Hino. Workshop Manual. Engine 2

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Текст

EN-S197E-01
WORKSHOP MANUAL
ENGINE
ENGINE
EN-1
EN-S197E-01
CHAPTER EN
ENGINE
Model F17E
DATA AND SPECIFICATIONS.................... EN-DS36A - 1
TROUBLE SHOOTING........................... EN-TS4A - 1
ENGINE OVERHAUL CRITERIA................... EN-OC15A - 1
ENGINE MOVING PARTS........................ EN-MP33A - 1
CYLINDER HEAD.......................... EN-MP33A - 1
CRANKSHAFT PULLEY...................... EN-MP33A -13
FLYWHEEL AND FLYWHEEL HOUSING.......... EN-MP33A -15
TIMING GEAR AND CAMSHAFT............... EN-MP33A -17
PISTON CRANKSHAFT CYLINDER BLOCK
AND OIL PAN............................ EN-MP33A -27
LUBRICATING SYSTEM......................... EN-LS31A - 1
OIL PUMP AND OIL STRAINER.............. EN-LS31A - 2
OIL FILTER AND OIL COOLER.............. EN-LS31A - 6
FUEL SYSTEM................................ EN-FS23A - 1
INJECTION NOZZLE....................... EN-FS23A - 2
FUEL INJECTION PUMP.................... EN-FS23A -12
COOLING SYSTEM............................. EN-CS31A - 1
COOLANT PUMP........................... EN-CS31A - 2
THERMOSTAT............................. EN-CS31A - 6
AIR INTAKE AND EXHAUST SYSTEM.............. EN-IE15A - 1
ELECTRICAL PARTS........................... EN-CP23A - 1
GENERATOR.............................. EN-CP23A - 1
STARTER................................ EN-CP23A - 2
ENGINE TUNE-UP............................. EN-TU25A - 1
ENGINE TUNE-UP ON TEST BENCH........... EN-TU25A - 4
PROCEDURE FOR INSTALLING JOINTS AND
GASKETS OF ENGINE PIPES.................... EN-PR5A - 1

ENGINE
EN-DS36A-1
DATA AND SPECIFICATIONS
Model F17E
Type Diesel, 4 cycle, 8 cylinder, V, overhead valve, water-cooled, direct injection.
Aspiration Natural aspirate.
Bore and stroke 139 x 142 mm {5.48 x 5.59 in}
Piston displacement 17.238 liters {1.051 cu.in}
Compression ratio 17.6 : 1
Firing order 1-8-4-2-7-3-6-5
Direction of rotation Counterclockwise viewed from flywheel
Compression pressure 2.9-3.2 MPa {30-33 kgf/cm2, 426-469 Ibf/in2} at 200 r/min
Maximum revolution (at full load) 2,200 r/min
Idling revolution 450-500 r/min
Dry weight Approx. 1,180kg{2,602 lb}
Valve seat angle Intake 30°
Exhaust 45°
Valve face angle Intake 30°
Exhaust 45°
Valve timing (flywheel travel) Intake opens 14° before top dead center.
Intake closes 37° after bottom dead center.
Exhaust opens 52° before botoom dead center.
Exhaust closes 16° after top dead center.
Valve clearance (when cold) Intake 0.48 mm {0.0189 in}
Exhaust 0.58 mm {0.0228 in}
Engine oil pump Type Drive Full forced pressure feed by gear pump. By gear
Engine oil cooler Multi plates type, water cooled
Injection nozzle Type Valve opening pressure Multi hole nozzle type 1st : 14.7 MPa {150 kgf/cm2, 2,133 lbf/in2} 2nd : 24.5 MPa {250 kgf/cm2, 3,556 lbf/in2}
Coolant pump Type Drive Forced circulation by volute pump. By gear
Thermostat Type Wax type, bottom bypass system
Injection timing (flywheel travel) 15° before top dead center for No. 1 cylinder on compression stroke.
ENGINE
EN-TS4A-1
TROUBLESHOOTING
Symptom
Possible cause
Remedy/Prevention
Engine overheating
— Coolant
• Insufficient coolant...........................Add coolant.
• Defective thermostat...........................Replace the thermostat.
• Overflow of coolant due to leakage of .........Repair.
exhaust into cooling system
• Coolant leakage from cylinder head gasket......Replace gasket.
• Defective coolant pump.........................Repair or replace.
— Radiator
• Clogged with rust and scale . Clean radiator.
• Clogged with iron oxide due to leakage . Clean coolant passage and
of exhaust into cooling system correct exhaust leakage.
• Clogged radiator core due to mud . Clean radiator.
or other debris
• Defective radiator cap pressure valve . Replace radiator cap.
— Abnormal combustion
• Incorrect injection timing . Adjust injection timing.
• Reduced injection pressure . Adjust injection pressure.
• Poor fuel t . Use good quality fuel.
• Poor nozzle spray . Adjust or replace nozzle.
• Unsatisfactory automatic timer advance angle . . Repair or replace timer.
— Other problems
• Defective or deteriorated engine oil..............Change engine oil.
• Unsatisfactory operation of oil pump............Replace or repair.
• Insufficient oil...................................Add oil.
• Brake drag.........................................Repair or adjust.
Excessive oil consumption
— Pistons, cylinder liners, and piston rings
• Wear of piston ring and cylinder liner..............
• Worn, sticking or broken piston rings...............
• Insufficient tension on piston rings .............
• Unsatisfactory break-in of piston rings..........
• Unsuitable oil (viscosity too low)................
• Incorrectly fitted piston rings...................
(upside down)
• Gaps of piston rings in line with each other. . . .
Replace piston rings and
cylinder liner.
Replace piston rings and
cylinder liner.
Replace piston rings and
cylinder liner.
Replace piston rings and
cylinder liner.
Change oil as required and replace
piston rings and cylinder liners.
Replace piston rings.
Reassemble piston rings.
EN-TS4A-2
ENGINE
Symptom
Possible cause
Remedy/Prevention
Excessive oil consumption
Valve and valve guides
• Worn valve stem Replace valve and valve guide.
• Worn valve guide Replace valve guide.
• Incorrectly fitted valve stem seal Replace the stem seal.
• Excessive lubricant on rocker arm Check clearance of rocker arm
and shaft.
— Excess oil feed |
• Defective oil level gauge Replace oil level gauge.
о Oil level too high Drain excess oil.
— Other problems
• Overcooled engine (low temperature wear) .... Warm up engine before mov-
ingvehicle. Check cooling
system.
• Oil leakage from miscellaneous parts ..........Repair.
Piston seizure
• • • • • • • • Operation Abrupt stoppage of engine after running Operate engine properly, at highspeed Hill climbing using unsuitable gear Select suitable gear. Oil Insufficient oil Add oil. Dirty oil Change oil. Poor quality oil Replace with proper engine oil High oil temperature Repair. Low oil pressure Repair. Defective oil pump Repair oil pump. Reduced performance due to worn Replace oil pump, oil pump Suction strainer sucking air Add oil and/or repair strainer.
— Abnormal combustion See Symptom: "Engine over-
Coolant nearing." See Symptom: "Engine over- heating."
Injection pump .....................................
Lack of power
Refer to CHAPTER IP,
FUEL INJECTION PUMP.
Intake
• Clogged air cleaner...........................
Overheating ..................................
Clean element or replace
element.
See Symptom:
"Engine overheating.”
ENGINE
EN-TS4A-3
Symptom
Possible cause
Remedy/Prevention
Lack of power
— Fuel and nozzle
• Poor nozzle spray.............................
• Clogged nozzle with carbon ...................
• Wear or seizure of nozzle.....................
• Air in fuel, system...........................
• Clogged fuel filter...........................
® Use of poor fuel...............................
— Abnormal combustion ...........................
Piston, cylinder liners, and piston rings ........
Adjust or replace injection
nozzle.
Clean nozzle.
Replace nozzle.
Repair and bleed air from fuel
system.
Replace element.
Use good quality fuel.
See Symptom:
"Engine overheating."
See Symptom "Engine over-
heating."
Difficulty starting engine
— Other problems
• Breakage of turbine or blower.................
Replace the turbine or blower
or turbocharger.
— Electrical system
• Discharged battery..............................
® Defective wiring in starter circuit..............
• Loose or open-circuit battery cable ............
• Breakdown of starter............................
• Break of glow plug or intake....................
air heater (If so equipped)
— Injection pump ..................................
Charge battery.
Repair wiring of starter.
Tighten battery terminal connec-
tions or replace battery cable.
Replace starter.
Replace
Refer to CHAPTER IP,
FUEL INJECTION PUMP.
— Air cleaner
• Clogged element.................................
— Fuel system
• No fuel in tank...............................
• Clogged fuel line.............................
• Air sucked into fuel system through...........
fuel line connections
• Clogged fuel filter...........................
* Loose connection in high-pressure line........
• Water in fuel ................................
Clean the element or replace the
element.
Supply fuel and bleed air from
fuel system.
Clean fuel line.
Tighten fuel line connections.
Replace element.
Tighten sleeve nut of high pres-
sure line.
Drain and clean fuel system
EN-TS4A-4
ENGINE
Symptom
Possible cause
Remedy/Prevention
Diffirultv ctartinn onnino - —— Nozzles
11 1 IL>U 1 ly □ Lui 111 IL| UliyillC
• Seized nozzle Replace nozzle. Broken or fatigued nozzle spring Replace spring.
— Oil system
• Oil viscosity too high Use proper viscosity oil, or install an oil immersion heater and warm up oil.
— Other problems
• • • • Seized piston Replace piston, piston rings, and liner. Seized bearing Replace bearing and/or crankshaft. Reduced compression pressure Overhaul engine. Ring gear damaged or worn Replace the ring gear and/or starter pinion. Improperly adjusted or broken Adjust or replace the accelerator accelerator cable cable.
Rough idling
Injection pump .....................................
— Nozzles
• Uneven injection pressure.....................
• Poor nozzle spray.............................
• Carbon deposit on nozzle tip .................
• Seized needle valve...........................
— Engine proper
• Improper valve clearance.......................
• Improper contact of valve seat ................
• Idling speed too low...........................
• Coolant temperature too low ..................
• Compression pressure of cylinders.............
markedly different from one another
Refer to CHAPTER IP,
FUEL INJECTION PUMP.
Adjust.
Adjust or replace nozzle.
Remove carbon.
Replace nozzle.
Adjust valve clearance.
Replace or repair valve and valve
seat.
Adjust idling speed.
Warm up engine.
Overhaul engine.
Leakage of exhaust gas
— Cylinder head gasket
• Fatigued gasket (aging) ...........................Replace gasket.
• Damage ............................................Replace gasket.
• Improper installation..............................Replace gasket.
ENGINE
EN-TS4A-5
Symptom
Possible cause
Remedy/Prevention
Leakage of exhaust
Cylinder head bolts
• Loose bolts Tighten bolt.
• Elongated bolts Replace bolt.
• Improper tight tightening sequ Cylinder block ening torque or ence Tighten properly.
• Cracking . . . . Replace cylinder block.
• Surface distortion Repair or replace.
• Fretting of cyl' portion (insuff cylinder liner) Cylinder head nder liner insertion cient projection of Replace cylinder liner or cylinder block.
• Cracking.......................................Replace cylinder head.
• Surface distortion.............................Repair or replace.
— Cylinder liners
• Cracking.......................................Replace cylinder liner.
• Corrosion......................................Replace cylinder liner.
• Insufficient projection of cylinder liner......Replace cylinder liner.
— Other problems
• Incorrect injection timing.......................Adjust injection timing.
MEMO
ENGINE
EN-0C15A-1
ENGINE OVERHAUL CRITERIA
SPECIAL TOOL
Prior to starting an engine overhaul, it is n ecessary to have these special tools.
COMPRESSION GAUGE
COMPRESSION GAUGE
FACTORS WHICH DETERMINE WHEN AT ENGINE OVERHAUL IS
NEEDED.
LOWERED COMPRESSION PRESSURE.
a. Before the measurement
a) Correct the valve clearance.
b) Warm up engine [Bring the coolant temperature to about 80°C
(176T)]
c) Charge the batter fully.
d) Remove the air cleaner.
b. Measurement
1) Measure at nozzle holder hole.
a) Remove the nozzle holders.
b) Install the gauge adapter (A) and (B) in the nozzle holder hole.
c) For model equipped with manual control type engine stop system.
Disconnect the engine stop cable (rod) from engine stop lever in
engine stop position with tape or string.
d) For model equipped with electrical motor control type engine stop
system.
Set the engine starter key at "OFF" position, then disconnect the
engine stop motor harness.
e) Connect a compression gauge to the gauge adapter.
f) Drive the engine with the starter and read the compression
pressure.
NOTE: Do not continuously operate the starter for more than 15
seconds at a time.
g) Measure the compression pressure for each cylinder. If the
compression pressure is low, be sure to repeat the measuring.
NOTE: Be sure not to leak through sealing face.
EN-0C15A-2
ENGINE
Unit: MPa {kg/cm2, Lb/in2)
Engine model Compression pressure Difference between each cylinder Engine speed (r/min)
Standard Limit
F17E 2.9-3.2 {30-33, 427-469} 2.55 {26, 369} 0.294 {3, 43} or less 200
c) After the measurement
Make sure the engine starter key is in "OFF" position and then
connect the engine stop motor harness.
WARNING
Do not connect the electric harness with the engine stop motor
while the engine starter key at "ON" position as this operate the
engine stop motor instantaneously and the link lever of the engine
stop motor and the engine stop lever of the fuel injection pump
move, resulting in your fingers caught by the lever.
DECREASED OIL PRESSURE
Check the oil pressure warning lamp when the oil and coolant
temperature is hot [about 80°C {176”F}].
a. If the warning lamp is lighted, check the oil level.
b. Check oil deterioration.
If oil quality is poor, replace with a suitable grade oil.
c. Remove the oil pressure switch and install the oil pressure gauge.
d. Measure the oil pressure at coolant temperature 80°C {176°F} or
more.
Standard oil pressure: 49-490 KPa {0.5-5.0 kg/cm2 7.11-71.10 lb/sq.in}
Service limit: 49 KPa {0.5 kg/cm2 (7.11 lb/sq.in)} or less
S.A.E. GRADE ATMOSPHERIC TEMPERATURE
-10 32 50 70 90100 °F
-23-18 10 21 32 39 °C
40
30
20W/20
15W/40
OTHER FACTORS
a. The blow-by gas increases.
b. The engine does not start easily.
c. Engine output decreases.
d. Fuel consumption increases.
e. Engine makes greater noise.
f. Excessive oil consumption.
ENGINE
EN-MP33A-1
ENGINE MOVING PARTS
CYLINDER HEAD
OVERHAUL
1. Cylinder head cover
2. Cylinder head cover gasket
3. Cylinder head gasket
4. Ventilator assembly
T = Tightening torque: N-m {kgf-cm, lbf-ft}
5. O-ring
6. Flange
7. Cylinder head bolt
8. Cylinder head
EN-MP33A-2
ENGINE
1. Intake valve seat
2. Exhaust valve seat
3. Push rod guide pipe
4. Stud
5. Expansion plug
6. Valve guide bushing
7. Valve stem oil seal
8. Spacer
9. Nut
10. Collar
11. Gasket
12. Cylinder head end plate 23. Valve adjusting screw
13. Intake valve 24. Plug
14. Exhaust valve 25. Retainer ring
15. Valve litter 26. Washer
16. Valve push rod 27. Valve adjusting screw nut
17. Valve stem cap 28. Valve rocker arm
18. Valve spring seat lower 29. Rocker arm support
19. Valve spring inner 30. O-ring
20. Valve spring outer 31. Rocker shaft oil pipe
21. Valve spring seat upper
22. Valve spring retainer lock
ENGINE
EN-MP33A-3
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
NOZZLE HOLDER ADAPTER
CYLINDER HEAD BOLT SOCKET
ENGINE HANGER
12281-1541
09491-1030
VALVE SPRING PRESS
09470-1020
For Valve stem seal
EN-MP33A-4
ENGINE
MPORTANT POINTS - DISASSEMBLY
REMOVE THE FUEL PIPES AND NOZZLE ASSEMBLY.
Refer to "INJECTION NOZZLE" in SECTION FUEL SYSTEM.
REMOVE THE ROCKER ARM ASSEMBLY.
Loosen the rocker arm support bolts and remove the rocker
arm assembly.
NOTE: Attention should be paid to the fact that the rocker arms of
the intake and exhaust valves are mounted different direc-
tions. Keep the components in their disassembly order for
easy reassembly.
REMOVE THE NOZZLE HOLDER ADAPTER.
1. Remove the nozzle holder adapter from the cylinder head
using the adapter wrench, if needs.
Special Tool: Nozzle Holder Adapter Wrench (09503-1010)
REMOVE THE CYLINDER HEAD.
Loosen the cylinder head bolts little by little in three stages
and in the numerical order as shown.
Special Tool: Cylinder Head Bolt Socket Wrench (09621-1110)
LIFT THE CYLINDER HEAD FROM THE DOWELS ON THE CYLINDER
BLOCK AND PLACE IT ON WOODEN BLOCKS.
1. If the cylinder head is difficult to lift off, pry with a chisel
between the cylinder head and block.
NOTE: Do not damage the machined surface of the head or block
when removing the cylinder head.
Special Tools: Engine Hanger (12281-1541)
Bolt (9401-14350)
Wire (09491-1020)
(09491-1030)
ENGINE
EN-MP33A-5
REMOVE THE VALVE SPRINGS.
1. Remove the valve stem retainer locks, upper spring seats, and
inner and outer valve springs from cylinder head.
Special Tool: Valve Spring Press (09470-1020)
2. Remove the intake and exhaust valves.
3. Tag valves to identify their cylinder numbers and to leave out
the valve lapping.
IMPORTANT POINTS - ASSEMBLY
CLEAN THE CYLINDER HEAD THOROUGHLY WITH A SUITABLE
SOLVENT.
NOTE: Be careful not to damage the cylinder head surface.
IF NECESSARY, HAND-LAP THE VALVE AND VALVE SEAT.
Lightly apply lapping compound to the valve face. Install the
valve and then using a special tool, tap and rotate the valve
against the seat.
Special Tool: Valve Lapping Tool (09431-1010)
IF NECESSARY, GRIND THE VALVES AND VALVE SEATS.
NOTE: o Grinding of valves and valve seats should only be per-
formed when hand-lapping does not result in proper
seating.
O After grinding, always recheck the valve sink.
Valve face angle and valve seat angle:
Refer to INSPECTION AND REPAIR.
EN-MP33A-6
ENGINE
IF NECESSARY, REPLACE THE VALVE SEAT.
1. Cut the circumference of a valve head at three places with a
grinder and install it into the seat as shown and weld the
valve to the seat. Then drive the valve and the seat out with a
hammer and a brass block.
2. Valve seat section machining specifications.
Unit: mm {in}
Intake Exhaust
Cylinder head dimension A 61.000-61.019 {2.4016-2.4023} 55.000-55.019 {2.1654-2.1661}
В 11.2-11.3 {0.4410-0.4448} 11.1-11.3 {0.438-0.4448}
Valve seat C 61.085-61.100 {2.405-2.406} 55.085-55.100 {2.168-2.169}
dimension D 9.8-10.0 {0.386-0.393} 8.8-9.0 {0.347-0.354}}
3. Valve seat installation.
Heat the cylinder head to about 80° - 100°C {176-212°F} with
hot water. On the other hand, cool the valve seat with dry ice
or liquid freon for about 30 minutes. Hold the seat with
pincers and place it into the heated cylinder head.
IF NECESSARY, REPLACE THE VALVE GUIDE.
1. Remove the valve stem seal.
2. Using a brass rod and hammer, drive out the valve guide.
3. Install the valve guide.
When installing a new valve guide, drive the guide straight
into the head allowing it to protrude as shown.
NOTE: Apply engine oil lightly to the valve guide outer circumfer-
ence before installation.
IF NECESSARY, REPLACE THE VALVE STEM SEAL.
1. Remove the valve stem seal.
2. Install the valve stem seal.
First, install the lower spring seat and valve. Then apply
engine oil to the lip of the stem seal and drive the stem seal
with a special tool.
Special Tool: Bar (09472-1660)
ENGINE
EN-MP33A-7
NOTE: О After installing stem seal, make sure that check the rub-
ber position for cracks or any other damage.
О Do not use the special tool if its tip (surface contacting
lower spring seat) is worn or deformed.
ASSEMBLE THE CYLINDER HEAD.
NOTE: О Apply engine oil to contact surfaces of all parts.
О Make sure that the valves are installed in the correct cyl-
inders.
О Install the valve springs with their painted side down,
since they have variable pitches.
SM3-1071
Press upper spring seats and install the retainer locks securely
in the upper spring seats.
Special Tool: Valve Spring Press (09470-1020)
NOTE: O When pressing with the valve spring press, be careful
not to damage the stem seals by contacting the upper
seats.
O Drive the valve stem lightly with a hammer to assure
proper fit the valve stem key.
ASSEMBLE THE ROCKER ARM.
Lubricate the rocker arm shaft and bushing.
EN-MP33A-8
ENGINE
Grade Identification label shape Identifying color
1 Green
2 Yellow
3 f Г Z~4 Z' Z^ I Red
INSTALL THE CYLINDER HEAD AND ROCKER ARM ASSEMBLY.
1. Apply engine oil to the valve lifter face and valve lifter guide
then install the valve lifter.
2. Install the cylinder head gasket.
NOTE: О Always use new cylinder head gasket after cleaning the
surface of the cylinder head, cylinder block and head
gasket free of all dirt, water and grease.
О This engine uses three types of cylinder head gaskets
depending on the pistons protrusion.
When replacing the cylinder head gasket, the pistons,
the crank shaft or other parts, select and install the cyl-
inder head gasket according to the following outline.
1) When replacing only the cylinder head gasket.
Determine the grade of the old cylinder head gasket from the
shape of the grade identification label or from color of the
push rod holes sealing rubber, or replace the gasket with one
that matches its product number.
A : Standard cylinder block position
В : Measuring position for piston protrusion
2) When replacing pistons, connecting rods or crank shaft
related parts.
a. Measure and record the piston protrusion from the upper
surface of the cylinder block at two locations in each cylinder
as shown in the figure.
NOTE: Cranking should be performed by rotating the pistons
slowly clockwise.
The piston protrusion is: В-A mm
b. Obtain the average measurement for each bank and select the
grade of the cylinder head gasket according to the following
table.
Unit: mm {in}
Grade Average piston protrusion
1 0.190 {0.0075} or less
2 0.190-0.243 {0.0075-0.0095}
3 0.244 {0.0096} or more
3. Install the cylinder head over the dowels on the cylinder block.
4. Tighten the eighteen cylinder head bolts in the numerical or-
der as shown (fig. 1).
NOTE: Apply engine oil to the bolt threads and under the bolt
head.
Tightening torque: 98 N m {1,000 kgf-cm, 72 lbf-ft}
Special Tool: Cylinder Head Bolt Socket Wrech (09621-1110)
ENGINE
EN-MP33A-9
5. Tighten the eighteen cylinder head bolts in the numerical
order as shown (fig. 2). Torque the bolts to specified
tightening torque.
Specified tightening torque: 294 N-m {3,000 kgf-cm, 216 Ibf-ft}
Fig. 3
6. Retighten the six cylinder head bolts in the numerical order as
shown (fig. 3).
Specified tightening torque: 294 N-m {3,000 kgf-cm, 216 Ibf-ft}
INSTALL THE ROCKER ARM.
1. Install the stem caps.
NOTE: Make sure that both the end of the valve stem and the in-
side of the valve stem cap are free from dust.
Apply engine oil to the valve stem ends and put the stem
caps on the valve stem ends. Be careful not to drop the
caps into the cylinder block.
SM3-624
2. Insert the push rods in correct order, after applying engine oil
to both ends.
3. Mount the rocker arm assembly on the cylinder head, make
sure that the push rods interlock with the adjusting screws.
NOTE: Always loosen the lock nut and raise the adjusting screws
fully to the top.
EN-MP33A-10
ENGINE
INSTALL THE NOZZLE HOLDER ADAPTER.
O-RING
GROOVE
SM3-1080
1. Insert the new О-ring to the nozzle holder adapter.
2. Using a special tool, screw-in into the cylinder head until it is
stopped.
Special Tool: Nozzle holder adapter wrench (09503-1010)
NOTE: When the adapter is removed, never forget to replace the
О-ring with a new one and apply engine oil.
3. Loosen the nozzle holder within 1/2 turns and adjust it so that
tapped holes on the adaptor flange align the direction of 90°
from valve spring line.
ENGINE
EN-MP33A-11
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Cylinder Head Flatness 0-0.05 {0-0.0019} 0.15 {0.0059} Regrind or replace SM3-831
Cylinder Head Cracks and Damage * Using a Dye Penetrant Replace, if necessary. Ж SM3-832
Valve Seating Condition * Using Red Lead Marking Compound There should be good contact around entire circumference of valve head. Hand-lap with lapping com- pound л n
ъ>£. SM3-833
Valve Seat Angle Intake Exhaust 44°-45°15' Regrind or replace valve and/or valve seat. jy MU
Valve face Angle Intake Exhaust 29°45'-30° 44°45'-45°
30° INTAKE x- - --J \/45e EXHAUST SM3-899
Adjusting Screws and Push Rods Damage Replace Visual check^ x SM3-1066
Rocker Arm and Cross Head Wear or Damage Resurface or replace Visual check SM3-1103
Upper Spring Seats and Lower Spring Seats Wear or Damage Resurface or replace Visual check SM3-529
EN-MP33A-12
ENGINE
Unit: mm {in}
inspection Item Standard Limit Remedy Inspection Procedure
Nozzle Protrusion from Cylinder Head Surface 3.00 {0.118} Replace nozzle gasket / / - -V--- I / / CYLINDER _ J> HEAD SM3-391
Intake Valve Sink 0.75-1.00 {0.0295-0.0393} - Replace valve and/or valve seat "0" IS CYLINDER © HEAD SURFACE .
Exhaust Valve Sink 0.45-0.70 {0.0177-0.0275} SIYI3 420
Intake Valve Stem Diameter 11.938-11.950 {0.4670-0.4704} 11.70 {0.4606} Replace / Г I 90’ \ л / I I V/T\ v i ХЛ?'- (b- A: 10 {0.394} SM3-834 В : 30 {1.181} C : 60 {2.362} Г J Г SM3-835
Exhaust Valve Stem Diameter 11.905-11.930 {0.4688-0.4696} 11.70 {0.4606}
Intake and Exhaust Valve Guide Diameter 12.000-12.018 {0.4725-0.4731}
Clearance between Valve Stem and Valve Guide (Intake) 0.05-0.08 {0.0020-0.0031} 0.3 {0.0118}
Clearance between Valve Stem and Valve Guide (Exhaust) 0.07-0.113 {0.0028-0.0044} 0.3 {0.0118}
Rocker Arm Shaft Diameter 27.967-27.980 {1.1011-1.1015} 27.85 {1.0965} Replace rocker arm bushing and/or shaft SM3-291
Rocker Arm Bushing Inside Diameter 28.024-28.079 {1.1034-1.1054} 28.15 {1.1083}
Clearance between Rocker Arm Shaft and Rocker Arm Bushing 0.044-0.112 {0.0018-0.0044}
ENGINE
EN-MP33A-13
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Rocker Arm End Play 0.05-0.65 {0.0020-0.0255} Replace Jf--Ж) WW
Valve Spring Setting Load Inner spring 212.8 N {21.7 kgf, 47.8 Ibf} at 55.5 {2.185} 195.2 N {19.9 kgf, 43.87 Ibf} Replace I id ii SM23-024
Outer spring 554.1 N {56.5 kgf, 124.6 Ibf} at 58.5 {2.303} 507.0 N {51.7 kgf, 113.98 Ibf}
Valve Spring Inner spring Straightness 3.0 {0.118} Replace Г SM3-303
Push Rod Bend 0.5 {0.0196} Replace ч и SM3-292
EN-MP33A-14
ENGINE
CRANKSHAFT PULLEY
OVERHAUL
Crankshaft pulley
Straight pin
Torsional damper
Pulley center
Dust slinger
T = Tightening torque: N-m {kgf-cm, lbf-ft}
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
For Dust slinger
9851-99101 and 9851-36104
ENGINE
EN-MP33A-15
IMPORTANT POINT - DISMOUNTING
REMOVE THE CRANKSHAFT PULLEY.
NOTE: О Use a puller if necessary.
О Do not remove the crankshaft gear unless it considered
absolutely necessary.
IMPORTANT POINTS - ASSEMBLY
IF NECESSARY, REPLACE THE DUST SLINGER.
1. Remove the dust slinger with levers.
2. Using special tools, install the dust slinger.
Special Tools: Dust Slinger Press (09402-1110)
O-ring (9851-99101) and (9851-36104)
NOTE: To prevent wear of the side lip of the oil seal, inject about
0.5 to 1 cm3 {0.031-0.061 cu.in) of grease (lithium-based)
into the "U" groove of the oil slinger.
IMPORTANT POINTS - MOUNTING
INSTALL THE CRANKSHAFT PULLEY.
NOTE: Apply engine oil to thread of the crankshaft.
EN-MP33A-16
ENGINE
FLYWHEEL AND FLYWHEEL HOUSING
SM3-428
IMPORTANT POINTS - ASSEMBLY
IF NECESSARY, REPLACE THE OIL SEAL.
1. Remove the oil seal.
2. Apply a small amount of clean engine oil on the outer
periphery of the oil seal and then install the oil seal to the oil
seal retainer, ensuring that it is flush with the end of the oil
seal retainer.
Special Tool: Oil Seal Guide (09471-1090)
NOTE: Ensure that the lip of the oil seal is coated with oil seal
lubricating grease (lithium-based.)
IF NECESSARY, REPLACE THE FLYWHEEL RING GEAR.
1. Remove the ring gear.
a. Heat the ring gear with a blow torch in a uniform manner
[Approx. 200°C {392°F}J.
b. Using a metal rod as a pad and strike all around the ring gear
in a uniform manner and remove the ring gear.
NOTE: Be careful not to overheat the ring gear.
ENGINE
EN-MP33A-17
2. Install the ring gear.
a. Heat the ring gear uniformly using a blow torch [Approx.
200°C {392°F}.]
b. Drive the ring gear with its chamfered gear teeth facing the
block onto the flywheel using a metal rod.
NOTE: Be careful not to overheat the ring gear.
INSTALL THE FLYWHEEL.
1. Install the flywheel and tighten the bolts through several repe-
tition the tightening order so as to reach specified torque
evenly and gradually, then slacken and tighten them one by
one to the specified torque.
WARNING
The flywheel is heavy, when installing, be careful not to drop it
on your feet.
NOTE: о Align the "O" mark on the flywheel and crankshaft collar
knock-pin.
О When tightening the bolt, apply engine oil to the threads
and flywheel surface of the bolts.
Tightening Torque: 255-284 N-m
{2,600-2,900 kgf-cm, 188-209 Ibf-ft}
2. Install the pilot bearing.
3. Install the lock plate with bolts.
SM3-1697
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Flywheel face alignment 0.3 {0.0118} 0.5 {0.0196} Regrind and/or replace Л SM3-908
EN-MP33A-18
ENGINE
TIMING GEAR AND CAMSHAFT
DESCRIPTION
1. Crankshaft gear
2. Air compressor drive gear
3. Power steering pump drive gear
4. Injection pump drive gear
5. Camshaft drive gear
6. Coolant pump drive gear
7. Engine oil pump drive gear
OVERHAUL
T = Tightening torque: N-m {kgf-cm, lbf-ft}
1. Oil seal
2. Timing gear case cover
3. Gasket
4. Air compressor drive gear
5. Power steering pump drive gear
6. Injection pump drive gear
assembly
7. Idler gear
8. Engine oil pump driven gear
9. Engine oil pump drive gear
10. Crankshaft gear
11. Camshaft gear
12. Coolant pump drive gear
13. Camshaft thrust plate
14. Key
15. Camshaft
16. Front end plate
17. Injection pump drive main gear
18. Spring
19. Injectio pump drive sub gear
20. Retainer ring
ENGINE
EN-MP33A-19
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
CAMSHAFT ATTACHMENT
TIMING GEAR PULLER
09420-1360
EN-MP33A-20
ENGINE
IMPORTANT POINTS - DISMOUNTING
REMOVE THE CAMSHAFT.
Remove the thrust plate set bolts and pull out the camshaft
with gear.
NOTE: Pull the camshaft, slowly turning it so as not to damage
the bearings.
Special Tool: Attachment (09481-1060)
IMPORTANT POINTS - ASSEMBLING
IF NECESSARY, REPLACE THE CAMSHAFT GEAR.
Holding the shaft assembly with a vice through wooden
plates. Remove the nut, then using a gear puller, remove the
gear.
Special Tool: Puller (09420-1360)
ASSEMBLE THE INJECTION PUMP DRIVE GEAR ASSEMBLY.
1. Install the spring and sub gear on to the main gear with
retainer ring.
NOTE: о Be sure painted side of spring face to the sub gear.
О Apply lithium based grease to (A).
O Align the sub gear matching marks with main gear.
О After assembling, make sure that there is clearance
0.6-0.8 mm {0.024-0.031 in} at all around the perimeter
of (B).
ENGINE
EN-MP33A-21
IMPORTANT POINTS - MOUNTING
IF NECESSARY, REPLACE THE TIMING GEAR COVER OIL SEAL.
1. Using a screwdriver, remove the oil seal.
2. Install the new oil seal.
Special Tool: Press (09482-1070)
INSTALL THE CAMSHAFT GEAR TO THE SHAFT.
Install the camshaft gear with thrust plate.
NOTE: When installing the gear to the camshaft:
О Heat the gear in hot water [Approx. 180°C {356°F}], then
install the gear to the camshaft by using a press.
O When tightening the nut, apply engine oil to the treads
and plate surface of the nut.
INSTALL THE TIMING GEAR PLATE.
1. Align the cylinder block and timing gear plate using dowel pin
(A) and (B).
NOTE: Fit the О-ring to the cylinder block water gallery and install
the timing gear plate with a gasket.
INSTALL THE CAMSHAFT.
1. Lubricate all journals of the camshaft and insert the camshaft
assembly into the cylinder block.
Special Tool: Attachment (09481-1060)
NOTE: Insert the camshaft, slowly turning while inserting so that
the bearing will not be damaged.
EN-MP33A-22
ENGINE
2. Align the camshaft gear matching marks with the crank shaft
gear.
NOTE: Incorrect installation can result in engine damage or lower-
ing of engine performance by causing improper injection
timing.
INSTALL THE INJECTION PUMP DRIVE GEAR.
1. Align the injection pump drive gear match mark with the idler
gear.
NOTE: Incorrect installation can results in engine damage or low-
ering of engine performance by causing improper injection
timing.
SM3-1137
MEASURE THE GEAR BACKLASH.
Measure the backlash of each gear using a dial gauge or
plastic gauge.
Replace the gear if necessary.
Refer to INSPECTION AND REPAIR.
NOTE: After measure the gear backlash, apply engine oil to face of
each gear.
INSTALL THE TIMING GEAR COVER.
Using a special tool, install the timing gear cover.
Special Tool: Front Oil Seal Guide (09471-1120)
INSTALL THE OIL PUMP AND OIL STRAINER.
Refer to "OIL PUMP AND OIL STRAINER" in SECTION LUBRI-
CATING SYSTEM.
INSTALL THE OIL PAN.
1. Cut the protrusion of the timing gear plate gasket and fly-
wheel housing gasket from the oil pan mounting surface.
ENGINE
EN-MP33A-23
2. Install the oil pan.
NOTE: Apply the silicon rubber sealer (room temperature valca-
nizer as of three bond No. 1211 or 1215 or equivalent) to
the oil pan gasket.
INSTALL THE AIR COMPRESSOR.
1. Set to top dead center of No.1 or No.7 cylinder by turning the
crankshaft.
2. Before install the air compressor, make sure that the align the
engraved make of air compressor drive gear and engraved
mark of idler gear.
EN-MP33A-24
ENGINE
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Gear Teeth for Pitting or Wear Replace, if necessary. Visual check SM3-845
Camshaft Bend 0.05 {0.0019} Replace * SM3-858
Camshaft Cam Height (Intake) 53.385 {2.1018} 52.585 {2.0703} Replace SM3-374
Camshaft Cam Height (Exhaust) 54.263 {2.1363} 53.463 {2.1048}
Camshaft End Play 0.10-0.33 {0.0040-0.0129} 0.40 {0.0158} Replace thrust bearing '-SM3-848
Oil Clearance between Camshaft Journal and Bearing 0.06-0.15 {0.0024-0.0059} 0.30 {0.0118} Replace shaft and/or bushing y3^ SM3-2487
ENGINE
EN-MP33A-25
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Back Lash Crankshaft Drive Gear to Camshaft Gear 0.081-0.202 {0.0032-0.0080} 0.40 {0.0157} Replace gear, if necessary. оЖМ SM3-844
Idler Gear to Injection Pump Drive Gear 0.054-0.224 {0.0022-0.0088)
Injection Pump Drive Gear to Power Steering Pump Drive Gear 0.061-0.140 {0.0025-0.0055}
Idler Gear to Air Compressor Drive Gear 0.045-0.257 {0.0018-0.0101}
Camshaft Drive Gear to Coolant Pump Drive Gear 0.04-0.261 {0.0016-0.0102}
Oil Pump Drive gear to Oil Pump Driven Gear 0.084-0.289 {0.0034-0.0113}
Clearance between Valve lifter and Valve lifter Guide 0.025-0.075 {0.0010-0.0029} 0.15 {0.0059} Replace tappet © SM3-293 ^—эмз^го
Tappet for Wear Should not be worn unevenly. Replace, if necessary. Visual check SM3-1122
Coolant Pump Oil Jet Clogged Clean SM3-1141
EN-NIP33A-26
ENGINE
INJECTION PUMP DRIVE
1. Drive gear
2. Front end plate
3. O-ring
4. Bearing holder case
5. Ball bearing
6. Key
7. Drive shaft
8. Shim
9. Gasket
10. Bearing retainer
11. Oil seal
12. Oil seal sleeve
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
INJECTION PUMP DRIVE
SHAFT SLEEVE PULLER
INJECTION PUMP DRIVE
O-RING (Used with 09482-1550)
IMPORTANT POINTS - ASSEMBLY
IF NECESSARY, REPLACE THE FUEL INJECTION PUMP DRIVE
SHAFT OIL SEAL SLEEVE.
1. Using a special tool, remove the sleeve.
a. Put the puller (1), (2) onto the sleeve.
b. Insert the hook portion of the puller between shaft and sleeve.
c. Insert the puller (3).
d. After inserting the puller, screw in the center bolt (4), then re-
move the sleeve.
Special Tool: Puller Assembly (09420-1180)
ENGINE
EN-MP33A-27
2. Using special tools, insert the shaft sleeve with a new O-ring.
a. Put the O-ring (5) into the press (6).
b. Insert the new oil seal sleeve with new O-ring into the press
and then insert them into the drive shaft.
c. Hitting the (A) lightly by hammer, contact the press end and
the shaft end (B), with this determine the oil seal sleeve posi-
tion.
NOTE: О Be sure to fit an O-ring on the sleeve and also apply a
liberal coating of oil to the shaft.
О When driving on the shaft sleeve, taking care that the
O-ring does not get cut or torn.
О Once a sleeve has been removed, it cannot be reused.
Special Tools: Press (09482-1330)
O-ring (9851-36104)
ASSEMBLE THE INJECTION PUMP DRIVE SHAFT ASSEMBLY.
Adjust the preload of drive shaft by shims.
Turning Torque: 0.39-1.17 N m {4-12 kgf-cm, 0.290-0.867 lbf-ft}
NOTE: Be sure that there is no loose rattling in the axis direction
of the drive shaft.
EN-MP33A-28
ENGINE
PISTON, CRANKSHAFT, CYLINDER BLOCK
AND OIL PAN
ft}
1. Cylinder block 11. Main hole plug 21. Balance weight bolt
2. Soft washer 12. Piston ring 22. Crankshaft
3. Plug 13. Piston 23. Key
4. Cut off valve 14. Piston pin 24. Crankshaft gear
5. Cylinder liner 15. Retainer ring 25. Oil pump drive gear
6. O-ring 16. Connecting rod bushing 26. Crankshaft thrust bearing
7. Side bolt 17^ Connecting rod 27. Collar
8. Oil jet pipe for piston cooling 18. Connecting rod bearing 28. Crankshaft main bearing
9. Straight pin 19. Sleeve 29. Crankshaft bearing cap
10. Camshaft bearing 20. Oil slinger 30. Main hole plug
ENGINE
EN-MP33A-29
OVERHAUL
: Screw in to an Aluminum body
О : Screw in to a cast iron body
1. Oil level gauge
2. Gasket
3. Cylinder block
4. Tappet chamber cover
5. Oil pan
6. Soft washer
7. Oil drain plug
8. Water gallery cover
9. Seal
10. Oil pan shield
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
For Piston ring
PISTON RING EXPANDER
09442-1220
09441-1310
For Main bearing cap dismounting
CYLINDER BLOCK EXPANDER
09440-1020
EN-MP33A-30
ENGINE
For Cylinder liner
For Piston cooling jet
For Front oil seal sleeve
PRESS
09402-1260
For Rear oil seal sleeve
For Rear oil slinger
For Connecting rod bushing
09407-1010
ENGINE
EN-MP33A-31
REMOVE THE PISTONS WITH CONNECTING RODS.
1. Remove the carbon from the upper end of the cylinder liner
with a scraper or emery paper (recommended: No.150) in a
circular direction.
2. Extract the piston and connecting rod assembly out through
the top of the cylinder.
NOTE: o Remove the connecting rod in such a way that the con-
necting rod does not contact the cooling jet.
Adjust the cooling jet if by any chance the rod and the
jet make.
О Arrange the piston and connecting rod caps in order.
REMOVE THE PISTON RINGS.
Special Tool: Piston Ring Expander (09442-1220)
NOTE: o Handle the piston rings carefully because they are made
of a special casting which is easily broken.
О Keep the rings for each cylinder separate.
REMOVE THE MAIN BEARING CAP.
1. Remove the side bolts.
2. Remove the main bearing cap bolts.
3. Using a special tool, open up the cylinder block.
Special Tool: Cylinder Block Expander (09440-1020)
NOTE: Be careful not to open up the cylinder block expander more
than 90°, as it may damage the block.
4. Remove the main bearing cap.
EN-MP33A-32
ENGINE
REMOVE THE CYLINDER LINER.
Before removing the cylinder liners, be sure to put match
marks on the cylinder block and liner flange with a pen.
NOTE: о Do not put match marks with a punch.
О After removing the cylinder liners, put numbers on their
periphery or arrange them in sequence.
Special Tool: Cylinder Liner Puller (09420-1290)
ENGINE
EN-MP33A-33
IMPORTANT POINTS - ASSEMBLY
INSPECT THE PISTON COOLING JET POSITIONING.
NOTE: o Do not remove the cooling jet except when performing
overhauls or when otherwise necessary.
О In the event that the cooling jet is removed, be sure to
replace it on the cylinder.
Inspection of the piston cooling jet positioning procedure are
as follows.
1. Remove the piston cooling jet connector bolt and install a
special tool.
Special Tool: Connector Bolt (9001-24272)
2. Use a commercially available oil pump [pressure about 2 kg/
cm2 {28.44 lb/sq.in}, flow rate about 2.5L/min {2.64 US.qts/
min}].
3. Prepare fresh engine oil.
4. Connect the oil lines.
Connect the oil pump outlet to a special tool (connector bolt).
5. Install a special tool on the cylinder block.
SM3-580
Special Tool: Target Plate (09444-1320)
SM3-581
6. Operate the oil pump, and with pressure at about 196 kPa {2
kg/cm2, 28.44 lb/in2}, pump fresh oil from the jet, and perform
a spray test. Conditions are normal if the center of stream hits
a target plate 0Ю mm {0.39 in}.
WARNING
Engine oil is flammable.
This spray test should be done in a well ventilated room and
away from any open flames or electric sparks.
EN-MP33A-34
ENGINE
7. If the spray of the cooling jet messes the circle on the target
plate, realign the cooling jet nozzle, using a special tool.
Special Tool: Adjuster Bar (09472-1620)
8. Spray pattern.
When inspecting the piston cooling jet positioning, check that
the spray is dispersed as shown in "4" and not as in "1", "2", or
"3" in the illustration at left.
NOTE: If the tip of the jet is damaged so that the spray pattern is
bad, replace the jet with a new one. When replacing the
cooling jet, always inspect the new piston cooling jet's
positioning.
9. After inspecting the piston cooling jet positioning, remove the
special tool (connector bolt), then install the cooling jet on the
cylinder block using the correct mounting bolt with’soft
washer.
Tightening Torque: 44-49 N-m
{450-500 kgf-cm, 33-36 Ibf-ft}
10. After installing the piston, make sure that there is no interfer-
ence between the cooling jet and the piston when the piston
is at bottom dead center.
IF NECESSARY, REPLACE THE MAIN OIL HOLE PLUG.
Fit two О-rings onto the plug of the main oil hole, be sure to
coat it with engine oil, then insert it into the cylinder block.
Evenry coat the taper plug of the oil hole with unaerobic ad-
hesive (as of Three bond No.203 or equivalent), then install
the taper plug. As shown in the detailed drawing, ensure that
plugs (3) and (4) do not protrude by more than 2 mm {0.0787
in}.
Special Tool: Main Oil Hole Plug Wrench (09412-1070)
ENGINE
EN-MP33A-35
INSERT THE CYLINDER LINER INTO THE CYLINDER BLOCK.
1. Install the О-ring to the cylinder block.
2. Apply the silicon rubber sealer (Room Temperature Valcanizar
as of Three bond No.1211 or equivalent) to the position ® to
cylinder liner.
О-ring (B); Ring color: light green. Marking color: pink.
О-ring (C); Ring color: black, Marking color: pink.
2. Make sure that the "9" mark at the top of the cylinder liner
aligning with "0" mark on the cylinder block.
SM3-1150
MEASURE THE PROTRUSION OF THE CYLINDER LINER FLANGE.
Install a special tool and measure the protrusion of the top
end of the cylinder liner from the cylinder block.
Special Tool: Cylinder Liner Puller (09420-1210)
Tightening Torque: 9.80 N m {100 kgfcm, 7.23 lbf-ft}
Standard: 0.04-0.10 mm {0.0016-0.0039 in}
IF NECESSARY, REPLACE THE CRANKSHAFT FRONT OIL SEAL
SLEEVE.
1. Remove the oil seal sleeve using a special tool.
Special Tool: Eye Bolt (09433-1010)
2. Install a new sleeve.
Be sure to fit an new О-ring on the sleeve and also apply a
liberal coating of oil to the pulley center side.
When driving on the crankshaft sleeve, use a crankshaft
sleeve press, taking care that the О-ring does not get cut or
torn.
Special Tool: Press (09402-1260)
EN-MP33A-36
ENGINE
IF NECESSARY, REPLACE THE CRANKSHAFT REAR OIL SEAL
SLEEVE.
1. Remove the crankshaft sleeve using a special tool.
Special Tool: Puller (09420-1060)
2. Install a new sleeve.
Be sure to fit an new O-ring on the sleeve and also apply a
liberal coating of oil to the crankshaft side.
When driving on the crankshaft sleeve, use a crankshaft
sleeve press, taking care that the O-ring does not get cut or
torn.
Special Tool: Press (09402-1070)
UNDER SIZE BEARING FOR CRANKSHAFT.
NOTE: o If the wear of the crankshaft pin or journal matches an
undersize bearing 4 types 0.25 mm {0.0098 in}, 0.50 mm
{0.0197 in), 0.75 mm {0.0295 in), 1.00 mm {0.0394 in), re-
place the bearing with an undersized one.
О The bearing is a set consisting of upper and lower
halves. Consequently, be sure to replace the bearing as a
set.
Unit: mm {in}
Bearing size Outside diameter
Crank pin Journal
0.25 83.695-83.715 {3.2951-3.2958} 89.66-89.68 {3.5400-3.5307}
0.50 83.445-83.465 {3.2853-3.2860} 89.41-89.43 {3.5201-3.5208}
0.75 83.195-83.215 {3.2754-3.2761} 89.16-89.18 {3.5103-3.5110}
1.00 82.945-83.965 {3.2656-8.2663} 88.91-88.93 {3.5004-3.5011}
INSPECT THE FILLET OF THE CRANK PIN AND JOURNAL.
Dimension of Fillet (R): 5.0-5.5 mm {0.196-0.216 in}
CORRECT
WRONG
SM3-441
ENGINE
EN-MP33A-37
INSTALL THE CRANKSHAFT.
1. Install the crankshaft bearings on the cylinder block and bear-
ing cap.
NOTE: О Install the bearing with the oil hole onto the block side
and the bearing without the oil hole onto the cap side.
О Apply fresh engine oil to each bearing surface.
2. Install the crankshaft on the cylinder block.
3. Insert the crankshaft thrust bearings along the groove of the
cylinder block.
4. Install the thrust bearings on the No.5 bearing cap sides.
NOTE: Apply fresh engine oil to each thrust bearing surface.
5. Using the special tool, open up the cylinder block.
Special Tool: Cylinder Block Expander (09440-1020)
NOTE: Be careful not to open up the cylinder block expander more
than 90° as it may damage the block.
6. Install the crankshaft bearing caps.
a. Align the collar on the cylinder block and bearing caps.
b. Install them from the flywheel side.
SM3-1171
7. Tighten the bearing cap bolts in three stages following the
tightening order.
Tightening Order: 1-2-3-4-5-6-7-8-9-10
Tightening torque
1 st step 50% of specified torque
2nd step 75% of specified torque
3rd step 100% of specified torque
Tightening Torque: 402-441 N-m
{4,100-4,500 kgf-cm, 297-325 Ibf-ft}
NOTE: О Apply engine oil to the bolt threads and under the bolt
head.
О Make sure that the crankshaft rotates smoothly.
О Inspect the crankshaft end play.
8. Tighten the side bolts in three stages following the tightening
order.
Tightening Order: 11-12-13-14-15-16-17-18-19-20
Tightening Torque: 117-147 N-m
{1,200-1,500 kgf-cm, 87-108 Ibf-ft}
EN-MP33A-38
ENGINE
IF NECESSARY, REPLACE THE CONNECTING ROD BUSHING.
1. Install the spindle and the guide on the bracket.
Special Tool: Connecting Rod Press Set (09407-1010)
NOTE: The tapered face on the spindle should be upward.
2. Mount the connecting rod. Install the guide on the connecting
rod housing with the bolt.
Tightening Torque: 98.07-117.67 N m
{1,000-1,200 kgf-cm, 72-86 Ibf-ft}
NOTE: Use following bolt:
Length: 165 mm {6.496 in)
3. Remove the spindle from the bottom.
4. Reinsert the spindle from the top onto the connecting rod
bushing.
NOTE: The tapered face on the spindle should be downward.
5. Install the cap on the spindle and push out the bushing using
a press.
6. Install a new connecting rod bushing.
a) Debar and clean the connecting rod bushing insert bore.
b) Mount a new connecting rod bushing on the spindle and
mount the cap. Tighten the cap set screw.
c) Make sure that the bushing oil hole coincides with the oil hole
of the connecting rod.
d) Install the bracket set screw in the bracket.
e) Press in the new bushing using a press.
NOTE: Make sure that the spindle groove coincides with the
bracket set screw.
f) Remove the spindle, and dismount the connecting rod from
the special tool.
ENGINE
EN-MP33A-39
FOR RIGHT BANK
ASSEMBLE THE PISTON.
1. Assemble the piston and connecting rod as shown.
NOTE: о R marks at the bottom of the pistons indicate use for the
right bank, L marks use for the left bank.
О Make sure that the О-mark at the top of the piston and
the arrow mark at the connecting rod in same directions.
"0" MARK
AND
ARROW
MARK
ARROW
MARK
SM3-295
INSTALL THE PISTON RING.
1. Install the piston rings in the sequence oil ring, third ring
second ring and top ring with the identification mark at the
top of the ring facing up.
NOTE: Apply oil to the piston rings.
Special Tool: Piston Ring Expander (09442-1220)
Ring No. Description
Top Pllff
2nd Zlifii
3rd
Oil
2. Connect the ends of the coil expander and then fit the coil
inside the piston ring after ensuring that the gap of the piston
ring is 180° away from the joint of the coil.
EN-MP33A-40
ENGINE
3. Arrange the piston rings so that their gaps are equally spaced.
INSTALL THE PISTON WITH CONNECTING ROD INTO THE CYLIN-
DER LINER.
1. Apply engine oil to the piston, cylinder liner and connecting
rod bearing surface.
2. Using a special tool, hold the piston rings and push the piston
with connecting rod assembly with a wooden rod.
NOTE: О Be sure that the О-mark on the top of the piston is near-
est the identification marks of cylinder block and liner or
water gallery cover side as shown.
The arrow marks on the pistons should face the timing
gear side.
о When installing the piston with connecting rod assem-
bly, be sure that the piston cooling jet is not struck by
the connecting rod. If the piston cooling jet is struck,
adjust or replace it.
Special Tool: Piston Ring Holder (09441-1310)
INSTALL THE CONNECTING ROD CAP.
1. Apply engine oil to the bearing surface.
2. Align the match marks on the connecting rod and cap.
ENGINE
EN-MP33A-41
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Cylinder Liner Inside Diameter 139 {5.47} 140.2 {5.5196} Replace liner 25 mm {0.984 in} SM3-910
Clearance between Piston and Cylinder Liner 0.206-0.235 {0.0082-0.0092} Replace piston and/or liner. /^^4 (? (C i у о ® V7 ILL i L)
E±E J; <0
।
— SM3-432 I SM3-313
Clearance between Piston Pin and Piston Pin Hole 0.001-0.015 {0.00004-0.00059} 0.005 {0.0019} Replace piston, piston pin and/or bushing. i г iL J
Clearance between Piston Pin and Connecting Rod Bearing 0.025-0.043 {0.00099-0.00169} 0.10 {0.0039} SM3-859
Crankshaft End Play 0.11-0.24 {0.0044-0.0094} 0.5 {0.0196} Replace thrust bearing I" ' SM3-1176
Connecting Rod Wear or Damage * Use a dye penetrate Replace SM 3-363
Connecting Rod Oil Hole Clogged Clean SM3-424
EN-MP33A-42
ENGINE
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Connecting Rod Straightness 0.1 {0.0039} per 200 {7.874} Replace / SM3-330
Connecting Rod Twist 0.1 {0.0039} per 200 {7.874} Replace □Ж ' SM3-331
Crank Pin Diameter 84 {3.3070} 83.80 {3.2992} Regrind undersize у ШУ SM3-860
82.80 {3.2598} Replace crankshaft
Clearance between Connecting Rod and Crank Pin 0.056-0.107 {0.0023-0.0042} 0.30 {0.0118} Replace bearing v SM3-300
Main Bearing Spread 116.75-117.25 {4.5965-4.6161} - Replace bearing
Connecting Rod Bearing Spread 89.75-90.25 {3.5335-3.5531} - .S SM3-298
Crankshaft Oil Hole Clogged Clean ЖжТ SM3-434
Crankshaft Cracks and Damage * Use a dye penetrate Replace У ж ну ж SM3-435
ENGINE
EN-MP33A-43
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Crankshaft Bend 0.06 {0.0023} Replace SM3-861
Piston Ring Breadth Ring No.: Top 3.306 {0.1302} 3.156 {0.1243} Replace \ к J / SM3-379
2nd 3.5 {0.1378} 3.35 {0.1318}
3rd 3.5 {0.1378} 3.35 {0.1318}
Oil 5.0 {0.1969} 4.95 {0.1948}
Piston Ring Groove Breadth Ring No.: Top 3.5 {0.1378} 3.65 {0.1438} Replace SM3-301
2nd 3.5 {0.1378} 3.65 {0.1438}
3rd 3.5 {0.1378} 3.65 {0.1438}
Oil 5.0 {0.1969} 5.05 {0.1989}
Clearance between Piston Ring and Piston Ring Breadth Ring No.: Top Not easily measured
2nd 0.07-0.11 {0.0028-0.0043} Replace piston ring and/or piston
3rd 0.07-0.11 {0.0028-0.0043}
Oil 0.04-0.08 {0.0016-0.0031}
Piston Ring Gap * Insert the Piston Rings Where the Wear of the Liner is Small. Ring No.: Top 0.45-0.60 {0.0178-0.0236} 1.5 {0.0590} Replace
2nd 0.45-0.60 {0.0178-0.0236} 1.5 {0.0590} M SM3-302
3rd 0.45-0.60 {0.0178-0.0236} 1.5 {0.0590}
Oil 0.35-0.55 {0.0138-0.0216} 1.0 {0.0393}
Cylinder Block Flatness 0.05 {0.0019} 0.15 {0.0059} Regrind and/or replace SM3-314
EN-MP33A-44
ENGINE
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Flywheel Face Alignment 0.3 {0.0118} 0.5 {0.0196} Regrind and/or replace © 5M3-1178
Cylinder Liner Protrusion 0.04-0.10 {0.0016-0.0039} Replace
ZVZVZ'Zd SM3-1092
/ PROTRUSION
Crankshaft Journal Diameter 110 {4.3307} -0.20 {-0.0078} Regrind undersize
108.80 {4.2834} Replace crankshaft kCvtW )) // Г • SM 3-860
Clearance between Crankshaft Journal and Main Bearing 0.066-0.117 {0.0026-0.0046} 0.30 {0.0118} Replace bearing SM3-1177
ENGINE
EN-LS31A-1
LUBRICATING SYSTEM
LUBRICATING SYSTEM DIAGRAM
Unit: kPa {kgf/cm2, Ibf/in2}
1. Oil pan
2. Suction strainer
3. Oil pump
4. Oil pump safety valve
784-931 {8.0-9.5, 114-135}
5. Delivery pipe
6. Oil cooler
7. Oil cooler safety valve
363-421 {3.7-4.3, 52.7-61.14}
8. Cut off valve
156. 9-196.1 {1.6-2.0, 22.8-28.4}
9. Bypass oil filter
10. Alarm device for clogging of oil
filter 147 {1.5,21.3}
11. Regulator valve
363-421 {3.7-4.3, 52.7-61.1}
12. Full-flow oil filter
13. Oil pressure unit
14. Oil filter safety valve
127.5 -166.7 {1.3-1.7,18.5-24.1}
15. Main oil hole (Left bank)
16. Piston cooling jet
17. Fuel injection pump drive shaft
18. Valve mechanism (Left bank)
19. Timing gear
20. Crankshaft
21. Camshaft
22. Piston
23. Sub oil hole (Right bank)
24. Low cup valve
25. Valve mechanism (Right bank)
26. Fuel injection pump
27. To Oil pan
28. Air compressor
29. Adjusting screw
30. Valve lifter
31. Valve stem seal
32. From cylinder head
33. Valve rocker arm
34. Valve guide
35. Valve
EN-LS31A-2
ENGINE
OVERHAUL
OIL PUMP AND OIL STRAINER
14
11
T = Tightening torque: N m {kgf-cm, lbf-ft}
1. Oil pump cover 6. Shim 11. Oil pump
2. Drive gear 7. Spring seat 12. Oil strainer
3. Oil pump body 8. Retainer ring 13. Oil feed pipe
4. Oil pump safety valve 9. O-ring 14. Strainer bracket
5. Oil pump safety valve spring 10. Plate 15. Oil pump inlet pipe
ENGINE
EN-LS31A-3
IMPORTANT POINTS - MOUNTING
OIL PUMP SAFETY VALVE AND RETAINER RING.
1. Adjust the safety valve opening pressure.
Using shims
Pressure: 784-931 kPa {8.0-9.5 kgf/cm2,114-135 lbf/in2}
Shim thickness: 1.2 mm {0.0472 in}
2. Retainer ring
Install a retainer ring to the safety valve holder.
NOTE: Bevelled edge of retainer ring towards outside.
INSTALL THE OIL STRAINER.
NOTE: Be sure to install O-ring and tighten the oil pipe set bolts
temporary, then tighten the set bolts to the specified
torque.
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Gear Backlash 0.10-0.26 {0.006-0.011} 0.4 {0.0157} Replace SM3-1117
EN-LS31A-4
ENGINE
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Drive Gear Shaft Diameter 23.967-23.980 {0.9436-0.9440} - Replace shaft and/or bushing SM3-1123
Bushing Inside Diameter 24.020-24.041 {0.9457-0.9464}
Clearance between Drive Shaft and Bushing 0.040-0.074 {0.0016-0.0029} 0.19 {0.0074} SM3-1107
Driven Gear Shaft Diameter 30.939-30.955 {1.2181-1.2187} - Replace
Driven Gear Inside Diameter 30.995-31.020 {1.2187-1.2212} - Replace г"""Il / Xi _ / SM3-1124
Clearance between Driven Gear and Shaft 0.040-0.081 {0.0016-0.0031} 0.19 {0.0035} Replace bushing and/or shaft W SM3-317
Clearance between Gear and Case 0.05-0.13 {0.0020-0.0051} 0.18 {0.0071} Replace gear and/or case SM3-1114
Gear End Play 0.06-0.105 {0.0024-0.0041} 0.15 {0.0059} Replace gear and/or case SM3-1112
Gear Teeth Pitting or Wear Replace, if necessary. Visual check SM3-845
ENGINE
EN-LS31A-5
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Oil pump safety valve for Wear or Damage -• - Replace, if necessary. Visual check
Gear Backlash between Crankshaft Gear and Oil Pump Drive Gear 0.10-0.26 {0.0040-0.0102} 0.4 {0.0157} Replace gear ’ ° ' SM3-844
EN-LS31A-6
ENGINE
OIL COOLER AND OIL FILTER
OIL FILTER
1. Oil filter cap
2. Regulator valve
3. Relief valve
4. Cut-off valve
5. O-ring
6. Oil filter element
7. Spring seat
8. Spring
9. Oil filter element cover
10. Center bolt
11. Drain plug
12. Oil cooler element
T = Tightening torque: N-m {kgf-cm, Ibf-ft}
13. Gasket
14. Oil cooler case
15. Safety valve
16. Coolant drain cock
INSPECTION AND REPAIR
Inspection Item Standard Limit Remedy Inspection Procedure
Oil Cooler Air Thickness Air Pressure: 588.39 kPa {6 kgf/cm2, 85.3 lbf/in2} — Replace, if necessary. 6kgW^ a|r WATER *~AIR I ELEMENT ,-лл * I - * J SM3-1088
Valve and Springs of Oil Cooler and Oil Filter Wear or Damage Replace, if necessary. 1. Sliding face of valve for possible damage. 2. Valve move smoothly.
ENGINE
EN-FS23A-1
FUEL SYSTEM
EN-FS23A-2
ENGINE
INJECTION NOZZLE
Maker ZEXEL (ZXL)
Type 2 Spring Type
DESCRIPTION
L : Needle valve full-lift
I : Needle valve pre-lift
ENGINE
EN-FS23A-3
OVERHAUL
1. Retainer nut
2. Nozzle assembly
59-78
{600-800, 44-57}
15 T= 15-19
{150-200,11-14}
14 T = 30-39
{300-400, 22-29}
13
3. Pin
SPECIAL TOOLS
4. Spacer
5. Lift piece
6. Second pressure spring
seat
7. Second pressure spring
8. Second pressure
adjusting shim
9. Nozzle holder
10. Push rod
11. First pressure spring
12. First pressure adjusting
screw
13. Gasket
14. Gap nut
15. Leakage bolt
T = Tightening torque: N-m {kgf-cm, Ibf-ft}
Prior to starting an engine overhaul, it is necessary to have these special tools.
NOTE: ZXL means ZEXEL
IDLER GEAR SLIDING HAMMER
NOZZLE HOLDER ADAPTER
ADJUSTING DEVICE
157892-4620: All in one set, ZXL make
EN-FS23A-4
ENGINE
IMPORTANT POINTS - DISMOUNTING
CLEAN OFF SURROUNDING AREA OF THE NOZZLE AND THE FUEL
LINE CONNECTORS.
NOTE: If foreign matter is allowed to enter the combustion
chamber, engine trouble may result.
REMOVE THE FUEL INJECTION PIPE.
NOTE: Cover open ends of the pipes and fuel injection pump to
prevent entry of dirt.
REMOVE THE NOZZLE HOLDER ASSEMBLY.
Remove the nozzle clamp bolt and nozzle clamp, then remove
the nozzle holder assembly by hand.
NOTE: After removal of the nozzle holder, cover the nozzle holder
with cloth. Also cover the cylinder head with a cloth to pre-
vent dust from getting in.
IMPORTANT POINTS - INSPECTION
CHECK THE NOZZLE OPERATING PRESSURE.
1. Install the nozzle older assembly to the nozzle tester, and
operate the lever at the rate of about 50 to 60 times per
minute.
WARNING
О Diesel fuel is flammable.
This nozzle adjusting should be done a well ventilated room
and away from any open flames or electric spark.
О The spray must always be covered. Keep your face and body
away from the spray. This is because of the risk of fuel oil get-
ting in your eyes or passing into your body.
2. At this time, check that the nozzle operating pressure (first
opening pressure) is in the specified vlaue. If not, disassemble
and adjust the nozzle holder assembly.
First opening pressure: K13C:17.2-18.0MPa{175-183Kgf/ail}
K13D: 15.2-16.0MPa{155-163Kgf/cri}
F17E: 15.2-16.0MPa{ 155-163Kgf/cni}
TEST THE SPRAY PROFILE.
In the case of the new nozzle, operating the lever at the rate of
30 to 60 strokes per minute, and for a used nozzle, operate the
lever at the rate of 15 to 60 strokes per minute.
ENGINE
EN-FS23A-5
TEST THE FUEL LEAKAGE.
When checking for fuel leakage from the nozzle, apply a pres-
sure of about 0.98-1.96 MPa {10-20 kg/cm2, 142-284 lb/in2}
lower than the correct injection pressure to the nozzle by
means of the nozzle.
TEST THE NOZZLE SINKING.
Wash the nozzle proper with diesel fuel oil, them immerse it in
diesel fuel oil.
Next slide the needle inside the nozzle proper and ensure that
it move smoothly. The needle valve should fall under its own
weight when withdrawn vertically about 1/3 and released. If
its motion is sluggish, replace the nozzle with a new one.
ASSEMBLING
NOTE: О The steps below for adjustment are made during parts assembly.
o Because the nozzle holder is adjusted in 1/100 mm units, it must be thoroughly washed to completely remove all
dirt and foreign objects.
Work steps
1. Adjustment of first opening pressure Adjust first opening pressure with the adjusting screw.

