6D34-TL diesel engine Shop Manual (for industrial use) SUPPLEMENT FOREWORD ‘This Shop Manual is published for the information and guid- ance of personnel responsible for maintenance of Mitsubishi 6034-TL seties diesel engine, and includes procedures for adjustment and maintenance services. We eamestly look forward to seeing that this manualis made full use of in order to perform correct services with no wast- age. ‘As this Shop Manal is published as a supplement tothe f lowing Shop Manuals, please refer to the followings for i formation not included in this manual. + Diesel Engine 6D34-T (for industrial use) ~» Pub. No. 97821-05001 For more details, please consult your nearest authorized Mitsubishi dealer or distributor. Kindly note that the specifications and maintenance service figures are subject to change without prior notice in tine with improvement which will be effected from time to time in the future. Applicable models, 6D34-TL. © 2000 Mitsubishi Motors Corporation Printed in Japan Pub. No, 97821-05100 GROUP INDEX MODIFICATION SUMMARY .. COOLING .. INTAKE AND EXHAUST .MODIFICATION SUMMARYMODIFICATION SUMMARY This manual is a supplement to the Mitsubishi 6D34-T industrial diesel engine shop manual (publication No. 97821-05001) and pertains only to those specifications and service procedures which are specific to the 6D34-TL engine. ‘When servicing the 6D34-TL engine, please understand its differences from the 6D34-T engine summarized below and follow the instructions in this supplement in addition to those contained in the above-mentioned manual. Group Contents of ferent points eee 11 | (1) The compression ratio is citferent as follows: tem ‘Specifications Engine model e0aaT e0aeTL ‘Type C-cyindor vine, water-cooled 4-cyce diesel ‘Combustion chamber type Direct injection type | Valve mechanism Overhead valve (OHV) type Bore x Stroke mm 104x115, “Total displacement ene 586 ‘Compression rao 165 Lee (@). The clearance between the piston and connecting rodassembly andthe cyindersieeveisaifer-| e) Grtt entas folows: Service standards Unit: mm Standard value — | Piston and connecting | [104] 0.08 10 0.13 = = to over- rod assombly-o-cyinder size or replace sleeve clearance 13 | (1) The injection pump and injecion nozzle specifications are different as follows: Oars Injection pump tem Specifications eoser 03 Manufacturer BOSCH AUTOMOTIVE SYSTEMS Model Bosch A Governar type ASV allspeed governor Feed pump type KE KS KS Injection pump Tier Spealications 6038-7 e0seTL Manufacturer ‘BOSCH AUTOMOTIVE SYSTEMS [Moder Holesype, single spring No, of holes 5 ~ Hole diameter mm] §081x2,9029%8 | pOStx2, | $0a2«2, (Identification mark"S") | 90.29x3 ] 9030%3 (dentitcaton | (entiation marke") | _mark“F*) iii Service Group Contents of different points procedure 13. | @ The govemoris fitted with a boost compensator. OGns 1 Eyebott 2 Boost hose * Govemor @ Tightening torque Usit: Nom (gt) Location | Paris tobetightened | Tightening iorque | __ Remarks 1 Eyebolt 415 10 145 (1210 15) | = (@) The service standards for the nozzles are different as follows: Cents entiation mark Service standards Location Maintenance value Standard Limit Femedy [Opening pressure | Kentiication | 17.7 MPa = ‘Adjust finjection nozzle [mark"=* | (180kgtem?) assembly Identification | 21.6 MPa =| Aajust mark {220kaHer2) 4 The installation procedure of the cooling fan is diferent Gene “The procedure for adjusting the V-belt tension is diferent. ena 15 | The service procedures forthe intake and exhaust manok are diferent due to addtion ofan | or grag intercooler. “The service procedure forthe intercooler is added Mens 54 | The specications ofthe aerator are as follows: Dawa Alternator Ter ‘Speciicaions Manufacturer MITSUBISHI ELECTRIC GORP. “Type ‘Aliernator with builtin voltage regulator Brush ype Tnierally installed fan Model ASTNSS99 ‘ASTNESOG Output Vea 24-35 (The pully ofthe ASTNSSEG atematoris diferent rom that of the ABTINSIIG allemalor) ittMODIFICATION SUMMARY vice Group Contents of different points proce ice 54 |The removal and installation sequences are different as follows: eass ‘© Removal sequence Adjusting bolt Vebelt ‘Adjusting shat Nut Alternator (2) Gr54 Spacer ‘Adjusting plate Moonen Timing gear case WARNING /i\, Before removing the alternator 5, be sureto disconnect the negative -) terminal ofthe battery and insulate it with a tape or something else. It the negative (-) terminal isnot disconnected, the battery voltage is stil present at terminal B and is dangerous. @ Installation sequence Follow the removal sequence in reverse. © Adjustment after installation Adjust the tension ofthe Vebalt 2. (14-2 ivGROUP 14 COOLING COOLING FAN, V-BELT AND WATER PUMP .............. 14-2 Forall the cooling system components other than the above, refer to “Group 14 Cooling’ inthe shop manual Diesel Engine 6034-T (for industrial use), Pub. No. 97821-05001.COOLING FAN, V-BELT AND WATER PUMP isassembly sequence Cooling fan 8 Oring Spacer V-belt +:Timing gear case ©) Grit Bolt ©: Non-reusable part Spacer Water pump pulley @ Assembly sequence Water pump assembly (2) Grt4 Reverse the order of disassembly. CAUTION /\ = The V-belts 3 must be replaced together as a set. Never replace either V-belt individually. * Apply soap suds to the O-ring 8 before fitting it. Do not apply engine oil to the O-ring since this would make it swell. Service standards Unit: mm Location Maintenance item Standard value Limit [ Remedy 3__| Vebelt tension 101015 = Adjust © Special tools Location Tool name and shape Part No. ‘Application Balt Tension 3 | aatge f Mri062345 | V-belt tension measuroment 09612 14-2c B A D @a244s E _ G H 03613) 03615 Service procedure 3] Vebett LInspection} Apply force of approximately 98 N (10kgf} to the center of the V-belt ‘3 and measure the extent of V-belt deflection A. B:Altemator pulley ‘Water pump pulley D: Crankshaft pulley @ Use of belt tension gauge ‘+ Setupper O-ring E of Belt Tension Gauge to 98 N (10kgf} (push load) on scale F. # Set lower O-ring G of E) Belt Tension Gauge to the V-bel’s correct ‘maximum deflection value on scale H. + Apply the €}Belt Tension Gauge tothe center of V-belt3, then push part J until O-ring E comes in contact with flange K. ‘+ Measure the extent of V-belt 3 deflection A. If the measurement does not conform with the standard value, adjust the V-belt as shown below. 14-3COOLING FAN, V-BELT AND WATER PUMP {Adjustment} ‘+ Loosen altemator mounting bolts L (2 places), then turn adjusting bolt M to adjust the tension of V-belt 3 properiy. ‘= Alter the adjustment, tighten the mounting bolts firmly CAUTION /\ + Excessive tension in V-belt 3 may damage the belt and related bearings. » Be sure to replace the V-belts 3 as a set to maintain even ten- sion between them. + Keep V-belt 3 free of oil. If the belt becomes oly, it will slip, re- ‘sulting in overheating of the engine and insufficient charging of the battery. 14-4GROUP 15 INTAKE AND EXHAUST INTAKE MANIFOLD ........ 2.2200 00eeeeeeeeeeeeeeeeeee 15-2 EXHAUST MANIFOLD ...........0 0000s eeeeeeeeeeeeeeee 15-3 INTERCOOLER ........ sc ceeeeee eect ene eeeeeeeeeeee ene 15-4 For all the intake and exhaust system components other than the above, refer to “Group 15 Intake and Exhaust” in the shop manual Diese! Engine 6D34-T (for industrial use), Pub. No. 97821-05001 15-1INTAKE MANIFOLD @ Disassembly sequence Clamp 2 Airintake pipe Clamp Air intake hose Plug Bolt Intake manifold Gasket eroMee * a: Cylinder head assembly (Grt1 * b: From intercooler ©: Non-reusable part @ Assembly sequence Follow the disassembly sequence in re- verse. é ° @43737 Lo b @ Tightening torque Unit: Nem {kof-m} Location Paris to be tightened “Tightening torque Remarks 13 Clamp (for connecting air intake pipe) 8.5 to 455 (0.35 t0 0.45) = 5 Plug 231035 (231035) = 6 Bolt fer mounting intake manifold) —_ 171025 (1.7 102.6) = AQ Sealant Location Points f application Kinds ‘Quantity 5 “Threads of plug “Tiwesbond 1211 ‘As required 15-2EXHAUST MANIFOLD ors735 @Tightening torque @ Disassembly sequence 1 Nut 2 Exhaust manifold assembly Gasket Front exhaust manifotd Seal ring Expansion ting Exhaust joint Rear exhaust manifold evans *:Gylinder head assembly (9 Grit ©: Non-reusable part @ Assembly sequence Follow the disassembly sequence in re- verse, it: N-m {kgf-m) Location Parts to be tightened Tightening torque Remarks 1 Nat for mounting exhaust maniond) i to84 (421055) = A 06185 6 LY 5 5 @asr36 + Service procedure 3 Installation of gasket Install the gasket 3 with the grommet fold-back portion A toward the cylinder head. Installation of expansion rings and seal rings ‘= Install seal rings 5 with end gaps A 180° away from each other. ‘= Any crest B of expansion ring 6 must not be in alignment with end ‘gaps A of seal ring 5. 15-3,INTERCOOLER @ Disassembly sequence 1 Clamp o 2 Bolt aS 3 Intercooler 4 Clamp 5 Inlet hose 4 6 Outlet hose ° * a: From turbocharger + b:To intake manifold @ Assembly sequence Follow the disassembly sequence in re- verse. easra0 @Tightening torque Unit: Nem fkaf-m) Location Parts to be tightened Tightening torque Remarks 7,4 | Glamps (for connecting inlet and outlet hoses) 35 t0 45 (0.3510 048) = Inspection + Putcap A on one ofthe air portsof intercooler and connecta hose ‘othe other airport. Place the intercooler in container of waterand apply an air pressure of 145 kPa (1.5 kg/om?} through the hose to ‘check for air leakage. # Replace intercooler 3 if itis leaky. 15-46D34-T diesel engine Shop Manual (for industrial use) FOREWORD ‘This Shop Manual is published for the information and guid- ance of personnel responsible for maintenance of Mitsubishi 6034-7 series diesel engine, and includes procedures for ad- justment and maintenance services. We eamestly look forward to seeing that this manual is made {ulluse of in order to perform correct service with no wastage. For more details, please consult your nearest authorized Mitsubishi dealer or distributor. Kindly note that the specifications and maintenance service figures are subject to change without prior notice in ine with improvement which will be effected from time to time in the future. Applicable models (603¢-TLE) (eose-tw) © 1996 Mitsubishi Motors Corporation Printed in Japan GROUP INDEX HOW TO READ THIS MANUAL GENERAL .. FUEL AND ENGINE ca 3 z INTAKE AND EXHAUST . FE ENGINE....... LUBRICATION ....... COOLING ... ELECTRICAL SYSTEM ..... EGROUP 00 GENERAL GENERAL SPECIFICATIONS .. ENGINE NUMBER, NAME PLATE AND CAUTION PLATE PRECAUTIONS FOR MAINTENANCE OPERATION TABLE OF STANDARD TIGHTENING TORQUES . 00GENERAL SPECIFICATIONS Tem ‘Specifications Engine model e03eT Type G-eylinder imine, water-cooled 4-cycle diesel Combustion chamber type Direct injection type Valve mechanism (Overhead valve (OHV) ype ‘Maximam output kWitpm (PS/tm) (ISO, SAE) 25/2100 (1707/2100) Maximum torque N-mirpm (kgf-mimpm) (ISO, SAE) '590/1600 (60/1600) Bore x Stroke mm 108K 15 Total cisplacement ce 5861 ‘Compression ratio 182 Emply mass kg" 480) * Empty mass as measured according to Mitsubishi Motors Corporation standard. 00-2HOW TO READ THIS HOW THIS MANUAL IS COMPILED ......... GENERAL EXPLANATION OF THIS MANUAL TERMS AND UNITS ....... 0. cece eee MANUALHOW TO READ THIS MANUAL How This Manual Is Com} d ‘+ This manual is compiled by classifying various systems into certain groups. ‘+ Each group contains specifications; troubleshooting; maintenance service standards; @ tightening torque; lubricant, fluid and sealant; 6) special tools; and service procedure. «Page enumeration is independent by every group where first page is always 1. Grouy Group denomination Contents No. 00 | General ‘General specifications, engine No. and name plate, precautions for mainte- nance operations, table of standard tightening torques it [Engine Engine body 12__| Lubrication Lubjication system 13__| Fuel and engine control Fuel system 14__ [Cooling Cooling system 16 __| Intake and exhaust Intake and exhaust system, turbocharger, intercooler 54 | Electrical system ‘Slater alternator, preheating system, engine start system, automatic stop systemGeneral Explanation of This Manual Particulars relative to maintenance service are made. @ Structure and operation (1) Regarding conventional equipment, descriptions are made in briet. (2) Regarding new equipment, descriptions of system and operating condition are made in detail. @ Troubleshooting ‘Symptoms of troubles and possible causes are described comparatively. @ Inspection and adjustment mounted in vehicle Descriptions are made regarding inspection and adjustment of units mounted in vehicle. @ Service procedure Inprinciple, an explanationis given at the spread ttle page so that the service procedure can be understood. Servicing points are explained as a supplementary explanation. Regarding the design of this manual === | . i; & fom aneeseananeneo ee Illustration for disassembly and assembly or removal and installation: 3-D exploded view of component parts is displayed. Names of parts show an example of the disassembly (removal) sequence. ‘When the assembly (installation) sequence differs from the disassembly (removal) sequence, an example of the assembly (installation) sequence is shown. Service standards are shown collectively, classified by focation. Tightening torques are shown collectively, classitied by location. Points of lubricant, fluid and sealant application are shown collectively, classified by location. ‘Special tools to be used are shown collectively, classified by location. ‘When itis considered hard to understand the service procedure, just by the foregoing description, a supple- mentary description of the service procedure is given. egaepHOW TO READ THIS MANUAL 1. Illustration for disassembly and assembly or removal and installation ‘This shows that the appropriate service proce. TI dure is described in the text. shows the key No. of the part. In the text, is No. is referred to uniformly throughout, CLUTCH BODY This shows an example of the disassembly (removal) sequence. This shows that the service procedure is described in another section. MPoo-co 4 actress + shows reference page 1 Seti within the same group. 