End of needle oce ef gt Loosen the blot around three threads gt Turn the injection pump counterclockwise like a photo then tighten it prematurely when the pump hits the block 108 INJECTION PUMP Page 95 gt Rotate the crankshaft clockwise viewed from front find the position where the dial gauge stops and set the O gt Rotate the crankshaft clockwise match the mark on the pulley with 5 degree For fine setting of BTDC 5 degree install a dial gauge on the upper side of the block gt Turn the injection pump until dial gauge shows 0 after loosen the bolt slightly gt Tighten the bolt completely gt Completed timing set of BTDC 5degree
43. e oversize piston d i 0 015 E Taper of bore cylinder NS maximum c A O E S y o 0 02 With main bearing cap 9 2 Out of round Masc eb installed bolts tightened jog S 19 o 0 05 ma Concentricity Maximum MAINTENANCE STANDARDS Page 22 Unit mm G Normal Assembly standard Repair limit Service limit R k ix SS size Standard clearance Clearance Clearance EE Oil clearance clearance Ge between crankshaft journal 0 035 to 0 100 0 200 2 E and main bearing ag gt 2 Width of thrust journals 22 mememeo to 23 000 z Inside diameter E 14 000 to 14 018 E 14 100 ab S D e CI bet prem a NP ii QU 0 016 to 0 052 0 080 Tappet and bore O x Inside diameter of saaoios4os0 030 to 54 050 bushing No 1 O s ang 54 030 to 54 050 Inside diameter of S E bores for camshaft o O ne 0 07 to 0 11 0 15 camshaft and journal 0 05 Regrind if 5 Warpage of bottom face VT 0 20 warpage iS os minor D Be Compressed thickness 13 1 27 to 1 35 of gasket Inet vee valve 7 940 to 7 955 Im 7 900 Diameter of o valve stem l m E 7 5 valve D ab gt S 9 I Inlet valve ewe 0 065 to 0 095 Ia 0 200 o a 9 Clearance between guide and stem Selen gt 0 080 to 0 115 CN valve H W i o o 2 4 gt Height to top of valve guide d NEN 17 9 18 1 NENNEN Age Valve margin 1 70 MAINTENANCE STANDARDS Page 23 Out of round of journ
44. een the piston top and the cylinder head If the piston projection is not correct check the various Checking piston projection parts for clearance Unit mm in 0 13 0 60 Compressed 1 27 1 35 thickness of gasket 0 0500 0 0531 Piston projection 0 0051 0 0236 Xx CAUTION Incorrect piston projection affects engine performance and causes valve interference with piston 101 CYLINDER HEAD amp valves Page 36 2 Inspection Check threads for stripping Check surface that makes contact with valve push rod for Wear Check surface that makes contact with valve cap for wear Check oil hole for clogging Check bushing for wear Check for pitted or fractured coils Test force and length Check for cracks or carbon or scale deposits Check face for pitting or ridging exhaust valve Check stem for scratches or scuff marks 101 CYLINDER HEAD amp valves Page 37 Cylinder head Using a heavy accurate straight edge and a feeler gauge Check for warpage in three positions lengthwise two crosswise and two widthwise as shown in the illustration If warpage exceeds the repair limit reface the head with a surface grinder Unit mm in Item Assembly Repair standard limit Warpage of 0 05maximum 0 20 0 0079 bottom face 0 0020 Checking cylinder head for warpage Valve seat Unit mm in Item Normal Assembly Service Valve seat widt size
45. ell as an increase in lube oil consumption and excessive blow by Lack of power increase in fuel consumption drop in lube oil pressure hard starting and abnormal sound are also engine troubles These troubles however are not always the result of low compression pressure and give no valid reason for overhauling the engine The engine develops troubles of widely different varieties when the compression pressure drops in it Following are the list of typical troubles caused by this compression pressure fault 1 Lack of power 2 Increase in fuel consumption 3 Increase in lube oil consumption 4 Excessive blow by through breather due to worn cylinders pistons etc 5 Excessive blow by due to poor seating of worn inlet and exhaust valves 6 Hard starting 7 Abnormal sound In most cases these troubles occur concurrently Some of them are directly caused by low compression pressure but others are not Among the troubles listed above 2 and 6 are caused by a fuel injection pump improperly adjusted with respect to injection quantity or injection timing faulty injection nozzles or poor care of the battery starter and alternator The trouble to be considered as the most valid reason for overhauling the engine is 4 in actually determining when to overhaul the engine it is reasonable to take this trouble into consideration in conjunction with the other troubles 2 Measuring the compression pressure otart by a
46. embly 1 magnet switch 7 middle bracket 12 pinion 2 rear bracket 8 reduction gear 13 spring 3 brush holder assembly 9 spring 14 pinion shaft 4 yoke assembly 10 C spring 15 lever 5 armature 11 pinion stop 16 front bracket 6 cap 105 STARTER Page 78 1 Main point of disassembl 1 H y connector 1 Undo nuts of terminal M and remove connector Remove the two bolts holding magnetic switch and remove it switch 2 Remove two bolts attaching the rear bracket Remove the rear bracket and the two smaller bolts attaching the brush holder being careful not to lose the adjusting washer in side of the bracket fixing bolt 3 Remove the two brushes Remove the yoke assembly and brush holder assembly from the armature 4 Remove the cover snap ring and washer 105 STARTER Page 79 5 Undo bolts and remove the center bracket At the same time remove the pinion shaft end adjusting washer 6 Place a round hollow object such as a pipe on the pinion stop Tapping with a hammer separate from clutch shaft and expose the stop ring Remove the stop ring with pliers and then remove the pinion Note when reassembling do not re use the stop ring 7 Remove the pinion shaft and separate the spring lever reduction gear and pinion shaft from the bracket Note Note the direction of offset in the lever for re assembly Remove the ball bearing in both ends of the armature wi