2. Checking of needle valve full lifts Check with nozzle cover method.

3. Checking of pre-lift Check with nozzle cover method. NOTE: If pre-lift is not within specified value, replace pins, lift piece, spacer and nozzle assembly with the nozzle service kit.

4. Checking of second opening pressure Check with nozzle cover method.

5. Adjusting of second opening pressure Adjust second opening pressurewith adjusting shim.

6. Replacement of the retaining nut Replace adjustable retaining nut with normal retain- ing nut.

7. Final inspection Check condition of the fuel spray with the nozzle and nozzle holder assembled.
EN-FS23A-6
ENGINE
FIRST PRESSURE^ ADJUSTING SCREW SECOND PRESSURE PUSH ROD .-FIRST PRESSURE ^SPRING

ADJUSTMENT OF FIRST OPENING PRESSURE.
1. Clamp the plate (special tool) into a vice.
Special tool: Plate assembly (15944-9520.ZXL make)
2. With the cap nut side facing downward, attach the nozzle
holder body to the plate.
3. Insert the adjusting shim, the second pressure spring and the
spring seat, in that order into the nozzle holder body.
NOTE: The second pressure spring is the same as the first
pressure spring.
4. Put the pins, the lift piece, and the spacer onto the nozzle
holder body.
5. Put the pin and the nozzle assembly onto the spacer.
6. Put gasket (special tool) onto the nozzle, then use adjustable
retaining nut (special tool) to hold the nozzle in place on the
nozzle holder.
Special tool: Gasket (157892-1500....ZXL make)
Adjustable retaining nut (157892-4000...ZXL make)
NOTE: О Check to make sure the pin is all the way in the nozzle
and then tighten adjustable retaining nut.
О Finger-tighten the adjustable retaining nut until it no
longer turns and tighten the nut to specified torque.
Tightening torque: 59-78 N-m {600-800 kgf-cm, 44-57 lbf-ft}
7. Turn over the nozzle holder, body so that the cap nut side is
facing upward, and attach the nozzle holder body to the plate.
8. Insert the second pressure push rod, the first pressure spring
and the first pressure adjusting screw, in that order, into the
nozzle holder body.
9. Attach the gasket and the cap nut onto the first pressure
adjusting screw.
ENGINE
EN-FS23A-7
10. Attach the nozzle and nozzle holder assembly to the nozzle
tester.
11. Adjust the first opening pressure to the specified value with
the first pressure adjusting screw.
First opening pressure: К1 зС:17.2-18.0MPa{175-183Kgf/cnl}
.
KI 3D: 15.2-16.0MPa{155-163Kgf/cnl}
F17E: 15.2-16.0MPa{155-163Kgf/cnl}
12. Hold the nozzle holder body using a cresent wrench, then
tighten the cap nut to the specified torque.
Tightening torque: 29-39 N-m {300-400 kgf-cm, 22-28 Ibf-ft)
CHECKING OF NEEDLE VALVE FULL-LIFTS.
1. Attach the gasket {special tool) and the plug (special tool) onto
the adjustable retaining nut.
Special tool: Gasket (026508-1140...ZXL make)
Plug (157892-1600...ZXL make)
2. Turn over the nozzle holder body so that the cap nut side is
facing upward, and attach the nozzle holder body to the plate.
3. Attach the holder (special tool) to the cap nut.
Special tool: Holder (157892-4100..ZXL make)
4. Temporary tighten the attachment nut (special tool) onto the
holder.
Special tool: Attachment nut (157892-1000..ZXL make)
EN-FS23A-8
ENGINE
5. Screw the pin (special tool) into dial gauge.
Special tool: Pin (157892-4200)
(157892-4300)
6. Tighten the attachment nut so that it holds the dial gauge in
place in the nozzle holder assembly and so that the pin is in
contact with the push rod upper surface.
NOTE: o Attach the dial gauge into place so that it can measure a
stroke of approx. 2 mm {0.079 in).
О Do not tighten the nut too much, the dial gauge shaft will
become stuck.
Г SECOND
PRESSURE
PUSH ROD
GASKET AND
PLUG
PRESSURE—►
7. Attach the nozzle and nozzle holder assembly to the nozzle
tester and zero the dial gauge.
8. Operate the nozzle tester to bleed air in the retaining nut.
Check to make sure there are no fuel leaks.
9. Operate the nozzle tester to raise pressure to 34.3-44.1 MPa
{350-450 kgf/cm2, 4,979-6,400 lbf/in2} and needle valve is lifts
fully. At this time, record the dimensions of full-lifts as "L".
NOTE: This check is made to determine whether the nozzle seat is
abnormally worn and whether the nozzle is correctly as-
sembled.
ENGINE
EN-FS23A-9
CHECKING OF PRE-LIFT.
1. When needle valve is full-lifted, release the nozzle tester
handle to lower pressure inside the tube and decrease the
needle valve lift value (value indicated on dial gauge).
2. When the second pressure spring stop to action and needle
valve drop ends (needle valve lift dimension " I") read the dial
gauge indication, checking to make sure it is within specified
values.
Pre-lift measuring points:
Read the dial gauge at [First opening pressure + approx. 1
MPa {10 kgf/cm1 2, 142 lbf/in2}.
NOTE: Watch the pressure drop to find the point.
Pre-lift U): K13C:0.07mm{0.0028in}
KI 3D(prestroke control pump):0.07mm{0.0028in}
KI 3D(P-type pump) :0.09mm{0.0035in}
F17E:0.07mm{0.0028in}
3. If pre-lift is not within specified value, replace the pins, the lift
piece, the spacer and the nozzle assembly with the nozzle ser-
vice kit.
4. CHECKING OF SECOND OPENING PRESSURE.
1. Check the pre-lift, then operate the nozzle tester to raise
pressure to 34.3-44.1 MPa {350-450 kgf/cm2, 4.979-6.400 Ibf/
in2} and lift the needle valve fully.
2. Release the nozzle tester handle to lower pressure inside the
tube, all the while watch the dial gauge indicate.
EN-FS23A-10
ENGINE
WHEN NEEDLE VALVE LIFT
: I + 0.05 mm
FULL-LIFT
- DIAL GAUGE-
3. Read the valve indicated on the pressure gauge at the instant
the dial gauge needle indicates the specified needle valve lift
value (pre-lift “ t" + 0.05 mm {0.0020 in}).
Second opening pressure: KI 3C:24.5-25.5MPa{250-260Kgf/cn5}
KI 30:22.6-23.6MPa{230-240Kgf/cM}
F17E:22.6-23.6MPa{230-240Kgf/cnl}
-PRESSURE GAUGE-
OPENING OPENING {350-450 kgf/cm2}
PRESSURE PRESSURE
PRESSURE----------►
ADJUSTMENT OF SECOND OPENING PRESSURE.
1. If the second opening pressure deviates from the specified
value, and the amount of that deviation is small, readjust the
first opening pressure but within the specified value.
NOTE: о If the second opening pressure is lower than the specified
value:
Readjust the first opening pressure to maximum speci-
fied value, then measure the second opening pressure.
О If the second opening pressure is higher than the speci-
fied value:
Readjust the first opening pressure to minimum specified
value.
2. If the first opening pressure has been readjusted and the
second opening pressure still diviates from the specified
value, disassemble the nozzle side of the nozzle holder and
remove the adjusting shim.
3. If the second opening pressure is higher than the specified
value, replace the adjusting shim with a thinner one.
4. After replacing the adjusting shim, remeasure the second
opening pressure, and adjust the pressure until it comes to
the specified value.
Second pressure adjusting shim line-up
Inside diameter: 9.5 mm {0.374 in}
Outside diameter: 4.5 mm {0.177 in}
Unit: mm {in}
Parts number Shim thickness Parts number Shim thickness
150538-4900 0.40 {0.0157} 150538-5300 0.56 {0.0220}
150538-5000 0.50 {0.0197} 150538-5400 0.58 {0.0228}
150538-5100 0.52 {0.0205} 150538-5500 0.60 {0.0236}
150538-5200 0.54 {0.0212} 150538-5600 0.70 {0.0276}
ENGINE
EN-FS23A-11
REPLACEMENT OF THE RETAINING NUT.
1. Remove the dial gauge, the nut, the holder and the gasket
from the cap nut.
2. Remove the adjustable retaining nut and the gasket, and
attach a normal retaining nut.
Tightening torque: 59-78 N-m (600-800. kgf-cm, 44-57 Ibf-ft}
7. FINAL INSPECTION
1. Attach the nozzle holder to the nozzle tester and check the first
opening pressure, the spray condition, the seat's oil seal, and
whether there are any oil leaks from any part.
2. To replace the nozzle, replace the nozzle, the lift piece, and the
spacer, which are all in one set, with the nozzle service kit.
NOTE: Replacing only the nozzle will cause the amount of pre-lift
to deviate from the specified value.
IMPORTANT POINT - MOUNTING
INSTALL THE NOZZLE HOLDER ASSEMBLY.
NOTE: Tighten the nozzle holder bolts alternately right and left,
tightening the bolts gradually until the specified torque is
reached evenly.
Tightening torque: 15-17 N-m {150-180 kgf-cm, 10.9-13.0 Ibf-ft}
WARNING
If a single bolt is tightened first to the specified torque, when
the other bolts are tightened the actual effective torque will be
excessive, resulting in possible damage to the nozzle holder and
or bolt. On the other hand, if the bolts are not tightened
sufficiently, gas way leak, resulting in scorching of the nozzle.
EN-FS23A-12
ENGINE
SPECIAL TOOL
FUEL INJECTION PUMP
Prior to starting an engine overhaul, it is necessary to have this special tool.
INJECTION PUMP COUPLING
IMPORTANT POINTS - DISMOUNTING
REMOVE THE FUEL INJECTION PUMP.
1. Disconnect the fuel lines, oil lines and engine control lines.
2. Remove the through bolt "B" and the two flange bolts "A" (in
slotted holes) at the coupling.
3. Remove the pump mounting bolts and then dismount the
pump.
NOTE: Cover open end of the pipes and pump to prevent entry of
dirt.
Special Tool: Wrench (09819-1705)
IMPORTANT POINTS - DISASSEMBLING AND ASSEM-
BLING
Refer to CHAPTER IP, FUEL INJECTION PUMP for details.
IMPORTANT POINTS - MOUNTING
INSTALL THE FUEL INJECTION PUMP.
1. Adjust the injection timing.
Turn the crankshaft counterclockwise viewed from the fly-
wheel side to align the injection timing mark on the flywheel
at A° before top dead center for No.1 cylinder on compression
stroke with pointer on the flywheel housing.
Injection timing (A0): Refer to SECTION DATA AND SPECIFICATION.
2. Check the push rods on No.1 cylinder are loose and push rods
on No.6 are tight.
NOTE: If not, turn the crankshaft one complete revolution and
align marks as above.
ENGINE
EN-FS23A-13
3. Slowly turn the automatic timer flange to clockwise viewed
from coupling side to align the injection timing mark on the
automatic timer with pump body pointer.
4. Position the pump on the pump bracket and adjust the posi-
tion of the pump so that its mounting holes align with those
of the bracket and then tighten the mounting bolts evenly.
Tightening Torque: 38-49. N-m {380-500 kgf-cm, 28-36 lbff-ft}
5. Using a special tool, tighten the two flange bolts (in slotted
holes) at the coupling.
NOTE: There should not be any gap between the laminated plates
or be any deformation of the flange due to pressure the
laminated plates.
Special Tool: Injection Pump Coupling Wrench (09819-1705)
Tightening Torque: 59-63 N-m
{600-650 kgf-cm, 44-46 Ibf-ft)
6. Tighten the through bolt at the flange.
NOTE: Do not tighten the through bolt before tightening the two
flange bolts.
Tightening Torque: 59-63 N-m {600-650 kgf-cm, 44-46 Ibf-ft}
7. Connect the fuel lines, oil lines and engine control lines.
ENGINE
EN-CS31A-1
COOLING SYSTEM
COOLING SYSTEM DIAGRAM
1. Radiator
2. Drain cock
3. Coolant pump
4. Timing gear cover
5. Cylinder block
6. Oil cooler
7. Cylinder head
8. Air compressor
9. Thermostat case
10. Bypass pipe
11. Header tank
12. Radiator cap
13. Reservoir tank
14. Air vent pipe
15. Suction pipe
16. Coolant temperature gauge
EN-CS31A-2
ENGINE
COOLANT PUMP
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
COOLANT PUMP VALVE PULLER
COOLANT PUMP, OIL SEAL PRESS
COOLANT PUMP, COOLANT
COOLANT PUMP VANE PRESS
09482-1700
ENGINE
EN-CS31A-3
IMPORTANT POINTS - DISASSEMBLY
REMOVE THE COOLANT PUMP VANE.
Remove the vane from the shaft with special tool.
Special Tool: Coolant pump vane puller (09420-1620)
REMOVE THE SETTING BOLTS.
Working from the side of the drive gear, use a hexagonal
wrench to remove the bolts.
REMOVE THE COOLANT PUMP SHAFT USING A PRESS.
IMPORTANT POINTS - ASSEMBLY
1. INSTALL THE OIL SEAL TO THE COOLANT CASE.
NOTE: о Apply engine oil to the coolant case side and install the
oil seal to the case.
O Apply lithium based grease to the main lip and between
main and sub-lip.
Special Tool: Coolant pump oil seal press (09482-1160)
2. INSTALL THE COOLANT PUMP SHAFT USING A PRESS.
EN-CS31A-4
ENGINE
3. TIGHTEN THE BOLTS.
4. INSTALL THE COOLANT SEAL TO THE CASE WITH SPECIAL TOOL.
Special Tool: Coolant seal press (09482-1690)
NOTE: When installing the coolant seal. Three Bond No.104 to the
outer and circumference of the coolant seal cage and install
the seal using a press.
5. INSTALL THE COOLANT PUMP VANE.
Special Tool: Coolant pump vane press (09482-1700)
NOTE: The coolant pump vane face until end of the shaft.
ENGINE
EN-CS31A-5
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Bearing Wear and Damage Replace pump shaft, if necessary. Visual check SM3-1501
Cover, Vane or Case Wear and Damage Replace, if necessary. Visual check SM3-1502
Water Drain Hole Clogged Clean SM3-1113
EN-CS31A-6
ENGINE
THERMOSTAT
IMPORTANT POINTS - INSPECTION AND REPAIR
INSPECT THE THERMOSTAT FUNCTION.
1. Place the thermostat in hot water and check the valve opening
temperature and the valve lift.
NOTE: The thermostat valve opening temperature (TJ is engraved
on the thermostat seat, and it should be confirmed.
Thermostat valve opening temperature;
Thermostat valve opening temp. (T,) Service standard
82°C 80-84°C {145-215°F}
Thermostat valve lift;
Thermostat valve opening temp. (T1) Measuring temp. (T2) Valve lift (g)
82°C 95°C {203°F} 10 mm {0.394 in} or more
2. Immerse a heated thermostat in water of normal temperature.
If it completely closes within 5 minutes it is satisfactory. If it re-
mains even slightly open, it is defective and must be replaced.
IMPORTANT POINTS - ASSEMBLY
MOUNT THE THERMOSTAT.
1. Remove the water and dirt adhering to the thermostat case.
2. Replace the gasket without fail if it is corroded, damaged or
flattened.
3. Before installing the hose, apply liquid gasket to the hose in-
stallation of the thermostat case cover.
4. In order to prevent clogging of the radiator, do not apply a
large amount of liquid gasket.
NOTE: О When installing the thermostat, be careful of the direc-
tion in which the bridge faces.
Be sure to install the thermostat with the jiggle valve at
the top, so as to enable bleeding of air during supply of
water.
ENGINE
EN-IE15A-1
AIR INTAKE AND EXHAUST SYSTEM
OVERHAUL
1. Intake manifold
2. Seal ring
3. Gasket
4. Intake pipe assembly
5. Intake air heater
6. O-ring
7. Control cylinder
8. Compression spring
9. Cushion
10. Exhaust manifold assembly
11. Helisert
IMPORTANT POINT - DISASSEMBLING
NOTE: Do not remove the lever rod, and valve from the intake
valve assembly. If removed, resulting in poor performance
of intake air control system.
EN-IE15A-2
ENGINE
1 ZSTUD BOLT %/ /CUSHION ^///INTAKE MANIFOLD
>---zNO BITE OR INSECURITY
\ ''gasket J APPLY ADHESIVE
IMPORTANT POINT - ASSEMBLY
ASSEMBLE THE EXHAUST MANIFOLD.
1. When installing seal rings on the exhaust manifold, fit new
seal rings in such a way that the gaps are equally spaced, as
shown, to prevent gas leakage.
IMPORTANT POINTS - MOUNTING
INSTALL THE INTAKE MANIFOLD.
NOTE: If remove the stud bolt from the cylinder head at dismount-
ing, apply adhesive (Three Bond 1322B or equivalent) to
cylinder head side thread of the stud bolt.
INSPECTION AND REPAIR
Inspection Item Standard Limit Remedy Inspection Procedure
Exhaust Seal Ring Wear or Damage Replace Visual check 0
Intake and Exhaust Manifolds Crack or Damage Exhaust Manifold Cracks, Wear or Damage Replace SM3-710
ENGINE
EN-CP23A-1
ELECTRICAL PARTS
GENERATOR
SPECIAL TOOL
Prior to starting an engine overhaul, it is necessary to have this special tool.
V-BELT TENSION GAUGE
IMPORTANT POINTS - DISASSEMBLING AND ASSEM-
BLING
Refer to CHAPTER GE, GENERATOR for details.
EN-CP23A-2
ENGINE
IMPORTANT POINTS - MOUNTING
V-BELT ADJUSTMENT.
1. Install the V-belts, and adjust the belt tension.
NOTE: o Do not under any circumstances apply the lever directly
against the generator body owing to the risk of damag-
ing the generator.
О When installing a new V-belt or adjusting the tension, be
sure to repeat the adjustment two or three times, after
running the engine for several minutes each time.
2. V-belt deflection.
Apply a load of about 98 N {10 kgf, 22 Ibf} by pressing with
your finger or special tool.
Assembly standard (A): 19-23 mm {0.75-0.90 in}
Special Tool: V-belt tension gauge (09444-1210)
NOTE: If the belt is excessively tensioned, there is a risk of damag-
ing the bearings of the generator or coolant pump and also
shorting the life of the V-belt.
Conversely, if there is insufficient tension on the V-belt, the
belt will slip, unusual noise will be emitted, the battery may
run down and the engine may overheat.
"B" and "E” terminal bolt tightening torque:
8-10 N-m {80-110 kgf-cm, 5.8-7.Э Ibf-ft}
Generator ground cable bolt Tightening Torque:
8-10 N-m {80-110 kgf-cm, 5.8-7.Э Ibf-ft}
STARTER
IMPORTANT POINTS - DISMOUNTING
REMOVE THE STARTER FROM THE ENGINE.
1. Disconnect the battery cable from the negative (-) terminal of
battery.
2. Put the match marks on the harness and starter terminals with
a pen and then disconnect the harness.
3. Remove the starter from the engine.
IMPORTANT POINTS - DISASSEMBLING AND ASSEM-
BLING
Refer to CHAPTER ST, STARTER for details.
IMPORTANT POINTS - MOUNTING
INSTALL THE STARTER ON THE ENGINE.
1. Install the starter on the engine.
2. Connect the harness to match the marks.
3. Connect the battery cable.
Terminal nut tightening torque:
16-22 N-m {165-225 kgf-cm, 12-16 Ibf-ft} for "B" terminal.
1.9- 2.4 N-m {19-25 kgf-cm, 1.4-1.8 Ibf-ft} for "C" terminal.
OTHER PARTS
IMPORTANT POINTS - INSPECTION, REPAIR AND
ADJUSTING
CHAPTER EE, ELECTRICAL EQUIPMENT.
ENGINE
EN-TU25A-1
ENGINE TUNE-UP
PUSH RODS: MOVE PUSH RODS: STANDING
(Compression stroke) (Overlapping stroke)
О
SM3-713
METHOD FOR DETERMINING IF THE NO.1 PISTON IS AT
THE TOP DEAD CENTER ON COMPRESSION STROKE.
NOTE: О Turn the crankshaft to align the mark "1-7" on the fly-
wheel with the pointer of the flywheel housing.
О In this position either the No.1 or No.7 piston is at the
top dead center on compression stroke.
The pointer and mark "1-7" are provided on some model
timing gear cover, and on the torsional damper, so use
these pointer and marker when adjusting the engine if
so equipped.
1. Move both the intake and the exhaust rocker arms of the No.1
or No.7 cylinder by hand; if both rocker arms can be moved,
the piston is at top dead center on the compression stroke.
2. If the injection timing mark is nearly aligned with the pointer,
the No.1 piston is at top dead center on compression stroke.
NOTE: If not, turn the crankshaft one complete revolution and
align marks as above.
3. While locking at the push rods of No.1 and No.7 pistons, turn
the crankshaft counterclockwise and clockwise about 30° to
40° (see left figure).
If the piston whose exhaust and inlet push rods do not move
during the interval, it is at the top dead center on compression
stroke.
If the piston whose push rods have moved, it is at the
completion of the exhaust and begun of the intake stroke
(overlapping stroke).
NOTE: Always loosen the lock nut and raise the adjusting screws
fully to the top. If the adjusting screws are too low, the
piston and valves may strike each other during valve
clearance adjustment.
VALVE CLEARANCE
[Valve clearance adjusting procedures]
BEFORE ADJUSTING
1. Before adjusting, make sure that the head bolts and the rocker
support bolts are tightened with the specified torque.
2. Make sure that there are no foreign matter and dust in be-
tween the valve stems and the rocker arms.
3. Set the piston in the particular cylinder to adjust for top dead
center on the compression stroke.
EN-TU25A-2
ENGINE
ADJUSTING
1. With the No.1 piston positioned at top dead center on
compression stroke, adjust the No.1 valve clearance using a
thickness gauge.
The thickness gauge should move with a very slight pull.
Valve Clearance: Refer to SECTION DATA AND SPECIFICATIONS.
2. Adjust the other valves.
Turn the crankshaft counterclockwise viewed from flywheel
side. Adjust the valve clearance for each cylinder in the firing
order.
Firing order and firing interval;
" " -—- Firing order Firing interval
Eight cylinder model 1-8-4-2-7-3-6-5 90°
INJECTION TIMING
INSPECT THE INJECTION TIMING.
1. Turn the crankshaft counterclockwise viewed from the fly-
wheel side to align the injection timing mark on the flywheel
or crankshaft pulley damper at A0 before top dead center for
No.1 cylinder on compression stroke with the pointer.
Injection timing (A°): Refer to SECTION DATA AND SPECIFICATION
2. Check that the injection timing mark (the scribe line, not the
notch) on the timer housing is aligned with the pointer (the
scribe line) timing plate on the pump housing.
If not, adjust the injection timing.
NOTE: When adjusting the injection timing, refer to "FUEL INJEC-
TION PUMP" for details.
AIR BLEEDING FROM FUEL SYSTEM
1. Bleed air from the fuel filter.
a. Loosen the bleeder plug on the fuel filter.
b. Loosen the priming pump knob.
c. Operate the priming pump knob until the air will not come out
from the bleeder plug.
d. Tighten the bleeder plug.
Tightening Torque: 3.93-5.88 N-m {40-60 kgf-cm, 3-4 Ibf-ft}
NOTE: The bleeder plug should be tightened while the priming
pump knob is operated.
ENGINE
EN-TU25A-3
2. Once again, operate the priming pump knob several times.
3. Push back the priming pump knob and tighten it.
NOTE: Wipe off any splashed fuel.
ENGINE TUNE-UP ON TEST BENCH
NOTE: o If the engine is started with the power steering oil pump
installed, the oil pump may burn or oil may spurt out, re-
move the oil pump from the engine and install a cover to
prevent oil leakage from the point of removal.
О Starting the engine when the generator is not connected
to the battery may damage the generator. Always con-
nect to the battery.
SET THE ENGINE ASSEMBLY ON A TEST BENCH.
1. Add the proper amount of the specified engine oil through the
oil filer cap on the cylinder head cover.
2. Add coolant.
Bleed out air from inside the coolant gallery through the cylin-
der block drain plug.
BLEED AIR FROM FUEL SYSTEM.
CHECK THE INJECTION TIMING.
Refer to "FUEL INJECTION PUMP".
CHECK THE VALVE CLEARANCE.
START THE ENGINE.
NOTE: Before starting the engine, make sure that the fuel cut lever
of the fuel injection pump is operating normally.
1. Check the oil feed to rocker arms.
a. Set the engine speed to 500-550 r/min.
b. When one minute after starting the engine, oil should flow to
the head (Face A) of all push rods and the head (Face B) of all
valves. If the time required for the oil to flow to the rocker
arms is long, various troubles such as seizing, abnormal wear
and unusual noise may occur.
EN-TU25A-4
ENGINE
RETIGHTENING CYLINDER HEAD BOLT
Retighten the cylinder head bolts according to the following
instructions.
(1) Retightening schedule
Retighten at the first 1,000 km (600 miles) following servicing
which involves the loosening or removal of any cylinder head
bolt. Such servicing includes replacement of the cylinder head
gasket, servicing of the valve gear parts, and the like.
(2) Retightening procedure
Step 1: Warm up the engine in the same way as in engine
turning.
Step 2: Following the cylinder head bolt tightening order as
shown, loosen the first cylinder head bolt by 1/4 to 1/2
turns as shown (SM3-457), then tighten into it to its
specified torque.
Repeat until all the bolts have been retightened.
Tightening order, Tightening torque and special tool:
Refer to "CYLINDER HEAD" in SECTION ENGINE MOVING
PARTS.
NOTE: О Be sure to loosen one bolt at a time, then retighten it be-
fore going on the next bolt.
О By retighten, face pressure of cylinder head is restored
from point В to C as shown.
RECHECK THE VALVE CLEARANCE, WHEN ENGINE IS COLD.
ENGINE
EN-PR5A-1
PROCEDURE FOR INSTALLING JOINTS AND GASKET OF
ENGINE PIPE
1. Gasket seal type (aluminum + rubber, asbestos or copper).
Tightening torque chart
Clamping screw size (Diameter) mm {in} Tightening torque N-m {kg-cm, lb-ft}
8(0.315} 12.75 {130,9.40}
10 {0.394} 19.61 {200,14.47}
12 {0.472} 24.52 {250,18.08}
14 {0.551} 24.52 {250,18.08}
16 {0.630} 29.42 {300, 21.70}
18 {0.709} 39.23 {400, 28.93}
20 {0.787} *39.23 {400, 28.93}
24 {0.945} 68.65 {700, 50.63}
28 {1.102} 127.49 {1,300, 94.02}
2. Metal seal type (Flares connector type).
Location of metal seal
BRACKET FLARE NUT
LOCK WASHER
Tightening torque chart
Clamping screw size (Diameter) mm {in} Tightening torque N-m {kg-cm, lb-ft}
12 {0.472} 19.61 {200,14.47}
14 {0.551} 31.38 {320,23.15}
16(0.630} 39.23 {400, 28.93}
18 {0.709} 58.84 {600, 43.40}
20 {0.787} 63.74 {650, 47.01}
EN-PR5A-2
ENGINE
3. Metal seal type (Nipples connectors type)
Location of metal seal
NUT
FLARE CONNECTOR
CONNECTOR
Tightening torque chart
Clamping screw size (Diameter) mm {in} Tightening torque N m {kg cm, Ib ft}
10 {0.394} 10.79 {110,7.96}
20 {0.787} 19.61 {200,14.47}
NOTE: О Before installing the joints, ensure that there is no dirt or burrs adhering to the various seat faces (pipe joints, gaskets,
etc.)
О Because the pipes can move relatively free during installation and the seat faces are liable to tilt, first temporarily tighten
the pipes, then tighten them to specification and ensure that there is no leakage from them.
О When tightening two pipes together, be very careful that they do not rotate together.
О After installing the pipes, apply the correct pressure to each pipe joint and ensure that there is no leakage.
О Ensure that the various tightening torques conform to the above table.
* If a soft washer #4840 FR-N (aluminum + rubber and carbon press fit part) is loosened or removed subsequent to being
installed, be sure and replace it with a new one.
There is no need to replace it, however, for normal retightening.
(K.P.)
HINO MOTORS, LTD.
PRINTED IN JAPAN
'94-7 (K.P.)
EN-S204E-01
WORKSHOP MANUAL
ENGINE
EN-S204E-01
CHAPTER EN
ENGINE
Model F17E
DATA AND SPECIFICATIONS.................. EN-DS36A - 1
TROUBLE SHOOTING......................... EN-TS4A - 1
ENGINE OVERHAUL CRITERIA................. EN-OC15A - 1
ENGINE MOVING PARTS...................... EN-MP34A - 1
CYLINDER HEAD........................ EN-MP34A - 1
CRANKSHAFT PULLEY.................... EN-MP34A -13
FLYWHEEL AND FLYWHEEL HOUSING........ EN-MP34A -15
TIMING GEAR AND CAMSHAFT............. EN-MP34A -17
PISTON CRANKSHAFT CYLINDER BLOCK
AND OIL PAN.......................... EN-MP34A -27
LUBRICATING SYSTEM ...................... EN-LS32A - 1
OIL PUMP AND OIL STRAINER............ EN-LS32A - 2
OIL FILTER AND OIL COOLER............ EN-LS32A - 6
FUEL SYSTEM.............................. EN-FS24A - 1
INJECTION NOZZLE..................... EN-FS24A - 2
FUEL INJECTION PUMP.................. EN-FS24A -12
COOLING SYSTEM........................... EN-CS32A - 1
COOLANT PUMP......................... EN-CS32A - 2
THERMOSTAT........................... EN-CS32A - 6
RADIATOR............................. EN-CS32A - 7
COOLING FAN.......................... EN-CS32A - 8
AIR INTAKE AND EXHAUST SYSTEM............ EN-IE16A - 1
ELECTRICAL PARTS......................... EN-CP23A - 1
GENERATOR............................ EN-CP23A - 1
STARTER.............................. EN-CP23A - 2
ENGINE TUNE-UP........................... EN-TU26A - 1
ENGINE TUNE-UP ON TEST BENCH......... EN-TU26A - 4
PROCEDURE FOR INSTALLING JOINTS AND
GASKETS OF ENGINE PIPES.................. EN-PR5A - 1