12 Bota vein M.eroo 13 Supporter 34 bushing 18 Suppor ever 7 Beng : shows reference group within the same book. 2 Pras plate ever asantly fear 2 Caton aes (© Aaseby sequence $6417 -12-11049-19-497- 46-95-4499 pale ch rns var No service procedure is referred to in this section, but the item can be an Meaning of symbols @: shows that the tightening torque is specified. A: shows that application of lubricant, fluid or sealant is required, shows that the part should not be reused, Oo: iv objective of various proce- dures. This is shown when the assembly (installation) ‘sequence is not the reverse of the disassembly (removal) sequence. This shows that a repair kit is available,2. Service standards table Only the relevant service standards are shown. ‘ Service standards Unit: mem Location Maintenance item ‘Standard value Limit Remedy Tet _| Gaara bowvoon sap botand sap pao Cor wate 03 | Replace 7 Pressure sping |insiaiog oad BEN BIT TION | Foplace (installed tangth 49.1) (72.3kgf a Bere 30 | Replace} ‘This shows the key No. of the relevant part. 3. Tightening torque table This shows specified tightening torque. @ Tightening torque Unit: N-m (kal-m} Location Parts to be tightened ‘Tightening torque Remarks. 1 ‘Strap bolts (Strap bolt mounting) ‘89 to 59 (4 to 6) = 4 [Bet Lack plato noua) Sow 7S wswOA wat ‘This shows the key No, of the relevant part. ‘This shows that the item is to be tightened wet. 4. Lubricant, fluid and sealant table Only the relevant lubricant, fluid and sealant are shown. | ‘This shows the application point, tuna tla sen | Tocation Pons fappicaion Tipe Guaniiy 1 Tread ofbat LooTmE ave As requind 716,16 |Frisonsuracos of rave aver pla and lease lover” | Malfodenum dulige grease ‘eroqared INLGI No. 2 (Li soap) ‘This shows the key No. of the relevant part. This shows the specified brand.HOW TO READ THIS MANUAL 5. Special tools table Only the relevant special tools are shown. Purpose of special tools is shown. ' © Special tools vat Coaton Toainana and ape Pani Tan Y st [ou enatr uwonost | Renetandansonf ct ewe oun 16 “Master plate = ‘MHO62291 Adjust release lever heights ~ i onl _| This shows the key No. of the relevant part. Quote this number when placing an order for the part. 6. Service procedure ‘This indicates a special This shows the key No. of the relevant part. service tool. Removal and installation of elutch cover + Depress pressure spring 7 using [E) clutch installer, then remove the following parts: Strap bolt 1, washer 2, washer 3, bol 4, lock plate 5, support nut 6 ‘+ Loosen the clutch installer aradually then remove clutch cover 1 when the pressure spring is fully released. + For installation, follow the removal sequence in reverse. Servicing procedures of disassembly (removal), assembly (installation), inspection, adjustment, etc. are shown collectively. The key No. referred to in the text is always the same as the key No, shown in the illustration, viTerms and Units ‘The terms and units in this manual are defined as follows. @ This service manual contains important cautionary instructions and supplementary information under the following four headings which identify the nature of the instructions and information: DANGER/\, ————— Precautions that should be taken in handling potentially dangerous substances such as battery fluid and coolant additives. WARNING /\, ———— Precautionary instructions, which, if not observed, could result in serious injury or death. CAUTION A, ———— Precautionary instructions, which, if not observed, could result in damage to or destruction ‘of equipment or parts. NOTE ‘Suggestions or supplementary information for more efficient use of equipment or a better understanding. © Front and rear The terms “front” is the fan side and “rear” the flywheels side of the engine. @ Left and right The terms “right” and “left” shall be used to indicate the side as viewed from the flywheel side of the engine. @ Terms of service standards (1) Standard value Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clearance between two parts when assembied, and the standard value for an assembly part, as the case may be. ‘The figure in }is the basic diameter. (2) Limit When the value of a part exceeds this, itis no longer serviceable in respect of performance and strength and must be replaced or repaired. @ Tightening torque Excessive or insufficient tightening torque has particular importance in respect of performance. Accordingly, tightening torque is specified in locations that are to be tightened. Where there is no specified figure for tightening torque, follow the table covering standard tightening torques. ‘When the item is to be tightened in a wet state, wet is indicated. Where there is no indication, read it as dry, and tighten at specified torque. eu Length, weight, surface area and capacity are in SI units. Imperial and metric units are given in brackets. Temperatures are given in degrees Celsius with degrees Fahrenheit given brackets, For the conversion into the foot-pound system, refer to the following conversion table. vitHOW TO READ THIS MANUAL Unit Sign of St unit Sign of foot-pound unit Conversion rate ‘Mass quantity of matter kg cy 1 kg = 2.2046 ib @ oz 11g =0.035274 oz Dimension 7m f m=3.2008 t mm. in, ‘mm = 0.09897 in. Capacity v al 7L=0.2682 gal. (US) 11 =0.220 gal. (Imp.) om® oz 1 cm? = 0.033814 oz (US) 11 em® = 0.035185 o7 (Imp) om? cui, 1 om? = 0.061028 cu.in. Fores N (Newton) cl N= 0.2246 It Pressure Pa (idlopascal) Totin? 1 kPa = 0.145 Iotin® 1 kPa = 0.2989 in. Ho ‘Stress Niom® bin? 1 Nom? = 1.45 bitin ‘Mament of force Nem bit T Nom = 0.7875 IER Output KW (klowatty He TAW= 1.34 HP "Temperature a F PC =(18PC + 98)°F viiiENGINE NUMBER, NAME PLATE AND CAUTION PLATE| 00 ‘The serial number for engine is assigned to the respective engine in manufacturing sequence: every engine has its own number. This number is required for incidental inspection of the engine. Please do not fail to mention this number to the dealers when ordering spare parts, Engine Number ‘The engine number is punch-marked on the shown location. 2i3t4 : Name plate : Caution plate 1 Engine model 2 Total displacement 3 Maximum output 4 Valve clearance 5 6 Firing order Fuel injection timing VALVE CLEARANCE (COLDJ INLETSEXHAUST 0, Gam 0, 016in)] IFiRING ORDER 1-5-3-6-2-4 [EUEL_INJECTION TIMING _17* BlDC}PRECAUTIONS FOR MAINTENANCE OPERATION In order to determine the condition of the vehicle adequately, attend the vehicle beforehand to find and keep record of the accumulated mileage, operating condition, what the customer's demand is, and other information that may be necessary. Prepare the steps to be taken and perform efficient and wasteless maintenance procedure. 