47. ge 21 Unit mm Assembly standard Repair limit service limit Group Item Normal size S Remarks tandard clearance Clearance Clearance Vary according to specifications Adjust governor setting Minimum speed no load Compression pressure 30 427 2940 370 20 30 Oil and water temp kgf cm psi kpa At 150 to 200 rom SC 20 to 30 C 68 to 86 F 2 to 4 28 to 57 196 to 392 5 21 3 Vr at rated rpm 147 Engine oil pressure Oil temperature 70 to kgf cm psi kpa 90 C 158 to 194 F Ee 1 14 2 98 minimum l 0 5 7 49 at low idle speed Inlet valves open 30 B T D C Inlet valves close 50 A T D C Valve timing Exhaust valves open 74 B T D C Exhaust valves close 30 A T D C 3 crank angle c O Both inlet and exhaust Valve clearance cold valves Standard injection timing is indicated here The timing for each model of engine varies according Fuel injection timing L3AS BTDC5 L3AL ATDC3 L3BL ATDC3 to its specification Be sure to verify the timing by referring to the specifications of each model L3AL L3BL Tier3 When belt is pushed inward with 10kgf 22lbf Fan water pump and 13 98N pressure exerted approx l alternator drive belt tension midway between crankshaft and alternator pulleys 0 05 ind i j maximum minor Inside diameter of bore 0 0 035 cylinder Increase bore 2 Out of round of bore 0 01 0 25 0 0098 cylinder Maximum 0 50 0 0197 Dd and D us
48. ghten each terminal When measuring speed in front of pinion be careful of the pinion being projected during operation When safety shield is removed operation of starter motor will be noisy 105 STARTER 2 Checking of magnetic switch Check the magnetic switch through three steps First remove the wire from the terminal 1 Test the current flow between terminal and Connect a wire from the battery ground to terminal and connect a wire from the positive post through a switch to terminal Turn the switch ON and if the pinion is projected the connection is correct 2 Test the current flow between terminal S and the body By using the same battery and switch as above connect the battery ground to the body and connect the wire from the switch to terminal Turn the switch ON and if the pinion is projected the connection is correct 3 Test the current flow between terminal and the body By using the same battery and switch as above connect the battery ground to the body and connect the wire from the switch to terminal Turn the switch ON and if the pinion is projected the connection is correct Page 76 Lo o e N f C fe starter emove the connector V j NU N E nel PD TOY EN E remove o CC ecto S d y lt mo CHILE MY E 105 STARTER Page 77 2 Disass
49. gs are installed so the bearing tabs fit into the notch in the crankcase and main bearing caps b Only the upper halves of the main bearings to be installed in the crankcase has an oil groove b Install the upper and lower halves of the main bearing having flange in the crankcase and main bearing cap for No 5 journal of he crankshaft c Apply a small amount of engine to the inside of the main bearings d Wash the crankshaft with cleaning solvent and blow dry with compressed air Make sure all oil holes in the crankshaft are clean Check the oil holes for condition e Fasten a hoist to the crankshaft and carefully install it in the crankcase f Apply a small amount of engine oil to the journals of the crankshaft g Install the main bearing caps in position so the Front mark arrow on the cap is toward the front of the engine and the number on the cap is the same as the number on the crankcase on the left side of each main bearing cap Xx NOTE The end faces No 1 and No 5 bearing caps must be i flush with the end faces of the crankcase engine cm 104 PISTON amp CRANKSHAFT Page 70 h Tighten the main bearing cap bolts evenly to the specified torque 8 50 5 kgf m Tightening torque 61 XA Ibf ft B3 355 N m i Make sure the crankshaft rotates smoothly j Check the crankshaft end play with a dial indicator as shown in the illustration Unit mm in Assembl
50. he bearing is fitted with a special tool bearing installer 2 The use of a hydraulic pusher will facilitate bearing installation and help prevent damage to the bearing 101 CYLINDER HEAD amp VALVES Page 33 1 DISASSEMBLY Replace rocker cover gasket Check thread for stripping Check surface that makes contact with valve push rod for i Check surface that makes Wear contact with valve cap for wear Check oil hole for clogging Check bushing for wear Check face for pitting or ridging exhaust valve Check stem for scratches or scuff marks A Notice 1 Every part should be handled carefully 2 Every tool should be used properly and wear a safety glasses and gloves 101 CYLINDER HEAD amp valves Page 34 1 Removing rocker shaft assemblies a Loosen the adjusting screw one turn b Loosen the bolts long and short that hold the rocker shaft bracket to the cylinder head Be sure to loosen the short bolt first Remove the rocker shaft assembly from the cylinder head Xx CAUTION If the long bolt is loosened first the rocker shaft bracket might suffer damage Removing rocker shaft assembly 2 Disassembling rocker shaft assemblies The rocker arms must be restored to the rocker shafts from which they were removed during disassembly After removing the rocker arms mark them for their rocker shafts to insure the original clearance between the arm and shaft at time of assembly 3
51. he big end of the connecting rod on the crankpin k Install the lower half of the connecting rod bearing in the connecting rod cap Make sure the tab on the back of the bearing is in the notch of the connecting rod cap Apply engine oil to the inside of the bearing l Install the connecting rod cap with the bearing to the connecting rod over the crankpin with the matching mark of the cap on the same side as the mark of the rod m Tighten the connecting rod cap nuts finger tight XX NOTE Do steps a through m are for the installation of the piston assemblies in the No 1 and No 4 cylinders Turn the crankshaft 180 and install the piston assemblies in the No 2 and No 3 cylinders n Tighten the connecting rod cap nuts evenly to the specified torque with a torque wrench 5 50 5 kgf m 4044 Ibf ft 54 5 N m Tightening torque o Check the thrust clearance of the connecting rod big end If the thrust clearance is less than the assembly standard retighten the cap nuts p Raise up the crankcase with the oil pan side up q Make sure the crankshaft rotates smoothly Front mark Front of engine Installing piston assembly 2 4 FUN Matching marks V p Installing connecting rod cap Raising crankcase Checking crankshaft rotation 104 PISTON amp CRANKSHAFT Testing and adjusting Break in Break in An engine should be tested on a dynamometer