ENGINE
EN-DS36A-1
DATA AND SPECIFICATIONS
Model F17E
Type Diesel, 4 cycle, 8 cylinder, V, overhead valve, water-cooled, direct injection.
Aspiration Natural aspirate.
Bore and stroke 139 x 142 mm {5.48 x 5.59 in}
Piston displacement 17.238 liters {1.051 cu.in)
Compression ratio 17.6 : 1
Firing order 1-8-4-2-7-3-6-5
Direction of rotation Counterclockwise viewed from flywheel
Compression pressure 2.9-3.2 MPa {30-33 kgf/cm2, 426-469 lbf/in2} at 200 r/min
Maximum revolution (at full load) 2,200 r/min
Idling revolution 450-500 r/min
Dry weight Approx. 1,180 kg {2,602 lb}
Valve seat angle Intake 30°
Exhaust 45°
Valve face angle Intake 30°
Exhaust 45°
Valve timing (flywheel travel) Intake opens 14° before top dead center.
Intake closes 37° after bottom dead center.
Exhaust opens 52° before botoom dead center.
Exhaust closes 16° after top dead center.
Valve clearance (when cold) Intake 0.48 mm {0.0189 in}
Exhaust 0.58 mm {0.0228 in}
Engine oil pump Type Drive Full forced pressure feed by gear pump. By gear
Engine oil cooler Multi plates type, water cooled
Injection nozzle Type Valve opening pressure Multi hole nozzle type 1st : 14.7 MPa {150 kgf/cm2, 2,133 lbf/in2} 2nd : 24.5 MPa {250 kgf/cm2, 3,556 lbf/in2}
Coolant pump Type Drive Forced circulation by volute pump. By gear
Thermostat Type Wax type, bottom bypass system
Injection timing (flywheel travel) 15° before top dead center for No. 1 cylinder on compression stroke.
ENGINE
EN-TS4A-1
TROUBLESHOOTING
Symptom
Possible cause
Remedy/Prevention
Engine overheating
— Coolant
• Insufficient coolant...........................
• Defective thermostat...........................
• Overflow of coolant due to leakage of .........
exhaust into cooling system
• Coolant leakage from cylinder head gasket......
• Defective coolant pump.........................
Add coolant.
Replace the thermostat.
Repair.
Replace gasket.
Repair or replace.
Radiator
• Clogged with rust and scale.....................
• Clogged with iron oxide due to leakage........ .
of exhaust into cooling system
• Clogged radiator core due to mud ...............
or other debris
• Defective radiator cap pressure valve ..........
— Abnormal combustion
• Incorrect injection timing......................
• Reduced injection pressure......................
• Poor fuel ......................................
•
• Poor nozzle spray...............................
• Unsatisfactory automatic timer advance angle . .
— Other problems
• Defective or deteriorated engine oil............
• Unsatisfactory operation of oil pump............
• Insufficient oil................................
• Brake drag......................................
Clean radiator.
Clean coolant passage and
correct exhaust leakage.
Clean radiator.
Replace radiator cap.
Adjust injection timing.
Adjust injection pressure.
Use good quality fuel.
Adjust or replace nozzle.
Repair or replace timer.
Change engine oil.
Replace or repair.
Add oil.
Repair or adjust.
Excessive oil consumption
— Pistons, cylinder liners, and piston rings
• Wear of piston ring and cylinder liner............
• Worn, sticking or broken piston rings.............
• Insufficient tension on piston rings .............
• Unsatisfactory break-in of piston rings...........
• Unsuitable oil (viscosity too low)................
• Incorrectly fitted piston rings...................
(upside down)
• Gaps of piston rings in line with each other. . . .
Replace piston rings and
cylinder liner.
Replace piston rings and
cylinder liner.
Replace piston rings and
cylinder liner.
Replace piston rings and
cylinder liner.
Change oil as required and replace
piston rings and cylinder liners.
Replace piston rings.
Reassemble piston rings.
EN-TS4A-2
ENGINE
Symptom
Possible cause
Remedy/Prevention
Excessive oil consumption
— Valve and valve guides
• Worn valve stem................................
• Worn valve guide ..............................
• Incorrectly fitted valve stem seal.............
• Excessive lubricant on rocker arm..............
— Excess oil feed |
• Defective oil level gauge......................
• Oil level too high ............................
— Other problems
• Overcooled engine (low temperature wear) ....
• Oil leakage from miscellaneous parts ..........
Piston seizure
Replace valve and valve guide.
Replace valve guide.
Replace the stem seal.
Check clearance of rocker arm
and shaft.
Replace oil level gauge.
Drain excess oil.
Warm up engine before mov-
ing vehicle. Check cooling
system.
Repair.
— Operation
• Abrupt stoppage of engine after running.......
at highspeed
• Hill climbing using unsuitable gear...........
—~oii~
• Insufficient oil..............................
• Dirty oil.....................................
• Poor quality oil .............................
• High oil temperature..........................
• Low oil pressure..............................
• Defective oil pump............................
• Reduced performance due to worn ..............
oil pump
• Suction strainer sucking air..................
— Abnormal combustion ...........................
— Coolant .......................................
Operate engine properly.
Select suitable gear.
Add oil.
Change oil.
Replace with proper engine oil.
Repair.
Repair.
Repair oil pump.
Replace oil pump.
Add oil and/or repair strainer.
See Symptom: "Engine over-
heating."
See Symptom: "Engine over-
heating."
Lack of power
ENGINE
EN-TS4A-3
Symptom
Possible cause
Remedy/Prevention
Lack of power
— Fuel and nozzle
• Poor nozzle spray.............................
• Clogged nozzle with carbon ...................
• Wear or seizure of nozzle.....................
• Air in fuel, system...........................
• Clogged fuel filter...........................
• .Use of poor fuel.............................
— Abnormal combustion ............................
Piston, cylinder liners, and piston rings ........
Adjust or replace injection
nozzle.
Clean nozzle.
Replace nozzle.
Repair and bleed air from fuel
system.
Replace element.
Use good quality fuel.
See Symptom:
“Engine overheating."
See Symptom "Engine over-
heating."
Difficulty starting engine
— Other problems
• Breakage of turbine or blower................
Replace the turbine or blower
or turbocharger.
— Electrical system
• Discharged battery.............................
• Defective wiring in starter circuit............
• Loose or open-circuit battery cable ...........
• Breakdown of starter...........................
• Break of glow plug or intake...................
air heater (If so equipped)
— Injection pump ..................................
— Air cleaner
• Clogged element.................................
— Fuel system
• No fuel in tank................................
• Clogged fuel line..............................
• Air sucked into fuel system through............
fuel line connections
• Clogged fuel filter............................
• Loose connection in high-pressure line.........
• Water in fuel..................................
Charge battery.
Repair wiring of starter.
Tighten battery terminal connec-
tions or replace battery cable.
Replace starter.
Replace
Refer to CHAPTER IP,
FUEL INJECTION PUMP.
Clean the element or replace the
element.
Supply fuel and bleed air from
fuel system.
Clean fuel line.
Tighten fuel line connections.
Replace element.
Tighten sleeve nut of high pres-
sure line.
Drain and clean fuel system
EN-TS4A-4
ENGINE
Symptom
Possible cause
Remedy/Prevention
Difficulty starting engine
Nozzles
• Seized nozzle.....................................
e Broken or fatigued nozzle spring..................
— Oil system
• Oil viscosity too high............................
Replace nozzle.
Replace spring.
Rough idling
— Other problems
• Seized piston................................
• Seized bearing...............................
• Reduced compression pressure ................
• Ring gear damaged or worn ...................
• Improperly adjusted or broken................
accelerator cable
Injection pump .....................................
— Nozzles
• Uneven injection pressure......................
• Poor nozzle spray..............................
• Carbon deposit on nozzle tip ..................
• Seized needle valve............................
— Engine proper
• Improper valve clearance.......................
• Improper contact of valve seat ................
• Idling speed too low...........................
• Coolant temperature too low ...................
• Compression pressure of cylinders..............
markedly different from one another
Use proper viscosity oil, or
install an oil immersion heater
and warm up oil.
Replace piston, piston rings, and
liner.
Replace bearing and/or crankshaft.
Overhaul engine.
Replace the ring gear and/or
starter pinion.
Adjust or replace the accelerator
cable.
Refer to CHAPTER IP,
FUEL INJECTION PUMP.
Adjust.
Adjust or replace nozzle.
Remove carbon.
Replace nozzle.
Adjust valve clearance.
Replace or repair valve and valve
seat.
Adjust idling speed.
Warm up engine.
Overhaul engine.
Leakage of exhaust gas
Cylinder head gasket
• Fatigued gasket (aging) ...........................Replace gasket.
• Damage ............................................Replace gasket.
• Improper installation..............................Replace gasket.
ENGINE
EN-TS4A-5
Symptom
Possible cause
Remedy/Prevention
Leakage of exhaust
— Cylinder head bolts
• Loose bolts....................................
• Elongated bolts ...............................
• Improper tightening torque or..................
tightening sequence
— Cylinder block
• Cracking.......................................
• Surface distortion.............................
• Fretting of cylinder liner insertion...........
portion (insufficient projection of
cylinder liner)
— Cylinder head
• Cracking.......................................
• Surface distortion.............................
— Cylinder liners
• Cracking.......................................
• Corrosion......................................
• Insufficient projection of cylinder liner......
— Other problems
• Incorrect injection timing.......................
Tighten bolt.
Replace bolt.
Tighten properly.
Replace cylinder block.
Repair or replace.
Replace cylinder liner or
cylinder block.
Replace cylinder head.
Repair or replace.
Replace cylinder liner.
Replace cylinder liner.
Replace cylinder liner.
Adjust injection timing.
01Л1Э1Л1
ENGINE
EN-0C15A-1
ENGINE OVERHAUL CRITERIA
SPECIAL TOOL
Prior to starting an engine overhaul, it is n ecessary to have these special tools.
COMPRESSION GAUGE
COMPRESSION GAUGE
FACTORS WHICH DETERMINE WHEN AT ENGINE OVERHAUL IS
NEEDED.
LOWERED COMPRESSION PRESSURE.
a. Before the measurement
a) Correct the valve clearance.
b) Warm up engine [Bring the coolant temperature to about 80°C
(176Т)]
c) Charge the batter fully.
d) Remove the air cleaner.
b. Measurement
1) Measure at nozzle holder hole.
a) Remove the nozzle holders.
b) Install the gauge adapter (A) and (B) in the nozzle holder hole.
c) For model equipped with manual control type engine stop system.
Disconnect the engine stop cable (rod) from engine stop lever in
engine stop position with tape or string.
d) Formodel equipped with electrical motorcontroltypeenginestop
system.
Set the engine starter key at "OFF" position, then disconnect the
engine stop motor harness.
e) Connect a compression gauge to the gauge adapter.
f) Drive the engine with the starter and read the compression
pressure.
NOTE: Do not continuously operate the starter for more than 15
seconds at a time.
g) Measure the compression pressure for each cylinder. If the
compression pressure is low, be sure to repeat the measuring.
NOTE: Be sure not to leak through sealing face.
EN-0C15A-2
ENGINE
Unit: MPa {kg/cm2, Lb/in2)
Engine model Compression pressure Difference between each cylinder Engine speed (r/min)
Standard Limit
F17E 2.9-3.2 {30-33, 427-469} 2.55 {26, 369} 0.294 {3, 43} or less 200
c) After the measurement
Make sure the engine starter key is in "OFF" position and then
connect the engine stop motor harness.
WARNING
Do not connect the electric harness with the engine stop motor
while the engine starter key at "ON" position as this operate the
engine stop motor instantaneously and the link lever of the engine
stop motor and the engine stop lever of the fuel injection pump
move, resulting in your fingers caught by the lever.
DECREASED OIL PRESSURE
Check the oil pressure warning lamp when the oil and coolant
temperature is hot [about 80°C {176°F}].
a. If the warning lamp is lighted, check the oil level.
b. Check oil deterioration.
If oil quality is poor, replace with a suitable grade oil.
c. Remove the oil pressure switch and install the oil pressure gauge.
d. Measure the oil pressure at coolant temperature 8СГС {176”F} or
more.
Standard oil pressure: 49-490 KPa {0.5-5.0 kg/cm2 7.11-71.10 Ib/sq.in}
Service limit: 49 KPa {0.5 kg/cm2 (7.11 lb/sq.in)} or less
S.A.E. ATMOSPHERIC TEMPERATURE
GRADE -1 0 0 32 50 70 90100 1 1 1 1 1 1 °F
-2 3-- 8 1 1 II 10 21 32 39 °C
40
30
20W/20
15W/40
OTHER FACTORS
a. The blow-by gas increases.
b. The engine does not start easily.
c. Engine output decreases.
d. Fuel consumption increases.
e. Engine makes greater noise.
f. Excessive oil consumption.
ENGINE
EN-MP34A-1
ENGINE MOVING PARTS
CYLINDER HEAD
EN-MP34A-2
ENGINE
1. Intake valve seat 12. Cylinder head end plate 23. Valve adjusting screw
2. Exhaust valve seat 13. Intake valve 24. Plug
3. Push rod guide pipe 14. Exhaust valve 25. Retainer ring
4. Stud 15. Valve litter 26. Washer
5. Expansion plug 16. Valve push rod 27. Valve adjusting screw nut
6. Valve guide bushing 17. Valve stem cap 28. Valve rocker arm
7. Valve stem oil seal 18. Valve spring seat lower 29. Rocker arm support
8. Spacer 19. Valve spring inner 30. O-ring
9. Nut 20. Valve spring outer 31. Rocker shaft oil pipe
10. Collar 21. Valve spring seat upper
11. Gasket 22. Valve spring retainer lock
ENGINE
EN-MP34A-3
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
NOZZLE HOLDER ADAPTER
CYLINDER HEAD BOLT SOCKET
VALVE SPRING PRESS
09470-1020
09491-1030
For Valve stem seal
EN-MP34A-4
ENGINE
IMPORTANT POINTS - DISASSEMBLY
REMOVE THE FUEL PIPES AND NOZZLE ASSEMBLY.
Refer to "INJECTION NOZZLE" in SECTION FUEL SYSTEM.
REMOVE THE ROCKER ARM ASSEMBLY.
Loosen the rocker arm support bolts and remove the rocker
arm assembly.
NOTE: Attention should be paid to the fact that the rocker arms of
the intake and exhaust valves are mounted different direc-
tions. Keep the components in their disassembly order for
easy reassembly.
REMOVE THE NOZZLE HOLDER ADAPTER.
1. Remove the nozzle holder adapter from the cylinder head
using the adapter wrench, if needs.
Special Tool: Nozzle Holder Adapter Wrench (09503-1010)
REMOVE THE CYLINDER HEAD.
Loosen the cylinder head bolts little by little in three stages
and in the numerical order as shown.
Special Tool: Cylinder Head Bolt Socket Wrench (09621-1110)
LIFT THE CYLINDER HEAD FROM THE DOWELS ON THE CYLINDER
BLOCK AND PLACE IT ON WOODEN BLOCKS.
1. If the cylinder head is difficult to lift off, pry with a chisel
between the cylinder head and block.
NOTE: Do not damage the machined surface of the head or block
when removing the cylinder head.
Special Tools: Engine Hanger (12281-1541)
Bolt (9401-14350)
Wire (09491-1020)
(09491-1030)
ENGINE
EN-MP34A-5
REMOVE THE VALVE SPRINGS.
1. Remove the valve stem retainer locks, upper spring seats, and
inner and outer valve springs from cylinder head.
Special Tool: Valve Spring Press (09470-1020)
2. Remove the intake and exhaust valves.
3. Tag valves to identify their cylinder numbers and to leave out
the valve lapping.
IMPORTANT POINTS - ASSEMBLY
CLEAN THE CYLINDER HEAD THOROUGHLY WITH A SUITABLE
SOLVENT.
NOTE: Be careful not to damage the cylinder head surface.
IF NECESSARY, HAND-LAP THE VALVE AND VALVE SEAT.
Lightly apply lapping compound to the valve face. Install the
valve and then using a special tool, tap and rotate the valve
against the seat.
Special Tool: Valve Lapping Tool (09431-1010)
IF NECESSARY, GRIND THE VALVES AND VALVE SEATS.
NOTE: О Grinding of valves and valve seats should only be per-
formed when hand-lapping does not result in proper
seating.
O After grinding, always recheck the valve sink.
INTAKE EXHAUST
Valve face angle and valve seat angle:
Refer to INSPECTION AND REPAIR.
SM3-894
EN-MP34A-6
ENGINE
IF NECESSARY, REPLACE THE VALVE SEAT.
1. Cut the circumference of a valve head at three places with a
grinder and install it into the seat as shown and weld the
valve to the seat. Then drive the valve and the seat out with a
hammer and a brass block.
2. Valve seat section machining specifications.
Unit: mm {in}
Intake Exhaust
Cylinder head dimension A 61.000-61.019 {2.4016-2.4023} 55.000-55.019 {2.1654-2.1661}
В 11.2-11.3 {0.4410-0.4448} 11.1-11.3 {0.438-0.4448}
Valve seat dimension C 61.085-61.100 {2.405-2.406} 55.085-55.100 {2.168-2.169}
D 9.8-10.0 {0.386-0.393} 8.8-9.0 {0.347-0.354}}
3. Valve seat installation.
Heat the cylinder head to about 80° - 100°C {176-212°F} with
hot water. On the other hand, cool the valve seat with dry ice
or liquid freon for about 30 minutes. Hold the seat with
pincers and place it into the heated cylinder head.
IF NECESSARY, REPLACE THE VALVE GUIDE.
1. Remove the valve stem seal.
2. Using a brass rod and hammer, drive out the valve guide.
3. Install the valve guide.
When installing a new valve guide, drive the guide straight
into the head allowing it to protrude as shown.
NOTE: Apply engine oil lightly to the valve guide outer circumfer-
ence before installation.
IF NECESSARY, REPLACE THE VALVE STEM SEAL.
1. Remove the valve stem seal.
2. Install the valve stem seal.
First, install the lower spring seat and valve. Then apply
engine oil to the lip of the stem seal and drive the stem seal
with a special tool.
Special Tool: Bar (09472-1660)
ENGINE
EN-MP34A-7
NOTE: о After installing stem seal, make sure that check the rub-
ber position for cracks or any other damage.
О Do not use the special tool if its tip (surface contacting
lower spring seat) is worn or deformed.
ASSEMBLE THE CYLINDER HEAD.
NOTE: о Apply engine oil to contact surfaces of all parts.
О Make sure that the valves are installed in the correct cyl-
inders.
О Install the valve springs with their painted side down,
since they have variable pitches.
Press upper spring seats and install the retainer locks securely
in the upper spring seats.
Special Tool: Valve Spring Press (09470-1020)
NOTE: о When pressing with the valve spring press, be careful
not to damage the stem seals by contacting the upper
seats.
О Drive the valve stem lightly with a hammer to assure
proper fit the valve stem key.
ASSEMBLE THE ROCKER ARM.
Lubricate the rocker arm shaft and bushing.
ROCKER ARM SUPPORT
ROCKER ARM
SM3-1071
EN-MP34A-8
ENGINE
Grade Identification label shape Identifying color
1 „,гч Green
2 Yellow
3 Red
INSTALL THE CYLINDER HEAD AND ROCKER ARM ASSEMBLY.
1. Apply engine oil to the valve lifter face and valve lifter guide
then install the valve lifter.
2. Install the cylinder head gasket.
NOTE: О Always use new cylinder head gasket after cleaning the
surface of the cylinder head, cylinder block and head
gasket free of all dirt, water and grease.
O This engine uses three types of cylinder head gaskets
depending on the pistons protrusion.
When replacing the cylinder head gasket, the pistons,
the crank shaft or other parts, select and install the cyl-
inder head gasket according to the following outline.
1) When replacing only the cylinder head gasket.
Determine the grade of the old cylinder head gasket from the
shape of the grade identification label or from color of the
push rod holes sealing rubber, or replace the gasket with one
that matches its product number.
A: Standard cylinder block position
В : Measuring position for piston protrusion
2) When replacing pistons, connecting rods or crank shaft
related parts.
a. Measure and record the piston protrusion from the upper
surface of the cylinder block at two locations in each cylinder
as shown in the figure.
NOTE: Cranking should be performed by rotating the pistons
slowly clockwise.
The piston protrusion is: В-A mm
b. Obtain the average measurement for each bank and select the
grade of the cylinder head gasket according to the following
table.
Unit: mm {in}
Grade Average piston protrusion
1 0.190 {0.0075} or less
2 0.190-0.243 {0.0075-0.0095}
3 0.244 {0.0096} or more
3. Install the cylinder head over the dowels on the cylinder block.
4. Tighten the eighteen cylinder head bolts in the numerical or-
der as shown (fig. 1).
NOTE: Apply engine oil to the bolt threads and under the bolt
head.
Tightening torque: 98 N m {1,000 kgfcm, 72 Ibf ft}
Special Tool: Cylinder Head Bolt Socket Wrech (09621-1110)
ENGINE
EN-MP34A-9
5. Tighten the eighteen cylinder head bolts in the numerical
order as shown (fig. 2). Torque the bolts to specified
tightening torque.
Specified tightening torque: 294 N-m {3,000 kgf-cm, 216 Ibf-ft}
Fig.3
6. Retighten the six cylinder head bolts in the numerical order as
shown (fig. 3).
Specified tightening torque: 294 N-m {3,000 kgf-cm, 216 Ibf-ft}
INSTALL THE ROCKER ARM.
1. Install the stem caps.
NOTE: Make sure that both the end of the valve stem and the in-
side of the valve stem cap are free from dust.
Apply engine oil to the valve stem ends and put the stem
caps on the valve stem ends. Be careful not to drop the
caps into the cylinder block.
SM3-1266
SM3-624
2. Insert the push rods in correct order, after applying engine oil
to both ends.
3. Mount the rocker arm assembly on the cylinder head, make
sure that the push rods interlock with the adjusting screws.
NOTE: Always loosen the lock nut and raise the adjusting screws
fully to the top.
EN-MP34A-10
ENGINE
INSTALL THE NOZZLE HOLDER ADAPTER.
1. Insert the new О-ring to the nozzle holder adapter.
2. Using a special tool, screw-in into the cylinder head until it is
stopped.
Special Tool: Nozzle holder adapter wrench (09503-1010)
NOTE: When the adapter is removed, never forget to replace the
О-ring with a new one and apply engine oil.
3. Loosen the nozzle holder within 1/2 turns and adjust it so that
tapped holes on the adaptor flange align the direction of 90°
from valve spring line.
ENGINE
EN-MP34A-11
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Cylinder Head Flatness 0-0.05 {0-0.0019} 0.15 {0.0059} Regrind or replace SM 3-831
Cylinder Head Cracks and Damage * Using a Dye Penetrant Replace, if necessary. VX\ \\ A SM3-832
Valve Seating Condition * Using Red Lead Marking Compound There should be good contact around entire circumference of valve head. Hand-lap with lapping com- pound Л - -I) SM3-833
Valve Seat Angle Intake Exhaust 44°-45°15' Regrind or replace valve and/or valve seat. yu
Valve face Angle Intake Exhaust 29°45'-30° 44°45'-45°
30° Vx INTAKE ( \/45e EXHAUST SM3-899
Adjusting Screws and Push Rods Damage Replace Visual check^^^^^ x SM3-1066
Rocker Arm and Cross Head Wear or Damage Resurface or replace Visual check Q. \— SM3-1103
Upper Spring Seats and Lower Spring Seats Wear or Damage Resurface or replace Visual check SM3-529
EN-MP34A-12
ENGINE
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Nozzle Protrusion from Cylinder Head Surface 3.00 {0.118} Replace nozzle gasket -— / / L / //.CYLINDER 1> HEAD SM3-391
Intake Valve Sink 0.75-1.00 {0.0295-0.0393} Replace valve and/or valve seat “0" IS CYLINDER 0 HEAD SURFACE ।
Exhaust Valve Sink 0.45-0.70 {0.0177-0.0275} v 1 SM3-420
Intake Valve Stem Diameter 11.938-11.950 {0.4670-0.4704} 11.70 {0.4606} Replace / T I 90* \ A (/?. •b“l f. A: 10 {0.394} SM3-834 В : 30 {1.181} C : 60 {2.362}
Exhaust Valve Stem Diameter 11.905-11.930 {0.4688-0.4696} 11.70 {0.4606}
Intake and Exhaust Valve Guide Diameter 12.000-12.018 {0.4725-0.4731}
Clearance between Valve Stem and Valve Guide (Intake) 0.05-0.08 {0.0020-0.0031} 0.3 {0.0118} - 5 / - SM3-835
Clearance between Valve Stem and Valve Guide (Exhaust) 0.07-0.113 {0.0028-0.0044} 0.3 {0.0118}
Rocker Arm Shaft Diameter 27.967-27.980 {1.1011-1.1015} 27.85 {1.0965} Replace rocker arm bushing and/or shaft SM3-291
Rocker Arm Bushing Inside Diameter 28.024-28.079 {1.1034-1.1054} 28.15 {1.1083}
Clearance between Rocker Arm Shaft and Rocker Arm Bushing 0.044-0.112 {0.0018-0.0044}
ENGINE
EN-MP34A-13
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Rocker Arm End Play 0.05-0.65 {0.0020-0.0255} Replace X
Valve Spring Setting Load Inner spring 212.8 l\l {21.7 kgf, 47.8 Ibf} at 55.5 {2.185} 195.2 N {19.9 kgf, 43.87 Ibf} Replace Jojf
Outer spring 554.1 N {56.5 kgf, 124.6 Ibf} at 58.5 {2.303} 507.0 N {51.7 kgf, 113.98 Ibf} SM23-024
Valve Spring Straightness Inner spring 3.0 {0.118} Replace L \ cSFjS ' SM3-303
Push Rod Bend 0.5 {0.0196} Replace SM3-292
EN-MP34A-14
ENGINE
CRANKSHAFT PULLEY
OVERHAUL
Crankshaft pulley
Straight pin
Torsional damper
Pulley center
Dust slinger
T = Tightening torque: N-m {kgf-cm, Ibf-ft}
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
For Dust slinger
9851-99101 and 9851-36104
ENGINE
EN-NIP34A-15
IMPORTANT POINT - DISMOUNTING
REMOVE THE CRANKSHAFT PULLEY.
NOTE: О Use a puller if necessary.
О Do not remove the crankshaft gear unless it considered
absolutely necessary.
IMPORTANT POINTS - ASSEMBLY
IF NECESSARY, REPLACE THE DUST SLINGER.
1. Remove the dust slinger with levers.
2. Using special tools, install the dust slinger.
Special Tools: Dust Slinger Press (09402-1110)
O-ring (9851-99101) and (9851-36104)
NOTE: To prevent wear of the side lip of the oil seal, inject about
0.5 to 1 cm3 {0.031-0.061 cu.in) of grease (lithium-based)
into the "U" groove of the oil slinger.
IMPORTANT POINT - MOUNTING
INSTALL THE CRANKSHAFT PULLEY.
NOTE: Apply engine oil to thread of the crankshaft.
EN-MP34A-16
ENGINE
FLYWHEEL AND FLYWHEEL HOUSING
14
1. Flywheel housing gasket 6. O-ring 11. Flywheel assembly
2. Flywheel housing 7. Oil seal retainer 12. Pilot bearing
3. Helisert 8. Oil seal 13. Bearing stopper
4. Rear engine mounting bracket 9. Flywheel ring gear 14. Straight pin
5. Dust cover 10. Spacer
IMPORTANT POINTS - ASSEMBLY
IF NECESSARY, REPLACE THE OIL SEAL.
1. Remove the oil seal.
2. Apply a small amount of clean engine oil on the outer
periphery of the oil seal and then install the oil seal to the oil
seal retainer, ensuring that it is flush with the end of the oil
seal retainer.
Special Tool: Oil Seal Guide (09471-1090)
NOTE: Ensure that the lip of the oil seal is coated with oil seal
lubricating grease (lithium-based.)
IF NECESSARY, REPLACE THE FLYWHEEL RING GEAR.
1. Remove the ring gear.
a. Heat the ring gear with a blow torch in a uniform manner
[Approx. 200°C {392°F}].
b. Using a metal rod as a pad and strike all around the ring gear
in a uniform manner and remove the ring gear.
NOTE: Be careful not to overheat the ring gear.
ENGINE
EN-NIP34A-17
2. Install the ring gear.
a. Heat the ring gear uniformly using a blow torch [Approx.
200°C {392°F}.]
b. Drive the ring gear with its chamfered gear teeth facing the
block onto the flywheel using a metal rod.
NOTE: Be careful not to overheat the ring gear.
SM3-1698
INSTALL THE FLYWHEEL.
1. Install the flywheel and tighten the bolts through several repe-
tition the tightening order so as to reach specified torque
evenly and gradually, then slacken and tighten them one by
one to the specified torque.
WARNING
The flywheel is heavy, when installing, be careful not to drop it
on your feet.
NOTE: о Align the "O" mark on the flywheel and crankshaft collar
knock-pin.
О When tightening the bolt, apply engine oil to the threads
and flywheel surface of the bolts.
Tightening Torque: 255-284 N-m
{2,600-2,900 kgf-cm, 188-209 Ibf-ft)
2. Install the pilot bearing.
3. Install the lock plate with bolts.
SM3-1697
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Flywheel face alignment 0.3 {0.0118} 0.5 {0.0196} Regrind and/or replace SM3-908
EN-MP34A-18
ENGINE
TIMING GEAR AND CAMSHAFT
DESCRIPTION
1. Crankshaft gear
2. Air compressor drive gear
3. Power steering pump drive gear
4. Injection pump drive gear
5. Camshaft drive gear
6. Coolant pump drive gear
7. Engine oil pump drive gear
OVERHAUL
T = Tightening torque: N-m {kgf-cm, Ibf-ft}
1. Oil seal 7. Idler gear 14. Key
2. Timing gear case cover 8. Engine oil pump driven gear 15. Camshaft
3. Gasket 9. Engine oil pump drive gear 16. Front end plate
4. Air compressor drive gear 10. Crankshaft gear 17. Injection pump drive main gear
5. Power steering pump drive gear 11. Camshaft gear 18. Spring
6. Injection pump drive gear 12. Coolant pump drive gear 19. Injection pump drive sub gear
assembly 13. Camshaft thrust plate 20. Retainer ring
ENGINE
EN-MP34A-19
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
CAMSHAFT ATTACHMENT
TIMING GEAR PULLER
09420-1360
EN-MP34A-20
ENGINE
IMPORTANT POINTS - DISMOUNTING
REMOVE THE CAMSHAFT.
Remove the thrust plate set bolts and pull out the camshaft
with gear.
NOTE: Pull the camshaft, slowly turning it so as not to damage
the bearings.
Special Tool: Attachment (09481-1060)
IMPORTANT POINTS - ASSEMBLING
IF NECESSARY, REPLACE THE CAMSHAFT GEAR.
Holding the shaft assembly with a vice through wooden
plates. Remove the nut, then using a gear puller, remove the
gear.
Special Tool: Puller (09420-1360)
ASSEMBLE THE INJECTION PUMP DRIVE GEAR ASSEMBLY.
1. Install the spring and sub gear onto the main gear with
retainer ring.
NOTE: o Be sure painted side of spring face to the sub gear.
О Apply lithium based grease to (A).
о Align the sub gear matching marks with main gear.
О After assembling, make sure that there is clearance
0.6-0.8 mm (0.024-0.031 in) at all around the perimeter
of (B).
ENGINE
EN-MP34A-21
IMPORTANT POINTS - MOUNTING
IF NECESSARY, REPLACE THE TIMING GEAR COVER OIL SEAL.
1. Using a screwdriver, remove the oil seal.
2. Install the new oil seal.
Special Tool: Press (09482-1070)
INSTALL THE CAMSHAFT GEAR TO THE SHAFT.
Install the camshaft gear with thrust plate.
NOTE: When installing the gear to the camshaft:
О Heat the gear in hot water [Approx. 180“C {356°F}], then
install the gear to the camshaft by using a press.
О When tightening the nut, apply engine oil to the treads
and plate surface of the nut.
INSTALL THE TIMING GEAR PLATE.
Align the cylinder block and timing gear plate using dowel pin
(A) and (B).
NOTE: Fit the O-ring to the cylinder block water gallery and install
the timing gear plate with a gasket.
INSTALL THE CAMSHAFT.
1. Lubricate all journals of the camshaft and insert the camshaft
assembly into the cylinder block.
Special Tool: Attachment (09481-1060)
NOTE: Insert the camshaft, slowly turning while inserting so that
the bearing will not be damaged.
EN-MP34A-22
ENGINE
2. Align the camshaft gear matching marks with the crank shaft
gear.
NOTE: Incorrect installation can result in engine damage or lower-
ing of engine performance by causing improper injection
timing.
INSTALL THE INJECTION PUMP DRIVE GEAR.
Align the injection pump drive gear match mark with the idler
gear.
NOTE: Incorrect installation can results in engine damage or low-
ering of engine performance by causing improper injection
timing.
MEASURE THE GEAR BACKLASH.
Measure the back lash of each gear using a dial gauge or
plastic gauge.
Replace the gear if necessary.
Refer to INSPECTION AND REPAIR.
NOTE: After measure the gear back lash, apply engine oil to face
of each gear.
INSTALL THE TIMING GEAR COVER.
Using a special tool, install the timing gear cover.
Special Tool: Front Oil Seal Guide (09471-1120)
INSTALL THE OIL PUMP AND OIL STRAINER.
Refer to "OIL PUMP AND OIL STRAINER" in SECTION LUBRI-
CATING SYSTEM.
INSTALL THE OIL PAN.
1. Cut the protrusion of the timing gear plate gasket and fly-
wheel housing gasket from the oil pan mounting surface.
ENGINE
EN-MP34A-23
2. Install the oil pan.
NOTE: Apply the silicon rubber sealer (room temperature valca-
nizer as of three bond No. 1211 or 1215 or equivalent) to
the oil pan gasket.
INSTALL THE AIR COMPRESSOR.
1. Set to top dead center of No.1 or No.7 cylinder by turning the
crankshaft.
2. Before install the air compressor, make sure that the align the
engraved make of air compressor drive gear and engraved
mark of idler gear.
EN-MP34A-24
ENGINE
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Gear Teeth for Pitting or Wear Replace, if necessary. Visual check SM3-845
Camshaft Bend 0.05 {0.0019} Replace ZTV'VX / Vе' J \ tn Jj/ ' SM3-858
Camshaft Cam Height (Intake) 53.385 {2.1018} 52.585 {2.0703} Replace SM3-374
Camshaft Cam Height (Exhaust) 54.263 {2.1363} 53.463 {2.1048}
Camshaft End Play 0.10-0.33 {0.0040-0.0129} 0.40 {0.0158} Replace thrust bearing '-SM3-848
Oil Clearance between Camshaft Journal and Bearing 0.06-0.15 {0.0024-0.0059} 0.30 {0.0118} Replace shaft and/or bushing wSSi I / "x SM3-2487
ENGINE
EN-N1P34A-25
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Back Lash Crankshaft Drive Gear to Camshaft Gear 0.081-0.202 {0.0032-0.0080} 0.40 {0.0157} Replace gear, if necessary. SM3-844
Idler Gear to Injection Pump Drive Gear 0.054-0.224 {0.0022-0.0088)
Injection Pump Drive Gear to Power Steering Pump Drive Gear 0.061-0.140 {0.0025-0.0055}
Idler Gear to Air Compressor Drive Gear 0.045-0.257 {0.0018-0.0101}
Camshaft Drive Gear to Coolant Pump Drive Gear 0.04-0.261 {0.0016-0.0102}
Oil Pump Drive Gear to Oil Pump Driven Gear 0.084-0.289 {0.0034-0.0113}
Clearance between Valve lifter and Valve lifter Guide 0.025-0.075 {0.0010-0.0029} 0.15 {0.0059} Replace tappet Jri 1© SM3-293 --'4 SM3-420
Tappet for Wear Should not be worn unevenly. Replace, if necessary. Visual check SM3-1122
Coolant Pump Oil Jet Clogged Clean SM3-1141
EN-MP34A-26
ENGINE
INJECTION PUMP DRIVE
1. Drive gear
2. Front end plate
3. O-ring
4. Bearing holder case
5. Ball bearing
6. Key
7. Drive shaft
8. Shim
9. Gasket
10. Bearing retainer
11. Oil seal
12. Oil seal sleeve
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
INJECTION PUMP DRIVE
SHAFT SLEEVE PULLER
INJECTION PUMP DRIVE
O-RING (Used with 09482-1550)
IMPORTANT POINTS - ASSEMBLY
IF NECESSARY, REPLACE THE FUEL INJECTION PUMP DRIVE
SHAFT OIL SEAL SLEEVE.
1. Using a special tool, remove the sleeve.
a. Put the puller (1), (2) onto the sleeve.
b. Insert the hook portion of the puller between shaft and sleeve.
c. Insert the puller (3).
d. After inserting the puller, screw in the center bolt (4), then re-
move the sleeve.
Special Tool: Puller Assembly (09420-1180)
ENGINE
EN-MP34A-27
2. Using special tools, insert the shaft sleeve with a new O-ring.
a. Put the O-ring (5) into the press (6).
b. Insert the new oil seal sleeve with new O-ring into the press
and then insert them into the drive shaft.
c. Hitting the (A) lightly by hammer, contact the press end and
the shaft end <B), with this determine the oil seal sleeve posi-
tion.
MOTE: о Be sure to fit an O-ring on the sleeve and also apply a
liberal coating of oil to the shaft.
О When driving on the shaft sleeve, taking care that the
O-ring does not get cut or torn.
О Once a sleeve has been removed, it cannot be reused.
Special Tools: Press (09482-1330)
O-ring (9851-36104)
ASSEMBLE THE INJECTION PUMP DRIVE SHAFT ASSEMBLY.
Adjust the preload of drive shaft by shims.
Turning Torque: 0.39-1.17 N-m (4-12 kgf-cm, 0.290-0.867 Ibf-ft)
NOTE: Be sure that there is no loose rattling in the axis direction
of the drive shaft.
EN-MP34A-28
ENGINE
PISTON, CRANKSHAFT, CYLINDER BLOCK
AND OIL PAN
ENGINE
EN-MP34A-29
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
For Piston ring
PISTON RING EXPANDER
09442-1220
09441-1310
For Main bearing cap dismounting
CYLINDER BLOCK EXPANDER
09440-1020
EN-MP34A-30
ENGINE
For Cylinder liner
For Piston cooling jet
For Front oil seal sleeve
PRESS
09402-1260
For Rear oil seal sleeve
For Rear oil slinger
For Connecting rod bushing
PRESS SET
09407-1010
ENGINE
EN-WIP34A-31
REMOVE THE PISTONS WITH CONNECTING RODS.
1. Remove the carbon from the upper end of the cylinder liner
with a scraper or emery paper (recommended: No.150) in a
circular direction.
2. Extract the piston and connecting rod assembly out through
the top of the cylinder.
NOTE: о Remove the connecting rod in such a way that the con-
necting rod does not contact the cooling jet.
Adjust the cooling jet if by any chance the rod and the
jet make.
О Arrange the piston and connecting rod caps in order.
REMOVE THE PISTON RINGS.
Special Tool: Piston Ring Expander (09442-1220)
NOTE: О Handle the piston rings carefully because they are made
of a special casting which is easily broken.
О Keep the rings for each cylinder separate.
REMOVE THE MAIN BEARING CAP.
1. Remove the side bolts.
2. Remove the main bearing cap bolts.
3. Using a special tool, open up the cylinder block.
Special Tool: Cylinder Block Expander (09440-1020)
NOTE: Be careful not to open up the cylinder block expander more
than 90°, as it may damage the block.
4. Remove the main bearing cap.
EN-MP34A-32
ENGINE
REMOVE THE CYLINDER LINER.
Before removing the cylinder liners, be sure to put match
marks on the cylinder block and liner flange with a pen.
NOTE: о Do not put match marks with a punch.
О After removing the cylinder liners, put numbers on their
periphery or arrange them in sequence.
Special Tool: Cylinder Liner Puller (09420-1290)
ENGINE
EN-NIP34A-33
IMPORTANT POINTS - ASSEMBLY
INSPECT THE PISTON COOLING JET POSITIONING.
NOTE: о Do not remove the cooling jet except when performing
overhauls or when otherwise necessary.
О In the event that the cooling jet is removed, be sure to
replace it on the cylinder.
Inspection of the piston cooling jet positioning procedure are
as follows.
1. Remove the piston cooling jet connector bolt and install a
special tool.
Special Tool: Connector Bolt (9001-24272)
2. Use a commercially available oil pump [pressure about 2 kg/
cm2 {28.44 lb/sq.in}, flow rate about 2.5L/min {2.64 US.qts/
min}].
3. Prepare fresh engine oil.
4. Connect the oil lines.
Connect the oil pump outlet to a special tool (connector bolt).
SM3-580
5. Install a special tool on the cylinder block.
Special Tool: Target Plate (09444-1320)
ABNORMAL
NORMAL
6. Operate the oil pump, and with pressure at about 196 kPa {2
kg/cm2, 28.44 lb/in2}, pump fresh oil from the jet, and perform
a spray test. Conditions are normal if the center of stream hits
a target plate 0Ю mm {0.39 in}.
WARNING
Engine oil is flammable.
This spray test should be done in a well ventilated room and
away from any open flames or electric sparks.
SM3-581
EN-MP34A-34
ENGINE
7. If the spray of the cooling jet messes the circle on the target
plate, realign the cooling jet nozzle, using a special tool.
Special Tool: Adjuster Bar (09472-1620)
8. Spray pattern.
When inspecting the piston cooling jet positioning, check that
the spray is dispersed as shown in "4" and not as in "1", "2", or
"3" in the illustration at left.
NOTE: If the tip of the jet is damaged so that the spray pattern is
bad, replace the jet with a new one. When replacing the
cooling jet, always inspect the new piston cooling jet's
positioning.
9. After inspecting the piston cooling jet positioning, remove the
special tool (connector bolt), then install the cooling jet on the
cylinder block using the correct mounting bolt with soft
washer.
Tightening Torque: 44-49 N-m
{450-500 kgf-cm, 33-36 Ibf-ft)
10. After installing the piston, make sure that there is no interfer-
ence between the cooling jet and the piston when the piston
is at bottom dead center.
IF NECESSARY, REPLACE THE MAIN OIL HOLE PLUG.
Fit two О-rings onto the plug of the main oil hole, be sure to
coat it with engine oil, then insert it into the cylinder block.
Evenly coat the taper plug of the oil hole with unaerobic ad-
hesive (as of Three bond No.203 or equivalent), then install
the taper plug. As shown in the detailed drawing, ensure that
plugs (3) and (4) do not protrude by more than 2 mm {0.0787
in).
Special Tool: Main Oil Hole Plug Wrench (09412-1070)
ENGINE
EN-MP34A-35
INSERT THE CYLINDER LINER INTO THE CYLINDER BLOCK.
1. Install the О-ring to the cylinder block.
2. Apply the silicon rubber sealer (Room Temperature Valcanizar
as of Three bond No.1211 or equivalent) to the position @ to
cylinder liner.
О-ring (B); Ring color: light green. Marking color: pink.
О-ring (C); Ring color: black. Marking color: pink.
2. Make sure that the "9" mark at the top of the cylinder liner
aligning with "0" mark on the cylinder block.
SM3-1150
MEASURE THE PROTRUSION OF THE CYLINDER LINER FLANGE.
Install a special tool and measure the protrusion of the top
end of the cylinder liner from the cylinder block.
Special Tool: Cylinder Liner Puller (09420-1210)
Tightening Torque: 9.80 N-m {100 kgf-cm, 7.23 lbf-ft}
Standard: 0.04-0.10 mm {0.0016-0.0039 in}
IF NECESSARY, REPLACE THE CRANKSHAFT FRONT OIL SEAL
SLEEVE.
1. Remove the oil seal sleeve using a special tool.
Special Tool: Eye Bolt (09433-1010)
2. Install a new sleeve.
Be sure to fit an new О-ring on the sleeve and also apply a
liberal coating of oil to the pulley center side.
When driving on the crankshaft sleeve, use a crankshaft
sleeve press, taking care that the О-ring does not get cut or
torn.
Special Tool: Press (09402-1260)
EN-MP34A-36
ENGINE
IF NECESSARY, REPLACE THE CRANKSHAFT REAR OIL SEAL
SLEEVE.
1. Remove the crankshaft sleeve using a special tool.
Special Tool: Puller (09420-1060)
2. Install a new sleeve.
Be sure to fit an new O-ring on the sleeve and also apply a
liberal coating of oil to the crankshaft side.
When driving on the crankshaft sleeve, use a crankshaft
sleeve press, taking care that the O-ring does not get cut or
torn.
Special Tool: Press (09402-1070)
UNDER SIZE BEARING FOR CRANKSHAFT.
NOTE: o If the wear of the crankshaft pin or journal matches an
undersize bearing 4 types 0.25 mm {0.0098 in), 0.50 mm
{0.0197 in), 0.75 mm {0.0295 in), 1.00 mm {0.0394 in), re-
place the bearing with an undersized one.
О The bearing is a set consisting of upper and lower
halves. Consequently, be sure to replace the bearing as a
set.
Unit: mm {in}
Bearing size Outside diameter
Crank pin Journal
0.25 83.695-83.715 {3.2951-3.2958} 89.66-89.68 {3.5400-3.5307}
0.50 83.445-83.465 {3.2853-3.2860} 89.41-89.43 {3.5201-3.5208}
0.75 83.195-83.215 {3.2754-3.2761} 89.16-89.18 {3.5103-3.5110}
1.00 82.945-83.965 {3.2656-8.2663} 88.91-88.93 {3.5004-3.5011}
INSPECT THE FILLET OF THE CRANK PIN AND JOURNAL.
Dimension of Fillet (R): 5.0-5.5 mm {0.196-0.216 in)
SM3-441
ENGINE
EN-MP34A-37
INSTALL THE CRANKSHAFT.
1. Install the crankshaft bearings on the cylinder block and bear-
ing cap.
NOTE: о Install the bearing with the oil hole onto the block side
and the bearing without the oil hole onto the cap side.
о Apply fresh engine oil to each bearing surface.
2. Install the crankshaft on the cylinder block.
3. Insert the crankshaft thrust bearings along the groove of the
cylinder block.
4. Install the thrust bearings on the No.5 bearing cap sides.
NOTE: Apply fresh engine oil to each thrust bearing surface.
5. Using the special tool, open up the cylinder block.
Special Tool: Cylinder Block Expander (09440-1020)
NOTE: Be careful not to open up the cylinder block expander more
than 90° as it may damage the block.
6. Install the crankshaft bearing caps.
a. Align the collar on the cylinder block and bearing caps.
b. Install them from the flywheel side.
SM3-1171
7. Tighten the bearing cap bolts in three stages following the
tightening order.
Tightening Order: 1-2-3-4-5-6-7-8-9-10
Tightening torque
1 st step 50% of specified torque
2nd step 75% of specified torque
3rd step 100% of specified torque
Tightening Torque: 402-441 N-m
{4,100-4,500 kgf-cm, 297-325 Ibf-ft}
NOTE: о Apply engine oil to the bolt threads and under the bolt
head.
О Make sure that the crankshaft rotates smoothly.
О Inspect the crankshaft end play.
8. Tighten the side bolts in three stages following the tightening
order.
Tightening Order: 11-12-13-14-15-16-17-18-19-20
Tightening Torque: 117-147 N m
{1,200-1,500 kgf-cm, 87-108 Ibf-ft}
EN-MP34A-38
ENGINE
IF NECESSARY, REPLACE THE CONNECTING ROD BUSHING.
1. Install the spindle and the guide on the bracket.
Special Tool: Connecting Rod Press Set (09407-1010)
NOTE: The tapered face on the spindle should be upward.
2. Mount the connecting rod. Install the guide on the connecting
rod housing with the bolt.
Tightening Torque: 98.07-117.67 N-m
{1,000-1,200 kgf-cm, 72-86 Ibf-ft)
NOTE: Use following bolt:
Length: 165 mm (6.496 in)
3. Remove the spindle from the bottom.
4. Reinsert the spindle from the top onto the connecting rod
bushing.
NOTE: The tapered face on the spindle should be downward.
5. Install the cap on the spindle and push out the bushing using
a press.
6. Install a new connecting rod bushing.
a) Debar and clean the connecting rod bushing insert bore.
b) Mount a new connecting rod bushing on the spindle and
mount the cap. Tighten the cap set screw.
c) Make sure that the bushing oil hole coincides with the oil hole
of the connecting rod.
d) Install the bracket set screw in the bracket.
e) Press in the new bushing using a press.
NOTE: Make sure that the spindle groove coincides with the
bracket set screw.
f) Remove the spindle, and dismount the connecting rod from
the special tool.
ENGINE
EN-MP34A-39
FOR RIGHT BANK
FOR LEFT BANK
ASSEMBLE THE PISTON.
1. Assemble the piston and connecting rod as shown.
NOTE: О R marks at the bottom of the pistons indicate use for the
right bank, L marks use for the left bank.
О Make sure that the О-mark at the top of the piston and
the arrow mark at the connecting rod in same directions.
“0" MARK
AND
ARROW
MARK
ARROW
MARK
SM3-295
INSTALL THE PISTON RING.
1. Install the piston rings in the sequence oil ring, third ring
second ring and top ring with the identification mark at the
top of the ring facing up.
NOTE: Apply oil to the piston rings.
Special Tool: Piston Ring Expander (09442-1220)
Ring No. Description
Top ЗИП
2nd
3rd
Oil
2. Connect the ends of the coil expander and then fit the coil
inside the piston ring after ensuring that the gap of the piston
ring is 180“ away from the joint of the coil.
SM3-443
EN-MP34A-40
ENGINE
3. Arrange the piston rings so that their gaps are equally spaced.
INSTALL THE PISTON WITH CONNECTING ROD INTO THE CYLIN-
DER LINER.
1. Apply engine oil to the piston, cylinder liner and connecting
rod bearing surface.
2. Using a special tool, hold the piston rings and push the piston
with connecting rod assembly with a wooden rod.
NOTE: О Be sure that the О-mark on the top of the piston is near-
est the identification marks of cylinder block and liner or
water gallery cover side as shown.
The arrow marks on the pistons should face the timing
gear side.
О When installing the piston with connecting rod assem-
bly, be sure that the piston cooling jet is not struck by
the connecting rod. If the piston cooling jet is struck,
adjust or replace it.
Special Tool: Piston Ring Holder (09441-1310)
INSTALL THE CONNECTING ROD CAP.
1. Apply engine oil to the bearing surface.
2. Align the match marks on the connecting rod and cap.
SM3-407
ENGINE
EN-NIP34A-41
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Cylinder Liner Inside Diameter 139 {5.47} 140.2 {5.5196} Replace liner 25 mm {0.984 in} SM3-910 //^V- © vT ' )) о 2 S ll 1
Clearance between Piston and Cylinder Liner 0.206-0.235 {0.0082-0.0092} Replace piston and/or liner.