47952 00015 * Determine where the fault exists and checisfor the cause to see wheth- erremoval or disassembly of the partis necessary. Then follow the pro cedure specified by this manual. + Perform maintenance work at a level area, + Prepare general and special tools necessary for the maintenance work WARNING AX, ———___________ Do not attempt to use tools other than special tools where use of special tools is specified in this manual. This will avoid injury or damage. + When removing o installing the engine, attach the liting wire rope hooks to the engine's titing eyes and hoist the engine slowly such that it does not touch other components. WARNING A\ Check that the wire rope and crane are sufficiently stron + Be particularly careful not to workin shoes that have olly soles and are slippery. When working as a team of two or more, arrange signals in advance and keep confirming safety. Be careful not to accidentally bump switches or levers. ‘© Check for cil leakage before cleaning the area having the fault other- wise you might miss detecting the leakage. + Prepare replacement part(s) beforehand, * Replace oil seals, packing, O-rings and other rubber parts; gaskets and split pins with new parts whenever any of them hasbeen removed. Use only genuine MITSUBISHI replacement parts.On disassembly, visually inspect all parts for wear and tear, cracks, ca age, deformation, degradation, rust, corrosion, smoothness in rotatio:, fatigue, clogging and any other possible defect. Put alignment marks on part combinations before disassembly and ar- range the disassembled parts neatly. This will help avoid mismating of the parts later, Put the alignment marks, punch marks, etc. where performance and ap- pearance will not be affected. Cover the area left open alter removal of parts to keep it free from dust. CAUTION AX, * Take care to avoid mixing up numerous parts, similar parts, left and right, etc, + Keep new parts for replacement and original (removed) parts sep- arate. Apply the specified oil or grease to U:packings, oil seals, dust seals and bearings during assembly. CAUTION /\ Use only the specified oil, grease, ‘Wear goggles when using a grinder or welder. Pay full attention to safety by wearing gloves when necessary. Watch out for sharp edges, etc. that might injure your hands or fingers. Before carrying out maintenance work on the electric system, disconnect the negative terminals of the batteries.PRECAUTIONS FOR MAINTENANCE OPERATION oonza| osr0e! 00-6 ‘* Take care when handling sensors, relays, ete. which are vulnerable to shock and heat, + Pull the connector, and not the hamess lead, o separate connectors. “To separate a lock-lype connector, fist push toward arrow mark. To re- connect a focktype connector, press the separated parts until they click together. ‘+ When washing the vehicle, cover the electric system parts and instru- ‘ments with waterproof material beforehand (Cover with vinyl sheet or the like). Keep water away from hamess wire connectors and sensors. If any of them should get wet, wipe them off immediately. + Toapply voltage fortesting, check that the positive and negative cables are connected properly, then increase voltage gradually from 0 volt. Do not apply voltage higher than the specified value, In particular, pay close attention to the electronic control unit and sen- sors, since they are not always supplied with 24V. ‘* Whenusing testers or the like for continuity tests, be careful notto allow test probes to touch the' wrong terminals.TABLE OF STANDARD TIGHTENING TORQUES 00 + Use specified bolts and nuts and tighten them at spe cited. ‘= Threads and contact seats shall be dry. ‘+ Where there is a difference in strength classification between the nut and bolt (or stud bolt), the torque specified for the bolt shall apply. fed torques according to the folowing table, unless otherwise spe- Hex-head Bolt and Stud Bolt Unit: N-m tkaf-m) Siengin classification aT 7 sr sentation] 7 kN VO © @ oman @ symbol ow (su) (swe) MS Fos 7 ai06 ~ SteT 7 fo2t003) foatoos) (05t007) Me 4106 ~ Tioti ~ Bio 12 ~ {0.4t0 0.6) {0710 1.1) (0.8 to 1.2) we 91014 7 "7026 7 201029 7 foster. (17028) @ot03.0) Mio 19 to 28 18 to 26. 36 to 52 33 to 49 | 45t0 60 41 to 59, (1.9 to 2.8} {1.8t02.7) {3.5 to 5.5) {3.3 to 5.0) {4.5 to 6.0) {4.3 to 6.9) wa | 35t050 311045 701095 B510 65 3510 110 75 t0 100, gates | eros | goes | @swes | esi) | 7st010) m4 201085 351075 12010160 | r10t0 140 | 130t0 140 | 1200 460 {6.0 to 6.5) {5.5 to 7.5) (12 to 16) {11 to 14} {13 to 18} {1210 17) me 2010 190 9010120 | 180t0240 | 160t0200 | 20010270 | 190t0260 story | ow | (18to29) ieto2) | @ot027) (191026) we 14010190) 12010160 | 26010340 | 22010290 | 29010300 | 26010340 {14 to 19} (12 to 16} (26 10 35) (22 to 30) {30 to 40}, (26 to. 35) 20 1900260] 170t290 | asowa70 | azdtoa20 | si0t0550 | a7010400 {19 to 26) {17 to 23) {36 to 48) {82 to 43) {41 to 56) {87 to 50) ze 2e0t0s40 | 230t0a00 | 4700640 | 43010670 | s50t0740 | 49010670 {26 to 35} {23 to 31} {48 to 65) {43 to 58} {56 to 75) {50 to 68) wae ‘34010450 | z00t0590 | G2010840 | 54010780 | 7a0t0060° | 62010840 {34 to 46) {29 to 40) {63 to 86) {55 to 74) {74 to 100) {64 to 86} Hex-head Flange Bolt Unit: Nem {kof-m) Sirengih 7 classification aT 7v or Ropre- sentation Diameter symbol | onist Me Fes ~ Biot ~ Tot 7 (oatoos, (0810 12) fo9t01.4) we Oto 18 7 19t028 ~~ 2tose ~ (1.0%015) (181028) 22toa3) M10 21 t0 30 20 to 28 | 39 10 58 37 t0 53 50 to 65 45 to. 65 {2.1 to 3.1) {1.9 to 2.9) [3.9 to 6.0) {3.6 to 5.4) {5.0 to 6.5) {4.5 to 6.5) m2 3810 54 251061 a0t0 110, 701095 9040 120 e510 10 gavss) | eaosa | own | goss | (oti | (stom, 00-7TABLE OF STANDARD TIGHTENING TORQUES Hex-head Nut Unit: N-m (kgf-m) Srengih classification aT or Repre- sentation xD ep Diameter 02185, symbol Standard screw | Coarce sorew Standard screw Coarse screw {2003 4106 MS {0.2to 0.3) - {0.4 to 0.6) > aoe | Toit ~ Me {0.4 to 0.6) {0.7 to 1.1} otot4 7926 Ms 0.80 1.4) > (1.7 102.8) - mo 191028 oi026 a6 tose Boe (9020) | (18027) (e5t055) (23t050) wa 351050 2110 46 701095 251085 g@4toso) | @itoan (701095) (65085) ma s0t0a5 351075 12016 160 Oto 140 [ fotos) | (551075) (120 16) {it t0 44) we $010 120 9010 120 180 10240 160 0 220 fstora) | @oto12) {180 28) (16 to 22) me 14010 180 | t20to 160 726010340, | 7220 to 290 (atta | (1210 16) (26 0.8) (e22to 00) wo 19010260 | 17010200 35010470 320 10 420 (to28) | _ 7023) £26 0.48) (@2t0 43) um 26010 340 | 2900 900 47010 640 490 10670 (26035) (eatoat) (4810.65) (43.0 58) we zaot0 450 | 29010 690 2010 640 340 10 780 41046) | (2910.40) (631086) (55 1074) Hex-head Flange Nut Unit N-m {kgt-m) Siengh classification aT Repre- sentation Diameter oatss symbol Standard screw | Coarse sero 406 ms (o4to05) - TOW is MB {1,0 to 1.5) = 211030 201028 uo 211031) | (1.91029) 3010 54 351051 wiz (38t055) | (34t05.2)Tightening torque for flare nut for general purpose Pipe diameter Gren | eeasmm genm | sim [oi eam Tightening torque 7 25 (2.6) 39 (4.0) 59/60) | 8819.0) 98 (10.0) Tightening torque for air piping nylon tube for general purpose {DIN type} Unit: Nm (kaf-m) Srandard dameior x imm 10x 1.25 mm Wx iS an Tex temm Tighoning torque 1 ] #59 | 99 +06 498 [45410 19.8 | go+t 49 | 5410 zeit faosge) [og (sere) [tt feos) | apt [son Tightening torque for air piping nylon tube for general purpose Unit: Nm {kgt-m)} {SAE type} ‘Standard diameter 44 in, T 378 in. 12 in. 5/8 in. Tin ae 23 {s924) | aot {a0-08) | at® fa0-28) | ent? [ase v2 (sar04] | att {2005} | anit? [50:05] | exit? [05:98]GROUP 11 ENGINE STRUCTURE AND OPERATION 2 TROUBLESHOOTING 5 ON-VEHICLE INSPECTION AND ADJUSTMENT + Measuring Compression Pressure .... 6 « Inspecting and Adjusting Valve Clearances 7 CYLINDER HEAD AND VALVE MECHANISM ..............000085 8 TIMING GEARS CAMSHAFT . 28 PISTONS, CONNECTING RODS, AND CYLINDER LINERS ....... 36 FLYWHEEL 2.2... 0.0 0cceee cece sete sense ec cece eeeeneeeneeeees 50 CRANKSHAFT AND CRANKCASE . 