52. he gear up to a temperature of 250 C 482 F c Drive the gear onto the camshaft Xx NOTE Install the thrust plate before installing the gear to the camshaft Thrust plate Camshaft gear ASSEMBLY 1 Installing front end plate a Put the front end plate and gasket on the front face of the crankcase Make sure the locating dowels enter their holes in the plate and gasket b Tighten two bolts to the specified torque 1 2 0 1 kgf m Tightening torque 8 70 7 lbf ft 12 51 N m 2 Installing camshaft a Apply engine oil to the journals and lobes of the camshaft b Install the camshaft with gear in the crankcase x NOTE Do not cause damage to the journals and lobes c Tighten the thrust plate bolts to the specified torque with a torque wrench and socket 34491 0030 1 2 0 1 kgf m Tightening torque 8 70 7 lbf ft 12 51 N m d Make sure the camshaft rotates smoothly Move the Installing camshaft 103 TIMING GEAR Page 53 camshaft back and forth in the axial direction to make sure it has correct end play 3 Installing oil pump a Install the oil pump in position in the crankcase Make sure the oil pump gear is meshing with the oil pump drive gear of the camshaft b Install the oil pump set bolt with gasket and tighten it to the specified torque Oil pump Set bolt 55204 kgf e mn Tightening torque 25 3 Ibf ft 3944 N ml 4
53. ifference between 10g average weight of all connecting rod 0 35 oz assemblies in one engine 09 Oz Weight rank mark Weight rank mark on connecting rod 3 Removing connecting rod caps a Put a mark on each cap so it can be installed in the same position from which it was removed b Remove the caps and the lower halves of the connecting rod bearings c Put a mark on each connecting rod bearing lower half so it can be installed in the same position from which it was removed XX NOTE Be careful not to cause damage to the bearings Removing connecting rod caps 104 PISTON amp CRANKSHAFT Page 58 4 Removing pistons a Remove carbon from the inner surface of the cylinders with a rag and sandpaper b Turn the crankshaft to bring the piston to the top dead center c Push the piston and connecting rod away from the crankshaft with the handle of a hammer until the piston rings are above the cylinder Then remove the piston and connecting rod from the crankcase 5 Removing piston rings Remove the piston rings with piston ring pliers 6 Removing piston pins a Remove the snap rings with a snap ring pliers b Remove the piston pin to separate the connecting rod from the piston Snap ring pliers Xx NOTE When it is difficult to remove the piston pin heat the piston in an oven or in hot water Removing snap ring 104 PISTON amp CRANKSHAFT Page 59 7 Checking end p
54. in the engine Adjust the intervals to meet the actual operating conditions 3 Perform service on items at multiples of the original requirement For example at every 250 service hours also service those items listed under Every 50 service hours and every 10 service hours Check clean wash or adjust Change 6 Relay on LS dealer if necessary Items to be services after initial 50 hours of operation of a new reconditioned or long stored engine Item Remarks Every 10 Every 50 Every 300 Every 600 Every 900 service hours service hours service hours service hours service hours Walk around Check Inspection EE SE E E E E Bolts and nuts SE cylinder head bolts S Check oil level oil level Oil pan E RN UON UU EE Oil filter Ch Cartridge oos Ile dj jo Fuel tank Fem o __ Injection nozzles nozzles Check Check coolant Radiator level Lubrication E H Kal o 2 LL Change coolant coolant Every 2 years Fan belt Check tension HEN Check indicator paper element type Check electrolyte cac de Battery level and specific d mom time to time Alternator sm o 1 o Cooling system Air inlet Electrical system 101 CYLINDER HEAD amp VALVES Page 30 ENGINE GENERAL 1 Decision of the repairing Generally when to overhaul the engine is to be determined by taking into consideration a drop in compression pressure as w
55. ing end play of camshaft Check the end plat with a dial indicator as shown in the illustration If the end plat exceeds the service limit replace the thrust plate Unit mm in Assembly Service Item standard limit End play of camshaft Ge Cep S 0 0039 to 0 0098 0 0118 7 Removing oil pan and gasket a Turn the crankcase upside down Turning crankcase upside down b Unscrew the bolts that hold the oil pan to the crankcase Remove the oil pan c Remove the gasket and U seal 8 Removing balancer shafts Removing oil pan and gasket a Unscrew the bolts that hold balancer shafts and remove the washers b Remove the gears from the balancer shafts with a gear puller c Remove the keys and snap rings from the balancer shafts d Remove the balancer shafts with bearings by tapping their read ends with a plastic hammer 103 TIMING GEAR Page 48 9 Removing oil pump Unscrew the set bolt and remove the oil pump from the crankcase Oil pump set bolt 10 Removing camshaft a Position the camshaft gear so that its lightening holes are on the top and bottom sides Unscrew the bolts that hold the thrust plate with socket 34491 00300 b Pull the camshaft from the crankcase x CAUTION Do not cause damage to the lobes or bushing journals when removing the camshaft 11 Removing from plate Unscrew the bolts that hold the front plate to the crankcase Remove the