— SM3-432 ^SM^313
Clearance between Piston Pin and Piston Pin Hole 0.001-0.015 {0.00004-0.00059} 0.005 {0.0019} Replace piston, piston pin and/or bushing. и SM3-859
Clearance between Piston Pin and Connecting Rod Bearing 0.025-0.043 {0.00099-0.00169} 0.10 {0.0039}
Crankshaft End Play 0.11-0.24 {0.0044-0.0094} 0.5 {0.0196} Replace thrust bearing / / / / ' SM3-1176
Connecting Rod Wear or Damage * Use a dye penetrate Replace SM3-363
Connecting Rod Oil Hole Clogged Clean SM3-424
EN-MP34A-42
ENGINE
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Connecting Rod Straightness 0.1 {0.0039} per 200 {7.874} Replace SM3-330
Connecting Rod Twist 0.1 {0.0039} per 200 {7.874} Replace SM3-331
Crank Pin Diameter 84 {3.3070} 83.80 {3.2992} Regrind undersize МЮ (^<4. SM3-860 ~ SM3-300
82.80 {3.2598} Replace crankshaft
Clearance between Connecting Rod and Crank Pin 0.056-0.107 {0.0023-0.0042} 0.30 {0.0118} Replace bearing
Main Bearing Spread 116.75-117.25 {4.5965-4.6161} - Replace bearing
V' Г/
Connecting Rod Bearing Spread 89.75-90.25 {3.5335-3.5531} - SM3-298
Crankshaft Oil Hole Clogged Clean w VW W SM3-434
Crankshaft Cracks and Damage * Use a dye penetrate Replace 4WV ДГ SM3-435
ENGINE
EN-MP34A-43
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Crankshaft Bend 0.06 {0.0023} Replace

IX/ wlfnr KJUMIkt

SM3-861
Piston Ring Breadth Ring No.: Top 3.306 {0.1302} 3.156 {0.1243} Replace \ J / SM3-379
2nd 3.5 {0.1378} 3.35 {0.1318}
3rd 3.5 {0.1378} 3.35 {0.1318}
Oil 5.0 {0.1969} 4.95 {0.1948}
Piston Ring Groove Breadth Ring No.: Top 3.5 {0.1378} 3.65 {0.1438} Replace
2nd 3.5 {0.1378} 3.65 {0.1438}
3rd 3.5 {0.1378} 3.65 {0.1438}
Oil 5.0 {0.1969} 5.05 {0.1989}
Clearance between Piston Ring and Piston Ring Breadth Ring No.: Top Not easily measured
2nd 0.07-0.11 {0.0028-0.0043} Replace piston ring and/or piston SM3-301
3rd 0.07-0.11 {0.0028-0.0043}
Oil 0.04-0.08 {0.0016-0.0031}
Piston Ring Gap * Insert the Piston Rings Where the Wear of the Liner is Small. Ring No.: Top 0.45-0.60 {0.0178-0.0236} 1.5 {0.0590} Replace
2nd 0.45-0.60 {0.0178-0.0236} 1.5 {0.0590} SM3-302
3rd 0.45-0.60 {0.0178-0.0236} 1.5 {0.0590}
Oil 0.35-0.55 {0.0138-0.0216} 1.0 {0.0393}
Cylinder Block Flatness 0.05 {0.0019} 0.15 {0.0059} Regrind and/or replace О » W— | SM3-314
EN-MP34A-44
ENGINE
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Flywheel Face Alignment 0.3 {0.0118} 0.5 {0.0196} Regrind and/or replace 3 c 5M3-1178
Cylinder Liner Protrusion 0.04-0.10 {0.0016-0.0039} Replace PROTRU SION I SM3-1092
Crankshaft Journal Diameter 110 {4.3307} -0.20 {-0.0078} Regrind undersize * Ж0 )) /) SM3-860
108.80 {4.2834} Replace crankshaft
Clearance between Crankshaft Journal and Main Bearing 0.066-0.117 {0.0026-0.0046} 0.30 {0.0118} Replace bearing SM3-1177
ENGINE
EN-LS32A-1
LUBRICATING SYSTEM
LUBRICATING SYSTEM DIAGRAM
23 24 19-^ 17 /• , 1 ЛЛЛЛЛЛЛЛ ! <A„; 22 / П 26 o-ГЦ / A / Lly-i4J / 18 No? / No3 Ho4 II ДНо5 tSHTOW-J Ж" Fl 'J qjn ПНП A ।—П" > тлтЛТЬиг т ц P ргтс.зжрШяЬ-] 2» и u L l PL bL -Л ^4-315 1зХ§ ===; ё 8 > 14 « 71 h/ifj'"12 ОД/ 9 10 , 5 2 _ P.T.O. LUBRICATION _ Г" (IF SO EQUIPPED) ~] | CAMSHAFT П T0 p T 0 GEAR । । BEARING No.5l^ у | 1 fl 1 1 (crankshaft , 1 i i BEARING No.5 1 i 7 । i i 27 29 31 34 'Z 32 35 30 VALVE MECHANISM
Unit: kPa {kgf/cm2, lbf/in2}
1. Oil pan
2. Suction strainer
3.
4.
11.
5.
Oil pump
Oil pump safety valve
784-931 {8.0-9.5,114-135}
Delivery pipe
6. Oil cooler
7.
8.
9.
10.
Oil cooler safety valve
363-421 {3.7-4.3, 52.7-61.14}
Cut off valve
156.9-196.1 {1.6-2.0, 22.8-28.4}
Bypass oil filter
Alarm device for clogging of oil
filter 147{1.5,21.3}
Regulator valve
363-421 (3.7-4.3, 52.7-61.1}
Full-flow oil filter
Oil pressure unit
Oil filter safety valve
127.5-166.7 {1.3-1.7,18.5-24.1}
15. Main oil hole (Left bank)
16.
17.
18.
19.
20. Crankshaft
21. Camshaft
22. Piston
12.
13.
14.
Valve mechanism (Right bank)
Fuel injection pump
To Oil pan
Air compressor
Adjusting screw
Piston cooling jet
Fuel injection pump drive shaft
Valve mechanism (Left bank)
Timing gear
23. Sub oil hole (Right bank)
24. Low cup valve
25.
26.
27.
28.
29.
30. Valve lifter
31. Valve stem seal
32. From cylinder head
33. Valve rocker arm
34. Valve guide
35. Valve
EN-LS32A-2
ENGINE
OIL PUMP AND OIL STRAINER
OVERHAUL
14
11
T = Tightening torque: Nm {kgfcm, Ibf-ft}
1. Oil pump cover 6. Shim 11. Oil pump
2. Drive gear 7. Spring seat 12. Oil strainer
3. Oil pump body 8. Retainer ring 13. Oil feed pipe
4. Oil pump safety valve 9. O-ring 14. Strainer bracket
5. Oil pump safety valve spring 10. Plate 15. Oil pump inlet pipe
ENGINE
EN-LS32A-3
IMPORTANT POINTS - MOUNTING
OIL PUMP SAFETY VALVE AMD RETAINER RING.
1. Adjust the safety valve opening pressure.
Using shims
Pressure: 784-931 kPa {8.0-9.5 kgf/cm2,114-135 lbf/in2}
Shim thickness: 1.2 mm {0.0472 in}
2. Retainer ring
Install a retainer ring to the safety valve holder.
NOTE: Bevelled edge of retainer ring towards outside.
INSTALL THE OIL STRAINER.
NOTE: Be sure to install O-ring and tighten the oil pipe set bolts
temporary, then tighten the set bolts to the specified
torque.
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Gear Back Lash 0.10-0.26 {0.006-0.011} 0.4 {0.0157} Replace SM3-1117
EN-LS32A-4
ENGINE
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Drive Gear Shaft Diameter 23.967-23.980 {0.9436-0.9440} - Replace shaft and/or bushing SM3-1123
Bushing Inside Diameter 24.020-24.041 {0.9457-0.9464} -
Clearance between Drive Shaft and Bushing 0.040-0.074 {0.0016-0.0029} 0.19 {0.0074} SM3-1107
Driven Gear Shaft Diameter 30.939-30.955 {1.2181-1.2187} - Replace
Driven Gear Inside Diameter 30.995-31.020 {1.2187-1.2212} - Replace Il / SM3-1124
Clearance between Driven Gear and Shaft 0.040-0.081 {0.0016-0.0031} 0.19 {0.0035} Replace bushing and/or shaft L W SM3-317
Clearance between Gear and Case 0.05-0.13 {0.0020-0.0051} 0.18 {0.0071} Replace gear and/or case к \ SM3-1114
Gear End Play 0.06-0.105 {0.0024-0.0041} 0.15 {0.0059} Replace gear and/or case SM3-1112
Gear Teeth Pitting or Wear Replace, if necessary. Visual check SM3-845
ENGINE
EN-LS32A-5
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Oil pump safety valve for Wear or Damage - Replace, if necessary. Visual check
Gear Back Lash between Crankshaft Gear and Oil Pump Drive Gear 0.10-0.26 {0.0040-0.0102} 0.4 {0.0157} Replace gear ° ’I SM3-844
EN-LS32A-6
ENGINE
OIL COOLER AND OIL FILTER
10
40-49
{400-500,
29-26}
OIL FILTER
1. Oil filter cap
2. Regulator valve
3. Relief valve
4. Cut-off valve
5. O-ring
6. Oil filter element
7. Spring seat
8. Spring
9. Oil filter element cover
10. Center bolt
11. Drain plug
12. Oil cooler element
T = Tightening torque: N-m {kgf-cm, Ibf-ft}
13. Gasket
14. Oil cooler case
15. Safety valve
16. Coolant drain cock
INSPECTION AND REPAIR
Inspection Item Standard Limit Remedy Inspection Procedure
Oil Cooler Air Thickness Air Pressure: 588.39 kPa {6 kgf/cm2, 85.3 lbf/in2} Replace, if necessary. 6k9/Cm2^ AIR WATER <-AIR I ELEMENT
I- SM3-1088
Valve and Springs of Oil Cooler and Oil Filter Wear or Damage - - Replace, if necessary. 1. Sliding face of valve for possible damage. 2. Valve move smoothly.
ENGINE
EN-FS24A-1
FUEL SYSTEM
EN-FS24A-2
ENGINE
INJECTION NOZZLE
Maker ZEXEL (ZXL)
Type 2 Spring Type
DESCRIPTION
L : Needle valve full-lift
£ : Needle valve pre-lift
ENGINE
EN-FS24A-3
OVERHAUL
1. Retainer nut
15-19
{150-200,11-14}
30-39
{300-400, 22-29}
2. Nozzle assembly
3. Pin
4. Spacer
5. Lift piece
6. Second pressure spring
seat
7. Second pressure spring
8. Second pressure
adjusting shim
9. Nozzle holder
10. Push rod
11. First pressure spring
12. First pressure adjusting
screw
13. Gasket
14. Gap nut
15. Leakage bolt
T = Tightening torque: N-m {kgf-cm, Ibf-ft}
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
NOTE: ZXL means ZEXEL
IDLER GEAR SLIDING HAMMER
ADJUSTING DEVICE
157892-4620: All in one set, ZXL make
EN-FS24A-4
ENGINE
IMPORTANT POINTS - DISMOUNTING
CLEAN OFF SURROUNDING AREA OF THE NOZZLE AND THE FUEL
LINE CONNECTORS.
NOTE: If foreign matter is allowed to enter the combustion
chamber, engine trouble may result.
REMOVE THE FUEL INJECTION PIPE.
NOTE: Cover open ends of the pipes and fuel injection pump to
prevent entry of dirt.
REMOVE THE NOZZLE HOLDER ASSEMBLY.
Remove the nozzle clamp bolt and nozzle clamp, then remove
the nozzle holder assembly by hand.
NOTE: After removal of the nozzle holder, cover the nozzle holder
with cloth. Also cover the cylinder head with a cloth to pre-
vent dust from getting in.
IMPORTANT POINTS - INSPECTION
CHECK THE NOZZLE OPERATING PRESSURE.
1. Install the nozzle older assembly to the nozzle tester, and
operate the lever at the rate of about 50 to 60 times per
minute.
WARNING
o Diesel fuel is flammable.
This nozzle adjusting should be done a well ventilated room
and away from any open flames or electric spark.
о The spray must always be covered. Keep your face and body
away from the spray. This is because of the risk of fuel oil get-
ting in your eyes or passing into your body.
2. At this time, check that the nozzle operating pressure (first
opening pressure) is in the specified vlaue. If not, disassemble
and adjust the nozzle holder assembly.
First opening pressure: 15.2-16.0 MPa
{155-163 kbf/cm2, 2,205-2,318 lbf/in2}
TEST THE SPRAY PROFILE.
In the case of the new nozzle, operating the lever at the rate of
30 to 60 strokes per minute, and for a used nozzle, operate the
lever at the rate of 15 to 60 strokes per minute.
ENGINE
EN-FS24A-5
TEST THE FUEL LEAKAGE.
When checking for fuel leakage from the nozzle, apply a pres-
sure of about 0.98-1.96 MPa {10-20 kg/cm2, 142-284 lb/in2}
lower than the correct injection pressure to the nozzle by
means of the nozzle.
TEST THE NOZZLE SINKING.
Wash the nozzle proper with diesel fuel oil, them immerse it in
diesel fuel oil.
Next slide the needle inside the nozzle proper and ensure that
it move smoothly. The needle valve should fall under its own
weight when withdrawn vertically about 1/3 and released. If
its motion is sluggish, replace the nozzle with a new one.
ASSEMBLING
NOTE: o The steps below for adjustment are made during parts assembly.
о Because the nozzle holder is adjusted in 1/100 mm units, it must be thoroughly washed to completely remove all
dirt and foreign objects.
Work steps
1. Adjustment of first opening Adjust first opening pressure with the adjusting
pressure screw.
2. Checking of needle valve full lifts Check with nozzle cover method.
3. Checking of pre-lift
-------------------Check with nozzle cover method.
NOTE: If pre-lift is not within specified value,
replace pins, lift piece, spacer and nozzle
assembly with the nozzle service kit.
4. Checking of second opening pressure Check with nozzle cover method.
5. Adjusting of second opening pressure Adjust second opening pressure with adjusting shim.
6. Replacement of the retaining nut Replace adjustable retaining nut with normal retain- ing nut.

7. Final inspection Check condition of the fuel spray with the nozzle and nozzle holder assembled.
EN-FS24A-6
ENGINE
ADJUSTMENT OF FIRST OPENING PRESSURE.
1. Clamp the plate (special tool) into a vice.
Special tool: Plate assembly (15944-9520.ZXL make)
2. With the cap nut side facing downward, attach the nozzle
holder body to the plate.
3. Insert the adjusting shim, the second pressure spring and the
spring seat, in that order into the nozzle holder body.
NOTE: The second pressure spring is the same as the first
pressure spring.
1 ^'SPACER ^-PIN ^''LIFT PIECE _ I _^_--NOZZLE ^-PIN

4. Put the pins, the lift piece, and the spacer onto the nozzle
holder body.
5. Put the pin and the nozzle assembly onto the spacer.
6. Put the gasket (special tool) onto the nozzle, then use adjusta-
ble retaining nut (special tool) to hold the nozzle in place on
the nozzle holder.
Special tool: Gasket (157892-1500...ZXL make)
Adjustable retaining nut (157892-4000...ZXL make)
NOTE: О Check to make sure the pin is all the way in the nozzle
and then tighten adjustable retaining nut.
О Finger-tighten the adjustable retaining nut until it no
longer turns and tighten the nut to specified torque.
Tightening torque: 59-78 N-m {600-800 kgf-cm, 44-57 Ibf-ft}
7. Turn over the nozzle holder, body so that the cap nut side is
facing upward, and attach the nozzle holder body to the plate.
8. Insert the second pressure push rod, the first pressure spring
and the first pressure adjusting screw, in that order, into the
nozzle holder body.
9. Attach the gasket and the cap nut onto the first pressure
adjusting screw.
ENGINE
EN-FS24A-7
10. Attach the nozzle and nozzle holder assembly to the nozzle
tester.
11. Adjust the first opening pressure to the specified value with
the first pressure adjusting screw.
First opening pressure: 15.2-16.0 MPa
{155-163 kgf/cm2 3 4,2,205-2,318 lbf/in2}
12. Hold the nozzle holder body using a cresent wrench, then
tighten the cap nut to the specified torque.
Tightening torque: 29-39 N-m {300-400 kgf-cm, 22-28 Ibf-ft}
CHECKING OF NEEDLE VALVE FULL-LIFTS.
1. Attach the gasket (special tool) and the plug (special tool) onto
the adjustable retaining nut.
Special tool: Gasket (026508-1140...ZXL make)
Plug (157892-1600...ZXL make)
2. Turn over the nozzle holder body so that the cap nut side is
facing upward, and attach the nozzle holder body to the plate.
3. Attach the holder (special tool) to the cap nut.
Special tool: Holder (157892-4100..ZXL make)
4. Temporary tighten the attachment nut (special tool) onto the
holder.
Special tool: Attachment nut (157892-1000...ZXL make)
EN-FS24A-8
ENGINE
5. Screw the pin (special tool) into dial gauge.
Special tool: Pin (157892-4200)
(157892-4300)
1 /DIAL GAUGE
((( T ATTACHMENT
to Ml /^NUT S^^^/HOLDER
^^^/PIN