54 pit) HeiSTRUCTURE AND OPERATION 1 Rocker arm 9 Piston, 2 Valve spring 40 Connecting rod 3 Camshaft 11 Timing gear 4 Cylinder sleeve 12 Tappet 5 Cylinder head 13 Inlet valve 6 Flywheel 14 Push rod 7 Crankshaft 8 Exhaust valve A: Direction of rotation U2 yess]Connecting Rods 0314s Pistons A B. c D aan 7084] 1 Connecting rod bushing 2 Connecting rod 3 Connecting rod cap 4 Connecting rod bolt 5 Upper connecting rod bearing 6 Lower connecting rod bearing AA: Alignment mark B: Weight mark stamp (A,B,0, 0,65 G) A: Part number B:"T" mark ‘©: Weight mark: D: Oversize mark (0.50,1.00) U3STRUCTURE AND OPERATION Timing Gears Ld 1 2 3 4 5 6 7 8 9 Ay Camshaft gear Injection pump gear Crankshaft gear Oil pump gear Idler gear Idler gear shaft Idler bushing Bott Thrust plate Oil hole Each gearis stamped with a timing gear align- ment mark (*1", "2" or *3") for correct gear ‘engagement during reassembly.TROUBLESHOOTING La) Symptoms Possible causes ‘Abnormal engine noise Remarks incorrect ol viscosity (aria Incorrectofectve fuel Incorrect valve clearance Defective oyiinder head gasket Worn valveNvalve seat, and carbon deposits ‘Weakened valve spring ‘Worn/damaged piston rinate) Wornldamaged piston ring groove(s) Incorrect injection timing Maris Defective injection pump ofofofofofofofo hers Defective cooling system orig Defective injection nozzie(=) ° meri Air trapped in fuel system ces Clogged air cleaner Moris Defective turbocharger ololofofolololofofofofofo]o|o] Low power output (aris [incrrcty ted pipefoyhosets) Injection pump, aliornator, or other auxiliary device(s) defeciivehincorrectly ited ers, 54 Loose/damaged V-belt Cart4 Incorrectly fitted crankshaft pulley Defective air cleaner or muffler Mar 15 Detective vaive springts) Defective rocker shatt and bracket Tneorrect lubrication of rocker shaft bracket incorrect baskiash In timing gears Incorrect lubrication of timing gear peripheries and idler shafts Defective injection nozzle spray condition erie ‘Worn connecting rod small end bushing and piston pin Wornldamaged crankshaft pin and connecting rod big end bearing ‘Worn/damaged crankshaft journal and main bearing Excessive end play in crankshaft and camshaft Wom tappet(s) and camshaft dlolofalalofofofofolafofojo[olofo| USON-VEHICLE INSPECTION AND ADJUSTMENT Measuring Compression Pressure Service standards [Location Maintenance item ‘Standard value Limit [Remedy = Compression | Each cylinder (at 200 rpm) 2550 kPa (26 kgt/cm?} | 1690 kPa (20 kgticm®} |_ Inspect | pressure Cylinderto-cylinder pressure difference = ‘390 kPa [4 katicm’) | Inspect ©) Special tools Unit: mm Location "Tool name and shape PartNo. Application | Compression jeasuring compression pressure = |Sameression wt081460 | Measuring compression p Mia 15 over LL 8200 U6 «Remove the injection nozzie, © Gris ‘© Cover the injection nozzle mounting hole A with a cloth B. Then, turn the engine over with the starter and check that no foreign matter ad- heres to the cloth, WARNING A, ——————____—_———— If any cylinder is cracked, coolant, engine oll, and fue! will enter the cylinder through the crack. When the engine is turned over, these substances will spray out of the nozzle mounting hole A at ahigh temperature. For safety, move away from the nozzle mount= 1g hole before turning over the engine. + Fit the ©) Compression Gauge Adapter onto the injection nozzle mounting hole A together with a gasket 2. Lock these items in position with the nozzle bridge 9, then connect the compression gauge 4. ‘+ Tum the engine over and measure the compression pressure. + Measure the compression pressure in every cylinder and determine the pressure differences between cylinders. Limit: 4 kg/em® maximum, ‘+ If any compression pressure or cylinder-to-cylinder pressure differ- ence exceeds the specified limit, pourallitie engine ollinto the cylinder via the injection nozzle mounting hole then take the measurement again. ‘= Ifthe compression pressure increases, there may be wear or dam- ‘age on piston rings and inner surfaces of cylinders. * If the compression pressure does not increase, valves may be seized or incorrectly seated, orthe cylinder head gasket may be de- fective.Inspecting and Adjusting Valve Clearances Service standards Units orn Toeation Maintenance ham ‘Standard value [tint] Remeay —_ | Valve clearance (when cold) 04 = Adjust 020s! \Valve clearances should be checked and adjusted when the engine is cold. ‘* Crankthe engine unti the “16” mark on the flywheel is aligned with the pointer in the flywheel housing inspection window. NOTE Pistons whose push rods are not pushing up their rockers are at the top-dead-center (TDC) positions of their compression strokes. + When piston No. 1 is at the TDC position of its compression stroke, check and adjust the clearance of each valve marked “O” in the follow- ing table. When piston No. 6 is at the TOC position ofits compression stroke, check and adjust the clearance of each valve marked" x" in the table. Be sure to check and adjust every valve. Piston No. +[2)]7s,*]s 1]. Valve arrangement [ih [e| in. [| te [Ex] im [ex [im [Ee | [Ex No piston at TOC of eom- pression stoke eyjol|o ojo ° No pon ak TDC ofcon xtx xlxl |xlx NOTE To measure the clearance, insert a feeler gauge 3. The gauge should be able to move in the gap, albeit not loosely. Accurate ‘measurements cannot be taken if the gauge moves loosely in the gap. ‘+ If any measurement is out of specification, make adjustments as fol- lows: Standard value: 0.4 mm [Agjustment) © Toadjust the valve clearance A, loosen the lock nut 4 and turn the a justing screw 5 until the feeler gauge 3 moves more stifly in the gap. ‘After adjusting the clearance, tighten the lock nut 4, At this time, use ‘a screwdriver 6 to stop the adjusting screw 5 from tuning. Next, insert the feeler gauge 3 once more to-confirm thatthe clearance A. is correct. IL-7CYLINDER HEAD AND VALVE MECHANISM @ Disassembly sequence 1 Oilfiler cap 2 Rocker cover gasket 3 Outer rocker cover 4 Cylinder head bolt 5 Rocker and bracket assembly (1)P.11-12 6 Push rod 7 Oylinder head assembly (1 P11-14 8 Cylinder head gasket 9 Tappet *:Crankease (1) P.11-54 A: Locating pin @:Non-reusable part @ Assembly sequence Reverse the order of disassembly. iid Service standards ‘ Unit: mm Location Maintenance term ease Lint | Remedy 3 [Pavotnmen = ta | Roplaes 9, * | Tappet-to-crankease clearance 128] 0.05 10 0.09 02 Replace tappet @ Tightening torques Unit: Nem {kgf-m} Location Parts tobe tightened Tightening torque Remarks 4 | Gviindernead bot | 445 (15) + 90 © Wet 2:0) |e Canbe roused upto 3times A Lubricants Location Points of application Type Quantity 4__ | Threads of eyindor head bons Engine ol ‘As required © _| Both ends of push rods Engine of! ‘As required ‘8 [Outer aurfaces of tappets Engine ofl As required 8©) Special tools i Location ‘Tool name and shape Part No. ‘Application 7 | Socket Wrench MH061560 | Tightening cylinder head bolts 1986 16 | Tappet Extractor MHo063329 | Removing tappets 05320 Service procedure o194a [Removal] sae] 6] Push rod runout 7] Cylinder head assembly lf the measurement exceeds the specified limit, replace the push rod 6, + Before loosening the cylinder head bolts 4, loosen the adjusting screw C on every rocker A that is compressing its valve spring B. ‘+ Loosen and remove the cylinder head bolts 4 in the sequence shown. Each cylinder head bolt should be loosened a litte at a time. doCYLINDER HEAD AND VALVE MECHANISM 2810] H-10 (Fitting) «The cylinder head bolts 4 can be reused only three times. Before