56. ing rocker shaft assembly Tighten the long bolts and short bolts in that order to the specified torque 1 5 0 2kgf m Long bolts 1141 4 Ibf ft Tightening aaa m torque 1 2 0 1kgf m Short bolts 8 70 7 Ibf ft 123 1 N m Installing rocker shaft assembly 101 CYLINDER HEAD amp valves Page 41 4 Valve clearance adjusting 1 Find the top dead center on the compression stroke for No 1 piston as outlined below a Put turning handle 30691 21800 on the crankshaft pulley nut Turn the crankshaft in the normal direction as seen from the front end until the 0 mark scribed on the crankshaft pulley is aligned with the pointer on the timing gear case as shown in the illustration b Try to move up and down the inlet and exhaust valve rocker arms of the No 1 cylinder to make sure they are not being pushed up by the push rods The No 1 piston is at the top dead center on the compression stroke when the rocker arms are not being pushed up by the push rods If the rocker arms are being pushed up turn crankshaft one turn 2 Insert a 0 25mm 0 0098in feeler gauge into between the rocker arm and valve cap 3 Loosen the lock nut for the adjusting screw and turn the adjusting screw in either direction until the feeler gauge is slightly gripped between the rocker arm and valve cap Unit mm in Assembly nem standard Valve Inlet valves 0 25 clearance cold setting Exhaust
57. lay of crankshaft a Turn the crankcase upside down with the oil pan side up b With a dial indicator at the end of the crankshaft check the end play as shown in the illustration If the end play exceeds the service limit replace the thrust bearings Unit mm in Item Assembly standard Service limit End play of 0 100 0 204 0 300 crankshaft 0 00394 0 00803 0 01181 8 Removing main bearing caps Remove the main bearing caps with lower halves of the main bearings Xx NOTE Be careful not to cause damage to the main bearings Put a mark on each bearing cap so it can be installed in the same position from which it was removed 9 Removing crankshaft Carefully remove the crankshaft x NOTE Be careful not to cause damage to the main journals and crankpins Put a mark on each bearing 9 Removing crankshaft 104 PISTON amp CRANKSHAFT Page 60 Inspection Check for scale deposits corrosion or other defects Check for wear Check for wear prdamage score marks cracks or carbon deposits Check for wear Check for wear or Clogged oil hole Check for wear or DA clogged oil hole f Check serrated di WES es H co Check for nicks chipping or portions for wear or df 6 dme yr Erp abnormal tooth contact cracks Typical failures for which main bearings are to be checked are scratches due to dirt embedded Into bearing material loss of overly due to lack of oil crate
58. le the opposite end of the governor spring is connected to the control lever shaft The control lever shaft is inserted into the governor cover and a control lever is attached to the control lever shaft The accelerator pedal is connected directly to the control lever by a linkage and the governor spring set force changes in response to the control lever position i e accelerator pedal position Injection quantity control is governed by the mutually opposing forces of the flyweights centrifugal force and the governor spring s set force The flyweights centrifugal force which changes in response to engine speed acts on the governor lever through the governor sleeve Page 93 The governor spring s set force which is dependant on control lever position i e accelerator pedal position acts on the governor lever through the retaining pin Injection Timing Control In the lower part of the injection pump is the timer in the centre of which the timer piston is positioned On the low pressure side of the timer piston is a timer spring with a predetermined set force the pump chamber fuel oil pressure acts on the opposite side high pressure side The timer piston position changes in accordance with the balance of these two forces to rotate the roller holder via the roller holder pin When the timer piston compresses the timer spring the injection timing is advanced the roller holder rotates in the reverse rotation directi
59. oil to the bores c Install the connecting rod cap bolts in the big end of the connecting rod so the flats of their heads fit on the connecting rod properly d Install the upper half of the connecting rod bearing in the big end of the connecting rod Make sure the tab on the back of the bearing is in the notch of the connecting rod Installing connecting rod bearings e Apply engine oil to the piston rings Thrust direction f Make sure the piston ring end gaps are arranged on the piston as shown in the illustration End gap of No 1 ring SE Piston pin End gap of End gap of Oil ring No 2 ring Anti thrust direction Arrangement of piston ring end gaps on piston g Turn the crankshaft to bring the No 1 or No 4 crankpin to the center h Put piston installer 30691 58100 on the top of the crankcase in alignment with the bore center Hold the installer in position by one hand i Put the piston Assembly in the crankcase through the installer Make sure the Front mark on the top of the piston is toward the front of the engine x NOTE Make sure the big end of the connecting rod fits SN Piston on the crankpin properly installer Installing piston assembly 1 104 PISTON amp CRANKSHAFT Page 73 XX NOTE Be careful not to cause damage to the crankpin when putting the connecting rod on the crankpin j Lightly tap the top of the piston with the handle of a hammer to put t
60. on and through timer piston movement in the opposite direction the injection timing is retarded Injection timing is controlled by the above Feed Pump The feed pump comprises a rotor blades and liner Drive shaft rotation is transmitted through a key to the rotor to rotate the rotor The inside circumference of the liner is eccentric to the centre of rotor rotation Four blades are installed in the rotor Centrifugal force forces the blades outwards during rotation to contact the inside surface of the liner and form four fuel oil chambers Therefore the volume of these four chambers increases through rotor rotation to suck fuel oil from the fuel tank Conversely when the volume of these four chambers decreases fuel oil is pressurized Regulating Valve Feed pump fuel oil delivery pressure increases proportionately with an increase in injection pump speed However the total fuel oil injection quantity necessary for the engine is considerably less than that delivered by the feed pump Therefore in order to prevent an excessive increase in the pump chamber pressure caused by the excess fuel oil and to adjust the pump chamber pressure so that it is usually within the specified limit a regulating valve is installed near the feed pump outlet The timer performs timing control using the pump chamber pressure which is regulated by the regulating valve 108 INJECTION PUMP Page 94 INJ PUMP timing setting How to set BTDC 5