^/SECOND 1 /^ PRESSURE PUSH ROD
1 /GASKET AND PLUG
6. Tighten the attachment nut so that it holds the dial gauge in
place in the nozzle holder assembly and so that the pin is in
contact with the push rod upper surface.
NOTE: о Attach the dial gauge into place so that it can measure a
stroke of approx. 2 mm {0.079 in).
О Do not tighten the nut too much, the dial gauge shaft will
become stuck.
7. Attach the nozzle and nozzle holder assembly to the nozzle
tester and zero the dial gauge.
8. Operate the nozzle tester to bleed air in the retaining nut.
Check to make sure there are no fuel leaks.
PRESSURE—*•
9. Operate the nozzle tester to raise pressure to 34.3-44.1 MPa
{350-450 kgf/cm2, 4,979-6,400 lbf/in2} and needle valve is lifts
fully. At this time, record the dimensions of full-lifts as "L".
NOTE: This check is made to determine whether the nozzle seat is
abnormally worn and whether the nozzle is correctly as-
sembled.
ENGINE
EN-FS24A-9
3. CHECKING OF PRE-LIFT.
1. When needle valve is full-lifted, release the nozzle tester
handle to lower pressure inside the tube and decrease the
needle valve lift value (value indicated on dial gauge).
PRESSURE
PRESSURE—►
2. When the second pressure spring stop to action and needle
valve drop ends (needle valve lift dimension " f") read the dial
gauge indication, checking to make sure it is within specified
values.
Pre-lift measuring points:
Read the dial gauge at [First opening pressure + approx. 1
MPa {10 kgf/cm2, 142 lbf/in2}.
NOTE: Watch the pressure drop to find the point.
Pre-lift ( «): 0.085 mm {0.0033 in}
3. If pre-lift is not within specified value, replace the pins, the lift
piece, the spacer and the nozzle assembly with the nozzle ser-
vice kit.
CHECKING OF SECOND OPENING PRESSURE.
1. Check the pre-lift, then operate the nozzle tester to raise
pressure to 34.3-44.1 MPa {350-450 kgf/cm2, 4.979-6.400 Ibf/
in2} and lift the needle valve fully.
2. Release the nozzle tester handle to lower pressure inside the
tube, all the while watch the dial gauge indicate;
EN-FS24A-10
ENGINE
WHEN NEEDLE VALVE LIFT
: t + 0.05 mm
FULL-LIFT
- DIAL GAUGE -
3. Read the valve indicated on the pressure gauge at the instant
the dial gauge needle indicates the specified needle valve lift
value (pre-lift “I" + 0.05 mm {0.0020 in}).
Second opening pressure: 22.6-23.6 MPa
{230-240 kgf/cm2, 3.272-3.413 lbf/in2}.
- PRESSURE GAUGE -
OPENING OPENING {350-450 kgf/cm2}
PRESSURE PRESSURE
PRESSURE----------►
ADJUSTMENT OF SECOND OPENING PRESSURE.
1. If the second opening pressure deviates from the specified
value, and the amount of that deviation is small, readjust the
first opening pressure but within the specified value.
NOTE: О If the second opening pressure is lower than the specified
value:
Readjust the first opening pressure to maximum speci-
fied value, then measure the second opening pressure.
о If the second opening pressure is higher than the speci-
fied value:
Readjust the first opening pressure to minimum specified
value.
2. If the first opening pressure has been readjusted and the
second opening pressure still diviates from the specified
value, disassemble the nozzle side of the nozzle holder and
remove the adjusting shim.
3. If the second opening pressure is higher than the specified
value, replace the adjusting shim with a thinner one.
4. After replacing the adjusting shim, remeasure the second
opening pressure, and adjust the pressure until it comes to
the specified value.
Second pressure adjusting shim line-up
Inside diameter: 9.5 mm {0.374 in}
Outside diameter: 4.5 mm {0.177 in}
Unit: mm {in}
Parts number Shim thickness Parts number Shim thickness
150538-4900 0.40 {0.0157} 150538-5300 0.56 {0.0220}
150538-5000 0.50 {0.0197} 150538-5400 0.58 {0.0228}
150538-5100 0.52 {0.0205} 150538-5500 0.60 {0.0236}
150538-5200 0.54 {0.0212} 150538-5600 0.70 {0.0276}
ENGINE
EN-FS24A-11
6. REPLACEMENT OF THE RETAINING NUT.
1. Remove the dial gauge, the nut, the holder and the gasket
from the cap nut.
2. Remove the adjustable retaining nut and the gasket, and
attach a normal retaining nut.
Tightening torque: 59-78 N-m (600-800. kgf-cm, 44-57 Ibf-ft}
7. FINAL INSPECTION
1. Attach the nozzle holder to the nozzle tester and check the first
opening pressure, the spray condition, the seat's oil seal, and
whether there are any oil leaks from any part.
2. To replace the nozzle, replace the nozzle, the lift piece, and the
spacer, which are all in one set, with the nozzle service kit.
NOTE: Replacing only the nozzle will cause the amount of pre-lift
to deviate from the specified value.
IMPORTANT POINT - MOUNTING
INSTALL THE NOZZLE HOLDER ASSEMBLY.
NOTE: Tighten the nozzle holder bolts alternately right and left,
tightening the bolts gradually until the specified torque is
reached evenly.
Tightening torque: 15-17 N-m {150-180 kgf-cm, 10.9-13.0 Ibf-ft}
WARNING
If a single bolt is tightened first to the specified torque, when
the other bolts are tightened the actual effective torque will be
excessive, resulting in possible damage to the nozzle holder and
or bolt. On the other hand, if the bolts are not tightened
sufficiently, gas way leak, resulting in scorching of the nozzle.
EN-FS24A-12
ENGINE
SPECIAL TOOL
FUEL INJECTION PUMP
Prior to starting an engine overhaul, it is necessary to have this special tool.
INJECTION PUMP COUPLING
IMPORTANT POINTS - DISMOUNTING
REMOVE THE FUEL INJECTION PUMP.
1. Disconnect the fuel lines, oil lines and engine control lines.
2. Remove the through bolt "B" and the two flange bolts “A" (in
slotted holes) at the coupling.
3. Remove the pump mounting bolts and then dismount the
pump.
NOTE: Cover open end of the pipes and pump to prevent entry of
dirt.
Special Tool: Wrench (09819-1705)
IMPORTANT POINTS - DISASSEMBLING AND ASSEM-
BLING
Refer to CHAPTER IP, FUEL INJECTION PUMP for details.
IMPORTANT POINTS - MOUNTING
INSTALL THE FUEL INJECTION PUMP.
1. Adjust the injection timing.
Turn the crankshaft counterclockwise viewed from the fly-
wheel side to align the injection timing mark on the flywheel
at A ° before top dead center for No.1 cylinder on compression
stroke with pointer on the flywheel housing.
Injection timing (A°): Refer to SECTION DATA AND SPECIFICATION.
2. Check the push rods on No.1 cylinder are loose and push rods
on No.6 are tight.
NOTE: If not, turn the crankshaft one complete revolution and
align marks as above.
ENGINE
EN-FS24A-13
3. Slowly turn the automatic timer flange to clockwise viewed
from coupling side to align the injection timing mark on the
automatic timer with pump body pointer.
4. Position the pump on the pump bracket and adjust the posi-
tion of the pump so that its mounting holes align with those
of the bracket and then tighten the mounting bolts evenly.
Tightening Torque: 38-49. N-m {380-500 kgf-cm, 28-36 Ibf-ft}
5. Using a special tool, tighten the two flange bolts (in slotted
holes) at the coupling.
NOTE: There should not be any gap between the laminated plates
or be any deformation of the flange due to pressure the
laminated plates.
Special Tool: Injection Pump Coupling Wrench (09819-1705)
Tightening Torque: 59-63 N-m
{600-650 kgf-cm, 44-46 Ibf-ft}
6. Tighten the through bolt at the flange.
NOTE: Do not tighten the through bolt before tightening the two
flange bolts.
Tightening Torque: 59-63 N-m {600-650 kgf-cm, 44-46 Ibf-ft}
7. Connect the fuel lines, oil lines and engine control lines.
ENGINE
EN-CS32A-1
COOLING SYSTEM
COOLING SYSTEM DIAGRAM
1. Radiator
2. Drain cock
3. Coolant pump
4. Timing gear cover
5. Cylinder block
6. Oil cooler
7. Cylinder head
8. Air compressor
9. Thermostat case
10. Bypass pipe
11. Header tank
12. Radiator cap
13. Reservoir tank
14. Air vent pipe
15. Suction pipe
16. Coolant temperature gauge
EN-CS32A-2
ENGINE
COOLANT PUMP
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
COOLANT PUMP VALVE PULLER
COOLANT PUMP, OIL SEAL PRESS
COOLANT PUMP, COOLANT
COOLANT PUMP VANE PRESS
09482-1700
ENGINE
EN-CS32A-3
IMPORTANT POINTS - DISASSEMBLY
REMOVE THE COOLANT PUMP VANE.
Remove the vane from the shaft with special tool.
Special Tool: Coolant pump vane puller (09420-1620)
REMOVE THE SETTING BOLTS.
Working from the side of the drive gear, use a hexagonal
wrench to remove the bolts.
REMOVE THE COOLANT PUMP SHAFT USING A PRESS.
IMPORTANT POINTS - ASSEMBLY
1. INSTALL THE OIL SEAL TO THE COOLANT CASE.
NOTE: o Apply engine oil to the coolant case side and install the
oil seal to the case.
О Apply lithium based grease to the main lip and between
main and sub-lip.
Special Tool: Coolant pump oil seal press (09482-1160)
2.
INSTALL THE COOLANT PUMP SHAFT USING A PRESS.
EN-CS32A-4
ENGINE
TIGHTEN THE BOLTS.
INSTALL THE COOLANT SEAL TO THE CASE WITH SPECIAL TOOL.
Special Tool: Coolant seal press (09482-1690)
NOTE: When installing the coolant seal. Three Bond No.104 to the
outer and circumference of the coolant seal cage and install
the seal using a press.
INSTALL THE COOLANT PUMP VANE.
Special Tool: Coolant pump vane press (09482-1700)
NOTE: The coolant pump vane face until end of the shaft.
ENGINE
EN-CS32A-5
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Bearing Wear and Damage Replace pump shaft, if necessary. Visual check SM3-1501
Cover, Vane or Case Wear and Damage Replace, if necessary. Visual check SM3-1502
Water Drain Hole Clogged Clean SM3-1113
EN-CS32A-6
ENGINE
THERMOSTAT
IMPORTANT POINTS - INSPECTION AND REPAIR
INSPECT THE THERMOSTAT FUNCTION.
1. Place the thermostat in hot water and check the valve opening
temperature and the valve lift.
NOTE: The thermostat valve opening temperature (T,) is engraved
on the thermostat seat, and it should be confirmed.
Thermostat valve opening temperature;
Thermostat valve opening temp. (T,) Service standard
82°C 80 - 84°C {145-215°F}
Thermostat valve lift;
Thermostat valve opening temp. (T,) Measuring temp. (T2) Valve lift (g)
82°C 95°C {203°F} 10 mm {0.394 in} or more
2. Immerse a heated thermostat in water of normal temperature.
If it completely closes within 5 minutes it is satisfactory. If it re-
mains even slightly open, it is defective and must be replaced.
IMPORTANT POINTS - ASSEMBLY
MOUNT THE THERMOSTAT.
1. Remove the water and dirt adhering to the thermostat case.
2. Replace the gasket without fail if it is corroded, damaged or
flattened.
3. Before installing the hose, apply liquid gasket to the hose in-
stallation of the thermostat case cover.
4. In order to prevent clogging of the radiator, do not apply a
large amount of liquid gasket.
NOTE: О When installing the thermostat, be careful of the direc-
tion in which the bridge faces.
Be sure to install the thermostat with the jiggle valve at
the top, so as to enable bleeding of air during supply of
water.
ENGINE
EN-CS32A-7
RADIATOR
WARNING
To avoid the danger of burns, do not drain the coolant while the
engine and radiator are still hot.
NOTE: When dismounting and mounting the radiator, do not
damage the radiator core.
INSPECTION AND REPAIR
Unit: kPa {kgf/cm2, lbf/in2}
Inspection Item Standard Limit Remedy Inspection Procedure
Coolant leakage - - Replace radiator SM3.975
Clogging of the fins - - Clean
Radiator cap valve opening pressure 0.5 39.3-58.8 {0.4-0.6, 5.7-8.5} Replace Oh 1 SM3-823
0.9 73.6-102.9 {0.75-1.05, 10.7-14.9}
NOTE: The coolant filler cap valve opening pressure is shown on the cap and it should be confirmed.
If the cap pressure is incorrect, there is a risk of abnormally high pressure being generated in the cooling system,
which may cause the hose to drop off or burst and, in turn, damage the engine.
EN-CS32A-8
ENGINE
OVERHAUL
COOLING FAN
1. Fan clutch
2. Cooling fan
3. Fan shroud
T = Tightening torque: N-m {kgf-cm, Ibf-ft}
1. Shock to the fan clutch and fan.
During maintenance and inspection, be careful not to drop or
strike the fan clutch or fan itself. The resulting damage may
lower the performance of the fan. Also, note that the fan is
made of plastic and may become damaged or deformed if
force is applied to it.
2. Replacing the fan.
Do not replace the fan unless it is faulty. When replacing the
fan, replace it with the same type as the one which was re-
moved. If the fan is replaced with one of a larger capacity be-
cause of overheating or, conversely is replaced with one of a
smaller capacity due to overcooling, the cooling performance
may in fact reduced and durability may be jeopardized.
3. Other items
Check the temperature detector (bimetal) to see if there is any
mud or dust on it.
If the bimetal is covered with mud of dust, the fan perfor-
mance will be erratic, and any result in overheating or over-
cooling. In such case, carefully remove mud and dust adher-
ing to the surface of the bimetal, using a wire brush, or the
like.
Take care not to apply excessive force particular.
Do not paint the fan or fan clutch.
Do not place any paint or other reagents which are likely to
dissolve plastic in contact with the fan.
ENGINE
EN-CS32A-9
INSPECTION AND REPAIR
Inspection Item Standard Limit Remedy Inspection Procedure
Cooling fan and fan clutch deformation and damage Replace, if necessary.
0IA13IAI
ENGINE
EN-IE16A-1
AIR INTAKE AND EXHAUST SYSTEM
OVERHAUL
1. Exhaust manifold
2. Seal ring
3. Gasket
4. -Intake pipe
5. Intake air heater
6. Intake air control valve
7. Compression spring
8. Cushion
9. Intake manifold
IMPORTANT POINT - DISASSEMBLING
NOTE: Do not remove the lever rod, and valve from the intake air
control valve assembly. If removed, resulting in poor per-
formance of intake air control system.
EN-IE16A-2
ENGINE
IMPORTANT POINT - ASSEMBLY
ASSEMBLE THE EXHAUST MANIFOLD.
1. When installing seal rings on the exhaust manifold, fit new
seal rings in such a way that the gaps are equally spaced, as
shown, to prevent gas leakage.
IMPORTANT POINTS - MOUNTING
INSTALL THE INTAKE MANIFOLD.
NOTE: If remove the stud bolt from the cylinder head at dismount-
ing, apply adhesive (Three Bond 1322B or equivalent) to
cylinder head side thread of the stud bolt.
INSPECTION AND REPAIR
Inspection Item Standard Limit Remedy Inspection Procedure
Exhaust Seal Ring Wear or Damage Replace Visual check X^^^SM3-456
Intake and Exhaust Manifolds Crack or Damage Replace
SM3-710
Exhaust Manifold Cracks, Wear or Damage
ENGINE
EN-CP23A-1
ELECTRICAL PARTS
GENERATOR
SPECIAL TOOL
Prior to starting an engine overhaul, it is necessary to have this special tool.
V-BELT TENSION GAUGE
09444-1210
IMPORTANT POINTS - DISASSEMBLING AND ASSEM-
BLING
Refer to CHAPTER GE, GENERATOR for details.
EN-CP23A-2
ENGINE
IMPORTANT POINTS - MOUNTING
V-BELT ADJUSTMENT.
1. Install the V-belts, and adjust the belt tension.
NOTE: о Do not under any circumstances apply the lever directly
against the generator body owing to the risk of damag-
ing the generator.
О When installing a new V-belt or adjusting the tension, be
sure to repeat the adjustment two or three times, after
running the engine for several minutes each time.
2. V-belt deflection.
Apply a load of about 98 N {10 kgf, 22 Ibf} by pressing with
your finger or special tool.
Assembly standard (A): 19-23 mm {0.75-0.90 in}
Special Tool: V-belt tension gauge (09444-1210)
NOTE: If the belt is excessively tensioned, there is a risk of damag-
ing the bearings of the generator or coolant pump and also
shorting the life of the V-belt.
Conversely, if there is insufficient tension on the V-belt, the
belt will slip, unusual noise will be emitted, the battery may
run down and the engine may overheat.
"B" and "E" terminal bolt tightening torque:
8-10 N-m {80-110 kgf-cm, S.8-7.9 Ibf-ft}
Generator ground cable bolt Tightening Torque:
8-10 N-m {80-110 kgf-cm, 5.8-7.Э Ibf-ft}
STARTER
IMPORTANT POINTS - DISMOUNTING
REMOVE THE STARTER FROM THE ENGINE.
1. Disconnect the battery cable from the negative (-) terminal of
battery.
2. Put the match marks on the harness and starter terminals with
a pen and then disconnect the harness.
3. Remove the starter from the engine.
IMPORTANT POINTS - DISASSEMBLING AND ASSEM-
BLING
Refer to CHAPTER ST, STARTER for details.
IMPORTANT POINTS - MOUNTING
INSTALL THE STARTER ON THE ENGINE.
1. Install the starter on the engine.
2. Connect the harness to match the marks.
3. Connect the battery cable.
Terminal nut tightening torque:
16-22 N-m {165-225 kgf-cm, 12-16 Ibf-ft} for "B" terminal.
1.9- 2.4 N-m {19-25 kgf-cm, 1.4-1.8 Ibf-ft} for "C" terminal.
OTHER PARTS
IMPORTANT POINTS - INSPECTION, REPAIR AND
ADJUSTING
CHAPTER EE, ELECTRICAL EQUIPMENT.
ENGINE
EN-TU26A-1
ENGINE TUNE-UP
PUSH RODS: MOVE PUSH RODS: STANDING
(Compression stroke) (Overlapping stroke)
SM3-713
METHOD FOR DETERMINING IF THE NO.1 PISTON IS AT
THE TOP DEAD CENTER ON COMPRESSION STROKE.
NOTE: О Turn the crankshaft to align the mark "1-7" on the fly-
wheel with the pointer of the flywheel housing.
О In this position either the No.1 or No.7 piston is at the
top dead center on compression stroke.
The pointer and mark "1-7" are provided on some model
timing gear cover, and on the torsional damper, so use
these pointer and marker when adjusting the engine if
so equipped.
1. Move both the intake and the exhaust rocker arms of the No.1
or No.7 cylinder by hand; if both rocker arms can be moved,
the piston is at top dead center on the compression stroke.
2. If the injection timing mark is nearly aligned with the pointer,
the No.1 piston is at top dead center on compression stroke.
NOTE: If not, turn the crankshaft one complete revolution and
align marks as above.
3. While locking at the push rods of No.1 and No.7 pistons, turn
the crankshaft counterclockwise and clockwise about 30° to
40° (see left figure).
If the piston whose exhaust and inlet push rods do not move
during the interval, it is at the top dead center on compression
stroke.
If the piston whose push rods have moved, it is at the
completion of the exhaust and begun of the intake stroke
(overlapping stroke).
NOTE: Always loosen the lock nut and raise the adjusting screws
fully to the top. If the adjusting screws are too low, the
piston and valves may strike each other during valve
clearance adjustment.
VALVE CLEARANCE
[Valve clearance adjusting procedures]
BEFORE ADJUSTING
1. Before adjusting, make sure that the head bolts and the rocker
support bolts are tightened with the specified torque.
2. Make sure that there are no foreign matter and dust in be-
tween the valve stems and the rocker arms.
3. Set the piston in the particular cylinder to adjust for top dead
center on the compression stroke.
EN-TU26A-2
ENGINE
ADJUSTING
1. With the No.1 piston positioned at top dead center on
compression stroke, adjust the No.1 valve clearance using a
thickness gauge.
The thickness gauge should move with a very slight pull.
Valve Clearance: Refer to SECTION DATA AND SPECIFICATIONS.
2. Adjust the other valves.
Turn the crankshaft counterclockwise viewed from flywheel
side. Adjust the valve clearance for each cylinder in the firing
order.
Firing order and firing interval;
Firing order Firing interval
Eight cylinder model 1-8-4-2-7-3-6-5 90°
INJECTION TIMING
INSPECT THE INJECTION TIMING.
1. Turn the crankshaft counterclockwise viewed from the fly-
wheel side to align the injection timing mark on the flywheel
or crankshaft pulley damper at A° before top dead center for
No.1 cylinder on compression stroke with the pointer.
Injection timing (A°): Refer to SECTION DATA AND SPECIFICATION
2. Check that the injection timing mark (the scribe line, not the
notch) on the timer housing is aligned with the pointer (the
scribe line) timing plate on the pump housing.
If not, adjust the injection timing.
NOTE: When adjusting the injection timing, refer to "FUEL INJEC-
TION PUMP" for details.
AIR BLEEDING FROM FUEL SYSTEM
1. Bleed air from the fuel filter.
a. Loosen the bleeder plug on the fuel filter.
b. Loosen the priming pump knob.
c. Operate the priming pump knob until the air will not come out
from the bleeder plug.
d. Tighten the bleeder plug.
Tightening Torque: 3.93-5.88 N-m {40-60 kgf-cm, 3-4 Ibf-ft}
NOTE: The bleeder plug should be tightened while the priming
pump knob is operated.
ENGINE
EN-TU26A-3
2. Once again, operate the priming pump knob several times.
3. Push back the priming pump knob and tighten it.
NOTE: Wipe off any splashed fuel.
ENGINE CONTROL
ADJUST THE ACCELERATOR CONTROL
1. Apply chassis grease to the pins, ball joints and bearings.
2. Prior to fitting the throttle cable turn the knob cunterclockwise
unti it stops then back off 4 turns from the position.
3. Check that accelerator pedal height is “A" mm. If not adjust
the pedal height with the control cable adjusting nut.
Dimension A: 149-159 mm {5.87-6.25 in}
4. After adjustment, check the engine idling speed.
5. Adjust the accelerator stopper bolt so that the clearanpe be-
tween the pedal and pedal stopper bolt is "B" mm when the
control lever on the fuel injection pump strikes the maximum
stopper bolt.
Clearance B: 2-5 mm {0.08-0.20 in}
NOTE: Eiminate slack in the cable of the control lever on the fuel
injection pump.
EN-TU26A-4
ENGINE
ADJUST THE ENGINE STOP CONTROL
1. Set the engine starter key at ON position.
NOTE: Do not start the engine.
2. Connect the connectors of the engine stop motor harness.
WARNING
Do not connect the electric harness with the engine stop motor
while the engine starter key at OFF or ACC position as this oper-
ate the engine stop motor instantaneously and the link lever of
the engine stop motor and the engine stop lever of the injection
pump move, resulting in your fingers caught by the lever.
3. Adjust the engine stop cable with adjusting nut to that the
clearance "A" between the clevis and cable stopper is 1-3 mm
{0.04-0.11 in}.
4. Set the starter key at OFF position.
NOTE: After adjustment, confirm correct execution of engine start
and stop.
ENGINE
EN-TU26A-5
ENGINE TUNE-UP ON TEST BENCH
NOTE: o If the engine is started with the power steering oil pump
installed, the oil pump may burn or oil may spurt out, re-
move the oil pump from the engine and install a cover to
prevent oil leakage from the point of removal.
О Starting the engine when the generator is not connected
to the battery may damage the generator. Always con-
nect to the battery.
SET THE ENGINE ASSEMBLY ON A TEST BENCH.
1. Add the proper amount of the specified engine oil through the
oil filer cap on the cylinder head cover.
2. Add coolant.
Bleed out air from inside the coolant gallery through the cylin-
der block drain plug.
BLEED AIR FROM FUEL SYSTEM.
CHECK THE INJECTION TIMING.
Refer to "FUEL INJECTION PUMP".
CHECK THE VALVE CLEARANCE.
START THE ENGINE.
NOTE: Before starting the engine, make sure that the fuel cut lever
of the fuel injection pump is operating normally.
1. Check the oil feed to rocker arms.
a. Set the engine speed to 500-550 r/min.
b. When one minute after starting the engine, oil should flow to
the head (Face A) of all push rods and the head (Face B) of all
valves. If the time required for the oil to flow to the rocker
arms is long, various troubles such as seizing, abnormal wear
and unusual noise may occur.
RETIGHTENING CYLINDER HEAD BOLT
Retighten the cylinder head bolts according to the following
instructions.
(1) Retightening schedule
Retighten at the first 1,000 km (600 miles) following servicing
which involves the loosening or removal of any cylinder head
bolt. Such servicing includes replacement of the cylinder head
gasket, servicing of the valve gear parts, and the like.
(2) Retightening procedure
Step 1: Warm up the engine in the same way as in engine
turning.
Step 2: Following the cylinder head bolt tightening order as
shown, loosen the first cylinder head bolt by 1/4 to 1/2
turns as shown (SM3-457), then tighten into it to its
specified torque.
Repeat until all the bolts have been retightened.
Tightening order, Tightening torque and special tool:
Refer to "CYLINDER HEAD" in SECTION ENGINE MOVING
PARTS.
NOTE: О Be sure to loosen one bolt at a time, then retighten it be-
fore going on the next bolt.
О By retighten, face pressure of cylinder head is restored
from point В to C as shown.
RECHECK THE VALVE CLEARANCE, WHEN ENGINE IS COLD.
ENGINE
EN-PR5A-1
PROCEDURE FOR INSTALLING JOINTS AND GASKET OF
ENGINE PIPE
1. Gasket seal type (aluminum + rubber, asbestos or copper).
Location of gasket seal
JOINT joint
Tightening torque chart
Clamping screw size (Diameter) mm {in} Tightening torque N m {kgcm, Ibft}
8 {0.315} 12.75 {130, 9.40}
10 {0.394} 19.61 {200,14.47}
12 {0.472} 24.52 {250,18.08}
14 {0.551} 24.52 {250,18.08}
16 {0.630} 29.42 {300, 21.70}
18 {0.709} 39.23 {400, 28.93}
20 {0.787} *39.23 {400, 28.93}
24 {0.945} 68.65 {700, 50.63}
28 {1.102} 127.49 {1,300, 94.02}
2. Metal seal type (Flares connector type).
Location of metal seal
BRACKET Д CONNECTOR FLARE NUT NUt\ £ГТ1 ^WAYJ0INT

I LOCK Ц-Ц WASHER\ /
BRACKET FLARE NUT
LOCK WASHER
Tightening torque chart
Clamping screw size (Diameter) mm {in} Tightening torque N m {kg cm, Ib ft}
12 {0.472} 19.61 {200,14.47}
14{0.551} 31.38(320,23.15}
16 {0.630} 39.23 {400,28.93}
18 {0.709} 58.84 {600, 43.40}
20 {0.787} 63.74 {650,47.01}
EN-PR5A-2
ENGINE
3. Metal seal type (Nipples connectors type)
Location of metal seal
FLARE CONNECTOR
CONNECTOR
Tightening torque chart
Clamping screw size (Diameter) mm {in} Tightening torque N-m {kg-cm, lb-ft}
10 {0.394} 10.79 {110,7.96}
20 {0.787} 19.61 {200,14.47}
NOTE: О Before installing the joints, ensure that there is no dirt or burrs adhering to the various seat faces (pipe joints, gaskets,
etc.)
О Because the pipes can move relatively free during installation and the seatfaces are liable to tilt, firsttemporarily tighten
the pipes, then tighten them to specification and ensure that there is no leakage from them.
О When tightening two pipes together, be very careful that they do not rotate together.
О After installing the pipes, apply the correct pressure to each pipe joint and ensure that there is no leakage.
О Ensure that the various tightening torques conform to the above table.
* If a soft washer #4840 FR-N (aluminum + rubber and carbon press fit part) is loosened or removed subsequent to being
installed, be sure and replace it with a new one.
There is no need to replace it, however, for normal retightening.
(K.P.)
HINO MOTORS, LTD.
PRINTED IN JAPAN
'94-7 (K.P.)
EN-Y203E-02
WORKSHOP MANUAL
ENGINE
Model F20C for FS905TD, FS906TD
ENGINE
EN-1
EN-Y203E-02
CHAPTER EN
ENGINE
Model F20C
DATA AND SPECIFICATIONS ...................DS - 1
TROUBLESHOOTING ...........................TS - 1
ENGINE OVERHAUL CRITERIA ..................ОС - 1
ENGINE ASSEMBLY DISMOUNTING AND MOUNTING ..DM - 1
ENGINE MOVING PARS ........................MP - 1
CYLINDER HEAD ...............................- 1
CRANKSHAFT PULLEY ...........................-13
FLYWHEEL AND FLYWHEEL HOUSING ...............-15
TIMING GEAR AND CAMSHAFT ....................-17
INJECTION PUMP DRIVE ........................-24
PISTON CRANKSHAFT CYLINDER BLOCK AND OIL PAN.-26
LIQUID GASKET AND APPLICATION POINTS ........-43
LUBRICATING SYSTEM ........................LS - 1
OIL PUMP AND OIL STRAINER ...................- 2
OIL FILTER AND OIL COOLER ...................- 6
FUEL SYSTEM ...............................FS - 1
INJECTION NOZZLE ............................- 2
FUEL INJECTION PUMP .........................-12
COOLING SYSTEM ............................CS - 1
COOLANT PUMP ................................- 2
THERMOSTAT ..................................- 6
RADIATOR ....................................- 7
COOLING FAN ............................FD - 1
AIR INTAKE AND EXHAUST SYSTEM .............IE - 1
ELECTRICAL PARTS ..........................CP - 1
GENERATOR ...................................- 1
STARTER .....................................- 2
ENGINE TUNE-UP ............................TU - 1
ENGINE TUNE-UP ON TEST BENCH ................- 5
PROCEDURE FOR INSTALLING JOINTS AND
GASKETS OF ENGINE PIPES ...................PR - 1
DSY23B
TSY1B
0CY9B
DMY1C
MPY19B
LSY9B
FSY5C
CSY5B
FDY9A
IEY8B
CPY13A
TUY12B
PRY1C
ENGINE
DS-1
DATA AND SPECIFICATIONS
Model F20C
Type Diesel, 4 cycle, 8 cylinder, V, overhead valve, water-cooled, direct injection.
Aspiration Natural aspirate.
Bore and stroke 146 x 147 mm {5.75 x 5.79 in}
Piston displacement 19.688 liters {1,201 cu.in}
Compression ratio 18.1 : 1
Firing order 1-8-4-2-7-3-6-5
Direction of rotation Counterclockwise viewed from flywheel
Compression pressure 2.9-3.2 MPa {30-33 kgf/cm2, 426-469 lbf/in2} at 200 r/min
Maximum revolution (at full load) 2,200 r/min
Idling revolution 450-500 r/min for FS905TD 550 r/min for FS906TD
Dry weight Approx. 1,300 kg {2,866 lb}
Valve seat angle Intake 30°
Exhaust 45°
Valve face angle Intake 30°
Exhaust 45°
Valve timing (flywheel travel) Intake opens 12° before top dead center.
Intake closes 36° after bottom dead center.
Exhaust opens 52° before botoom dead center.
Exhaust closes 16° after top dead center.
Valve clearance (when cold) Intake 0.45 mm {0.0177 in}
Exhaust 0.65 mm {0.0256 in}
Engine oil pump Type Drive Full forced pressure feed by gear pump. By gear
Engine oil cooler Multi plates type, water cooled
Injection nozzle Type Valve opening pressure Multi hole nozzle type 1st : 14.7 MPa {150 kgf/cm2, 2,133 lbf/in2} 2nd : 24.5 MPa {250 kgf/cm2, 3,556 lbf/in2}
Coolant pump Type Drive Forced circulation by volute pump. By gear
Thermostat Type Wax type, bottom bypass system
Injection timing (flywheel travel) 12° before top dead center for No.1 cylinder on compression stroke for FS905TD. 15° before top dead center for No.1 cylinder on compression stroke for FS906TD.
Y23B
ENGINE
TS-1
Symptom
TROUBLESHOOTING
Possible cause
Remedy/Prevention
Engine overheating • •
9
9
9
9
9
9
9
9
9
9
9
9
•
•
•
•
Excessive oil consumption———
•
•
•
•
•
•
•
Coolant
Insufficient coolant...........................
Defective thermostat...........................
Overflow of coolant due to leakage of..........
exhaust into cooling system
Coolant leakage from cylinder head gasket......
Defective coolant pump.........................
Radiator
Clogged with rust and scale....................
Clogged with iron oxide due to leakage.........
of exhaust into cooling system
Clogged radiator core due to mud...............
or other debris
Defective radiator cap pressure valve..........
Abnormal combustion
Incorrect injection timing.....................
Reduced injection pressure.....................
Poor fuel......................................
Poor nozzle spray..............................
Unsatisfactory automatic timer advance angle...
Other problems
Defective or deteriorated engine oil...........
Unsatisfactory operation of oil pump...........
Insufficient oil...............................
Brake drag.....................................
Pistons, cylinder liners, and piston rings
Wear of piston ring and cylinder liner.........
Worn, sticking or broken piston rings...........
Insufficient tension on piston rings...........
Unsatisfactory break-in of piston rings........
Unsuitable oil (viscosity too low).............
Incorrectly fitted piston rings................
(upside down)
Gaps of piston rings in line with each other...
Add coolant.
Replace the thermostat.
Repair.
Replace gasket.
Repair or replace.
Clean radiator.
Clean coolant passage and
Correct exhaust leakage.
Clean radiator.
Replace radiator cap
Adjust injection timing.
Adjust injection pressure.
Use good quality fuel.
Adjust or replace nozzle.
Repair or replace timer.
Change engine oil.
Replace or repair.
Add oil.
Repair or adjust.
Replace piston rings and cylinder
liner.
Replace piston rings and cylinder
liner.
Replace piston rings and cylinder
liner.
Replace piston rings and cylinder
liner.
Change oil as required and replace
piston rings and cylinder liners.
Replace piston rings.
Reassemble piston rings.
Y1B
TS-2
ENGINE
Symptom
Excessive oil consumption
Possible cause
Remedy/Prevention
— Valve and valve guides
• Worn valve steam.............................
• Worn valve guide.............................
• Incorrectly fitted valve stem seal...........
• Excessive lubricant on rocker arm............
— Excess oil feed
• Defective oil level gauge....................
• Oil level too high...........................
— Other problems
• Overcooled engine (low temperature wear).....
• Oil leakage from miscellaneous parts.........
Replace valve and valve guide.
Replace valve guide.
Replace the stem seal.
Check clearance of rocker arm and
shaft.
Replace oil level gauge.
Drain excess oil.
Warm up engine before moving
vehicle. Check cooling system.
Repair.
Piston seizure
— Operation
• Abrupt stoppage of engine after running......
At highspeed
• Hill climbing using unsuitable gear..........
- Oil
• Insufficient oil.............................
• Dirty oil....................................
• Poor quality oil.............................
• High oil temperature.........................
• Low oil pressure.............................
• Defective oil pump...........................
• Reduced performance due to worn oil..........
pump
• Suction strainer sucking air.................
— Abnormal combustion ........................
— Coolant ....................................
Operate engine properly.
Select suitable gear.
Add oil.
Change oil.
Replace with proper engine oil.
Repair.
Repair.
Repair oil pump.
Replace oil pump.
Add oil and/or repair strainer.
See Symptom: "Engine overheat-
ing."
See Symptom: "Engine overheat-
ing."
Lack of power
Injection pump .....................................
Refer to CHAPTER IP, FUEL
INJECTION PUMP.
— Intake
• Clogged air cleaner...........................
Overheating
Clean element or replace element.
See Symptom: "Engine overheat-
ing."
Y1B
ENGINE
TS-3
Remedy/Prevention
Symptom
Possible cause
I Ark nf ПП\Л/РГ Fuel and nozzle
L— Cl VIX w 1 M V V v 1
• • • • • Poor nozzle spray Clogged nozzle with carbon Wear or seizure of nozzle Air in fuel system Clogged fuel filter Use of poor fuel
— Abnormal combustion

— Piston, cylinder liners, and piston rings
Adjust or replace injection nozzle.
Clean nozzle.
Replace nozzle.
Repair and bleed air from fuel
system.
Replace element.
Use good quality fuel.
See Symptom:
"Engine overheating."
See Symptom: "Engine over-
heating."
Other problems
• Breakage of turbine or blower .............. Refer to CHAPTER TU, TURBO-
(If so equipped turbocharger) CHARGER.
Difficult starting engine
— Electrical system
• Discharged battery ...........................
• Defective wiring in starter circuit ..........
• Loose or open-circuit battery cable ..........
• Break of glow plug or intake..................
air heater (If so equipped)
— Injection pump ..............................
— Air cleaner
• Clogged element................................
— Fuel system
• No fuel in tank...............................
• Clogged fuel line ............................
• Air sucked into fuel system through ..........
fuel line connections.
• Clogged fuel filter ..........................
• Loose connection in high-pressure line........
• Water in fuel ................................
Charge battery.
Repair wiring of starter.
Tighten battery terminal connec-
tions or replace battery cable.
Replace
Refer to CHAPTER IP, FUEL
INJECTION PUMP
Clean the element or replace the
element.
Supply fuel and bleed air from fuel
system.
Clean fuel line.
Tighten fuel line connections.
Replace element.
Tighten sleeve nut of high pres-
sure line.
Drain and clean fuel system
Y1B
TS-4
ENGINE
Symptom
Possible cause
Remedy/Prevention
Difficulty starting engine --------------------- Nozzles
• • Seized nozzle Broken or fatigued nozzle spring
— Oil system |
• Oil viscosity too high
— Other problems
• • • • Seized piston Seized bearing Reduced compression pressure Ring gear damaged or worn Improperly adjusted or broken accelerator cable
RziiiriK irl 1 ir»rt Injection pump
nuuyi 1 lUlIl ly

— Nozzles
• • • • Uneven injection pressure Poor nozzle spray Carbon deposit on nozzle tip Seized needle valve
— Engine proper
• • • Improper valve clearance Improper contact of valve seat Idling speed too low Compression pressure of cylinders markedly different from one another
1 лТ’ » t ______________________ Cylinder head gasket
La.0 Cl I\L1 у О ОТ GXl luuvl
• • • Fatigued gasket (aging) Damage Improper installation
Replace nozzle.
Replace spring.
Use proper viscosity oil, or install
an oil immersion heater and warm
up oil.
Replace piston, piston rings, and
liner.
Replace bearing and/or crankshaft.
Overhaul engine.
Replace the ring gear and/or
starter pinion.
Adjust or replace the accelerator
cable.
Refer to CHAPTER IP, FUEL
INJECTION PUMP.
Adjust.
Adjust or replace nozzle.
Remove carbon.
Replace nozzle.
Adjust valve clearance.
Replace or repair valve and valve
seat.
Warm up engine.
Overhaul engine.
Replace gasket.
Replace gasket.
Replace gasket.
Y1B
ENGINE
TS-5
Symptom
Possible cause
Remedy/Prevention
Leakage of exhaust
— Cylinder head bolts
• Loose bolts...................................
• Elongated bolts...............................
• Improper tightening torque or.................
tightening sequence
— Cylinder block
• Cracking......................................
• Surface distortion............................
• Fretting of cylinder liner insertion..........
portion (insufficient projection of
cylinder liner)
— Cylinder head
• Cracking......................................
• Surface distortion............................
—- Cylinder liners
• Cracking......................................
• Corrosion.....................................
• Insufficient projection of cylinder liner.....
— Other problems
• Incorrect injection timing .....................
Tighten bolt.
Replace bolt.
Tighten properly.
Replace cylinder block.
Repair or replace.
Replace cylinder liner or
cylinder block.
Replace cylinder head.
Repair or replace.
Replace cylinder liner.
Replace cylinder liner.
Replace cylinder liner.
Adjust injection timing.
Y1B
ENGINE
ОС-1
ENGINE OVERHAUL CRITERIA
SPECIAL TOOL
Prior to starting an engine overhaul, it is n ecessary to have these special tools.
COMPRESSION GAUGE
COMPRESSION GAUGE
FACTORS WHICH DETERMINE WHEN AT ENGINE OVERHAUL IS
NEEDED.
LOWERED COMPRESSION PRESSURE.
a. Before the measurement
a) Correct the valve clearance.
b) Warm up engine [Bring the coolant temperature to about 80“C
(176°F)]
c) Charge the batter fully.
d) Remove the air cleaner.
b. Measurement
1) Measure at nozzle holder hole.
a) Remove the nozzle holders.
b) Install the gauge adapter (A) and (B) in the nozzle holder hole.
c) For model equipped with manual control type engine stop system.
Disconnect the engine stop cable (rod) from engine stop lever in
engine stop position with tape or string.
d) For model equipped with electrical motor control type engine stop
system.
Set the engine starter key at "OFF" position, then disconnect the
engine stop motor harness.
e) Connect a compression gauge to the gauge adapter.
f) Drive the engine with the starter and read the compression
pressure.
NOTE: Do not continuously operate the starter for more than 15
seconds at a time.
g) Measure the compression pressure for each cylinder. If the
compression pressure is low, be sure to repeat the measuring.
NOTE: Be sure not to leak through sealing face.
Y9B
ОС-2
ENGINE
Unit: MPa {kgf/cm2, lbf/in2}
Engine model Compression pressure Difference between each cylinder Engine speed (r/min)
Standard Limit
F20C 2.9-3.2 {30-33, 427-469} 2.55 {26, 369} 0.294 {3, 43} or less 200
c. After the measurement
Make sure the engine starter key is in "OFF" position and then
connect the engine stop motor harness.
WARNING
Do not connect the electric harness with the engine stop motor
while the engine starter key at "ON" position as this operate the
engine stop motor instantaneously and the link lever of the engine
stop motor and the engine stop lever of the fuel injection pump
move, resulting in your fingers caught by the lever.
DECREASED OIL PRESSURE
Check the oil pressure warning lamp when the oil and coolant
temperature is hot [about 80°C {176°F}].
a. If the warning lamp is lighted, check the oil level.
b. Check oil deterioration.
If oil quality is poor, replace with a suitable grade oil.
c. Remove the oil pressure switch and install the oil pressure gauge.
d. Measure the oil pressure at coolant temperature 80’C {176Т} or
more.
Standard oil pressure: 49-490 KPa {0.5-5.0 kgf/cm2 7.11-71.10 Ibf/
sq.in}
Service limit: 49 KPa {0.5 kgf/cm2 (7.11 Ibf/sq.in)} or less
S.A.E. GRADE ATMOSPHERIC TEMEPRATURE
-10 32 50 70 90100 'F
-23-18 10 21 32 39 °C
40
30
20W/20
15W/40
OTHER FACTORS
a. The blow-by gas increases.
b. The engine does not start easily.
c. Engine output decreases.
d. Fuel consumption increases.
e. Engine makes greater noise.
f. Excessive oil consumption.
Y9B
ENGINE
DM-1
ENGINE ASSEMBLY DISMOUNTING AND MOUNTING
IMPORTANT POINT — DISMOUNTING
DISMOUNT THE ENGINE ASSEMBLY.
1. Park the vehicle on level ground and then block the wheels.
2. Tilt the cab.
3. Drain coolant from the radiator and cylinder block, and engine oil
from the oil pan.
WARNING
To avoid the danger of burns, do not drain the coolant and engine oil
while the engine and radiator are still hot.
4. Disconnect the power steering hydraulic lines and drain fluid.
NOTE: Refer to CHAPTER PS, POWER STEERING for details.
5. Disconnect the engine stop cable.
a) Set the engine starter key at ON position.
NOTE: о Do not start the engine.
О Clacking the engine stop inner cable by setting the engine
starter key at ON position facilitate dismounting, mounting and
adjustment of the cable.
ENGINE
STOP
POSITION
ENGINE
RUNNING
POSITION