refit ting the cylinder head bolts, make a punch mark on the head of each ‘one to indicate how many times it has been reused. CAUTION /\. W any bolt already has three punch marks, again; replace it with a new one. ‘Tighten the cylinder head bolts 4 tothe specitied torque [145N-m (15 kgf-m)] in the sequence shown. Then, tum the bol further in accor- dance with the following procedure. * :Tighten together with rocker and bracket assembly © Before fiting the (€) Socket Wrench over a cylinder head bolt, urn the holder D counter-clockwise to tension the built-in spring. E: Socket Rod G: Rod (extension) * Set the socket such that the built-in spring force forces the rod G against the rocker shaft bracket, an injection pipe, or another nearby part ‘+ On the holder D, select the inscribed line H that is easiest to see. + Using the selected ine as a reference, tumthe socket E 80° clockwise. (One gradation on the scale J represents 5°.) CAUTION A, A Since the cylinder head bolts 4 utilize the plastic region tightening method, they must not be tightened further after this procedure. 3] Cylinder head gasket [Removal] CAUTION A, ———__ ‘When removing the cylinder head gasket 8, be careful not to scratch the cylinder head and valve assembly 7 and the crank- case *. (Fitting) © Fitthe cylinder head gasket 8 with the “UP mark positioned as shown.(i) [3] Tappet removal _ 9] E] Tappet-to-crankcase clearance It any measurement exceeds the specified limit, replace the defective part(s). UUCYLINDER HEAD AND VALVE MECHANISM Rocker and Bracket Assembly @ Disassembly sequence Set bolt Rocker shatt bracket Rocker assembly Rocker bushing Lock nut Adjusting screw Rocker Rocker shaft spring Rocker shaft woransen+ © Assembly sequence Reverse the order of disassembly. 8 3 2 canay Service standards Unit: mm tic Standard value imit Location Maintenance item (Basic diameter in [}) Limit Remedy 4,9 _ | Rocker bushing-to-rocker shaft clearance 119] 0.06 10 0.11 02 Replace A Lubricants ovation Points of application Type. Quantity “4 __ | Rocker bushing innor surface Engine ol [As roquired © Special tools Unit: eam Location ‘Tool name and shape Part No. ‘Application Rocker 4 | Bushing Puller MHO51978 Removing and installing rocker bushings U-I2952} 6009) os2ea' (ii | Service procedure 7] [3] Rocker bushing and rocker shaft Linspection} if any clearance exceeds the specified limit, replace the defective paris). Rocker bushing [Removal] [Installation} ‘= Align the oilhole A in the rocker bushing 4 with the oil hole D in the rock- er7. ‘= Position the notch E and seam F on the rocker bushing 4 as shown. ‘= Install the rocker bushing 4 into the rocker 7 from the chamfered side 6. [3] instating rocker shat Install the rocker shaft 9 with the engine oil supply hole A (this is provided for lubrication) toward the front of the engine B. C:Hole for set bolt 1 U-13CYLINDER HEAD AND VALVE MECHANISM Cylinder Head and Vaive Assembly {_ CAUTION /\ 12426| @ Disassembly sequence Valve cap Valve cotter Upper retainer Outer valve spring Inner vaive spring Valve stem seal Inlet valve Exhaust valve Nut 10 Connecting plate 11 Glow plug (1) Gr 54 12 Bott 13 Nozzle bridge 14 Nozzle tip gasket 15 O-ring 16 Injection nozzle (1) Gr 13, 17 Inlet vaive guide 18 Exhaust valve guide 19 Inlet valve seat 20 Exhaust valve seat 21 Water director 22 Stud 23 Cylinder head wavonsona ©: Non-reusable part ‘The injection nozzles 16 and glow plugs 11 project from the bottom surface of cylinder head 23, Take care not to damage them. © Assembly sequence Reverse the order of disassembly. NOTE Any valve stem seal 6 removed from an exhaust valve 8 or inlet valve 7 must be replaced. U4Service standards US fe Standard value 1 Location Maintenance item panna Limit Outer [Free length wat oa 4 [Y2Ne,_ [installed toad (at 47:25 installed tength) 2402 12N 205 N spring (245 44.2 kt) (20.8 kof) Squareness = 25 immer [Freelength S507 Bei | Replace 5 valve Installed load (at 40.3 installed length) 93.£4.4N (9.5 + 0.45 kgf} TON spring (2.1 gf ‘Squareness = 2 Tniet [Stem outside diameter 98.9610 687 aes | Replace valve ‘Sinkage from cylinder head bottom sur- 0.78 to 1.25 18 Inspect ev- 7 face ery location Valve margin 1s 12 | Relace or replace Seat angle aais = Correct Inlet valve stenvto-vaive guide clearance {970.04 t0 0.08 018 | Replace Exhaust | Siom ouside dametor 289510804 9685 | Replace valve | Sinkage from cylinder head bottom sur- (0.7510 1.25 7 Inspect ev- ° face ery location Valve margin 18 12 | Relace or replace Seat angle wate = Correct @, 18 _| Exhaust valve slomto-valve guide clearance (007 toa 02 | Replace yo | inlet valve coat wiath 2E02 28 | Corrector roplace 20 | Exhaust valve seat wath 2E02 28 | Cowector replace ‘Gyinder | Bottom surlace distortion 0.05 arose 02 | Correct or 23 (head replace eight from top to botiom surlace 204 8458 | Replace @ Tightening torques Unit: N+ fkgf-m} Location Parts to be tightened Tightening torque Remarks 71 | Glow plug 15 to20(1.5t020) = 13 Bolt (nozzle bridge installation) 25 (2.5) —CYLINDER HEAD AND VALVE MECHANISM A Lubricants Location Points of application Type Guanity 7__| Rocker contact surface on valve cap top Engine ol As required 6 [Uf valve tem seal Engine a As required 7.8 [Vavestem Engine of Asrequired © Special tools Uri: mm Location Tool name and shape PartNo. ‘Appiction Se , 4 Removing and instating 2 |Valetiter 30091-08500 valve eaters sees hive Stem Sea! nstater Instating vave stem 6 | Valve Stem Sea Install vl witos1290 wet o1s57 7,8 | Vave Lepper 30091-07500 Lapping valves ane vale sect o19 Valve Guide Remover vo61066 Removing vale guides $ * orose 17,18 1 a | , . ‘s Instatinginlt and ox Vatve Guide int hi vost068 Intating il! an 18 osco U-16i Location ‘Tool name and shape Part No. Application Caan Tal B: Gauging cine Caner | son | hc muoet067 wwrosrare | 9478 S:M061275 re) | sctating 419,20 j m1 MHOG'279 Cle) | ating va sais ¢o — I eres) Caigem sion BA oss61 wHosi069 | $406 Service procedures 2] Valve cotters [Removal] To remove the valve cotter 2, use the E] Valve Liter to evenly compress. the valve springs 4, 8. [Installation] To install vaive cotters, follow the removal instructions in reverse. CAUTION A\, Do not compress the valve springs 4, 5 more than is necessary. Ifthe valve springs are compressed excessively, the upperretain- 3 can touch the valve stem seal 6 and be damaged. os25a] 4] [5] Installing outer and inner valve springs Fit the outer and inner valve springs 4, 5 onto the cylinder head 23 as shown, ‘A: Tightly wound portion 01964: 6] Installing valve stem seals + Apply engine oil to the lip A ofthe valve stem seal 6. ‘+ Install the valve stem seal 6 using the ] Valve Stem Seal Installer. Strike the Valve Stem Installer unti it sits snugly on the cylinder head 2. 