61. place element Prime Replace Replace Replace Replace Reinstall by matching marks Replace Replace Repair link properly and place lever in neutral position Re lubricate or repair Replace Replace Replace Reinstall by matching marks Readjust governor setting on bench Repair link properly and place lever in neutral position Readjust governor setting on bench Reinstall by matching marks Repair or replace Repair or replace Replace Shim adjust fuel injection pressure on tester Remove carbon Retime by moving fuel injection pump away from engine Reinstall timing gears TROUBLESHOOTING Page 19 Cause Correction Fuel injection pump improperly installed Retime by moving fuel injection pump toward engine Fuel injection timing retarded Timing gears incorrectly installed Reinstall timing gears Fuel injection pump bearings worn Replace Bad quality fuel Use good quality fuel Not enough oil un oil pan Add oil to correct level Air in oil strainer Replace damaged pipe s or packing s Retighten loose part s l l Oil pump defective Repair Pumping up of oil Deg l Oil lines restricted Flush Relief valve defective Repair or replace Oil filter clogged Replace element and oil Leak in oil lines Repair Air cleaner clogged Clean or replace element Not enough intake air l Intake manifold clogged Clean l Repair or replace Valve seat s defective Repair or place
62. plate with the injection pump from the crankcase Removing front plate 103 TIMING GEAR Page 49 2 Inspection Check teeth for wear nicks burrs or chips Cheer teeth for wear or damage Check for cracks AT or wear Check for cracks or defective dowel holes A Ns a9 NS Replace Check V belt groove and oil seal running surface for wear Crankshaft pulley Check the V belt groove for wear To do so wrap a new V belt around the pulley and press it in the groove to see if the top of the belt is above the groove of the pulley If the belt top is uniformly above the groove all the way around the pulley is serviceable If the top sinks into the groove more than 1 6mm 0 1in replace the pulley Check the oil seal running surface of the pulley for wear If the surface is badly worn replace the pulley 103 TIMING GEAR Page 50 Idler gear 1 Checking clearance between idler gear and shaft Measure the inside diameter of the idler gear and the diameter of the shaft as shown in the illustration to check the clearance If the clearance exceeds the service limit replace the gear or shaft whichever is badly worn Unit mm in standard limit Clearance between idler gear 0 025 to 0 075 0 100 and shaft 0 00098 to 0 00295 0 00394 2 Replacing idler gear bushing a To replace the bushing use idler gear bushing installer 30691 51900 boss b When installing a replacement bushing
63. press it into position until its end is flush with the end of the gear c After installing the bushing finish its inside diameter to 36 1 42 H7 3 Replacing idler gear shaft To remove the shaft for replacement use idler gear shaft puller MH061077 x NOTE When installing a replacement shaft to the crankcase make sure the oil hole in the shaft points upward Camshaft 1 Checking lobe lift To fine the lobe lift use the procedure that follows a Measure lobe height A b Measure base circle B c Subtract base circle B from lobe height A The difference is lobe lift C If the lobe lift is less than the service limit replace the camshaft Unit mm in Nominal Assembly Service Item Size standard limit Inlet 46 916 1 84708 6684 6 184 lobe Valves lobe height 0 26315 0 24346 ife Exhaust 45 944 1 80882 7 344 6 844 valves lobe height 0 28913 0 26945 2 Checking clearance between camshaft journal and bore in crankcase or bushing Measure the diameter of the camshaft journal and the inside diameter of the bore in the crankcase or bushing for camshaft as shown in the illustration to check the clearance If the clearance exceeds the service limit replace the camshaft Measuring part oh F Measuring direction m Measuring camshaft lobe Measuring part _ Sg Be dp Lem Kid i y Measuring direction AL S feig Measuring camshaft journal 103 TIMING GEAR
64. rankshaft is counterclockwise when seen from flywheel end 100 ENGINE GENERAL Page 5 Specifications Tvpe 3cy water 3cy water e cooled diesel cooled diesel Displacement 2003 1915 mE General Combustion chamer Swirl chamber Swirl chamber Specification kgf m r Max Torque omm 12 1800 10 4 1800 nem Idle 2800 2800 Cie 2800 10 30 mE Fuel Injection Pump Type Fuel Injection Timing degree ATDC 3 AIDC 3 Fuel System Injector Opening GC Pressure Helief Pressure SC 3 0 e 0 5 d m 0 9 m Lubrication Oil Capacity odii System eus 5 51 2 59 bo LF oe Lubrication Oil 15W 40 15W 40 Intake Intake Resistance mmH20 Max 250 Max 250 oystem c dt Exhaust Back Pressure mmH20 Max 680 Max 680 oystem Max Oil Temperature 100 ENGINE GENERAL Page 6 Cooling system Exhaust gas Exhaust manifold Intake manifold LH EE EE When replacing rounded surface should be facing toward manifold 100 ENGINE GENERAL Page 7 Construction of cooling system Cooling system consists of water jacket thermostat radiator cooling fan and water pump When cold Water jacket X Thermostat Water pump When not cold Water jacket Thermostat X Radiator Te Water pump 100 ENGINE GENERAL Page 8 Water pump amp fan Inspection Visually check the water pump and replace it as an assembly if any defect is found Water leak bad rotation or torn gasket