SM3-1920
b) Make sure that the engine stop lever of the fuel injection pump is
engine running position, then disconnect the connectors of the
engine stop motor harness.
c) Set the engine starter key at OFF position.
6. Disconnect the electric lines, fuel lines, air lines, speedometer
cable accelerator control cables and parking brake cable (For
model with center parking brake).
NOTE: О Disconnect the battery cable from the negative terminal (-)
of the battery and then disconnect the electric lines.
О Cover open ends of the pipes, hoses and pumps to prevent
entry of dirt.
7. Disconnect the hoses (coolant, heater and air intake) and remove
the radiator or radiator with intercooler.
NOTE: Do not damage the radiator and intercooler (if equipped) core.
8. Disconnect the air intake and exhaust lines.
9. Disconnect transmission control and transmission with clutch
housing from the flywheel housing.
NOTE: Refer to CHAPTER TC, TRANSMISSION CONTROL and CHAP-
TER TM, TRANSMISSION for details.
10. Remove the cab mounting member from the frame.
DM-2
ENGINE
11. Connect cable from an engine hanger to the hanger bracket (1
point) on the front of the engine, and to the hanger brackets (2
points) on the upper flywheel housing at the rear of the en-
gine. Usin^ a hoist, raise the hanger is to that there is a bit of
slack in the cables.
Engine Weight: Refer to section DATA AND SPECIFICATIONS.
12. Remove the engine mounting fitting nuts (front and rear, both
sides).
13. Lift the engine hanger so that the cables are fully tightened,
and then, after checking that the cables are securely gently
and remove it from the vehicle.
IMPORTANT POINTS - MOUNTING
MOUNT THE ENGINE ASSEMBLY.
Mount the engine assembly in the reverse order of dismount-
ing.
NOTE: Check to see that there are no oil leaks, fuel leaks, coolant
leaks, or air leaks.
CONNECT THE ENGINE STOP CABLE.
1. Set the engine starter key at ON position.
NOTE: Do not start the engine.
2. Connect the connectors of the engine stop motor harness.
WARNING
Do not connect the electric harness with the engine stop motor
while the engine starter key at OFF or ACC position as this oper-
ate the engine stop motor instantaneously and the link lever of
the engine stop motor and the engine stop lever of the ihjection
pump move, resulting in your fingers caught by the lever.
3. Connect and adjust the engine stop cable with adjusting nut
to that the clearance "A" between the clevis and cable stopper
is 1-3 mm {0.04-0.11 in}.
4. Set the starter key at OFF position.
NOTE: After adjustment, confirm correct execution of engine start
and stop.
Y1C
ENGINE
MP-1
ENGINE MOVING PARTS
CYLINDER HEAD
OVERHAUL
T = Tightening torque: N-m {kgf-cm, Ibf-ft}
1. Cylinder head cover 8. Ventilator assembly
2. Injection pipe oil seal 9. Clamp
3. Cylinder head cover gasket 10. Vent hose
4. Cylinder head gasket 11. Soft washer
5. Cylinder head 12. Plug
6. Cylinder head bolt 13. Union
7. Oil filler cap 14. Bracket
Y19B
NIP-2
ENGINE
15 14 T = Tightening torque: N-m {kgf-cm, Ibf-ft}
1. Intake valve seat 13. Cylinder head
2. Exhaust valve seat 14. Intake valve
3. Expansion plug 15. Exhaust valve
4. Stud 16. Valve lifter
5. Spacer 17. Valve push rod
6. Nut 18. Valve spring seat lower
7. Cross head pin 19. Valve spring inner
8. Gasket 20. Valve spring outer
9. Injection nozzle seat 21. Valve spring seat upper
10. Valve guide bushing 22. Valve spring retainer lock
11. Valve stem oil seal 23. Valve adjusting screw
12. Push rod guide pipe 24. Valve rocker support
25. Rocker arm bushing
26. Valve rocker arm
27. Valve adjusting screw nut
28. Collar
29. Valve rocker shaft subassembly
30. Rocker arm support bolt
31. Set screw
32. Lock washer
33. Valve adjusting
34. Crosshead
Y19B
ENGINE
MP-3
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
BOLT
WIRE
09491-1020
09491-1030
For Valve stem seal
BAR
09472-1880
For Nozzle sleeve
STEEL BALL
Y19B
МР-4
ENGINE
IMPORTANT POINTS - DISASSEMBLY
REMOVE THE FUEL PIPES AND NOZZLE ASSEMBLY.
Refer to "INJECTION NOZZLE" in SECTION FUEL SYSTEM.
REMOVE THE ROCKER ARM ASSEMBLY AND CYLINDER HEAD.
1. Remove the rocker arm supports bolts.
Loosen the rocker arm support bolts and cylinder head bolts
little by little in three stages and in the numerical order as
shown.
2. Remove the cylinder head bolts.
Loosen the cylinder head bolts little by little in three stages
and in the numerical order as shown.
LIFT THE CYLINDER HEAD FROM THE DOWELS ON THE CYLINDER
BLOCK AND PLACE IT ON WOODEN BLOCKS.
1. If the cylinder head is difficult to lift off, pry with a chisel
between the cylinder head and block.
NOTE: Do not damage the machined surface of the head or block
when removing the cylinder head.
Special Tools: Engine Hanger (12281-1541)
Bolt (9401-14350)
Wire (09491-1020)
(09491-1030)
REMOVE THE VALVE SPRINGS.
1. Remove the valve stem cotters, upper valve seats, and inner
and outer valve springs from cylinder head.
Special Tool: Valve Spring Press (09470-1022)
2. Remove the intake and exhaust valves.
3. Tag valves to identify their cylinder numbers and to eliminate
valve lapping.
Y19B
ENGINE
MP-5
IMPORTANT POINTS - ASSEMBLY
CLEAN THE CYLINDER HEAD THOROUGHLY WITH A SUITABLE
SOLVENT.
NOTE: Be careful not to damage the cylinder head surface.
IF NECESSARY, HAND-LAP THE VALVE AND VALVE SEAT.
Lightly apply lapping compound to the valve face. Install the
valve and then using a special tool, tap and rotate the valve
against the seat.
Special Tool: Valve Lapping Tool (09431-1010)
IF NECESSARY, GRIND THE VALVES AND VALVE SEATS.
NOTE: О Grinding of valves and valve seats should only be per-
formed when hand-lapping does not result in proper
seating.
О After grinding, always recheck the valve sink.
Valve face angle and valve seat angle:
Refer to INSPECTION AND REPAIR.
IF NECESSARY, REPLACE THE VALVE SEAT.
1. Cut the circumference of a valve head at three places with a
grinder and install it into the seat as shown and weld the
valve to the seat. Then drive the valve and the seat out with a
hammer and a brass block.
Y19B
МР-6
ENGINE
2. Valve seat section machining specifications.
Unit: mm {in}
Intake Exhaust
Cylinder head dimension A 52.000-52.019 {2.0472-2.0479) 48.500-48.519 {1.9095-1.9101}
В 9.9-10.1 {0.388-0.3976) 9.6-Э.8 {0.3780-0.3858}
Valve seat C 52.085-52.100 {2.0506-2.0511} 48.585-48.600 {1.9128-1.9133}
dimension D 8.5-8.7 {0.3347-0.3425} 8.0-8.2 {0.3150-0.3228}
3. Valve seat installation.
Heat the cylinder head to about 80° - 100°C {176-212°F} with
hot water. On the other hand, cool the valve seat with dry ice
or liquid freon for about 30 minutes. Hold the seat with
pincers and place it into the heated cylinder head.
IF NECESSARY, REPLACE THE VALVE GUIDE.
1. Remove the valve stem seal.
2. Using a brass rod and hammer, drive out the valve guide.
3. Install the valve guide.
NOTE: Apply engine oil lightly to the valve guide outer circumfer-
ence before installation.
IF NECESSARY, REPLACE THE VALVE STEM SEAL.
1. Remove the valve stem seal.
2. Install the valve stem seal.
First, install the lower spring seat and valve. Then apply
engine oil to the lip of the stem seal and drive the stem seal
with a special tool.
Special Tool: Bar (09472-1880)
NOTE: О After installing stem seal, make sure that check the rub-
ber position for cracks or any other damage.
О Do not use the special tool if its tip (surface contacting
lower spring seat) is worn or deformed.
Y19B
ENGINE
MP-7
IF NECESSARY, REPLACE THE NOZZLE SLEEVE.
1. Remove the nozzle sleeve.
Place a brass rod with a diameter of 12 mm {0.47 in} at the
nozzle hole at the bottom of the cylinder head and remove the
cylinder head by hitting the nozzle sleeve.
2. Install the nozzle sleeve.
Set the O-ring into the cylinder head.
Apply adhesive (Super Three Bond No.1210 or equivalent) to
the lower part of the new copper nozzle sleeve and carefully
insert the nozzle sleeve into the cylinder head.
NOTE: A damaged O-ring may cause leaks and lead to overheating
or cracked heads.
3. Stick the nozzle sleeve fast to the cylinder head by pressing
with the special tool.
Insert the seat press (Special tool) into the nozzle sleeve. Push
the ball little by little through the hole with the special tool. So
that the end of the nozzle sleeve with stick fast to the cylinder
head.
Special Tools: Sleeve Bar (09472-1210)
Steel Ball (9800-06100)
ASSEMBLE THE CYLINDER HEAD.
NOTE: o Apply engine oil to contact surfaces of all parts.
О Make sure that the valves are installed in the correct cyl-
inders.
О Install the valve springs with their painted side down,
since they have variable pitches.
Press upper spring seats and install the valve stem keys
securely in the upper spring seats.
Special Tool: Valve Spring Press (09470-1022)
NOTE: О When pressing with the valve spring press, be careful
not to damage the stem seals by contacting the upper
seats.
О Drive the valve stem lightly with a hammer to assure
proper fit the valve stem key.
Y19B
МР-8
ENGINE
ASSEMBLE THE ROCKER ARM.
Lubricate the rocker arm shaft and bushing.
INSTALL THE CYLINDER HEAD AND ROCKER ARM ASSEMBLY.
1. Apply engine oil to the tappet face and tappet guide then
install the tappet.
2. Install the cylinder head gasket.
NOTE: Always use new cylinder head gasket after cleaning the
surface of the cylinder head, cylinder block and head gasket
free of all dirt, water and grease.
3. Install the cylinder head over the dowels on the cylinder block.
4. Tighten the thirteen cylinder head bolts in the numerical order
as shown (fig. 1).
NOTE: Apply engine oil to the bolt threads and under the bolt
head.
Tightening torque: 98 N-m {1,000 kgf-cm, 72 Ibf-ft}
Fig. 2-1
5. Set the No.1 piston to top dead center on compression stroke.
Refer to SECTION ENGINE TUNE UP.
6. Insert the push rods in correct order, after applying engine oil
to both ends.
7. Put the rocker arm support on the cylinder head upper sur-
face, and temporarily tighten the eight rocker arm support
bolts in the numerical order as shown (fig. 2), until the rocker
arm support fits on the cylinder head upper surface.
NOTE: О Make sure that the push rods inter lock with the adjust-
ing screws.
О Always loosen the locknut and raise the adjusting
screws fully to the top.
Y19B
ENGINE
MP-9
Fig. 3
Fig. 4
Fig. 5
8. Tighten the five cylinder head bolts in the numerical order as
shown (fig. 3).
Tightening torque: 98 N-m {1,000 kgf-cm, 72 Ibf-ft}
9. Tighten the eighteen cylinder head bolts in the numerical or-
der as shown (fig. 4). Torque the bolts to specified tightening
torque.
Specified tightening torque: 294 N-m {3,000 kgf-cm, 216 Ibf-ft}
10. Retighten the six cylinder head bolts in the numerical order as
shown (fig. 5).
Tightening torque: 294 N-m {3,000 kgf-cm, 216 Ibf-ft}
11. Finally, tighten the eight rocker arm support bolts in the
numerical order as shown (fig. 2-1).
Torque the bolts to specified torque.
Specified tightening torque: 108-118 N-m
{1,100-1,200 kgf-cm, 80-86 Ibf-ft}
INSTALL THE NOZZLE HOLDER.
Refer to "INJECTION NOZZLE" in SECTION FUEL SYSTEM.
Y19B
МР-10
ENGINE
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Cylinder Head Flatness 0-0.05 {0-0.0019} 0.15 {0.0059} Regrind or replace SM3-831
Cylinder Head Cracks and Damage * Using a Dye Penetrant Replace, if necessary. 2—У SM3-832
Valve Seating Condition * Using Red Lead Marking Compound There should be good contact around entire circumference of valve head. Hand-lap with lapping com- pound Л n
(OUG (b SM3-833
Valve Seat Angle Intake Exhaust 30° 44°-45°15‘ Regrind or replace valve and/or valve seat. uy yu
Valve face Angle Intake Exhaust 29°45'-30° 44°45‘_45°
30° INTAKE 1 \/45e EXHAUST SM 3-899
Adjusting Screws and Push Rods Damage Replace Visual checlt^^^ X SM3-1066
Rocker Arm and Cross Head Wear or Damage Resurface or replace Visual check nMA-—& C) SM3-1103
Upper Spring Seats and Lower Spring Seats Wear or Damage Resurface or replace Visual check SM3-529
Y19B
ENGINE
MP-11
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Exhaust Seal Ring Wear or Damage Replace Visual check .ppp III ^^^^^^13-456
Intake and Exhaust Manifolds Crack or Damage Replace SM3-710
Exhaust Manifold Cracks, Wear or Damage
Nozzle Protrusion from Cylinder Head Surface 3.00 {0.118} Replace nozzle gasket -- J / Z CYLINDER 1 _L> HEAD SM3-391
Intake Valve Sink Exhaust Valve Sink 0.75-1.00 {0.0295-0.0393} 0.45-0.70 {0.0177-0.0275} - Replace valve and/or valve seat "0" IS CYLINDER (+) HEAD SURFACE Y Yn (All SM3-420
Intake Valve Stem Diameter 11.925-11.950 {0.4695-0.4704} 11.85 {0.4664} Replace v yUJf4- A : 10 {0.394} SM3-834 В : 30 {1.181} C : 60 {2.362}
Exhaust Valve Stem Diameter 11.905-11.930 {0.4688-0.4696} 11.80 {0.4645}
Intake and Exhaust Valve Guide Diameter 12.000-12.018 {0.4725-0.4731}
Clearance between Valve Stem and Valve Guide (Intake) 0.05-0.08 {0.0020-0.0031} 0.3 {0.0118} >*- Д _< SM3-835
Clearance between Valve Stem and Valve Guide (Exhaust) 0.07-0.113 {0.0028-0.0044} 0.3 {0.0118}
Y19B
NIP-12
ENGINE
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Rocker Arm Shaft Diameter 27.967-27.980 {1.1011-1.1015} 27.88 {1.0976} Replace rocker arm bushing and/or shaft A
Rocker Arm Bushing Inside Diameter 28.014-28.079 {1.1034-1.1054} 28.12 {1.1070} SM3-291
Clearance between Rocker Arm Shaft and Rocker Arm Bushing 0.044-0.112 {0.0018-0.0044}

Rocker Arm End Play 0.05-0.65 {0.0020-0.0255} Replace
Valve Spring Setting Load Inner spring 212.8 N {21.7 kgf, 47.8 Ibf} at 55.5 {2.185} 195.2 N {19.9 kgf, 43.87 Ibf} Replace 1 E 5-^ г SM23-024
Outer spring 554.1 N {56.5 kgf, 124.6 Ibf} at 58.5 {2.303} 507.0 N {51.7 kgf, 113.98 Ibf}
Valve Spring Straightness 3.0 {0.118} Replace 1 '1 ' - SM3-303
Push Rod Bend 0.5 {0.0196} Replace 1 SM3-292
У19В
ENGINE
NIP-13
CRANKSHAFT PULLEY
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
For Dust slinger
Y19B
МР-14
ENGINE
IMPORTANT POINT - DISMOUNTING
REMOVE THE CRANKSHAFT PULLEY.
NOTE: О Use a puller if necessary.
О Do not remove the crankshaft gear unless it considered
absolutely necessary.
IMPORTANT POINTS - ASSEMBLY
IF NECESSARY, REPLACE THE DUST SLINGER.
1. Remove the dust slinger with levers.
2. Using special tools, install the dust slinger.
Special Tools: Dust Slinger Press (09402-1110)
O-ring (9851-99101)
NOTE: To prevent wear of the side lip of the oil seal, inject about
0.5 to 1 cm3 (0.031-0.061 cu.in} of grease (lithium-based)
into the "U" groove of the dust slinger.
IMPORTANT POINTS - MOUNTING
INSTALL THE CRANKSHAFT PULLEY.
NOTE: Apply engine oil to thread of the crankshaft.
У19В
ENGINE
MP-15
FLYWHEEL AND FLYWHEEL HOUSING
OVERHAUL
1. Flywheel housing gasket
2. Flywheel housing
3. Helisert
4, Rear engine mounting bracket
5. Dust cover
6. O-ring
7. Oil seal retainer
8. Oil seal
9. Flywheel ring gear
10. Spacer
11. Flywheel assembly
12. Pilot bearing
13. Bearing stopper
14. Straight pin
IMPORTANT POINTS - ASSEMBLY
IF NECESSARY, REPLACE THE OIL SEAL.
1. Remove the oil seal.
2. Apply a small amount of clean engine oil on the outer periph-
ery of the oil seal and then install the oil seal to the oil seal re-
tainer, ensuring that it is flush with the end of the oil seal re-
tainer.
Special Tool: Oil Seal Guide (09471-1090)
NOTE: Ensure that the lip of the oil seal is coated with oil seal
lubricating grease (lithium-based.)
IF NECESSARY, REPLACE THE FLYWHEEL RING GEAR.
1. Remove the ring gear.
a. Heat the ring gear with a blow torch in a uniform manner
[Approx. 100°C {212°F)J.
b. Using a metal rod as a pad and strike all around the ring gear
in a uniform manner and remove the ring gear.
NOTE: Be careful not to overheat the ring gear.
Y19B
МР-16
ENGINE
2. Install the ring gear.
a. Heat the ring gear uniformly using a blow torch [Approx.
100°C {212°F}.]
b. Drive the ring gear with its chamfered gear teeth facing the
block onto the flywheel using a metal rod.
NOTE: Be careful not to overheat the ring gear.
SM3-1698
INSTALL THE FLYWHEEL.
1. Install the flywheel and tighten the bolts through several repe-
tition the tightening order so as to reach specified torque
evenly and gradually, then slacken and tighten them one by
one to the specified torque.
WARNING
The flywheel is heavy, when installing, be careful not to drop it
on your feet.
NOTE: О Align the "O" mark on the flywheel and crankshaft collar
knock-pin.
О When tightening the bolt, apply engine oil to the threads
and flywheel surface of the bolts.
Tightening Torque: 255-284 N-m
{2,600-2,900 kgf-cm, 188-209 Ibf-ft}
2. Install the pilot bearing.
3. Install the lock plate with bolts.
SM3-1697
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Flywheel face alignment 0.3 {0.0118} 0.5 0.0196} Regrind and/or replace SM3-908
Y19B
ENGINE
MP-17
TIMING GEAR AND CAMSHAFT
DESCRIPTION
1. Crankshaft gear
2. Air compressor drive gear
3. Power steering pump drive gear
4. Injection pump drive gear
5. Camshaft drive gear
6. Coolant pump drive gear
7. Engine oil pump drive gear
OVERHAUL
T = Tightening torque: N m {kgf cm, Ibf-ft}
1. Oil seal 7. Idler gear 14. Key
2. Timing gear case cover 8. Engine oil pump driven gear 15. Camshaft
3. Gasket 9. Engine oil pump drive gear 16. Front end plate
4. Air compressor drive gear 10. Crankshaft gear 17. Injection pump drive main gear
5. Power steering pump drive gear 11. Camshaft gear 18. Spring
6. Injection pump drive gear 12. Coolant pump drive gear 19. Injection pump drive sub gear
assembly 13. Camshaft thrust plate 20. Retainer ring
Y19B
МР-18
ENGINE
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
CAMSHAFT ATTACHMENT
TIMING GEAR PULLER
Y19B
ENGINE
NIP-19
IMPORTANT POINTS - DISMOUNTING
REMOVE THE CAMSHAFT.
Remove the thrust plate set bolts and pull out the camshaft
with gear.
NOTE: Pull the camshaft, slowly turning it so as not to damage
the bearings.
Special Tool: Attachment (09481-1060)
IMPORTANT POINTS - ASSEMBLING
IF NECESSARY, REPLACE THE CAMSHAFT GEAR.
Holding the shaft assembly with a vice through wooden
plates. Remove the nut, then using a gear puller, remove the
gear.
Special Tool: Puller (09420-1360)
ASSEMBLE THE INJECTION PUMP DRIVE GEAR ASSEMBLY.
1. Install the spring and sub gear on to the main gear with
retainer ring.
NOTE: o Be sure painted side of spring face to the sub gear.
О Apply lithium based grease to (A).
О Align the sub gear matching marks with main gear.
О After assembling, make sure that there is clearance
0.6-0.8 mm {0.024-0.031 in) at all around the perimeter
of (B).
Y19B
МР-20
ENGINE
IMPORTANT POINTS - MOUNTING
IF NECESSARY, REPLACE THE TIMING GEAR COVER OIL SEAL.
1. Using a screwdriver, remove the oil seal.
2. Install the new oil seal.
Special Tool: Press (09482-1070)
INSTALL THE CAMSHAFT GEAR TO THE SHAFT.
Install the camshaft gear with thrust plate.
NOTE: When installing the gear to the camshaft:
О Heat the gear in hot water [Approx. 100°C {212°F}], then
install the gear to the camshaft by using a press.
О When tightening the nut, apply engine oil to the treads
and plate surface of the nut.
INSTALL THE CAMSHAFT.
1. Lubricate all journals of the camshaft and insert the camshaft
assembly into the cylinder block.
Special Tool: Attachment (09481-1060)
NOTE: Insert the camshaft, slowly turning while inserting so that
the bearing will not be damaged.
2. Align the camshaft gear matching marks with the crank shaft
gear.
NOTE: Incorrect installation can result in engine damage or lower-
ing of engine performance by causing improper injection
timing.
INSTALL THE INJECTION PUMP DRIVE GEAR.
1. Align the injection pump drive gear match mark with the idler
gear.
NOTE: Incorrect installation can results in engine damage or low-
ering of engine performance by causing improper injection
timing.
Y19B
ENGINE
MP-21
MEASURE THE GEAR BACKLASH.
Measure the backlash of each gear using a dial gauge or
plastic gauge.
Replace the gear if necessary.
Refer to INSPECTION AND REPAIR.
NOTE: After measure the gear backlash, apply engine oil to face of
each gear.
INSTALL THE TIMING GEAR COVER.
Using a special tool, install the timing gear cover.
Special Tool: Front Oil Seal Guide (09471-1120)
INSTALL THE AIR COMPRESSOR.
1. Set to top dead center of No.1 or No.7 cylinder by turning the
crankshaft.
2. Before install the air compressor, make sure that the align the
engraved make of air compressor drive gear and engraved
mark of idler gear.
MATCH MARK
IDLER GEAR
SM3-342
Y19B
МР-22
ENGINE
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Gear Teeth for Pitting or Wear Replace, if necessary. Visual check SM3-845
Camshaft Bend 0.05 {0.0019} Replace SM3-858
Camshaft Cam Height (Intake) 53.385 {2.1018} 52.585 {2.0703} Replace SM3-374
Camshaft Cam Height (Exhaust) 53.961 {2.1244} 53.161 {2.0929}
Camshaft End Play 0.10-0.33 {0.0040-0.0129} 0.40 {0.0158} Replace thrust bearing '"'SM3-848
Oil Clearance between Camshaft Journal and Bearing 0.06-0.15 {0.0024-0.0059} 0.30 {0.0118} Replace shaft and/or bushing J I "I 3 1 / SM3-850
Y19B
ENGINE
MP-23
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Crankshaft Drive Gear to Camshaft Gear 0.08-0.21 {0.0032-0.0082} 0.40 {0.0157} Replace gear, if necessary. SM3-844
Idler Gear to Injection Pump Drive Gear 0{0}
Injection Pump Drive Gear to Power Steering Pump Drive Gear 0.07-0.25 {0.0028-0.0098}
Idler Gear to Air Compressor Drive Gear 0.05-0.24 {0.0020-0.0094}
Camshaft Drive Gear to Coolant Pump Drive Gear 0.04-0.27 {0.0016-0.0102}
Oil Pump Drive gear to Oil Pump Driven Gear 0.09-0.29 {0.0035-0.0114}
Clearance between Valve Lifter and Valve Lifter Guide 0.025-0.075 {0.0010-0.0029} 0.15 {0.0059} Replace tappet iy £ P SM3-293 Ф l_ SM3-420
Valve Lifter for Wear Should not be worn unevenly. Replace, if necessary. Visual check SM3-1122
Coolant Pump Oil Jet Clogged Clean SM3-1141
Y19B
МР-24
ENGINE
INJECTION PUMP DRIVE
1. Drive gear
2. Front end plate
3. O-ring
4. Bearing holder case
5. Ball bearing
6. Key
7. Drive shaft
8. Shim
9. Gasket
10. Bearing retainer
11. Oil seal
12. Oil seal sleeve
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
INJECTION PUMP DRIVE
INJECTION PUMP DRIVE
O-RING (Used with 09482-1550)
IMPORTANT POINTS - ASSEMBLY
IF NECESSARY, REPLACE THE FUEL INJECTION PUMP DRIVE
SHAFT OIL SEAL SLEEVE.
1. Using a special tool, remove the sleeve.
a. Put the puller (1), (2) onto the sleeve.
b. Insert the hook portion of the puller between shaft and sleeve.
c. Insert the puller (3).
d. After inserting the puller, screw in the center bolt (4), then re-
move the sleeve.
Special Tool: Puller Assembly (09420-1180)
Y19B
ENGINE
MP-25
2. Using special tools, insert the shaft sleeve with a new O-ring.
a. Put the O-ring (5) into the press (6).
b. Insert the new oil seal sleeve with new O-ring into the press
and then insert them into the drive shaft.
c. Hitting the (A) lightly by hammer, contact the press end and
the shaft end (B), with this determine the oil seal sleeve posi-
tion.
NOTE: о Be sure to fit an O-ring on the sleeve and also apply a
liberal coating of oil to the shaft.
О When driving on the shaft sleeve, taking care that the
O-ring does not get cut or torn.
О Once a sleeve has been removed, it cannot be reusec}.
Special Tools: Press (09482-1330)
O-ring (9851-36104)
ASSEMBLE THE INJECTION PUMP DRIVE SHAFT ASSEMBLY.
Adjust the preload of drive shaft by shims.
Turning Torque: 0.39-1.17 N-m {4-12 kgf-cm, 0.290-0.867 Ibf-ft}
NOTE: Be sure that there is no loose rattling in the axis direction
of the drive shaft.
Y19B
МР-26
ENGINE
PISTON, CRANKSHAFT, CYLINDER BLOCK
AND OIL PAN
OVERHAUL
2
T = Tightening torque: N-m {kgf-cm, Ibf-ft}
1. Cylinder block 11. Piston ring 21. Key
2. Plug 12. Piston 22. Crankshaft
3. Soft washer 13. Piston pin 23. Balance weight bolt
4. Flange 14. Retainer ring 24. Oil slinger
5. O-ring 15. Connecting rod 25. Crankshaft main bearing
6. Cylinder liner 16. Connecting rod bushing 26. Crankshaft thrust bearing
7. Oil jet pipe for piston cooling 17. Connecting rod bearing 27. Collar
8. Main hole plug 18. Sleeve 28. Crankshaft bearing cap
9. Straight pin 19. Oil pump drive gear
10. Camshaft bearing 20. Crankshaft gear
У19В
ENGINE
MP-27
OVERHAUL
1. Encloser cover
2. Seal
3. Water gallery cover
4. O-ring
5. Coolant drain cock
6. Soft washer
T = Tightening torque: N-m {kgf-cm, Ibf-ft}
7. Oil drain plug
8. Oil pan shield
9. Oil pan
10. Gasket
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
For Piston ring
PISTON RING EXPANDER
For Main bearing cap dismounting
CYLINDER BLOCK EXPANDER
Y19B
МР-28
ENGINE
For Cylinder liner
For Connecting rod bushing
For Piston cooling jet
For Front oil seal sleeve
PRESS
09402-1260
For Rear oil seal sleeve
Y19B
ENGINE
MP-29
REMOVE THE PISTONS WITH CONNECTING RODS.
1. Remove the carbon from the upper end of the cylinder liner
with a scraper or emery paper (recommended: No.150) in a
circular direction.
2. Extract the piston and connecting rod assembly out through
the top of the cylinder.
NOTE: О Remove the connecting rod in such a way that the con-
necting rod does not contact the cooling jet.
Adjust the cooling jet if by any chance the rod and the
jet make.
О Arrange the piston and connecting rod caps in order.
REMOVE THE PISTON RINGS.
Special Tool: Piston Ring Expander (09442-1220)
NOTE: О Handle the piston rings carefully because they are made
of a special casting which is easily broken.
О Keep the rings for each cylinder separate.
REMOVE THE MAIN BEARING CAP.
1. Remove the side bolts.
2. Remove the main bearing cap bolts.
3. Using a special tool, open up the cylinder block.
Special Tool: Cylinder Block Expander (09440-1020)
NOTE: Be careful not to open up the cylinder block expander more
than 90°, as it may damage the block.
4. Remove the main bearing cap.
Y19B
МР-30
ENGINE
REMOVE THE CYLINDER LINER.
Before removing the cylinder liners, be sure to put match
marks on the cylinder block and liner flange with a pen.
NOTE: О Do not put match marks with a punch.
О After removing the cylinder liners, put numbers on their
periphery or arrange them in sequence.
Special Tool: Cylinder Liner Puller (09420-1700)
Y19B
ENGINE
NIP-31
IMPORTANT POINTS - ASSEMBLY
INSPECT THE PISTON COOLING JET POSITIONING.
NOTE: О Do not remove the cooling jet except when performing
overhauls or when otherwise necessary.
О In the event that the cooling jet is removed, be sure to
replace it on the cylinder.
Inspection of the piston cooling jet positioning procedure are
as follows.
1. Remove the piston cooling jet connector bolt and install a
special tool.
Special Tool: Connector Bolt (9001-24262)
2. Use a commercially available oil pump [pressure about 2 kg/
cm2 {28.44 lb/sq.in}, flow rate about 2.5L/min {2.64 US.qts/
min}].
3. Prepare fresh engine oil.
4. Connect the oil lines.
Connect the oil pump outlet to a special tool (connector bolt).
5. Install a special tool on the cylinder block.
Special Tool: Target Plate (09444-1450)
6. Operate the oil pump, and with pressure at about 196 kPa {2
kg/cm2, 28.44 lb/in2}, pump fresh oil from the jet, and perform
a spray test. Conditions are normal if the center of stream hits
a target plate 0Ю mm {0.39 in}.
WARNING
Engine oil is flammable.
This spray test should be done in a well ventilated room and
away from any open flames or electric sparks.
Y19B
МР-32
ENGINE
7. If the spray of the cooling jet messes the circle on the target
plate, realign the cooling jet using a special tool.
Special Tool: Adjuster Bar (09472-1620)
8. Spray pattern.
When inspecting the piston cooling jet positioning, check that
the spray is dispersed as shown in "4" and not as in "1'', "2", or
"3" in the illustration at left.
NOTE: If the tip of the jet is damaged so that the spray pattern is
bad, replace the jet with a new one. When replacing the
cooling jet, always inspect the new piston cooling jet's
positioning.
9. After inspecting the piston cooling jet positioning, remove the
special tool (connector bolt), then install the cooling jet on the
cylinder block using the correct mounting bolt with soft
washer.
Tightening Torque: 20-22.5 N-m
(200-230 kgf-cm, 19.62-22.55 Ibf-ft}
10. After installing the piston, make sure that there is no interfer-
ence between the cooling jet and the piston when the piston
is at bottom dead center.
Y19B
ENGINE
NIP-33
О о О Oo o h )/Z \\O/Z \\ / \ ll°\ ЛХ / IDENTICAL MARKS \ T/rA О/ ° ( ] IDENTICAL MARKS7 SM3-387
TABLE OF IDENTICAL MARKS APPLICATION
CYLINDER BLOCK CYLINDER LINER
A A
В В
C C
D D
E E
F F
INSERT THE CYLINDER LINER INTO THE CYLINDER BLOCK.
1. When a new cylinder liner is used, make sure that the liner
has the same mark as the mark on the cylinder block.
NOTE: Cylinder liners and cylinder block are subject to selective
fitting, and so, in case new cylinder liners are to be used,
confirm the identical marks stamped at the flange areas of
cylinder liners and any combination of the identical marks
stamped collectively at the upper or side surface of the
cylinder block and insert the ones with identical marks.
2. When reusing a liner, insert the liner in its original position,
aligning the marking marked before disassembly.
3. Apply a small amount of clean engine oil on the outer
periphery of the liner, and apply pressure on the entire flange
section of the liner. If insertion by hand is difficult, use a
cylinder liner guide, and the cylinder liner will easily be
pushed in.
Special Tool: Cylinder Liner Guide (09480-1160)
NOTE: О Do not use a liner that has been dropped.
О Take extra care when handling the liner since the liner is
easily deformed.
MEASURE THE PROTRUSION OF THE CYLINDER LINER FLANGE.
Install a special tool and measure the protrusion of the top end of
the cylinder liner from the cylinder block.
Special Tool: Cylinder Liner Puller (09420-1210)
Tightening Torque: 9.80 N-m {100 kgf-cm, 7.23 Ibf-ft)
Standard: 0.04-0.10 mm (0.0016-0.0039 in)
У19В
МР-34
ENGINE
IF NECESSARY, REPLACE THE CRANKSHAFT FRONT OIL SEAL
SLEEVE.
1. Remove the oil seal sleeve using a special tool.
Special Tool: Eye Bolt (09433-1010)
2. Install a new sleeve.
Be sure to fit an new O-ring on the sleeve and also apply a
liberal coating of oil to the pulley center side.
When driving on the crankshaft sleeve, use a crankshaft
sleeve press, taking care that the O-ring does not get cut or
torn.
Special Tool: Press (09402-1260)
IF NECESSARY, REPLACE THE CRANKSHAFT REAR OIL SEAL
SLEEVE.
1. Remove the crankshaft sleeve using a special tool.
Special Tool: Puller (09420-1060)
2. Install a new sleeve.
Be sure to fit an new O-ring on the sleeve and also apply a
liberal coating of oil to the crankshaft side.
When driving on the crankshaft sleeve, use a crankshaft
sleeve press, taking care that the O-ring does not get cut or
torn.
Special Tool: Press (09402-1070)
Unit: mm {in}
Bearing size Outside diameter
Crank pin Journal
Standard 83.935-83.965 {3.3045-3.3057} 109.90-109.92 {4.3268-4.3276}
0.25 83.695-83.715 {3.2951-3.2958} 109.65-109.67 {4.3170-4.3177}
0.50 83.445-83.465 {3.2853-3.2860} 109.40-109.42 {4.3071-4.3078}
0.75 83.195-83.215 {3.2754-3.2761} 109.15-109.17 {4.2973-4.2980}
1.00 82.945-82.965 {3.2656-3.2663} 108.90-108.92 {4.2875-4.2882}
IF NECESSARY, GRIND THE CRANKSHAFT PIN OR JOURNAL AND
USE UNDER SIZE BEARINGS.
DIMENSIONS OF FILTER R:
Crank Pin: 5.0-5.5 mm {0.1969-0.2165 in)
Journal: 5.0-5.5 mm {0.1969-0.2165}
WRONG
SM3-441
Y19B
ENGINE
MP-35
INSTALL THE CRANKSHAFT.
1. Install the crankshaft bearings on the cylinder block and bear-
ing cap.
NOTE: о Install the bearing with the oil hole on the block side and
the bearing without the oil hole on the cap side.
О Apply fresh engine oil to each bearing surface.
2. Install the crankshaft on the cylinder block.
3. Insert the crankshaft thrust bearings along the groove of the
cylinder block.
4. Install the thrust bearings on the No.5 bearing cap sides.
NOTE: Apply fresh engine oil to each thrust bearing surface.
5. Using the special tool, open up the cylinder block.
Special Tool: Cylinder Block Expander (09440-1020)
NOTE: Be careful not to open up the cylinder block expander more
than 90° as it may damage the block.
6. Install the crankshaft bearing caps.
a. Align the collar on the cylinder block and bearing caps.
b. Install them from the flywheel side.
SM3-1152
7. Tighten the bearing cap bolts in three stages following the
tightening order.
Tightening Order: 1-2-3-4-5-6-7-8-9-10
Tightening torque
1 st step 50% of specified torque
2nd step 75% of specified torque
3rd step 100% of specified torque
NOTE: о Apply engine oil to the bolt threads and under the bolt
head.
О Make sure that the crankshaft rotates smoothly.
О Inspect the crankshaft end play.
8. Tighten the side bolts in three stages following the tightening
order.
Tightening Order: 11-12-13-14-15-16-17-18-19-20
Y19B
NIP-36
ENGINE
IF NECESSARY, REPLACE THE CONNECTING ROD BUSHING.
1. Install the spindle and the guide on the bracket.
Special Tool: Connecting Rod Press Set (09407-1010)
NOTE: The tapered face on the spindle should be upward.
2. Mount the connecting rod. Install the guide on the connecting
rod housing, and tighten a second the bolt.
Tightening Torque: 98.07-117.67 N-m
{1,000-1,200 kgf-cm, 72-86 Ibf-ft)
NOTE: Use following bolt:
Length: 165 mm {6.496 in)
3. Remove the spindle from the bottom.
4. Reinsert the spindle from the top onto the connecting rod
bushing.
NOTE: The tapered face on the spindle should be downward.
5. Install the cap on the spindle and push the bushing out using
a press.
6. Install a new connecting rod bushing.
a) Deber and clean the connecting rod bushing insert bore.
b) Mount a new connecting rod bushing on the spindle and
mount the cap. Tighten the cap's set screw.
c) Make sure that the bushing oil hole coincides with the oil hole
of the connecting rod.
d) Install the bracket set screw in the bracket.
e) Press in the new bushing using a press.
NOTE: Make sure that the spindle groove coincides with the
bracket set screw.
f) Remove the spindle, and dismount the connecting rod from
the special tool.
Y19B
ENGINE
NIP-37
FOR LEFT BANK
ASSEMBLE THE PISTON.
1. Assemble the piston and connecting rod as shown.
NOTE: О R marks at the bottom of the pistons indicate use for the
right bank, L marks use for the left bank.
О Make sure that the О-mark at the top of the piston and
the arrow mark at the connecting rod in same directions.
"0" MARK
AND
ARROW
MARK
ARROW
MARK
SM3-295
INSTALL THE PISTON RING.
1. Install the piston rings in the sequence oil ring, third ring
second ring and top ring with the identification mark at the
top of the ring facing up.
NOTE: Apply oil to the piston rings.
Special Tool: Piston Ring Expander (09442-1220)
Ring No. Description
Top IBS
2nd IIOII
3rd
Oil
2. Connect the ends of the coil expander and then fit the coil
inside the piston ring after ensuring that the gap of the piston
ring is 180° away from the joint of the coil.
Y19B
МР-38
ENGINE
3. Arrange the piston rings so that their gaps are equally spaced.
INSTALL THE PISTON WITH CONNECTING ROD INTO THE CYLIN-
DER LINER.
1. Apply engine oil to the piston, cylinder liner and connecting
rod bearing surface.
2. Using a special tool, hold the piston rings and push the piston
with connecting rod assembly with a wooden rod.
NOTE: o Be sure that the О-mark on the top of the piston is near-
est the identification marks of cylinder block and liner or
water gallery cover side as shown.
The arrow marks on the pistons should face the timing
gear side.
О When installing the piston with connecting rod assem-
bly, be sure that the piston cooling jet is not struck by
the connecting rod. If the piston cooling jet is struck,
adjust or replace it.
Special Tool: Piston Ring Holder (09441-1310)
INSTALL THE CONNECTING ROD CAP.
1. Apply engine oil to the bearing surface.
2. Align the match marks on the connecting rod and cap.
Y19B
ENGINE
MP-39
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Cylinder Liner Inside Diameter 146 {5.74} 146.15 {5.7539} Replace liner 25 mm {0.984 in} SM3-910 7 T 1
Clearance between Piston and Cylinder Liner 0.206-0.235 {0.0082-0.0092} Replace piston and/or liner.
— ХЕШ I

SM3-432 ^SM3-313
Clearance between Piston Pin and Piston Pin Hole 0.001-0.0115 {0.00004-0.00045} 0.005 {0.0019} Replace piston, piston pin and/or bushing. \ ; J xi r . . чл— ’ " r i SM3-859
Clearance between Piston Pin and Connecting Rod Bearing 0.025-0.043 {0.00099-0.00169} 0.10 {0.0039}
Crankshaft End Play 0.11-0.24 {0.0044-0.0094} 0.5 {0.0196} Replace thrust bearing <и ' SM3-1176
Connecting Rod Wear or Damage * Use a dye penetrate Replace SM3-363
Connecting Rod Oil Hole Clogged Clean SM3-424
Y19B
МР-40
ENGINE
Unit: mm {in}
Inspection item Standard Limit Remedy Inspection Procedure
Connecting Rod Straightness 0.1 {0.0039} per 200 {7.874} Replace V ) SM3-330
Connecting Rod Twist 0.1 {0.0039} per 200 {7.874} Replace / SM3-331
Crank Pin Diameter 84 {3.3070} 83.8 {3.2992} Regrind undersize SM3-860
82.80 {3.2598} Replace crankshaft
Clearance between Connecting Rod and Crank Pin 0.056-0.107 {0.0023-0.0042} 0.30 {0.0118} Replace bearing (/ SM3-300
Main Bearing Spread 116.75-117.25 {4.5965-4.6161} Replace bearing SM3-298
Connecting Rod Bearing Spread 89.75-90.25 {3.5335-3.5531}
Crankshaft Oil Hole Clogged Clean SM3-434
Crankshaft Cracks and Damage * Use a dye penetrate Replace yll (r SM3-435
Y19B
ENGINE
MP-41
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Crankshaft Bend 0.06 {0.0023} Replace SM3-861
Piston Ring Breadth Ring No.: Top 3.306 {0.1302} 3.156 {0.1243} Replace ‘1 h SM3-379
2nd 3.5 {0.1378} 3.35 {0.1318}
3rd 3.5 {0.1378} 3.35 {0.1318}
Oil 5.0 {0.1969} 4.95 {0.1948}
Piston Ring Groove Breadth Ring No.: Top 3.5 {0.1378} 3.65 {0.1438} Replace SM3-301
2nd 3.5 {0.1378} 3.65 {0.1438}
3rd 3.5 {0.1378} 3.65 {0.1438}
Oil 5.0 {0.1969} 5.05 {0.1989}
Clearance between Piston Ring and Piston Ring Breadth Ring No.: Top Not easily measured
2nd 0.07-0.11 {0.0028-0.0043} Replace piston ring and/or piston
3rd 0.07-0.11 {0.0028-0.0043}
Oil 0.04-0.08 {0.0016-0.0031}
Piston Ring Gap * Insert the Piston Rings Where the Wear of the Liner is Small. Ring No.: Top 0.45-0.60 {0.0178-0.0236} 1.5 {0.0590} Replace SM3-302
2nd 0.45-0.60 {0.0178-0.0236} 1.5 {0.0590}
3rd 0.45-0.60 {0.0178-0.0236} 1.5 {0.0590}
Oil 0.35-0.55 {0.0138-0.0216} 1.0 {0.0393}
Cylinder Block Flatness 0.05 {0.0019} 0.15 {0.0059} Regrind and/or replace ' SM3-314
Y19B
МР-42
ENGINE
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Cylinder Liner Protrusion 0.04-0.10 {0.0016-0.0039} Replace
PROTRUSION SM3-1092
Crankshaft Journal Diameter 110 {4.3307} 109.8 {4.3228} Regrind undersize SM3-860
108.80 {4.2834} Replace :rankshaft
Clearance between Crankshaft Journal and Main Bearing 0.066-0.117 {0.0026-0.0046} -0.20 {-0.0078} Replace bearing SM3-1177
Y19B
ENGINE
MP-43
LIQUID GASKET AND APPLICATION POINTS
The engine use liquid gasket instead of conventional sheet gaskets. Apply liquid gasket, therefore, taking the following items
into account.
1. LIQUID GASKET APPLICATION POINTS AND COATING WIDTH
Recommended liquid gasket;
Three Bond TB1207D: 04132-1207
Unit: mm {in}
2. COATING LIQUID GASKET AND PARTS ASSEMBLY PROCEDURE
1. Completely remove old liquid gasket from each part and the respective mating part, and remove oil, water, and
dirt using cloth.
2. Be careful not to apply excessive or insufficient liquid gasket. Also, be sure to overlap the start and end of each
coating.
3. When assembling coated parts, be careful that there is no misalignment between mating parts. If there is any
misalignment, coat the parts again.
4. Assemble the various parts within 20 minutes after applying liquid gasket. If more than 20 minutes have elapsed,
remove the liquid gasket and apply it again.
5. After assembling the various parts wait for at least 15 minutes before starting the engine.
3. REMOVING PARTS
When removing each part, do not attempt to pry one portion of the flange alone but use the flange collar or clearance to
pry the flange at several points alternately.
NOTE: When removing the oil pan, the flange of the oil pan may sometimes become deformed preventing it from
being reused. To prevent this, therefore, first insert plates with a thin edge at several points around the
periphery of the oil pan, then remove the oil pan using a screwdriver.
Y19B
ENGINE
LS-1
LUBRICATING SYSTEM
LUBRICATING SYSTEM DIAGRAM
25
2 5
Unit: kPa {kgf/cm2, lbf/in2}
1. Oil pan 11. Regulator valve 22. Piston
2. Suction strainer 363-421 {3.7-4.3, 52.7-61.1}' 23. Sub oil hole (Right bank)
3. Oil pump 12. Full-flow oil filter 24. P.T.O. gear (If so fitted)
4. Oil pump safety valve 13. Oil pressure unit 25. Valve mechanism (Right bank)
784-931 {8.0-9.5,114-135} 14. Oil filter safety valve 26. Fuel injection pump
5. Delivery pipe 127.4-166.6 {1.3-1.7,18.5-24.1} 27. To oil pan
6. Oil cooler 15. Main oil hole (Left bank) 28. Fuel injection pump drive shaft
7. Oil cooler safety valve 16. Piston cooling jet 29. Timing gear
363-421 {13.7-14.3,195-203} 17. Check valve 30. Valve lifter
8. Cut off valve 294 {3.0, 42.7} 31. Valve push rod
156.4-215.2 {1.6-2.0, 22.8-28.4} 18. Valve mechanism (Left bank) 32. Cylinder head
9. Bypass oil filter 19. Timing gear 33. Valve rocker arm
10. Alarm device for clogging of oil 20. Crankshaft 34. Crosshead
filter 147 {1.5,21.3} 21. Camshaft 35. Air compressor
Y9B
LS-2
ENGINE
OIL PUMP AND OIL STRAINER
OVERHAUL
T = Tightening torque: N-m {kgf-cm, Ibf-ft}
1. Oil pump cover 5. Oil pump safety valve spring 9. O-ring
2. Drive gear 6. Shim 10. Plate
3. Oil pump body 7. Spring seat 11. Oil pump
4. Oil pump safety valve 8. Retainer ring 12. Oil strainer
Y9B
ENGINE
LS-3
IMPORTANT POINTS - MOUNTING
OIL PUMP SAFETY VALVE AND RETAINER RING.
1. Adjust the safety valve opening pressure.
Using shims
Pressure: 785-931 kPa {8.0-9.5 kgf/cm2,114-135 lbf/in2}
Shim thickness t: 1.2 mm {0.0472 in}
2. Retainer ring
Install a retainer ring to the safety valve holder.
NOTE: Bevelled edge of retainer ring towards outside.
INSTALL THE OIL STRAINER.
NOTE: Be sure to install О-ring and tighten the oil pipe setting
bolts temporary then tighten the bolts to the specified
torque.
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Gear Backlash 0.10-0.26 {0.006-0.011} 0.4 {0.0157} Replace s’ 7 SM3-1117
Y9B
LS-4
ENGINE
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Drive Gear Shaft Diameter 23.967-23.980 {0.9436-0.9440} - Replace shaft and/or bushing SM3-1123 SM3-1107
Bushing Inside Diameter 24.020-24.041 {0.9457-0.9464}
Clearance between Drive Shaft and Bushing 0.040-0.074 {0.0016-0.0029} 0.19 {0.0074}
Drive Gear Shaft Diameter 30.939-30.955 {1.2181-1.2187} Replace
Driven Gear Inside Diameter 30.995-31.020 {1.2187-1.2212} - Replace __Уli / SM3-1124
Clearance between Driven Gear and Shaft 0.040-0.081 {0.0016-0.0031} 0.15 {0.0059} Replace bushing and/or shaft SM3-317
Clearance between Gear and Case 0.060-0.105 {0.0024-0.0041} 0.15 {0.0059} Replace gear and/or case yyyJ SM3-1114
Gear End Play 0.04-0.10 {0.0016-0.0039} 0.15 {0.0059} Replace gear and/or case SM3-1112
Gear Teeth Pitting or Wear Replace, if necessary. Visual check SM3-845
Y9B
ENGINE
LS-5
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Oil pump safety valve for Wear or Damage - Replace, if necessary. Visual check
Gear Backlash between Crankshaft Gear and Oil Pump Drive Gear 0.09-0.29 {0.0036-0.0114} 0.4 {0.0157} Replace gear ilMO) ) SM3-844
Y9B
LS-6
ENGINE
OIL COOLER AND OIL FILTER
INSPECTION AND REPAIR
Inspection Item Standard Limit Remedy Inspection Procedure
Oil Cooler Air Thickness Air Pressure: 588.39 kPa {6 kgf/cm2,85.3 lbf/in2} Replace, if necessary. kg/cm2 ffi WATER I — A,R | ELEMENT