41-17CYLINDER HEAD AND VALVE MECHANISM z+ 78 onzsa H-18 7] [B] Inlet and exhaust valves {Inspection} (1) Valve stem outside diameter Replace the valve 7, Bifits stem’s outside diameter is below specifica. tion or severely worn, CAUTION A, A$ Whenever a valve 7, 8 is replaced, be sureto lap the valve and valve seat 19, 20. (1) P.11-20 (2) Valve seat angle and valve margin Reface or replace the valve 7, 8 ifthe valve seat angle or valve margin exceeds the specified limits. Valve seat angle B: Vaive margin [Rectification] NOTE © Keep grinding to a minimum, + If the valve margin is below speci the valve 7, 8. + After grinding, be sure to lap the valve and 7,8 valve seat 19, 20. mMpst-20 tion after grinding, replace [7] [18] valves and valve guides. {Inspection} Hany clearance exceeds the specified limit, replace the defective part(s). ~ Valve guides [Removal]17,18 0256: {installation} Install the valve guide 17, 18 using the E) Valve Guide Installer. Strike the Valve Guide Installer unti it sits snugly on the cylinder head 23. CAUTION /A\. ‘© The valve guides 17, 18 must be pressed in to the specified depth A. Be sure to use the [E] Valve Guide Installer for this operation. A:10 mm + Exhaust valve guides 18 are longer than inlet valve guides 17. Be sure to install the correct type of guide in each location. 7] (8) £9 2d] valves and vaive seats A ex S\odB-= Sse | Se {inspection} ‘Apply an even coat of minium to the valve seat 19, 20 surface A that ‘makes contact with the valve 7, 8 ‘+ Using the ) Valve Lapper, strike the valve 7, 8 against the valve seat 19, 20 once. Do not rotate the valve during this operation. NOTE Carry out these inspections after inspecting the valves 7, 8 and valve guides 17, 18. « Ifthe minium deposited on the valve 7, 8 indicates a poor contact pat- tem, rectify the contact pattem as follows: Contact Corrective action Miner defect Lapping Serious defect Feface or replace valve and valve seat or960) [Refacing] 01870] Lap the vaive in accordance with the following procedure: ‘* Apply a thin, even coat of lapping compound to the surface A of the valve 7, 8 that makes contact with the valve seat 19, 20, CAUTION A, Ensure that no compound adheres to the stem B of the valve 7, 8 NOTE © Start with intermediate-mesh compound (120 to 150 mesh) and finisti with fine-mesh compound (200 mesh or more). + The addition of a small amount of engine oil makes lapping com- pound easier to apply. U-19CYLINDER HEAD AND VALVE MECHANISM 18 19,20 01975: «© Using the &] Valve Lapper, lightly strike the valve 7, B against the valve seat 19, 20 while turning it ttle by tie, © Wash away the compound with gas oll or a similar fluid. ‘+ Apply engine oil to the contact surfaces A of the valve seat 19, 20 and rub it in so that the contact surfaces are lubricated and mate together snugly. ‘© Inspect the contact patter of the valve 7, 8 and valve seat 19, 20 once more, ithe contact pattem is still defective, replace the valve seat 19, 20. (5) vai seats {inspection} (1) Valve seat width Ifthe measurement exceeds the specified limit, rectify or replace the valve seat A: Valve seat width NOTE Whenever a valve seat 19, 20is rectified or replaced, be sure to lap the valve seat 19, 20 and valve 7, 8. (2) Valve sinkage from cylinder head bottom surface lt any measurement exceeds the specified limit, rectify or replace the defective parts). B: Valve sinkage [Rectification] + Grindthe valve seat 19, 20 using a valve seat cutter or valve seat grind- er. ‘© After grinding, put some sandpaper of around #400 grade between the cutter and valve seat and grind the valve seat lightly. «Use a 15° or 75° cutter to achieve the specified valve seat width A. C:Valve seat angle CAUTION A\ 1-20 Ensure that grinding does not cause the valve sinkage B to ex- ceed the specified limit. ‘= After rectification, lap the valve 7, 8 and valve seat 19, 20.19,20 Bb 05t0 1.0mm 11 01979] [Removal] Valve seats 19, 20 are installed by expansion fitting. To remove a valve seat, grind the inside surface to reduce its thickness, then remove the valve seat at room temperature. D: Material to remove Linstallation} ‘© Check that the valve seat hole diameters in the cylinder head 23 con- form with the values shown below. Unit: mm Inlet valve seat hole (E) ae gm Exhaust valve seat hole (F) are 08400 * Cool the valve seat 19, 20 by immersing it in iquid nitrogen. Install the valve seat in the cylinder head using the Ja Caulking Too! Body and jb Caulking Ring, CAUTION A\, Place the Caulking Ring's chamfered side G on the inlet and exhaust valve seats 19, 20 when installing them. ‘© After instaling the valve seat 19, 20, lap the valve seat and valve 7, 8. os2e2_ 2]] instatting water directors ‘+ With the notch A aligned as shown, strike the water directors 21 into the cylinder head 23 to the specified dept, [23] inspecting cylinder head ‘+ Measure the extent of distortion inthe cylinder head's 23 bottom sur- face. + Hfthe degree of distortion exceeds the specified limit, recy the distor- tion with a surface grinder, CAUTION /\ Ensure that grinding does not cause the cylinder head’s top sur- face-to-bottom surface distance to fall below the specified limit, u-21TIMING GEARS 17956 @ Disassembly sequence Nut Taper cone Oring Crankshatt pully Bott Oil seal Timing gear case Bott Thrust plate 10 Idler gear assembly earausens @ Assembly sequence Reverse the order of disassembly. 4-22 " 12 8B a: 92: 43: a: Front oll seal singer (1) P.11-54 +5: Idler gear bushing ©: Non-rousable part Idler gear Idler shatt CAUTION A; Do not remove the front oll seal 6 Crankshaft gear (1) P.11-54 unless defects are evident. Ol pump gear (1) Gr 12 Camshatt gear[1) P.11-28 Injection pump gear (1 Gr 13Service standards Unit: mm Standard value ir Location Maintenance item ealangard yale Limit | Remegy — [Gear | Between idler gar assembly and 0.071 0.18 03 | Replace backiash | crankshatt gear 1 ‘Between idler goar assombly and car oo7e 07 08 shaft gear Botwoen ilar goar ascombiy and ine O07 e047 08 tion pump gear Between camshalt gear and ol pump oro 038 gear —_ idler gear end play 0.05%0.15 oS inspect Ti, 13 _| Idler gear bushing-to-shaft clearance 145] 0.08 to 0.06 ot Replace @ Tightening torques Unit: N-m tkgf-m} Location Parts to be tightened Tightening torque Remarks 1 _| Teper cone mounting aut 49050), Wet & | Thrstplato mounting bot 2a ea) = A Lubricants and sealants Location Points of application Type ‘Quantity {a __[Natthread Engine of ‘As quired 3 [Oring Engine of ‘As required 6 _| Frontollseallip Engine of ‘As required 7__| Timing gear case mounting surface ‘Theesbond 12076 Metz @_ |Botthvead Engine ol ‘As required © Special tools Unit: mm Location “Tool name and shape Part No. ‘Application 2 | Cone Putter MHos2496 Flomoving taper cone aac 12700 49 + Bushing Put Removing and fiting 14 | Idler Gear Bushing Puller Muos2228 merowngne ous saz 4-23TIMING GEARS 4-24 Service procedure @ Pre-disassembly inspection (1) Gear backlash For each gear pair, measure backlash at three or more points. If any measurement exceeds the specified limit, replace the defective part(s). (2) Idler gear end play It the measurement exceeds the specified value, replace the defective part(s). 