65. re doesn t reach when something is clogged at the valve this case the valve should be cleaned after disassembling of the filter Air vent at injection pump Loosen air vent plug on the injection pump Unplug the cap and operate the engine Tighten the air vent plug when the fuel flows free of bubbles Torque 80 kgf cm 0 Caution Be careful of fuel flowing and fire when doing this 100 ENGINE GENERAL Page 10 Fuel filter and nozzle Fuel filter Water separation included his filter keep the fuel clean by filtering some impurities contained in the fuel Moreover it senses the water on the bottom and activate the stop solenoid at the injection pump accordingly With this function engine stalls just after sensing the water immediately Apply engine oil on the packing when assembling back Check clogging torn of cartridge Replace every 300 hours D Air vent plug 2 Plug 8 Sensor Filter cartridge Body assembly Oil ring Hose NOZZLE e Injection pressure is 150kg ctr Check for wear is Check for defect Check for wear SES a a Ba Check for carbon on tip or in orifice CD Retaining nut 2 Nozzle tip assembly S Piece Pin Spring Washer Nozzle body 100 ENGINE GENERAL Page 11 Construction of lubrication system Lubrication system consists of oil pan oil pump relief valve and oil filter When lubrication system has a problem on it it
66. rming any service work 3 Use only good quality lubricants Be sure to apply a coat of oil grease or sealant to parts as specified 4 Be sure to use a torque wrench to tighten parts for which torques are specified 5 Replace gaskets and packing with new ones 101 CYLINDER HEAD amp VALVES Page 32 4 Oil seal o ring and bearing installation 4 1 Oil seals When installing a lip type seal observe the following basic precautions Installing oil seal in housing 1 Check the lip of the seal for damage before installing the seal When installing the seal position it so that the lip is toward the inside of a housing 2 Apply a thin coat of cement to the surface of the outer case of the seal 3 Using a special tool oil seal installer for guiding the lip of the seal install the seal squarely in the housing Do not hit the seal with a hammer Damage to the seal can be the result Installing oil seal on shaft 1 Apply a thin coat of grease to the lip of the seal 2 When installing the seal on a shaft having splines threads or keyway use a special tool oil seal guide to prevent damage to the lip fo the seal 4 2 O rings When installing an o ring on a shaft having splines threads or keyway use a special tool o ring guide to prevent damage to the o ring Apply a thin coat of grease to the o ring before installing it 4 3 Bearing 1 When installing a bearing be sure to push the inner or outer race by which t
67. rs or pockets due to fatigue failure Failure due to poor seating radius ride etc 104 PISTON amp CRANKSHAFT Page 61 Pistons piston rings and piston pins 1 Checking diameter of pistons Direction a Measure the diameter of the piston at shirt in the mn Transverse direction transverse to the piston pin with a micrometer as j shown in the illustration If the piston is worn beyond the service limit replace it When replacing the piston select a new piston so that the difference between average weight of all pistons in one engine does not exceeds the maximum permissible limit Unit mm in m L3AL L3AS Normal Assembly Service Item Ge size standard limit S 89 970 89 955 89 985 89 770 D Standard e 3 4634 3 4628 3 4640 3 4555 e 0 25 0 0098 90 220 90 205 88 285 90 020 2 oversize 3 4732 3 4726 3 4738 3 4654 0 50 0 0197 90 470 90 445 88 485 90 270 Weiaht 2 oversize 3 4831 3 4825 3 4837 3 4752 9 identification Maximum permissible diff erence 5g 0 20z between average weight of all maximum pistons in one engine m L3BL Item Normal Assembly Service Size size standard limit identification 2 Identification on top of piston Ss Get 88 220 88 405 88 23 88 000 oversize 5 2 D 0 50 0 0197 88 470 988 445 88 48 No 1 ring 88 270 oversize 5 Maximum permissible diff erence 59 0 202 between average weight of all pistons maximum in one engine
68. ssible difference between average 5g 0 2 oz weight of all pistons in one Maximum engine So rings if service E E limit is not o o g No 2 ring 0 045 to 0 085 exceeded c S Replace piston S 0 150 if service limit 2 2 o SC is exceeded SC Oo Oil ring 0 025 to 0 065 Clearance No 1 and 0 20 35 0 25 to 0 40 WE No 2 ring 0 4 0 6 1 50 eo ends of D E E gt Piston pins Connecting rods Clearance between pin and bore Clearance between pin and bushing Inside diameter of bushing Twist bend Clearance between crankpin and connecting rod bearing oil clearance End play Maximum permissible difference between average weight of all connecting rods in one engine Face run out 28 0 000 to 0 016 0 020 to 0 051 28 020 to 28 045 0 05 100 maximum 0 03 to 0 09 0 15 to 0 35 10g 0 4 oz maximum 0 15 Maximum 0 25 Maximum Replace pin if service limit is not exceeds Replace piston if service limit is exceeds 0 050 Replace pin or bushing Ream if necessary 0 080 0 15 100 0 20 Replace onnecting rod O1 0 50 Flywheel MAINTENANCE STANDARDS Page 25 Unit mm SEH os Normal Assembly standard Repair limit Service limit Gerbe n size Standard clearance Clearance Clearance 0 02 Straighten by Bending M 0 05 cold working aximum or replace O Intake valves 6 684 6 184 Q g Exhaust valves 7
69. th bearing pliers It is not possible to replace the ball bearing pressed into the front bracket Replace the front bracket assembly if worn SY ESI Any E CG f Sir I Y bracket ER adjusting washer tool n magnet switch bracket Ee e pinion shaft C l reduction gear lever Y De spring 105 STARTER Page 80 2 Inspecting of each component 1 Checking the wear limit of brushes Check the brushes and replace if they have reached the wear limit line This is below a mark surrounded with a trademark Replace the brush holder assembly if over the limit 2 Brush spring test Assemble the new brush in the holder and attach a hand scale to the spring While gradually pulling read the weight of the movement where the spring is separated from the brush If below the minimum limit replace the spring dp Assembly Minimum standard limit Scale reading 3 1 3 9 kg 3 Check the insulation between the brush holder and body Replace the holder assembly if not insulated 4 Measure the outer diameter of the armature assembly in contact with the brush If below the minimum limit replace the armature standard limit 105 STARTER Page 81 5 Check the shaking in the contact face of the brush If above the maximum limit repair is necessary Assembly Maximum standard limit armature 6 Measuring the depth in the contact face of brush