SM3-1088
Valve and Springs of Oil Cooler and Oil Filter Wear or Damage — Replace, if necessary. 1. Sliding face of valve for possible damage. 2. Valve move smoothly.
Y9B
ENGINE
FS-1
FUEL SYSTEM
FUEL SYSTEM DIAGRAM
1. Fuel tank
2. Water separator
(If so fitted)
3. Fuel filter (primary)
(If so fitted)
4. Fuel feed pump
5. Fuel filter (secondary)
6. Fuel injection pump
7. Injection nozzle
8. Over flow pipe
9. Drain plug
10. Bleeder plug
11. Through feed valve
OVERHAUL
1.
2.
3.
T = 24.5-27.5 {250-280,18-20}
2
T = Tightening torque: N-m {kgf-cm, Ibf-ft)
Injection nozzle
Nozzle holder clamp
Fuel injection pump
4. Fuel filter
5. Injection pump drive shaft
assembly
Y5C
FS-2
ENGINE
INJECTION NOZZLE
Maker ZEXEL (ZXL)
Type 2 Spring Type
DESCRIPTION
L : Needle valve full-lift
I : Needle valve pre-lift
Y5C
ENGINE
FS-3
1. Retainer nut
2. Nozzle assembly
3. Pin
4. Spacer
5. Lift piece
6. Second pressure spring
seat
7. Second pressure spring
8. Second pressure
adjusting shim
9. Nozzle holder
10. Push rod
11. First pressure spring
12. First pressure adjusting
screw
13. Gasket
14. Gap nut
15. Leakage bolt
T = Tightening torque: N-m {kgf-cm, Ibf-ft}
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
NOTE: ZXL means ZEXEL
IDLER GEAR SLIDING HAMMER
NOZZLE HOLDER ADAPTER
ADJUSTING DEVICE
157892-4620 : All in one set, ZXL make
Y5C
FS-4
ENGINE
IMPORTANT POINTS - DISMOUNTING
CLEAN OFF SURROUNDING AREA OF THE NOZZLE AND THE FUEL
LINE CONNECTORS.
NOTE: If foreign matter is allowed to enter the combustion
chamber, engine trouble may result.
REMOVE THE FUEL INJECTION PIPE.
NOTE: Cover open ends of the pipes and fuel injection pump to
prevent entry of dirt.
REMOVE THE NOZZLE HOLDER ASSEMBLY.
Remove the nozzle clamp bolt and nozzle clamp, then remove
the nozzle holder assembly by hand.
If the nozzle holder is difficult to remove by hand, use the spe-
cial tools.
Special Tools: Sliding Hammer (09420-1442)
Adapter (09462-1130)
NOTE: After removal of the nozzle holder, cover the nozzle holder
with cloth. Also cover the cylinder head with a cloth to pre-
vent dust from getting in.
IMPORTANT POINTS - INSPECTION
CHECK THE NOZZLE OPERATING PRESSURE.
1. Install the nozzle older assembly to the nozzle tester, and
operate the lever at the rate of about 50 to 60 times per
minute.
WARNING
О Diesel fuel is flammable.
This nozzle adjusting should be done a well ventilated room
and away from any open flames or electric spark.
О The spray must always be covered. Keep your face and body
away from the spray. This is because of the risk of fuel oil get-
ting in your eyes or passing into your body.
2. At this time, check that the nozzle operating pressure (first
opening pressure) is in the specified vlaue. If not, disassemble
and adjust the nozzle holder assembly.
First opening pressure: 15.2-16.0 MPa
{155-163 kgf/cmz, 2,205-2,318 lbf/in2}
TEST THE SPRAY PROFILE.
In the case of the new nozzle, operating the lever at the rate of
30 to 60 strokes per minute, and for a used nozzle, operate the
lever at the rate of 15 to 60 strokes per minute.
Y5C
ENGINE
FS-5
TEST THE FUEL LEAKAGE.
When checking for fuel leakage from the nozzle, apply a pres-
sure of about 0.98-1.96 MPa {10-20 kg/cm2, 142-284 lb/in2}
lower than the correct injection pressure to the nozzle by
means of the nozzle.
TEST THE NOZZLE SINKING.
Wash the nozzle proper with diesel fuel oil, them immerse it in
diesel fuel oil.
Next slide the needle inside the nozzle proper and ensure that
it move smoothly. The needle valve should fall under its own
weight when withdrawn vertically about 1/3 and released. If
its motion is sluggish, replace the nozzle with a new one.
ASSEMBLING
NOTE: о The steps below for adjustment are made during parts assembly.
О Because the nozzle holder is adjusted in 1/100 mm units, it must be thoroughly washed to completely remove all
dirt and foreign objects.
Work steps
1. Adjustment of first opening pressure Adjust first opening pressure with the adjusting screw.

2. Checking of needle valve full lifts Check with nozzle cover method.

3. Checking of pre-lift Check with nozzle cover method.
NOTE: If pre-lift is not within specified value, replace pins, lift piece, spacer and nozzle assembly with the nozzle service kit.
4. Checking of second opening pressure Check with nozzle cover method.

5. Adjusting of second opening pressure Adjust second opening pressurewith adjusting shim.

6. Replacement of the retaining nut Replace adjustable retaining nut with normal retain- ing nut.

7. Final inspection Check condition of the fuel spray with the nozzle and nozzle holder assembled.
Y5C
FS-6
ENGINE
1. ADJUSTMENT OF FIRST OPENING PRESSURE.
1. With the cap nut side facing downward, attach the nozzle
holder body to the plate.
2. Insert the adjusting shim, the second pressure spring and the
spring seat, in that order into the nozzle holder body.
NOTE: The second pressure spring is the same as the first
pressure spring.
3. Put the pins, the lift piece, and the spacer onto the nozzle
holder body.
4. Put the pin and the nozzle assembly onto the spacer.
5. Put gasket (special tool) onto the nozzle, then use adjustable
retaining nut (special tool) to hold the nozzle in place on the
nozzle holder.
Special tool: Gasket (157892-1500...ZXL make)
Adjustable retaining nut (157892-4000...ZXL make)
NOTE: о Check to make sure the pin is all the way in the nozzle
and then tighten adjustable retaining nut.
О Finger-tighten the adjustable retaining nut until it no
longer turns and tighten the nut to specified torque.
Tightening torque: 59-78 N-m {600-800 kgf-cm, 44-57 Ibf-ft}
6. Turn over the nozzle holder body so that the cap nut side is
facing upward.
7. Insert the second pressure push rod, the first pressure spring
and the first pressure adjusting screw, in that order, into the
nozzle holder body.
8. Attach the gasket and the cap nut onto the first pressure
adjusting screw.
Y5C
ENGINE
FS-7
9. Attach the nozzle and nozzle holder assembly to the nozzle
tester.
10. Adjust the first opening pressure to the specified value with
the first pressure adjusting screw.
First opening pressure: 15.2-16.0 MPa
{155-163 kgf/cm2 3 4, 2,205-2,318 lbf/in2}
11. Hold the nozzle holder body using a cresent wrench, then
tighten the cap nut to the specified torque.
Tightening torque: 29-39 N-m {300-400 kgf-cm, 22-28 Ibf-ft}
2. CHECKING OF NEEDLE VALVE FULL-LIFTS.
1. Attach the gasket (special tool) and the plug (special tool) onto
the adjustable retaining nut.
Special tool: Gasket (026508-1140...ZXL make)
Plug (157892-1600...ZXL make)
2. Turn over the nozzle holder body so that the cap nut side is
facing upward.
3. Attach the holder (special tool) to the cap nut.
Special tool: Holder (157892-4100 .ZXL make)
4. Temporary tighten the attachment nut (special tool) onto the
holder.
Special tool: Attachment nut (157892-1000 ..ZXL make)
Y5C
FS-8
ENGINE
5. Screw the pin (special tool) into dial gauge.
Special tool: Pin (157892-4200)
(157892-4300)
1 /DIAL GAUGE
, ATTACHMENT
to JJ) /^NUT g^'-'''^/HOLDER
^^/PIN Cl
J /SECOND PRESSURE PUSH ROD
J /GASKET AND 31/-'^ PLUG
6. Tighten the attachment nut so that it holds the dial gauge in
place in the nozzle holder assembly and so that the pin is in
contact with the push rod upper surface.
NOTE: o Attach the dial gauge into place so that it can measure a
stroke of approx. 2 mm (0.079 in).
О Do not tighten the nut too much, the dial gauge shaft will
become stuck.
PRESSURE—►
7. Attach the nozzle and nozzle holder assembly to the nozzle
tester and zero the dial gauge.
8. Operate the nozzle tester to bleed air in the retaining nut.
Check to make sure there are no fuel leaks.
9. Operate the nozzle tester to raise pressure to 34.3-44.1 MPa
{350-450 kgf/cm2, 4,979-6,400 lbf/in2} and needle valve is lifts
fully. At this time, record the dimensions of full-lifts as "L".
NOTE: This check is made to determine whether the nozzle seat is
abnormally worn and whether the nozzle is correctly as-
sembled.
Y5C
ENGINE
FS-9
3. CHECKING OF PRE-LIFT.
1. When needle valve is full-lifted, release the nozzle tester
handle to lower pressure inside the tube and decrease the
needle valve lift value (value indicated on dial gauge).
2. When the second pressure spring stop to action and needle
valve drop ends (needle valve lift dimension " f") read the dial
gauge indication, checking to make sure it is within specified
values.
PRESSURE
PRESSURE—►
Pre-lift measuring points:
Read the dial gauge at [First opening pressure + approx. 1
MPa {10 kgf/cm2, 142 lbf/in2}.
NOTE: Watch the pressure drop to find the point.
Pre-lift (£) : 0.05-0.08 mm {0.0020-0.0031 in}
3. If pre-lift is not within specified value, replace the pins, the lift
piece, the spacer and the nozzle assembly with the nozzle ser-
vice kit.
CHECKING OF SECOND OPENING PRESSURE.
1. Check the pre-lift, then operate the nozzle tester to raise
pressure to 34.3-44.1 MPa {350-450 kgf/cm?, 4.979-6.400 Ibf/
in2} and lift the needle valve fully.
2. Release the nozzle tester handle to lower pressure inside the
tube, all the while watch the dial gauge indicate.
Y5C
FS-10
ENGINE
WHEN NEEDLE VALVE LIFT
: I + 0.05 mm
FULL-LIFT
-DIAL GAUGE -
3. Read the valve indicated on the pressure gauge at the instant
the dial gauge needle indicates the specified needle valve lift
value (pre-lift " Г' + 0.05 mm {0.0020 in}).
Second opening pressure: 25.5-26.5 MPa
{250-260 kgf/cm2, 3,556-3,697 lbf/in2}
-PRESSURE GAUGE-
OPENING OPENING {350-450 kgf/cm2}
PRESSURE PRESSURE
PRESSURE
ADJUSTMENT OF SECOND OPENING PRESSURE.
1. If the second opening pressure deviates from the specified
value, and the amount of that deviation is small, readjust the
first opening pressure but within the specified value.
NOTE: o If the second opening pressure is lower than the specified
value:
Readjust the first opening pressure to maximum speci-
fied value, then measure the second opening pressure.
О If the second opening pressure is higher than the speci-
fied value:
Readjust the first opening pressure to minimum specified
value.
2. If the first opening pressure has been readjusted and the
second opening pressure still diviates from the specified
value, disassemble the nozzle side of the nozzle holder and
remove the adjusting shim.
3. If the second opening pressure is higher than the specified
value, replace the, adjusting shim with a thinner one.
4. After replacing the adjusting shim, remeasure the second
opening pressure, and adjust the pressure until it comes to
the specified value.
Second pressure adjusting shim line-up
Inside diameter: 9.5 mm {0.374 in}
Outside diameter: 4.5 mm {0.177 in}
Unit: mm {in}
Parts number Shim thickness Parts number Shim thickness
150538-4900 0.40 {0.0157} 150538-5300 0.56 {0.0220}
150538-5000 0.50 {0.0197} 150538-5400 0.58 {0.0228}
150538-5100 0.52 {0.0205} 150538-5500 0.60 {0.0236}
150538-5200 0.54 {0.0212} 150538-5600 0.70 {0.0276}
Y5C
ENGINE
FS-11
REPLACEMENT OF THE RETAINING NUT.
1. Remove the dial gauge, the nut, the holder and the gasket
from the cap nut.
2. Remove the adjustable retaining nut and the gasket, and
attach a normal retaining nut.
Tightening torque: 59-78 N-m (600-800 kgf-cm, 44-57 Ibf-ft}
FINAL INSPECTION
1. Attach the nozzle holder to the nozzle tester and check the first
opening pressure, the spray condition, the seat's oil seal, and
whether there are any oil leaks from any part.
2. To replace the nozzle, replace the nozzle, the lift piece, and the
spacer, which are all in one set, with the nozzle service kit.
NOTE: Replacing only the nozzle will cause the amount of pre-lift
to deviate from the specified value.
IMPORTANT POINT - MOUNTING
INSTALL THE NOZZLE HOLDER ASSEMBLY.
1. Insert the nozzle holder assembly into the nozzle sleeve and
temporarily install the nozzle clamp with the bolt.
NOTE: Be sure to install the O-rig.
2. Temporary secure the injection pipe nut.
NOTE: Be sure to install the O-ring.
3. Tighten the nozzle clamp fitting bolt to specified torque.
Tightening Torqe: 25-27 N-m {250-280 kgf-cm, 18.08-20.24 Ibf-ft}
NOTE: Make sure the nozzle clamp fits on the rock on the cylinder
head (A).
4. Tighten the injection pipe nut to specified torque.
Tightening Torque: 29-49 N-m {300-500 kgf-cm, 21.70-36.15 Ibf-ft}
Y5C
FS-12
ENGINE
FUEL INJECTION PUMP
SPECIAL TOOL
Prior to starting an engine overhaul, it is necessary to have this special tool.
INJECTION PUMP COUPLING
IMPORTANT POINTS - DISMOUNTING
REMOVE THE FUEL INJECTION PUMP.
1. Disconnect the fuel lines, oil lines and engine control lines.
2. Remove the through bolt "B“ and the two flange bolts "A" (in
slotted holes) at the coupling.
3. Remove the pump mounting bolts and then dismount the
pump.
NOTE: Cover open end of the pipes and pump to prevent entry of
dirt.
Special Tool: Wrench (09819-1705)
IMPORTANT POINTS - DISASSEMBLING AND ASSEM-
BLING
Refer to CHAPTER IP, FUEL INJECTION PUMP for details.
IMPORTANT POINTS - MOUNTING
INSTALL THE FUEL INJECTION PUMP.
1. Adjust the injection timing.
Turn the crankshaft counterclockwise viewed from the fly-
wheel side to align the injection timing mark on the flywheel
at A° before top dead center for No.1 cylinder on compression
stroke with pointer on the flywheel housing.
Injection timing (A°): Refer to SECTION DATA AND SPECIFICATION.
2. Check the push rods on No.1 cylinder are loose and push rods
on No.6 are tight.
NOTE: If not, turn the crankshaft one complete revolution and
align marks as above.
Y5C
ENGINE
FS-13
3. Slowly turn the automatic timer flange to clockwise viewed
from coupling side to align the injection timing mark on the
automatic timer with pump body pointer.
4. Position the pump on the pump bracket and adjust the posi-
tion of the pump so that its mounting holes align with those
of the bracket and then tighten the mounting bolts evenly.
Tightening Torque: 38-49. N-m {380-500 kgf-cm, 28-36 Ibf-ft}
5. Using a special tool, tighten the two flange bolts (in slotted
holes) at the coupling.
NOTE: There should not be any gap between the laminated plates
or be any deformation of the flange due to pressure the
laminated plates.
Special Tool: Injection Pump Coupling Wrench (09819-1705)
Tightening Torque: 59-63 N-m
{600-650 kgf-cm, 44-46 Ibf-ft)
6. Tighten the through bolt at the flange.
NOTE: Do not tighten the through bolt before tightening the two
flange bolts.
Tightening Torque: 59-63 N-m {600-650 kgf-cm, 44-46 Ibf-ft}
7. Connect the fuel lines, oil lines and engine control lines.
Y5C
ENGINE
CS-1
COOLING SYSTEM
COOLING SYSTEM DIAGRAM
1. Radiator
2. Drain cock
3. Coolant pump
4. Timing gear cover
5. Cylinder block
6. Oil cooler
7. Cylinder head
8. Air compressor
9. Thermostat case
10. Bypass pipe
11. Header tank
12. Radiator cap
13. Reservoir tank
14. Air vent pipe
15. Suction pipe
16. Coolant temperature gauge
Y5B
CS-2
ENGINE
COOLANT PUMP
OVERHAUL
1. Coolant pump case
2. Coolant seal
3. Coolant pump vane
4. Gasket
5. Coolant pump cover
6. Coolant pump shaft
7. Oil seal
T = Tightening torque: N-m {kgf-cm, Ibf-ft}
SM3-1498
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
COOLANT PUMP VALVE PULLER
COOLANT PUMP, OIL SEAL PRESS
COOLANT PUMP, COOLANT
COOLANT PUMP VANE PRESS
Y5B
ENGINE
CS-3
IMPORTANT POINTS - DISASSEMBLY
REMOVE THE COOLANT PUMP VANE.
Remove the vane from the shaft with special tool.
Special Tool: Coolant pump vane puller (09420-1620)
REMOVE THE SETTING BOLTS.
Working from the side of the drive gear, use a hexagonal
wrench to remove the bolts.
REMOVE THE COOLANT PUMP SHAFT USING A PRESS.
IMPORTANT POINTS - ASSEMBLY
1. INSTALL THE OIL SEAL TO THE COOLANT CASE.
NOTE: о Apply engine oil to the coolant case side and install the
oil s'eal to the case.
о Apply lithium based grease to the main lip and between
main and sub-lip.
Special Tool: Coolant pump oil seal press (09482-1670)
2.
INSTALL THE COOLANT PUMP SHAFT USING A PRESS.
Y5B
CS-4
ENGINE
TIGHTEN THE BOLTS.
INSTALL THE COOLANT SEAL TO THE CASE WITH SPECIAL TOOL.
Special Tool: Coolant seal press (09482-1690)
NOTE: When installing the coolant seal. Three Bond No.104 to the
outer and circumference of the coolant seal cage and install
the seal using a press.
INSTALL THE COOLANT PUMP VANE.
Special Tool: Coolant pump vane press (09482-1700)
NOTE: The coolant pump vane face until end of the shaft.
Y5B
ENGINE
CS-5
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Bearing Wear and Damage Replace pump shaft, if necessary. Visual check SM3-1501
Cover, Vane or Case Wear and Damage Replace, if necessary. Visual check SM3-1502
Water Drain Hole Clogged Clean SM3-1113
Y5B
CS-6
ENGINE
THERMOSTAT
IMPORTANT POINTS - INSPECTION AND REPAIR
INSPECT THE THERMOSTAT FUNCTION.
1. Place the thermostat in hot water and check the valve opening
temperature and the valve lift.
NOTE: The thermostat valve opening temperature (T,) is engraved
on the thermostat seat, and it should be confirmed.
Thermostat valve opening temperature;
Thermostat valve opening temp. (T,) Service standard
82°C 80-84°C {145-215°F}
Thermostat valve lift;
Thermostat valve opening temp. (T,) Measuring temp. (T2) Valve lift (£)
82°C 95°C {203°F} 10 mm {0.394 in} or more
2. Immerse a heated thermostat in water of normal temperature.
If it completely closes within 5 minutes it is satisfactory. If it
remains even slightly open, it is defective and must be
replaced.
IMPORTANT POINTS - ASSEMBLY
MOUNT THE THERMOSTAT.
1. Remove the water and dirt adhering to the thermostat case.
2. Replace the gasket without fail if it is corroded, damaged or
flattened.
3. Before installing the hose, apply liquid gasket to the hose in-
stallation of the thermostat case cover.
4. In order to prevent clogging of the radiator, do not apply a
large amount of liquid gasket.
NOTE: О When installing the thermostat, be careful of the direc-
tion in which the bridge faces.
Be sure to install the thermostat with the jiggle valve at
the top, so as to enable bleeding of air during supply of
water.
Y5B
ENGINE
CS-7
RADIATOR
WARNING
To avoid the danger of burns to not drain the coolant while the
engine and radiator are still hot.
NOTE: When dismounting and mounting the radiator, do not
damage the radiator core.
INSPECTION AND REPAIR
Unit: kPa {kgf/cm2, lbf/in2}
Inspection Item Standard Limit Remedy Inspection Procedure
Coolant leakage Replace radiator SM3.g75
Clogging of the fins — Clean
Radiator cap valve opening pressure 0.5 39.3-58.8 {0.4-0.6, 5.7-8.5} Replace I SM3-823
0.9 73.6-102.9 {0.75-1.05,10.7-14.9}
NOTE: The coolant filler cap valve opening pressure is shown on the cap and it should be confirmed.
If the cap pressure is incorrect, there is a risk of abnormally high pressure being generated in the cooling system,
which may cause the hose to drop off or burst and, in turn, damage the engine.
Y5B
ENGINE
FD-1
COOLING FAN
1. Shock to the fan clutch and fan.
During maintenance and inspection, be careful not to drop or
strike the fan clutch or fan itself. The resulting damage may
lower the performance of the fan. Also, note that the fan is
made of plastic and may become damaged or deformed if
force is applied to it.
2. Replacing the fan.
Do not replace the fan unless it is faulty. When replacing the
fan, replace it with the same type as the one which was re-
moved. If the fan is replaced with one of a larger capacity be-
cause of overheating or, conversely is replaced with one of a
smaller capacity due to overcooling, the cooling performance
may in fact reduced and durability may be jeopardized.
3. Other items
Check the temperature detector (bimetal) to see if there is any
mud or dust on it.
If the bimetal is covered with mud of dust, the fan perfor-
mance will be erratic, and any result in overheating or over-
cooling. In such case, carefully remove mud and dust adher-
ing to the surface of the bimetal, using a wire brush, or the
like.
Take care not to apply excessive force particular.
Do not paint the fan or fan clutch.
Do not place any paint or other reagents which are likely to
dissolve plastic in contact with the fan.
У9А
FD-2
ENGINE
INSPECTION AND REPAIR
Inspection Item Standard Limit Remedy Inspection Procedure
Cooling fan and fan clutch deformation and damage Replace, if necessary.
Y9A
ENGINE
IE-1
AIR INTAKE AND EXHAUST SYSTEM
OVERHAUL
1. Exhaust manifold 6. Compression spring
2. Seal ring 7. Heliseat
3. Gasket 8. Intake manifold
4. Heat insulator 9. Intake pipe assembly
5. Cushion 10. Intake air heater
11. Noise suppressor
12. Intake air control valve
IMPORTANT POINT - DISASSEMBLING
NOTE: Do not remove the lever rod, and valve from the intake air
control valve assembly. If removed, resulting in poor per-
formance of intake air control system.
Y8B
IE-2
ENGINE
IMPORTANT POINT - ASSEMBLY
ASSEMBLE THE EXHAUST MANIFOLD.
1. When installing seal rings on the exhaust manifold, fit new
seal rings in such a way that the gaps are equally spaced, as
shown, to prevent gas leakage.
IMPORTANT POINTS - MOUNTING
INSTALL THE INTAKE MANIFOLD.
NOTE: If remove the stud bolt from the cylinder head at dismount-
ing, apply adhesive (Three Bond 1322B or equivalent) to
cylinder head side thread of the stud bolt.
Y8B
ENGINE
CP-1
ELECTRICAL PARTS
GENERATOR
SPECIAL TOOL
Prior to starting an engine overhaul, it is necessary to have this special tool.
V-BELT TENSION GAUGE
Y13A
CP-2
ENGINE
IMPORTANT POINTS - DISASSEMBLING AND ASSEM-
BLING
Refer to CHAPTER GE, GENERATOR for details.
IMPORTANT POINTS - MOUNTING
V-BELT ADJUSTMENT.
1. Install the V-belts, and adjust the belt tension.
NOTE: О Do not under any circumstances apply the lever directly
against the generator body owing to the risk of damag-
ing the generator.
О When installing a new V-belt or adjusting the tension, be
sure to repeat the adjustment two or three times, after
running the engine for several minutes each time.
2. V-belt deflection.
Apply a load of about 98 N {10 kgf, 22 Ibf} by pressing with
your finger or special tool.
Assembly standard (A): 16-22 mm {0.63-0.86 in}
Special Tool: V-belt tension gauge (09444-1210)
NOTE: If the belt is excessively tensioned, there is a risk of damag-
ing the bearings of the generator and also shorting the life
of the V-belt.
Conversely, if there is insufficient tension on the V-belt, the
belt will slip, unusual noise will be emitted, the battery
may run down and the engine may overheat.
"B" and "E" terminal bolt tightening torque:
3.2- 4.4 N-m (33-45 kgf-cm, 2.4-3.2 Ibf-ft}
STARTER
IMPORTANT POINTS - DISMOUNTING
REMOVE THE STARTER FROM THE ENGINE.
1. Disconnect the battery cable from the negative (-) terminal of
battery.
2. Put the match marks on the harness and starter terminals with
a pen and then disconnect the harness.
3. Remove the starter from the engine.
IMPORTANT POINTS - DISASSEMBLING AND ASSEM-
BLING
Refer to CHAPTER ST, STARTER for details.
IMPORTANT POINTS - MOUNTING
INSTALL THE STARTER ON THE ENGINE.
1. Install the starter on the engine.
2. Connect the harness to match the marks.
3. Connect the battery cable.
Terminal nut tightening torque:
16.2-22.0 N-m {165-225 kgf-cm, 12-16 Ibf-ft} for "B" terminal.
1.9-2.4 N-m (19-25 kgf-cm, 1.4-1.8 Ibf-ft} for "C" terminal.
OTHER PARTS
IMPORTANT POINTS - INSPECTION, REPAIR AND
ADJUSTING
CHAPTER EE, ELECTRICAL EQUIPMENT.
Y13A
ENGINE
TU-1
ENGINE TUNE-UP
METHOD FOR DETERMINING IF THE NO.1 PISTON IS AT
THE TOP DEAD CENTER ON COMPRESSION STROKE.
NOTE: О Turn the crankshaft to align the mark "1-7" on the fly-
wheel with the pointer of the flywheel housing.
O In this position either the No.1 or No.7 piston is at the
top dead center on compression stroke.
The pointer and mark "1-7" are provided on some model
timing gear cover, and on the torsional damper, so use
these pointer and marker when adjusting the engine
when so equipped.
1. Move both the intake and the exhaust rocker arms of the No.1
or No.7 cylinder by hand; if both rocker arms can be moved,
the piston is at top dead center on the compression stroke.
2. If the injection timing mark is nearly aligned with the pointer,
the No.1 piston is at top dead center on compression stroke.
NOTE: If not, turn the crankshaft one complete revolution and
align marks as above.
PUSH RODS: MOVE PUSH RODS: STANDING
(Compression stroke) (Overlapping stroke)
о
3. While locking at the push rods of No.1 and No.x pistons, turn
the crankshaft counterclockwise and clockwise about 30° to
40° (see left figure).
If the piston whose exhaust and inlet push rods do not move
during the interval, it is at the top dead center on compression
stroke.
If the piston whose push rods have moved, it is at the
completion of the exhaust and begun of the intake stroke
(overlapping stroke).
NOTE: Always loosen the lock nut and raise the adjusting screws
fully to the top. If the adjusting screws are too low, the
piston and valves may strike each other during valve
clearance adjustment.
SM3-713
Y12B
TU-2
ENGINE
VALVE CLEARANCE
[Valve clearance adjusting procedures]
BEFORE ADJUSTING
1. Before adjusting, make sure that the cylinder head and the
rocker support bolts are tightened with the specified torque.
2. Make sure that there are no foreign matter and dust in be-
tween the cross heads (if so fitted) and the valve stems, and
between the rocker arms and the cross heads.
3. Set the piston in the particular cylinder to adjust for top dead
center on the compression stroke.
ADJUSTING
1. With the No.1 piston positioned at top dead center on
compression stroke, adjust the No.1 valve clearance using a
thickness gauge as follows.
The thickness gauge should move with a very slight pull.
Valve Clearance: Refer to SECTION DATA AND SPECIFICATIONS.
a. Loosen the lock nut of the cross head. Then loosen the adjust-
ing screw until the screw is completely apart (14 mm {0.55 in}
or more) from the valve stem.
b. Insert the thickness gauge between the rocker arm and the
cross head, adjust the clearance with the adjusting screw of
the rocker arm, and lock the screw with the lock nut. The tight-
ness of the thickness gauge should be same as that of the
usual clearance adjustment.
c. With the thickness gauge remain inserted, loosen the adjust-
ing screw of cross head, and make sure that the tightness of
the thickness gauge remain as step "b".
If not, do over again from step "a".
d. Tighten the adjusting screw of the cross head until the thick-
ness gauge hardly move.
e. Loosening the adjusting screw of the cross head gradually un-
til the clearance gets right. Then, lock the adjusting screw with
the lock nut. The tightness of the thickness gauge should be
same as that of the usual clearance adjustment.
NOTE: Do not over-loosen the adjusting screw, over-loosen the
screw resulting the condition turn back to the step "b".
And even if the tightness of the thickness gauge is right,
the gap between the adjusting screw and the valve stem
may be large. Therefore correct clearance can not obtained.
2. Adjust the other valves.
Turn the crankshaft counterclockwise viewed from flywheel
side. Adjust the valve clearance for each cylinder in the firing
order.
Firing order and firing interval;
Eight cylinder model
Firing order
1-8-4-2-7-3-6-5
Firing interval
90°
Y12B
ENGINE
TU-3
INJECTION TIMING
INSPECT THE INJECTION TIMING.
1. Turn the crankshaft counterclockwise viewed from the fly-
wheel side to align the injection timing mark on the flywheel
or crankshaft pulley damper at A° before top dead center for
No.1 cylinder on compression stroke with the pointer.
Injection timing (A°): Refer to SECTION DATA AND SPECIFICATION
2. Check that the injection timing mark (the scribe line, not the
notch) on the timer housing is aligned with the pointer (the
scribe line) timing plate on the pump housing.
If not, adjust the injection timing.
NOTE: When adjusting the injection timing, refer to "FUEL INJEC-
TION PUMP" for details.
AIR BLEEDING FROM FUEL SYSTEM
1. Bleed air from the fuel filter.
a. Loosen the bleeder plug on the fuel filter.
b. Loosen the priming pump knob.
c. Operate the priming pump knob until the air will not come out
from the bleeder plug.
d. Tighten the bleeder plug.
Tightening Torque: 3.93-5.88 N-m {40-60 kgf-cm, 3-4 Ibf-ft}
NOTE: The bleeder plug should be tightened while the priming
pump knob is operated.
2. Once again, operate the priming pump knob several times.
3. Push back the priming pump knob and tighten it.
NOTE: Wipe off any splashed fuel.
Y12B
TU-4
ENGINE
ENGINE CONTROL
ADJUST THE ACCELERATOR CONTROL.
1. Apply chassis grease to the pins, ball joints and bearings.
2. Prior to fitting the throttle cable turn the knob counterclock-
wise until it stops then back off 4 turns from the position.
3. Check that accelerator pedal height is "A" mm. If not adjust
the pedal height with the control cable adjusting nut.
Dimension A: 155-165 mm {5.91-6.49 in}
4. After adjustment, check the engine idling speed.
5. Adjust the accelerator stopper bolt so that the clearance be-
tween the pedal and pedal stopper bolt is "B" mm when the
control lever on the fuel injection pump strikes the maximum
stopper bolt.
Clearance B: 2-5 mm {0.08-0.20 in}
NOTE: Eliminate slack in the cable of the control lever on the fuel
injection pump.
ADJUST THE ENGINE STOP CONTROL.
1. Set the engine starter key at ON position.
NOTE: Do not start the engine.
2. Connect the connectors of the engine stop motor harness.
WARNING
Do not connect the electric harness with the engine stop motor
while the engine starter key at OFF or ACC position as this oper-
ate the engine stop motor instantaneously and the link lever of
the engine stop motor and the engine stop lever of the injection
pump move, resulting in your fingers caught by the lever.
3. Adjust the engine stop cable with adjusting nut to that the
clearance "A" between the clevis and cable stopper is 1-3 mm
{0.04-0.11 in}.
4. Set the starter key at OFF position.
NOTE: After adjustment, confirm correct execution of engine start
and stop.
Y12B
ENGINE
TU-5
ENGINE TUNE-UP ON TEST BENCH
NOTE: О If the engine is started with the power steering oil pump
installed, the oil pump may burn or oil may spurt out, re-
move the oil pump from the engine and install a cover to
prevent oil leakage from the point of removal.
О Starting the engine when the generator is not connected
to the battery may damage the generator. Always con-
nect to the battery.
SET THE ENGINE ASSEMBLY ON A TEST BENCH.
1. Add the proper amount of the specified engine oil through the
oil filer cap on the cylinder head cover.
2. Add coolant.
Bleed out air from inside the coolant gallery through the cylin-
der block drain plug.
BLEED AIR FROM FUEL SYSTEM.
CHECK THE INJECTION TIMING.
Refer to "FUEL INJECTION PUMP".
CHECK THE VALVE CLEARANCE.
START THE ENGINE.
NOTE: Before starting the engine, make sure that the fuel cut lever
of the fuel injection pump is operating normally.
1. Check the oil feed to rocker arms.
a. Set the engine speed..
Engine speed: Refer to SECTION DATA AND SPECIFICATION.
b. When one minute after starting the engine, oil should flow to
the head (Face A) of all push rods and the head (Face B) of all
valves. If the time required for the oil to flow to the rocker
arms is long, various troubles such as seizing, abnormal wear
and unusual noise may occur.
RETIGHTENING CYLINDER HEAD BOLT
Retighten the cylinder head bolts according to the following
instructions.
(1) Retightening schedule
Retighten at the first 1,000 km (600 miles) following servicing
which involves the loosening or removal of any cylinder head
bolt. Such servicing includes replacement of the cylinder head
gasket, servicing of the valve gear parts, and the like.
(2) Retightening procedure
Step 1: Warm up the engine in the same way as in engine
turning.
Step 2: Following the cylinder head bolt tightening order as
shown, loosen the first cylinder head bolt by 1/4 to 1/2
turns as shown (SM3-457), then tighten into it to its
specified torque.
Repeat until all the bolts have been retightened.
Tightening order. Tightening torque and special tool:
Refer to "CYLINDER HEAD" in SECTION ENGINE MOVING
PARTS.
NOTE: o Be sure to loosen one bolt at a time, then retighten it be-
fore going on the next bolt.
О By retighten, face pressure of cylinder head is restored
from point В to C as shown.
RECHECK THE VALVE CLEARANCE, WHEN ENGINE IS COLD.
Y12B
ENGINE
PR-1
PROCEDURE FOR INSTALLING JOINTS AND GASKET OF
ENGINE PIPE
1. Gasket seal type (aluminum + rubber, asbestos or copper).
Location of gasket seal
2. Metal seal type (Flares connector type).
Location of metal seal
BRACKET FLARE NUT
LOCK WASHER
Tightening torque chart
Clamping screw size (Diameter) mm {in} Tightening torque N-m {kgf-cm, Ibf-ft}
8 {0.315} 13 {130, 9}
10 {0.394} 20 {200,14}
12 {0.472} 25 {250,18}
14 {0.551} 25 {250,18}
16 {0.630} 29 {300, 22}
18 {0.709} 39 {400, 29}
20 {0.787} *39 {400, 29}
24 {0.945} 69 {700, 51}
28 {1.102} 127 {1,300, 94}
Tightening torque chart
Clamping screw size (Diameter) mm {in} Tightening torque N-m {kgf-cm, Ibf-ft}
12 {0.472} 20 {200,14}
14{0.551} 31 {320, 23}
16 {0.630} 39 {400, 29}
18 {0.709} 59 {600, 43}
20 {0.787} 64 {650, 47}
Y1C
PR-2
ENGINE
3. Metal seal type (Nipples connectors type)
Location of metal seal
CONNECTOR
Tightening torque chart
Clamping screw size (Diameter) mm {in} Tightening torque N-m {kgf-cm, Ibf-ft}
10 {0.394} 11 {110, 8}
20 {0.787} 20 {200,14}
NOTE: о Before installing the joints, ensure that there is no dirt or burrs adhering to the various seat faces (pipe joints, gaskets,
etc.)
О Because the pipes can move relatively free during installation and the seat faces are liable to tilt, first temporarily tighten
the pipes, then tighten them to specification and ensure that there is no leakage from them.
О When tightening two pipes together, be very careful that they do not rotate together.
о After installing the pipes, apply the correct pressure to each pipe joint and ensure that there is no leakage.
О Ensure that the various tightening torques conform to the above table.
* If a soft washer #4840 FR-N (aluminum + rubber and carbon press fit part) is loosened or removed subsequent to being
installed, be sure and replace it with a new one.
There is no need to replace it, however, for normal retightening.
(K.P.)
Y1C
HINO MOTORS, LTD.
PRINTED IN JAPAN
'95-11 (K.P.)
EN-Y203E-01
WORKSHOP MANUAL
ENGINE
Model F20C for FS905TD
ENGINE
EN-1
EN-Y203E-01
CHAPTER EN
ENGINE
Model F20C
DATA AND SPECIFICATIONS ...................DS - 1
TROUBLESHOOTING ..........................TS - 1
ENGINE OVERHAUL CRITERIA .................ОС - 1
ENGINE ASSEMBLY DISMOUNTING AND MOUNTING .DM - 1
ENGINE MOVING PARS ........................MP - 1
CYLINDER HEAD ...............................- 1
CRANKSHAFT PULLEY ...........................-13
FLYWHEEL AND FLYWHEEL HOUSING ...............-15
TIMING GEAR AND CAMSHAFT ....................-17
INJECTION PUMP DRIVE ........................-24
PISTON CRANKSHAFT CYLINDER BLOCK AND OIL PAN.-26
LIQUID GASKET AND APPLICATION POINTS ........-43
LUBRICATING SYSTEM ........................LS - 1
OIL PUMP AND OIL STRAINER ...................- 2
OIL FILTER AND OIL COOLER ...................- 6
FUEL SYSTEM ...............................FS - 1
INJECTION NOZZLE ............................- 2
FUEL INJECTION PUMP .........................-12
COOLING SYSTEM ............................CS - 1
COOLANT PUMP ................................- 2
THERMOSTAT ..................................- 6
RADIATOR ....................................- 7
COOLING FAN ........................... FD - 1
AIR INTAKE AND EXHAUST SYSTEM .............IE - 1
ELECTRICAL PARTS .........................CP - 1
GENERATOR ...................................- 1
STARTER .....................................- 2
ENGINE TUNE-UP ...........................TU - 1
ENGINE TUNE-UP ON TEST BENCH ................- 5
PROCEDURE FOR INSTALLING JOINTS AND
GASKETS OF ENGINE PIPES ...................PR - 1
DSY23A
TSY1B
0CY9A
DMY1C
MPY19A
LSY9B
FSY5B
CSY5B
FDY9A
IEY8B
CPY13A
TUY12A
PRY1B
ENGINE
DS-1
DATA AND SPECIFICATIONS
Model F20C
Type Diesel, 4 cycle, 8 cylinder, V, overhead valve, water-cooled, direct injection.
Aspiration Natural aspirate.
Bore and stroke 146x 147 mm {5.75x 5.79 in}
Piston displacement 19.688 liters {1,201 cu.in}
Compression ratio 18.1 : 1
Firing order 1-8-4-2-7-3-6-5
Direction of rotation Counterclockwise viewed from flywheel
Compression pressure 2.9-3.2 MPa {30-33 kgf/cm2, 426-469 lbf/in2} at 200 r/min
Maximum revolution (at full load) 2,200 r/min
Idling revolution 450-500 r/min
Dry weight Approx. 1,300 kg {2,866 lb}
Valve seat angle Intake 30°
Exhaust 45°
Valve face angle Intake 30°
Exhaust 45°
Valve timing (flywheel travel) Intake opens 12° before top dead center.
Intake closes 36° after bottom dead center.
Exhaust opens 52° before botoom dead center.
Exhaust closes 16° after top dead center.
Valve clearance (when cold) Intake 0.45 mm {0.0177 in}
Exhaust 0.65 mm {0.0256 in}
Engine oil pump Type Drive Full forced pressure feed by gear pump. By gear
Engine oil cooler Multi plates type, water cooled
Injection nozzle Type Valve opening pressure Multi hole nozzle type 1st : 14.7 MPa {150 kgf/cm2, 2,133 lbf/in2} 2nd : 24.5 MPa {250 kgf/cm2, 3,556 lbf/in2}
Coolant pump Type Drive Forced circulation by volute pump. By gear
Thermostat Type Wax type, bottom bypass system
Injection timing (flywheel travel) 12° before top dead center for No. 1 cylinder on compression stroke.
Y23A
ENGINE
TS-1
TROUBLESHOOTING
Symptom Possible cause
Fnninp nvprhpatinл Coolant

• • • • • Insufficient coolant Defective thermostat Overflow of coolant due to leakage of exhaust into cooling system Coolant leakage from cylinder head gasket Defective coolant pump
— Radiator
• • • • Clogged with rust and scale Clogged with iron oxide due to leakage of exhaust into cooling system Clogged radiator core due to mud or other debris Defective radiator cap pressure valve
— Abnormal combustion
• • • • • Incorrect injection timing Reduced injection pressure Poor fuel Poor nozzle spray Unsatisfactory automatic timer advance angle...
— Other problems
• • • • Defective or deteriorated engine oil Unsatisfactory operation of oil pump Insufficient oil Brake drag
Excessive oil consumption Pistons, cylinder liners, and piston rings

• • • • • • • Wear of piston ring and cylinder liner Worn, sticking or broken piston rings Insufficient tension on piston rings Unsatisfactory break-in of piston rings Unsuitable oil (viscosity too low) Incorrectly fitted piston rings (upside down) Gaps of piston rings in line with each other
Remedy/Prevention
Add coolant.
Replace the thermostat.
Repair.
Replace gasket.
Repair or replace.
Clean radiator.
Clean coolant passage and
Correct exhaust leakage.
Clean radiator.
Replace radiator cap
Adjust injection timing.
Adjust injection pressure.
Use good quality fuel.
Adjust or replace nozzle.
Repair or replace timer.
Change engine oil.
Replace or repair.
Add oil.
Repair or adjust.
Replace piston rings and cylinder
liner.
Replace piston rings and cylinder
liner.
Replace piston rings and cylinder
liner.
Replace piston rings and cylinder
liner.
Change oil as required and replace
piston rings and cylinder liners.
Replace piston rings.
Reassemble piston rings.
Y1B
TS-2
ENGINE
Symptom Possible cause Remedy/ Prevention
Pvrocci\/Q r»il nnnei imntinn Valve and valve guides

• • • • Worn valve steam Replace valve and valve guide. Worn valve guide Replace valve guide. Incorrectly fitted valve stem seal Replace the stem seal. Excessive lubricant on rocker arm Check clearance of rocker arm and shaft.
— Excess oil feed
• • Defective oil level gauge Replace oil level gauge. Oil level too high Drain excess oil.
— Other problems
• • Overcooled engine (low temperature wear) Warm up engine before moving vehicle. Check cooling system. Oil leakage from miscellaneous parts Repair.
Operation
• • • • • • • • • •
Abrupt stoppage of engine after running Operate engine properly. At highspeed Hill climbing using unsuitable gear Select suitable gear. Oil Insufficient oil Add oil. Dirty oil Change oil. Poor quality oil Replace with proper engine oil. High oil temperature Repair. Low oil pressure Repair. Defective oil pump Repair oil pump. Reduced performance due to worn oil Replace oil pump, pump Suction strainer sucking air Add oil and/or repair strainer.
Abnormal combustion See Symptom: "Engine overheat-
ing." '

— Coolant ....
ing."
Injection pump Refer to CHAPTER IP, FUEL

INJECTION PUMP.