70. the rear end of the drive gear which is doweled to the crankshaft Make sure the locating dowels enter their holes in the flywheel b Tighten four bolts with washers to the specified torque 8 5 0 5 kgf m Tightening torque 61 4 Ibf ft 833 5 N M 4 Checking face run out and pilot bearing bore run out of flywheel Set a dial indicator at the friction vertical surface and turn the flywheel one full revolution to check the face run out axial eccentricity Set a dial indicator at the horizontal surface of the pilot bearing bore and turn the flywheel one full revolution to check the bore run out Excessive run out of the flywheel in either position will probably be caused by dirt in the mounting face or improper tightening of the bolts Unit mm in Item Assembly Repair otandard limit Face and pilot 0 25 0 50 Checking flywheel run out bearing bore run out 0 0098 0 0197 Page 45 103 TIMING GEAR 1 Disassembly 6 P T O Idler gear 7 11 Plate 12 Gasket 5 Pump drive gear 4 Bearing case 10 Oil pan gasket 3 Oil pan 2 Cover 1 Crankshaft pulley Timing gear case 13 Drain plug Idler gear 9 8 Plate 14 U seal 103 TIMING GEAR Page 46 1 Removing crankshaft pulley a Install two bolts M12 x 1 25 to the rear end of the crankshaft and put a bar between the bolts to hold the crankshaft as shown in the illustration b
71. tion points Flywheel and ring gear 1 Flatness of flywheel Put the flywheel on the surface plate Set a dial indicator at one side of the friction surface and move it over to the opposite side of the surface as shown in the illustration If the friction surface is not flat over the repair limit regrind it Unit mm in Item Assembly Repair standard Limit Flatness of 0 15maximum 0 50 flywheel 0 0059 0 0020 2 Replacing ring gear Removal a Heat the ring gear evenly with an acetylene torch b Tap the ring gear all the way around with a bar and a hammer to remove it from the flywheel Installation Heat a replacement ring gear up to 150 C 302 F with a piston heater and install it to the flywheel with the unchamfered side of the gear teeth foremost Removing ring gear 102 FLYWHEEL Page 44 3 Assembly 1 Installing rear housing rear end plate oil seal Rear housing Install the seal to the rear housing from the chamfered side of the housing Oil seal 2 Installing rear housing a Apply engine oil to the lip of the seal b Install the rear housing and a new gasket to the rear face of the crankcase Make sure the locating dowels enter their holes in the gasket and housing c Tightening 14 bolts to the specified torque 3 40 3 kgf m Apply engine oil to oil seal Tightening torque 25 x2 Ibf ft 333 3 N M 3 Installing flywheel a Install the flywheel to
72. torque Check the valve and valve seat for condition Also check 5 0t0 5 kgf m i the spring for damage 7 em EZ V by Pressure relief valve Uj Chaat ff WC H Emil Check the valve opening pressure the oil pressure when the engine is running at the rated rpm If the pressure is not correct make an adjustment by adding or removing shim The pressure tap RP 1 8 thread is located near the oil filter gt Unit kgf cm Valve opening pressure 3 5 0 5 TROUBLESHOOTING Page 14 Fuel system Lubrication system Air intake system Complaint Cause No fuel to injection pump Greater variance of fuel injection quantity Injection pump oil seals defective Insufficient injection quantity Excessive injection quantity Injection nozzle defective Excessive fuel return from injection nozzles Injection timing advanced Injection timing retarded Engine speed too low Failure to stop Bad quality fuel Fuel oil viscosity high Bad quantity oil Oil viscosity high Oil viscosity low Oil pressure low Oil leaks Excessive pumping up of oil Oil filter clogged Oil pressure switch or lamp defective Not enough air for combustion Poor compression High temperature or low barometric pressure at high altitude Hard starting Engine will turn Excessive exhaust smoke Cranking speed low No exhaust smoke Little exhaust smoke Engine will not Engine can be cr
73. ull the pinion stop out until it is locked into the stop ring 3 Adjusting the movement of the end of pinion 1 Insert the adjustment shims and secure with snap ring Check the clearance of the end of pinion 2 If the clearance is above 0 5 mm adjust by inserting more shims 4 Assembly of lever Insure proper direction of offset in the lever 5 Check of pinion gap 1 In the position where the pinion is completely projected push it completely in and release allowing the shaft to freely come out to a shorter length than previously at 2 Measure the length of projection from the end of the pinion to the front bracket If the length is less than O 1 mm or longer than 2 5 mm adjustment is necessary 3 Increase or decrease the number of shims in the area where the magnetic switch is installed for adjustment reduction adjusting gear washer bracket lever gt lever spring packing 0 17 2 ben 105 ALTERNATOR 1 Inspection before disassembly 1 The main point of checking Determine detective parts by checking the charging system for the following problems Some disassembly may be required for checking 1 Over charging high current weak battery 2 Discharging low current low output of alternator excessive power consumption 2 Precautions in checking Observe the following precautions 1 Do not reverse connections to the battery 2 Do not use a high current tester