— Intake -leaner Clean element or replace element.
• Clogged air c
Overheating See Symptom: "Engine overheat-
ing."
Y1B
ENGINE
TS-3
Symptom
Lack of power
Possible cause
Remedy/Prevention
— Fuel and nozzle
• Poor nozzle spray ..........................
• Clogged nozzle with carbon .................
• Wear or seizure of nozzle ..................
• Air in fuel system .........................
• Clogged fuel filter ........................
• Use of poor fuel............................
— Abnormal combustion ........................
— Piston, cylinder liners, and piston rings ..
— Other problems
• Breakage of turbine or blower ...............
Adjust or replace injection nozzle.
Clean nozzle.
Replace nozzle.
Repair and bleed air from fuel
system.
Replace element.
Use good quality fuel.
See Symptom:
"Engine overheating."
See Symptom: "Engine over-
heating."
Refer to CHAPTER TU, TURBO-
(If so equipped turbocharger) CHARGER.
Difficult starting engine
— Electrical system
• Discharged battery ...........................
• Defective wiring in starter circuit ..........
• Loose or open-circuit battery cable ..........
• Break of glow plug or intake..................
air heater (If so equipped)
— Injection pump ..............................
— Air cleaner
• Clogged element................................
— Fuel system
• No fuel in tank...............................
• Clogged fuel line.............................
• Air sucked into fuel system through ..........
fuel line connections.
• Clogged fuel filter ..........................
• Loose connection in high-pressure line........
• Water in fuel ................................
Charge battery.
Repair wiring of starter.
Tighten battery terminal connec-
tions or replace battery cable.
Replace
Refer to CHAPTER IP, FUEL
INJECTION PUMP
Clean the element or replace the
element.
Supply fuel and bleed air from fuel
system.
Clean fuel line.
Tighten fuel line connections.
Replace element.
Tighten sleeve nut of high pres-
sure line.
Drain and clean fuel system
Y1B
TS-4
ENGINE
Symptom
Possible cause
Remedy/Prevention
Nozzles ozzle Replace nozzle.
•
Seized n
• Broken or fatigued nozzle spring Oil system Replace spring.
• Oil viscosity too high Other problems Use proper viscosity oil, or install an oil immersion heater and warm up oil.
• Seized piston Replace piston, piston rings, and liner.
• Seized bearing Replace bearing and/or crankshaft.
• Reduced compression pressure Overhaul engine.
• Ring gear damaged or worn Replace the ring gear and/or starter pinion.
• Improperly adjusted or broken accelerator cable Adjust or replace the accelerator cable.
Rough idling
Leakage of exhaust
— Injection pump .................................
— Nozzles
• Uneven injection pressure.....................
• Poor nozzle spray.............................
• Carbon deposit on nozzle tip..................
• Seized needle valve...........................
— Engine proper
• Improper valve clearance......................
• Improper contact of valve seat................
• Idling speed too low..........................
• Compression pressure of cylinders.............
markedly different from one another
— Cylinder head gasket
• Fatigued gasket (aging).......................
• Damage........................................
• Improper installation.........................
Refer to CHAPTER IP, FUEL
INJECTION PUMP.
Adjust.
Adjust or replace nozzle.
Remove carbon.
Replace nozzle.
Adjust valve clearance.
Replace or repair valve and valve
seat.
Warm up engine.
Overhaul engine.
Replace gasket.
Replace gasket.
Replace gasket.
Y1B
ENGINE
TS-5
Symptom
Possible cause
Remedy/Prevention
Leakage of exhaust
— Cylinder head bolts
• Loose bolts....................................
• Elongated bolts................................
• Improper tightening torque or..................
tightening sequence
— Cylinder block
• Cracking.......................................
• Surface distortion.............................
• Fretting of cylinder liner insertion...........
portion (insufficient projection of
cylinder liner)
— Cylinder head
• Cracking.......................................
• Surface distortion.............................
— Cylinder liners
• Cracking.......................................
• Corrosion......................................
• Insufficient projection of cylinder liner......
— Other problems
• Incorrect injection timing......................
Tighten bolt.
Replace bolt.
Tighten properly.
Replace cylinder block.
Repair or replace.
Replace cylinder liner or
cylinder block.
Replace cylinder head.
Repair or replace.
Replace cylinder liner.
Replace cylinder liner.
Replace cylinder liner.
Adjust injection timing.
Y1B
01Л!31Л1
ENGINE
ОС-1
ENGINE OVERHAUL CRITERIA
SPECIAL TOOL
Prior to starting an engine overhaul, it is n ecessary to have these special tools.
COMPRESSION GAUGE
COMPRESSION GAUGE
FACTORS WHICH DETERMINE WHEN AT ENGINE OVERHAUL IS
NEEDED.
LOWERED COMPRESSION PRESSURE.
a. Before the measurement
a) Correct the valve clearance.
b) Warm up engine [Bring the coolant temperature to about 80°C
(176T)]
c) Charge the batter fully.
d) Remove the air cleaner.
b. Measurement
1) Measure at nozzle holder hole.
a) Remove the nozzle holders.
b) Install the gauge adapter (A) and (B) in the nozzle holder hole.
c) For model equipped with manual control type engine stop system.
Disconnect the engine stop cable (rod) from engine stop lever in
engine stop position with tape or string.
d) For model equipped with electrical motor control type engine stop
system.
Set the engine starter key at "OFF" position, then disconnect the
engine stop motor harness.
e) Connect a compression gauge to the gauge adapter.
f) Drive the engine with the starter and read the compression
pressure.
NOTE: Do not continuously operate the starter for more than 15
seconds at a time.
g) Measure the compression pressure for each cylinder. If the
compression pressure is low, be sure to repeat the measuring.
NOTE: Be sure not to leak through sealing face.
Y9A
ОС-2
ENGINE
Unit: MPa {kg/cm2, Lb/in2)
Engine model Compression pressure Difference between each cylinder Engine speed (r/min)
Standard Limit
F20C 2.9-3.2 {30-33, 427-469} 2.55 {26, 369} 0.294 {3, 43} or less 200
S.A.E. GRADE ATMOSPHERIC TEMEPRATURE
-10 I 32 50 70 90100 I L I _ I T
-23-18 I I II 10 21 32 39 •C
40
30
20W/20
15W/40
c) After the measurement
Make sure the engine starter key is in "OFF" position and then
connect the engine stop motor harness.
WARNING
Do not connect the electric harness with the engine stop motor
while the engine starter key at "ON" position as this operate the
engine stop motor instantaneously and the link lever of the engine
stop motor and the engine stop lever of the fuel injection pump
move, resulting in your fingers caught by the lever.
DECREASED OIL PRESSURE
Check the oil pressure warning lamp when the oil and coolant
temperature is hot [about 80”C {176°F}].
a. If the warning lamp is lighted, check the oil level.
b. Check oil deterioration.
If oil quality is poor, replace with a suitable grade oil.
c. Remove the oil pressure switch and install the oil pressure gauge.
d. Measure the oil pressure at coolant temperature 80°C {176°F} or
more.
Standard oil pressure: 49-490 KPa {0.5-5.0 kg/cm2 7.11-71.10 lb/sq.in}
Service limit: 49 KPa {0.5 kg/cm2 (7.11 lb/sq.in)} or less
OTHER FACTORS
a. The blow-by gas increases.
b. The engine does not start easily.
c. Engine output decreases.
d. Fuel consumption increases.
e. Engine makes greater noise.
f. Excessive oil consumption.
Y9A
ENGINE
DM-1
ENGINE ASSEMBLY DISMOUNTING AND MOUNTING
IMPORTANT POINT — DISMOUNTING
DISMOUNT THE ENGINE ASSEMBLY.
1. Park the vehicle on level ground and then block the wheels.
2. Tilt the cab.
3. Drain coolant from the radiator and cylinder block, and engine oil
from the oil pan.
WARNING
To avoid the danger of burns, do not drain the coolant and engine oil
while the engine and radiator are still hot.
4. Disconnect the power steering hydraulic lines and drain fluid.
NOTE: Refer to CHAPTER PS, POWER STEERING for details.
5. Disconnect the engine stop cable.
a) Set the engine starter key at ON position.
NOTE: О Do not start the engine.
О Clacking the engine stop inner cable by setting the engine
starter key at ON position facilitate dismounting, mounting and
adjustment of the cable.
b) Make sure that the engine stop lever of the fuel injection pump is
engine running position, then disconnect the connectors of the
engine stop motor harness.
c) Set the engine starter key at OFF position.
6. Disconnect the electric lines, fuel lines, air lines, speedometer
cable accelerator control cables and parking brake cable (For
model with center parking brake).
NOTE: о Disconnect the battery cable from the negative terminal (-)
of the battery and then disconnect the electric lines.
О Cover open ends of the pipes, hoses and pumps to prevent
entry of dirt.
7. Disconnect the hoses (coolant, heater and air intake) and remove
the radiator or radiator with intercooler.
NOTE: Do not damage the radiator and intercooler (if equipped) core.
8. Disconnect the air intake and exhaust lines.
9. Disconnect transmission control and transmission with clutch
housing from the flywheel housing.
NOTE: Refer to CHAPTER TC, TRANSMISSION CONTROL and CHAP-
TER TM, TRANSMISSION for details.
10. Remove the cab mounting member from the frame.
Y1C
DM-2
ENGINE
11. Connect cable from an engine hanger to the hanger bracket (1
point) on the front of the engine, and to the hanger brackets (2
points) on the upper flywheel housing at the rear of the en-
gine. Using a hoist, raise the hanger is to that there is a bit of
slack in the cables.
Engine Weight: Refer to section DATA AND SPECIFICATIONS.
12. Remove the engine mounting fitting nuts (front and rear, both
sides).
13. Lift the engine hanger so that the cables are fully tightened,
and then, after checking that the cables are securely gently
and remove it from the vehicle.
IMPORTANT POINTS - MOUNTING
MOUNT THE ENGINE ASSEMBLY.
Mount the engine assembly in the reverse order of dismount-
ing.
NOTE: Check to see that there are no oil leaks, fuel leaks, coolant
leaks, or air leaks.
CONNECT THE ENGINE STOP CABLE.
1. Set the engine starter key at ON position.
NOTE: Do not start the engine.
2. Connect the connectors of the engine stop motor harness.
WARNING
Do not connect the electric harness with the engine stop motor
while the engine starter key at OFF or ACC position as this oper-
ate the engine stop motor instantaneously and the link lever of
the engine stop motor and the engine stop lever of the ihjection
pump move, resulting in your fingers caught by the lever.
3. Connect and adjust the engine stop cable with adjusting nut
to that the clearance "A" between the clevis and cable stopper
is 1-3 mm {0.04-0.11 in}.
4. Set the starter key at OFF position.
NOTE: After adjustment, confirm correct execution of engine start
and stop.
Y1C
ENGINE
MP-1
ENGINE MOVING PARTS
CYLINDER HEAD
1. Cylinder head cover
2. Injection pipe oil seal
3. Cylinder head cover gasket
4. Cylinder head gasket
5. Cylinder head
6. Cylinder head bolt
7. Oil filler cap
T = Tightening torque: N-m {kgf-cm, Ibf-ft}
8. Ventilator assembly
9. Clamp
10. Vent hose
11. Soft washer
12. Plug
13. Union
14. Bracket
Y19A
МР-2
ENGINE
15 14 Т = Tightening torque: N-m {kgf-cm, Ibf-ft}
1. Intake valve seat 13. Cylinder head 25. Rocker arm bushing
2. Exhaust valve seat 14. Intake valve 26. Valve rocker arm
3. Expansion plug 15. Exhaust valve 27. Valve adjusting screw nut
4. Stud 16. Valve lifter 28. Collar
5. Spacer 17. Valve push rod 29. Valve rocker shaft subassembly
6. Nut 18. Valve spring seat lower 30. Rocker arm support bolt
7. Cross head pin 19. Valve spring inner 31. Set screw
8. Gasket 20. Valve spring outer 32. Lock washer
9. Injection nozzle seat 21. Valve spring seat upper 33. Valve adjusting
10. Valve guide bushing 22. Valve spring retainer lock 34. Crosshead
11. Valve stem oil seal 23. Valve adjusting screw
12. Push rod guide pipe 24. Valve rocker support
Y19A
ENGINE
MP-3
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
BOLT
WIRE
09491-1020
09491-1030
For Valve stem seal
BAR
09472-1880
For Nozzle sleeve
STEEL BALL
Y19A
МР-4
ENGINE
IMPORTANT POINTS - DISASSEMBLY
REMOVE THE FUEL PIPES AND NOZZLE ASSEMBLY.
Refer to "INJECTION NOZZLE" in SECTION FUEL SYSTEM.
REMOVE THE ROCKER ARM ASSEMBLY AND CYLINDER HEAD.
1. Remove the rocker arm supports bolts.
Loosen the rocker arm support bolts and cylinder head bolts
little by little in three stages and in the numerical order as
shown.
2. Remove the cylinder head bolts.
Loosen the cylinder head bolts little by little in three stages
and in the numerical order as shown.
LIFT THE CYLINDER HEAD FROM THE DOWELS ON THE CYLINDER
BLOCK AND PLACE IT ON WOODEN BLOCKS.
1. If the cylinder head is difficult to lift off, pry with a chisel
between the cylinder head and block.
NOTE: Do not damage the machined surface of the head or block
when removing the cylinder head.
Special Tools: Engine Hanger (12281-1541)
Bolt (9401-14350)
Wire (09491-1020)
(09491-1030)
REMOVE THE VALVE SPRINGS.
1. Remove the valve stem cotters, upper valve seats, and inner
and outer valve springs from cylinder head.
Special Tool: Valve Spring Press (09470-1022)
2. Remove the intake and exhaust valves.
3. Tag valves to identify their cylinder numbers and to eliminate
valve lapping.
Y19A
ENGINE
MP-5
IMPORTANT POINTS - ASSEMBLY
CLEAN THE CYLINDER HEAD THOROUGHLY WITH A SUITABLE
SOLVENT.
NOTE: Be careful not to damage the cylinder head surface.
IF NECESSARY, HAND-LAP THE VALVE AND VALVE SEAT.
Lightly apply lapping compound to the valve face. Install the
valve and then using a special tool, tap and rotate the valve
against the seat.
Special Tool: Valve Lapping Tool 109431-1010)
IF NECESSARY, GRIND THE VALVES AND VALVE SEATS.
NOTE: о Grinding of valves and valve seats should only be per-
formed when hand-lapping does not result in proper
seating.
О After grinding, always recheck the valve sink.
Valve face angle and valve seat angle:
Refer to INSPECTION AND REPAIR.
IF NECESSARY, REPLACE THE VALVE SEAT.
1. Cut the circumference of a valve head at three places with a
grinder and install it into the seat as shown and weld the
valve to the seat. Then drive the valve and the seat out with a
hammer and a brass block.
Y19A
МР-6
ENGINE
2. Valve seat section machining specifications.
Unit: mm {in)
Intake Exhaust
Cylinder head dimension A 52.000-52.019 (2.0472-2.0479) 48.500-48.519 {1.9095-1.9101}
В 9.9-10.1 {0.388-0.3976} 9.6-9.8 {0.3780-0.3858}
Valve seat C 52.085-52.100 {2.0506-2.0511} 48.585-48.600 {1.9128-1.9133}
dimension D 8.5-8.7 {0.3347-0.3425} 8.0-8.2 {0.3150-0.3228}
3. Valve seat installation.
Heat the cylinder head to about 80° - 100°C {176-212°F} with
hot water. On the other hand, cool the valve seat with dry ice
or liquid freon for about 30 minutes. Hold the seat with
pincers and place it into the heated cylinder head.
IF NECESSARY, REPLACE THE VALVE GUIDE.
1. Remove the valve stem seal.
2. Using a brass rod and hammer, drive out the valve guide.
3. Install the valve guide.
NOTE: Apply engine oil lightly to the valve guide outer circumfer-
ence before installation.
IF NECESSARY, REPLACE THE VALVE STEM SEAL.
1. Remove the valve stem seal.
2. Install the valve stem seal.
First, install the lower spring seat and valve. Then apply
engine oil to the lip of the stem seal and drive the stem seal
with a special tool.
Special Tool: Bar (09472-1880)
NOTE: О After installing stem seal, make sure that check the rub-
ber position for cracks or any other damage.
O Do not use the special tool if its tip (surface contacting
lower spring seat) is worn or deformed.
Y19A
ENGINE
NIP-7
IF NECESSARY, REPLACE THE NOZZLE SLEEVE.
1. Remove the nozzle sleeve.
Place a brass rod with a diameter of 12 mm {0.47 in} at the
nozzle hole at the bottom of the cylinder head and remove the
cylinder head by hitting the nozzle sleeve.
2. Install the nozzle sleeve.
Set the О-ring into the cylinder head.
Apply adhesive (Super Three Bond No.1210 or equivalent) to
the lower part of the new copper nozzle sleeve and carefully
insert the nozzle sleeve into the cylinder head.
NOTE: A damaged О-ring may cause leaks and lead to overheating
or cracked heads.
3. Stick the nozzle sleeve fast to the cylinder head by pressing
with the special tool.
Insert the seat press (Special tool) into the nozzle sleeve. Push
the ball little by little through the hole with the special tool. So
that the end of the nozzle sleeve with stick fast to the cylinder
head.
Special Tools: Sleeve Bar (09472-1210)
Steel Ball (9800-06100)
ASSEMBLE THE CYLINDER HEAD.
NOTE: О Apply engine oil to contact surfaces of all parts.
О Make sure that the valves are installed in the correct cyl-
inders.
О Install the valve springs with their painted side down,
since they have variable pitches.
Press upper spring seats and install the valve stem keys
securely in the upper spring seats.
Special Tool: Valve Spring Press (09470-1022)
NOTE: О When pressing with the valve spring press, be careful
not to damage the stem seals by contacting the upper
seats.
О Drive the valve stem lightly with a hammer to assure
proper fit the valve stem key.
Y19A
МР-8
ENGINE
ASSEMBLE THE ROCKER ARM.
Lubricate the rocker arm shaft and bushing.
INSTALL THE CYLINDER HEAD AND ROCKER ARM ASSEMBLY.
1. Apply engine oil to the tappet face and tappet guide then
install the tappet.
2. Install the cylinder head gasket.
NOTE: Always use new cylinder head gasket after cleaning the
surface of the cylinder head, cylinder block and head gasket
free of all dirt, water and grease.
3. Install the cylinder head over the dowels on the cylinder block.
4. Tighten the thirteen cylinder head bolts in the numerical order
as shown (fig. 1).
NOTE: Apply engine oil to the bolt threads and under the bolt
head.
Tightening torque: 98 N-m {1,000 kgf-cm, 72 Ibf-ft}
Fig. 2-1
5. Set the No.1 piston to top dead center on compression stroke.
Refer to SECTION ENGINE TUNE UP.
6. Insert the push rods in correct order, after applying engine oil
to both ends.
7. Put the rocker arm support on the cylinder head upper sur-
face, and temporarily tighten the eight rocker arm support
bolts in the numerical order as shown (fig. 2), until the rocker
arm support fits on the cylinder head upper surface.
NOTE: О Make sure that the push rods inter lock with the adjust-
ing screws.
О Always loosen the locknut and raise the adjusting
screws fully to the top.
Y19A
ENGINE
MP-9
Fig. 3
Fig. 4
Fig. 5
8. Tighten the five cylinder head bolts in the numerical order as
shown (fig. 3).
Tightening torque: 98 N-m {1,000 kgf-cm, 72 Ibf-ft}
9. Tighten the eighteen cylinder head bolts in the numerical or-
der as shown (fig. 4). Torque the bolts to specified tightening
torque.
Specified tightening torque: 294 N-m {3,000 kgf-cm, 216 Ibf-ft}
10. Retighten the six cylinder head bolts in the numerical order as
shown (fig. 5).
Tightening torque: 294 N-m {3,000 kgf-cm, 216 Ibf-ft}
11. Finally, tighten the eight rocker arm support bolts in the
numerical order as shown (fig. 2-1).
Torque the bolts to specified torque.
Specified tightening torque: 108-118 N-m
{1,100-1,200 kgf -cm, 80-86 Ibf -ft}
INSTALL THE NOZZLE HOLDER.
Refer to "INJECTION NOZZLE" in SECTION FUEL SYSTEM.
Y19A
МР-10
ENGINE
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Cylinder Head Flatness 0-0.05 {0-0.0019} 0.15 {0.0059} Regrind or replace SM3-831
Cylinder Head Cracks and Damage * Using a Dye Penetrant Replace, if necessary. OX5>'O о SM3-832
Valve Seating Condition * Using Red Lead Marking Compound There should be good contact around entire circumference of valve head. Hand-lap with lapping com- pound \ \ L SM3-833
Valve Seat Angle Intake Exhaust 30° 44°-45°15' Regrind or replace valve and/or valve seat. uu MU
Valve face Angle Intake Exhaust 29°45'-30° 44°45'_45°
n— 30е INTAKE 34-—j— \/45e EXHAUST SM3-899
Adjusting Screws and Push Rods Damage Replace Visual checlt^^^^ / ' x ' SM3-1066
Rocker Arm and Cross Head Wear or Damage Resurface or replace Visual check EL/ SM3-1103
Upper Spring Seats and Lower Spring Seats Wear or Damage Resurface or replace Visual check SM3-529
Y19A
ENGINE
MP-11
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Exhaust Seal Ring Wear or Damage Replace Visual check_^S>^ tt\ ^^^ХСМЗ^бб
Intake and Exhaust Manifolds Crack or Damage Exhaust Manifold Cracks, Wear or Damage Replace SM3-710
Nozzle Protrusion from Cylinder Head Surface 3.00 {0.118} Replace nozzle gasket — $ ft / / -I / Z- CYLINDER HEAD SM3-391
Intake Valve Sink 0.75-1.00 {0.0295-0.0393} - Replace valve and/or valve seat "0“ HE, IS CYLINDER (+) AD SURFACE Y
Exhaust Valve Sink 0.45-0.70 {0.0177-0.0275} — SM3-420
Intake Valve Stem Diameter 11.925-11.950 {0.4695-0.4704} 11.85 {0.4664} Replace / ! I 90* \ A A : 10 {0.394} SM3-834 В : 30 {1.181} C : 60 {2.362}
Exhaust Valve Stem Diameter 11.905-11.930 {0.4688-0.4696} 11.80 {0.4645}
Intake and Exhaust Valve Guide Diameter 12.000-12.018 {0.4725-0.4731}
Clearance between Valve Stem and Valve Guide (Intake) 0.05-0.08 {0.0020-0.0031} 0.3 {0.0118} ) I I { f fl
Clearance between Valve Stem and Valve Guide (Exhaust) 0.07-0.113 {0.0028-0.0044} 0.3 {0.0118} SM3-835
Y19A
МР-12
ENGINE
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Rocker Arm Shaft Diameter 27.967-27.980 {1.1011-1.1015} 27.88 {1.0976} Replace rocker arm bushing and/or shaft \
Rocker Arm Bushing Inside Diameter 28.014-28.079 {1.1034-1.1054} 28.12 {1.1070} SM3-291
Clearance between Rocker Arm Shaft and Rocker Arm Bushing 0.044-0.112 {0.0018-0.0044}
Rocker Arm End Play 0.05-0.65 {0.0020-0.0255} Replace
Valve Spring Inner spring Setting Load 212.8 N {21.7 kgf, 47.8 Ibf} at 55.5 {2.185} 195.2 N {19.9 kgf, 43.87 Ibf} Replace
ж 4V
SM23-024
Outer spring 554.1 N {56.5 kgf, 124.6 Ibf} at 58.5 {2.303} 507.0 N {51.7 kgf, 113.98 Ibf}
Valve Spring Straightness 3.0 {0.118} Replace Ж

r -- - —•-=} i 4
- 'И -==-SM3-303
Push Rod Bend 0.5 {0.0196} Replace SM3-292
Y19A
ENGINE
NIP-13
CRANKSHAFT PULLEY
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
For Dust slinger
Y19A
МР-14
ENGINE
IMPORTANT POINT - DISMOUNTING
REMOVE THE CRANKSHAFT PULLEY.
NOTE: О Use a puller if necessary.
О Do not remove the crankshaft gear unless it considered
absolutely necessary.
IMPORTANT POINTS - ASSEMBLY
IF NECESSARY, REPLACE THE DUST SLINGER.
1. Remove the dust slinger with levers.
2. Using special tools, install the dust slinger.
Special Tools: Dust Slinger Press (09402-1110)
O-ring (9851-99101)
NOTE: To prevent wear of the side lip of the oil seal, inject about
0.5 to 1 cm3 {0.031-0.061 cu.in) of grease (lithium-based)
into the "U" groove of the dust slinger.
IMPORTANT POINTS - MOUNTING
INSTALL THE CRANKSHAFT PULLEY.
NOTE: Apply engine oil to thread of the crankshaft.
Y19A
ENGINE
MP-15
FLYWHEEL AND FLYWHEEL HOUSING
OVERHAUL
1. Flywheel housing gasket 6. O-ring 11. Flywheel assembly
2. Flywheel housing 7. Oil seal retainer 12. Pilot bearing
3. Helisert 8. Oil seal 13. Bearing stopper
4. Rear engine mounting bracket 9. Flywheel ring gear 14. Straight pin
5. Dust cover 10. Spacer
IMPORTANT POINTS - ASSEMBLY
IF NECESSARY, REPLACE THE OIL SEAL.
1. Remove the oil seal.
2. Apply a small amount of clean engine oil on the outer periph-
ery of the oil seal and then install the oil seal to the oil seal re-
tainer, ensuring that it is flush with the end of the oil seal re-
tainer.
Special Tool: Oil Seal Guide (09471-1090)
NOTE: Ensure that the lip of the oil seal is coated with oil seal
lubricating grease (lithium-based.)
IF NECESSARY, REPLACE THE FLYWHEEL RING GEAR.
1. Remove the ring gear.
a. Heat the ring gear with a blow torch in a uniform manner
[Approx. 100°C {212°F}].
b. Using a metal rod as a pad and strike all around the ring gear
in a uniform manner and remove the ring gear.
NOTE: Be careful not to overheat the ring gear.
Y19A
МР-16
ENGINE
2. Install the ring gear.
a. Heat the ring gear uniformly using a blow torch [Approx.
100°C {212°F}.]
b. Drive the ring gear with its chamfered gear teeth facing the
block onto the flywheel using a metal rod.
NOTE: Be careful not to overheat the ring gear.
INSTALL THE FLYWHEEL.
1. Install the flywheel and tighten the bolts through several repe-
tition the tightening order so as to reach specified torque
evenly and gradually, then slacken and tighten them one by
one to the specified torque.
WARNING
The flywheel is heavy, when installing, be careful not to drop it
on your feet.
NOTE: О Align the "0“ mark on the flywheel and crankshaft collar
knock-pin.
о When tightening the bolt, apply engine oil to the threads
and flywheel surface of the bolts.
Tightening Torque: 255-284 N-m
{2,600-2,900 kgf-cm, 188-209 Ibf-ft}
2. Install the pilot bearing.
3. Install the lock plate with bolts.
SM3-1697
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Flywheel face alignment 0.3 {0.0118} 0.5 0.0196} Regrind and/or replace SM3-908
Y19A
ENGINE
MR-17
TIMING GEAR AND CAMSHAFT
1. Crankshaft gear
2. Air compressor drive gear
3. Power steering pump drive gear
4. Injection pump drive gear
5. Camshaft drive gear
6. Coolant pump drive gear
7. Engine oil pump drive gear
OVERHAUL
T = Tightening torque: N-m {kgf-cm, Ibf-ft}
1. Oil seal 7. Idler gear 14. Key
2. Timing gear case cover 8. Engine oil pump driven gear 15. Camshaft
3. Gasket 9. Engine oil pump drive gear 16. Front end plate
4. Air compressor drive gear 10. Crankshaft gear 17. Injection pump drive main gear
5. Power steering pump drive gear 11. Camshaft gear 18. Spring
6. Injection pump drive gear 12. Coolant pump drive gear 19. Injection pump drive sub gear
assembly 13. Camshaft thrust plate 20. Retainer ring
Y19A
МР-18
ENGINE
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
CAMSHAFT ATTACHMENT
TIMING GEAR PULLER
Y19A
ENGINE
MP-19
IMPORTANT POINTS - DISMOUNTING
REMOVE THE CAMSHAFT.
Remove the thrust plate set bolts and pull out the camshaft
with gear.
NOTE: Pull the camshaft, slowly turning it so as not to damage
the bearings.
Special Tool: Attachment (09481-1060)
IMPORTANT POINTS - ASSEMBLING
IF NECESSARY, REPLACE THE CAMSHAFT GEAR.
Holding the shaft assembly with a vice through wooden
plates. Remove the nut, then using a gear puller, remove the
gear.
Special Tool: Puller (09420-1360)
ASSEMBLE THE INJECTION PUMP DRIVE GEAR ASSEMBLY.
1. Install the spring and sub gear on to the main gear with
retainer ring.
NOTE: О Be sure painted side of spring face to the sub gear.
О Apply lithium based grease to (A).
О Align the sub gear matching marks with main gear.
О After assembling, make sure that there is clearance
0.6-0.8 mm {0.024-0.031 in) at all around the perimeter
of (B).
Y19A
МР-20
ENGINE
IMPORTANT POINTS - MOUNTING
IF NECESSARY, REPLACE THE TIMING GEAR COVER OIL SEAL.
1. Using a screwdriver, remove the oil seal.
2. Install the new oil seal.
Special Tool: Press (09482-1070)
INSTALL THE CAMSHAFT GEAR TO THE SHAFT.
Install the camshaft gear with thrust plate.
NOTE: When installing the gear to the camshaft:
О Heat the gear in hot water [Approx. 100°C {212°F)J, then
install the gear to the camshaft by using a press.
О When tightening the nut, apply engine oil to the treads
and plate surface of the nut.
INSTALL THE CAMSHAFT.
1. Lubricate all journals of the camshaft and insert the camshaft
assembly into the cylinder block.
Special Tool: Attachment (09481-1060)
NOTE: Insert the camshaft, slowly turning while inserting so that
the bearing will not be damaged.
2. Align the camshaft gear matching marks with the crank shaft
gear.
NOTE: Incorrect installation can result in engine damage or lower-
ing of engine performance by causing improper injection
timing.
INSTALL THE INJECTION PUMP DRIVE GEAR.
1. Align the injection pump drive gear match mark with the idler
gear.
NOTE: Incorrect installation can results in engine damage or low-
ering of engine performance by causing improper injection
timing.
Y19A
ENGINE
MP-21
MEASURE THE GEAR BACKLASH.
Measure the backlash of each gear using a dial gauge or
plastic gauge.
Replace the gear if necessary.
Refer to INSPECTION AND REPAIR.
NOTE: After measure the gear backlash, apply engine oil to face of
each gear.
INSTALL THE TIMING GEAR COVER.
Using a special tool, install the timing gear cover.
Special Tool: Front Oil Seal Guide (09471-1120)
INSTALL THE AIR COMPRESSOR.
1. Set to top dead center of No.1 or No.7 cylinder by turning the
crankshaft.
2. Before install the air compressor, make sure that the align the
engraved make of air compressor drive gear and engraved
mark of idler gear.
MATCH MARK
IDLER GEAR
SM3-342
Y19A
МР-22
ENGINE
INSPECTION AND REPAIR
Unit: mm {in}
Inspection Item Standard Limit Remedy Inspection Procedure
Gear Teeth for Pitting or Wear Replace, if necessary. Visual check SM3-845
Camshaft Bend 0.05 {0.0019} Replace / A SM3-858
Camshaft Cam Height (Intake) 53.385 {2.1018} 52.585 {2.0703} Replace SM3-374
Camshaft Cam Height (Exhaust) 53.961 {2.1244} 53.161 {2.0929}
Camshaft End Play 0.10-0.33 {0.0040-0.0129} 0.40 {0.0158} Replace thrust bearing CO
Oil Clearance between Camshaft Journal and Bearing 0.06-0.15 {0.0024-0.0059} 0.30 {0.0118} Replace shaft and/or bushing ж Yr- \ 1 'r S SM3-850
Y19A
ENGINE
MP-23
Unit: mm {in}
Inspection Item Standard Limit Remedy inspection Procedure
Crankshaft Drive Gear to Camshaft Gear 0.08-0.21 {0.0032-0.0082} 0.40 {0.0157} Replace gear, if necessary. SM3-844
Idler Gear to Injection Pump Drive Gear 0{0}
Injection Pump Drive Gear to Power Steering Pump Drive Gear 0.07-0.25 {0.0028-0.0098}
Idler Gear to Air Compressor Drive Gear 0.05-0.24 {0.0020-0.0094}
Camshaft Drive Gear to Coolant Pump Drive Gear 0.04-0.27 {0.0016-0.0102}
Oil Pump Drive gear to Oil Pump Driven Gear 0.09-0.29 {0.0035-0.0114}
Clearance between Valve Lifter and Valve Lifter Guide 0.025-0.075 {0.0010-0.0029} 0.15 {0.0059} Replace tappet Ж |O 1 j SM3-293 3-420
Valve Lifter for Wear Should not be worn unevenly. Replace, if necessary. Visual check SM3-1122
Coolant Pump Oil Jet Clogged Clean SM3-1141
Y19A
МР-24
ENGINE
INJECTION PUMP DRIVE
1. Drive gear
2. Front end plate
3. O-ring
4. Bearing holder case
5. Ball bearing
6, Key
7. Drive shaft
8. Shim
9. Gasket
10. Bearing retainer
11. Oil seal
12. Oil seal sleeve
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
INJECTION PUMP DRIVE
INJECTION PUMP DRIVE
O-RING (Used with 09482-1550)
IMPORTANT POINTS - ASSEMBLY
IF NECESSARY, REPLACE THE FUEL INJECTION PUMP DRIVE
SHAFT OIL SEAL SLEEVE.
1. Using a special tool, remove the sleeve.
a. Put the puller (1), (2) onto the sleeve.
b. Insert the hook portion of the puller between shaft and sleeve.
c. Insert the puller (3).
d. After inserting the puller, screw in the center bolt (4), then re-
move the sleeve.
Special Tool: Puller Assembly (09420-1180)
Y19A
ENGINE
MP-25
2. Using special tools, insert the shaft sleeve with a new O-ring.
a. Put the O-ring (5) into the press (6).
b. Insert the new oil seal sleeve with new O-ring into the press
and then insert them into the drive shaft.
c. Hitting the (A) lightly by hammer, contact the press end and
the shaft end (B), with this determine the oil seal sleeve posi-
tion.
NOTE: о Be sure to fit an O-ring on the sleeve and also apply a
liberal coating of oil to the shaft.
О When driving on the shaft sleeve, taking care that the
O-ring does not get cut or torn.
О Once a sleeve has been removed, it cannot be reusec|.
Special Tools: Press (09482-1330)
O-ring (9851-36104)
ASSEMBLE THE INJECTION PUMP DRIVE SHAFT ASSEMBLY.
Adjust the preload of drive shaft by shims.
Turning Torque: 0.39-1.17 N-m {4-12 kgf-cm, 0.290-0.867 Ibf-ft)
NOTE: Be sure that there is no loose rattling in the axis direction
of the drive shaft.
Y19A
МР-26
ENGINE
PISTON, CRANKSHAFT, CYLINDER BLOCK
AND OIL PAN
OVERHAUL
T = Tightening torque: N-m {kgf-cm, Ibf-ft)
1. Cylinder block IT. Piston ring 21. Key
2. Plug 12. Piston 22. Crankshaft
3. Soft washer 13. Piston pin 23. Balance weight bolt
4. Flange 14. Retainer ring 24. Oil slinger
5. O-ring 15. Connecting rod 25. Crankshaft main bearing
6. Cylinder liner 16. Connecting rod bushing 26. Crankshaft thrust bearing
7. Oil jet pipe for piston cooling 17. Connecting rod bearing 27. Collar
8, Main hole plug 18. Sleeve 28. Crankshaft bearing cap
9. Straight pin 19. Oil pump drive gear
10. Camshaft bearing 20. Crankshaft gear
Y19A
ENGINE
NIP-27
OVERHAUL
1. Encloser cover
2. Seal
3. Water gallery cover
4. O-ring
5. Coolant drain cock
6. Soft washer
T = Tightening torque: N-m {kgf-cm, Ibf-ft}
7. Oil drain plug
8. Oil pan shield
9. Oil pan
10. Gasket
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have these special tools.
For Piston ring
PISTON RING EXPANDER
For Main bearing cap dismounting
CYLINDER BLOCK EXPANDER
Y19A