74. valves 0 0098 4 After adjusting tighten the lock nut and recheck the clearance 5 Adjust the valve clearance on the remaining cylinders by turning the crankshaft 180 at a time in the firing order Sequence cylinder No Turning angle 1 3 4 2 180 Xx CAUTION After adjusting the valve clearance on all cylinders turn the crankshaft two or three turns and recheck the clearance Finding top dead center on compression Stroke for No 1 piston 1 Finding top dead center on compression Stroke for No 1 piston 1 Adjusting screw 120 Mark 102 FLYWHEEL Page 42 1 Disassembly 1 Removing flywheel a Have someone hold the crankshaft pulley with a wrench to prevent the flywheel from turning during removal b Remove one of the bolts that hold the flywheel c Screw safety bar M12 x 1 25 in the bolt hole and remove the remaining bolts d Remove the flywheel from the crankshaft by pulling it straight x CAUTION When removing the flywheel wear heavy gloves to protect your hands 2 Removing rear housing rear end plate The rear housing rear end plate is doweled To remove the housing pull it as straight as possible Removing rear end plate 102 FLYWHEEL Page 43 2 Inspection Check friction surface for cracking scoring or other defects that affect serviceability Examine ring gear worn or defective teeth Replace Replace Inspec
75. wiring connection A 4 Screw in the fuel solenoid until solenoid valve shaft touches tie rod Ls 0 150 200 5 Unscrew the fuel solenoid about 30 45 and tighten nut 6 Start the engine and push the rear of solenoid to make sure that the engine stops 108 INJECTION PUMP Page 91 Specification o Mem Specification Number of cylinders 2 3 4 50r6 Direction of rotation Clockwise counterclockwise kees Maximum allowable speed pump 3000 r p m 2 4 5 Se 2500 r p m 3 6 cylinders Plunger diameters 8 9 10 11 or 12mm Injection timing control opeed timer 2 4 5 cylinders 110 Maximum 3 6 cylinders 7 Maximum Load Timer Maximum 3 to 4 Speed load timer 2 4 5 cylinders 11 Maximum 3 6 cylinders 7 Maximum Speed governing Variable speed governor All speed governor Minimum maximum speed governor limited speed governor Combination governor Half all speed governor Engine reverse rotation prevention Because the inlet port opens during the compression stroke if the engine rotates in the reverse direction fuel cannot be delivered and injection cannot occur Additional devices Installation of boost compensator pump speed sensor cold start device etc is possible 108 INJECTION PUMP Furl system Feed Pump Fuel filter Page 92 Overflow pipe Fuel cut solenoid Gs Eun Qr 7 VE type injection pump Figure sows an example of a fuel system The injection pump
76. y E Item onda Repair limit End play of 0 100 to 0 204 0 300 crankshaft 0 0039 to 0 0080 0 0118 If the end play is less than the assembly standard retighten the main bearing cap bolts If it exceeds the service limit replace the flanged bearings 3 Assembling pistons a Put the connecting rod in position in the piston with the matching mark of the rod on the same side as the weight identification on the top of the piston b Apply engine oil to the piston pin and install it in position Matching Assembling piston 1 104 PISTON amp CRANKSHAFT Page 71 c Install the snap rings in the grooves in the piston with a pliers Make sure the snap rings fit in the grooves properly x NOTE The snap ring ends must be toward the bottom of piston 4 Installing piston rings Using piston ring pliers 31391 12900 install the compression No 1 and No 2 rings and oil ring on the piston with the mark R toward the top of the piston Xx NOTE The oil ring must be installed on the piston with the ring end gap 180 from the oil ring spring joint 5 Installing piston assemblies a Lay the crankcase on its side Assembling piston 2 Mark R fj a LJ No 1 ring pe 5 No 2ring Piston and piston rings EC A ze eat Coil spring joint Laying crankcase on its side 104 PISTON amp CRANKSHAFT Page 72 b Clean the bores with a clean rag and apply engine
77. y precautions The safety precautions contained herein however are not for the whole of service work It is the responsibility of the service personnel to know that specific requirements precautions and work hazards exist and to discuss These with his foreman or supervisor Following is a list of basic precautions that should always be observed 3 1 Disassembly 1 Always use tools that are in good condition and be sure you understand how to use them before performing any service work 2 Use an overhaul stand or a work bench if necessary Also use bins to keep engine parts in order of removal 3 Lay down the disassembled and cleaned parts in the order in which they were removed to save time for assembly 4 Pay attention to marks on assemblies components and parts for their positions or directions Put on marks if necessary to aid assembly 5 Carefully check each part for any sign of faulty condition during removal or cleaning The part will tell you how it acted or what was abnormal about it more accurately during removal or cleaning 6 When lifting or carrying a part too heavy or too awkward for one person to handle get another person s help and if necessary use a jack or a hoist 3 2 Assembly 1 Wash all parts except for oil seals o rings rubber sheets etc with cleaning solvent and dry them with pressure air 2 Always use tools that are in good condition and be sure you understand how to use them before perfo
78. zzles o Co P Oil tightness of 20kgf cm 284psi 1961 kpa Wash or replace needle valve seat lower than valve opening pressure nozzle tip For 10 seconds nee ne Commu Tator pw fe f D Brushes kgf E 2 amp Ge OQ E No load characteristics Magnetic switch operating voltage Voltage V Speed rpm 8 volts maximum with pinion held at 2mm 0 08 in position 130 max 3750 min from cranking position C x Resistance between slip rings At 20 C TORQUES ON MAJOR ITEMS Page 27 2 TIGHTENING TORQUES 2 1 Major bolts and nuts Parts to be fastened Cylinder head Rocker cover Rocker shaft bracket long bolt Main bearing cap Connecting rod cap Flywheel Camshaft thrust plate Front end plate Timing gear case and cover Crankshaft pulley Rear housing Oil pan Oil pan drain plug Oil filter shaft Oil filter Fuel injection nozzle Fuel leak off pipe Fuel injection pump gear distributor type B terminal of starter Glow plug body terminal Pressure relief valve Coolant drain plug Thread dia x pitch mm Width across flats men s p c ee el es e poem ver wes p o eem o9 Le s pes se CNN H 61 x4 9 JE N em 118 L 5 a Ed o cR 7 83 t5 5445 CO 845 Tu2 Ke UE ee El d 392 35 10 504 066 De o mme o mes p o eme wee me p o poem o es ox oem

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