2] Removing taper cone 7] installing timing gear case Apply an even, unbroken bead of sealant A to the mounting surface of the timing gearcase 7. Fit the timing gear case onto the front plate within three minutes of applying the sealant. CAUTION AX, $$ * When fitting the timing gear case, hold it firmly in position to pre- vent spreading the sealant. + Before applying the sealant, make sure the application surface is free of oil and other contamination. * Applyanew bead of sealant whenever the bolts 5 have been loos- ened. '* After fitting the timing gear case, wait at least an hour before start- ing the engine.i Installing thrust plate ‘A: Champhered end [10 installing idler gear assembly '* Fit the idler gear assembly 10 such that the alignment marks ("I", 3", ‘and"4")on the idler gear are aligned with those on the gears with which it mates, #1: Crankshaft gear *3:Camshatt gear +*4: Injection pump gear NOTE ‘Align the gear alignment marks with pistons No. 1 and 6 in their top-dead-center positions. [19] [19] tder shaft and idler gear bushing {inspection) If the clearance exceeds the specified limit, replace the detective part(s). Idler gear bushing [Removal] A: Press U-25TIMING GEARS {installation} Press the idler gear bushing 11 into the idler gear 12 from the side of the gear whose intemal diameter is chamfered B. Make sure the oil holes C in the idler gear and bushing are aligned. ‘After installation, ream the idler gear bushing 11 to achieve the spect- fied clearance between the bushing and idler shaft 13, A: Press 1-26(ait | MEMO 1-27CAMSHAFT @ Disassembly sequence 1 Bott 7 Key 2 Camshaft assembly 8 Camshaft 3 Bolt 9 No. 4 camshaft bushing 4 Washer 10 No. 2 camshaft bushing 5 Camshatt gear 11 Sealing cap 6 Thrust plate NOTE Do not remove the camshaft gear 5 unless defects are evident. @ Assembly sequence Reverse the order of disassembly. 1-28 12 No. 4 camshaft bushing 13 No. 3 camshaft bushing +: Crankease (1) P.11-54 @: Non-reusable part 12009Service standards i1 Unit: mm Location Maintenance item eaeeayeNe Limit | Remedy =| Gamehat assembly end play 0.0510 022 03 | Inapect coach pat @ | Camshatt | Gamat telat 7.198008 370 | Replace. Lobe height: A705 Base ctcle diameter: 39.910 Exhaust 7aai £008 62 | Replace Lobe hoight 46979 Base circle ameter 39.658, Bend Oe orless 005 | Replace 9,10, [Camshaft joumalto-camshatt [Not Journal 1545) 0.0310 008 0.15 | Correct or 12,13, | bushing clearance No.2 journal [5451 0.03 10.0,08 Replace No, 3 journal {54.5} 0.03 to 0.08 [ Re. journal 163] 00910008 @ Tightening torques Unit: N-m (kgf>m) Location Paris to be lightened Tightening torque Remarks 3 [Camshaft gear mounting bok 775 (18) Wet A Lubricants [Location Points of application Type ‘Quantity 3 __[Boithreads Engine of as required 9, 10, | inside surfaces of camshaft bushings Engine of ‘As required 12,13, 1-29CAMSHAFT © Special tools thie om {Location “Tool name and shape Part No. ‘Application Gear Puller MH061326 Removing camaheft ss ces 5 europe on vecooue —_| Demat ~~ shaft gear vets css RRR Ase, Pa ¢ Za nonin in 9,40, | [No.1 | 9585 | 9545 MHos1276 ling camshaft bush- 12,13 | [No.2 ings ves | oats mer eb as wn L ¢ Service procedure @ Pre-disassembly inspection Camshaft end play I'the end play measurement exceeds the specified limit, replace the de- fective parts). 2] Camshaft assembly 11-30 [Removal] Loosen and remove the bolts 1 through the holes in the camshaft gear 5, then remove the camshaft assembly 2, CAUTION A\. ‘Take care not to damage the camshaft bu: removing the camshaft assembly 2. ings 9,10, 12,13 when2882 [installation] © Before installing the camshatt assembly 2, measure the end play be- tween the thrust plate 6 and camshaft 8, © Ifthe measurement exceeds the specified limit, replace the defective part(s). ‘+ With the alignment marks lined up on the camshaft gear 5 and No. 2 idler gear, ft the camshaft assembly. (1 P.11-28, onsa7 0550 5] Camshaft gear [Removal] ‘+ Do not tap off the camshatt gear since this could damage it ear Puller lug {Installation] + Fit the camshaft gear onto the camshaft with the "2" alignment marks positioned as shown. + Do not forget to fit the key 7. 6] Installing thrust plate Fit the thrust plate with the “F" mark positioned as shown. U-31CAMSHAFT p< A 7.8 nim | 7.5 mit 1 A 2090 Inspecting camshaft (1) Cam tft IK any base crcle-o-lobe height diference is ess than the required val- ue, replace the camshatt 8. NOTE ‘Since the cams are tapered, they must be measured atthe posi- tion A shown in the diagram. B: Lobe height ©: Base circle diameter D: Front of engine (2) Camshaft bend ‘Support the camshaft Bat its No. 1 journal E and No. 4 journal F, then take measurements atthe No. 2 journal G and No. 3journal H. if either measurement exceeds the specified limit, replace the camshaft. NOTE ‘Turn the camshaft 11 through one revolution. One-half of the dial indicator reading represents the camshaft’s bend, sees 1-32 to[{G, [, [9 camshaft and camshatt bushings {inspection} It any clearance exceeds the specified limi, replace the defective part(s) Camshaft bushings [Removal] Remove the No. 3 and 4 camshaft bushings (12 and 13) from the rear end of the crankcase.ye o2 9,10, 12,13 ga04 9, 10, 12, 13 ones! 05231 11 [Fiting} Identify the No. 1 to 4 camshaft bushings (9, 10, 12, and 13) from their identification marks (“1”, “2”, “3", and “4") in accordance with the table below. If any bushing's identification mark is unclear, identify the bushing from its outside diameter A. Bushing No. ‘entiation mark | Outer dametor A {tom front f engine) (com) Nos 7 95850 No2 2 $58.06 Noa | 3 57.50 No é 57.06 + Install the bushings using the ) Camshaft Bushing Installer and Extractor with the appropriate guide B fitted. + Install the camshaft bushings (9, 10, 12, and 13) in the following order. No. 4, No. 8, No. 2, No. 1. * Fitthe No. 4 camshatt bushing 12 from the rear of the engine. Fit the No.3, No. 2, and No, 1 camshaft bushings (13, 10, and9) fromthe front of the engine. ‘+ Make sure the oil hole C in the No. 4 camshaft bushing 12 is aligned as shown, ‘+ Press in the No. 4 camshaft bushing 12 until its end surface D is flush with the chamfer E on the crankcase *. F: Front of engine 1-33CAMSHAFT es a (4G i013 >I ooze kK 8 4-34 + Make sure the oilholes Gin the No.2 and No. 3 camshaft bushings 10, 1 are aligned as shown. ‘+ Press in the No. 2 and No. 3 camshaft bushings 10, 19 until their end surfaces H are flush with the end surface J of the crankcase *. F: Front of engine ‘+ Press in the No. 3 camshaft bushing using the type of jig K shown in the drawing. ‘+ Make sure the oil holes L, M in the No. 1 camshaft bushing 9 are aligned as shown, L:¢3mm M68 mm * Make sure the oil hole Min the No. 1 camshaft bushing 8s aligned with the oil hole N in the crankcase *. Press in the camshaft bushing until its end surface P is flush with the orankcase end surface Q. F:Front of engine11 Fi] instating seating cap ‘Tap the sealing cap 11 into the crankcase * to the specified depth. ‘A: Front of engine 4-35PISTONS, CONNECTING RODS, AND CYLINDER LINERS 17957| @ Removal sequence 1 Bolt 5 Piston and connecting rod #1:Crankshaft (1) P.11-54 2 Lower connecting rod bearing assembly [1] P.11-44 #2: Crankcase [Y) P.11-54 3 Connecting rod cap 6 Cylinder liner +3: Oil pan (1) Gr 12 4 Upper connecting rod bearing @ installation sequence Reverse the order of removal. 11-3611 Service standards Unit: mm Location Maintenance item eae Limit | Remedy — [Piston projection 0.48 100.69 = Inspect each loca: tion Connecting rod end play eed inspect | 2,4 | Connecting redbearing [Ollclearance (60)0.0410 0.08 Replace ‘Span when free = %, 6 | Piston and connecting rod assembly-to-cyinder (104) 007 oti = Bore to liner clearance ovenize ce @ | Cylinder ner inside diameter 104 0 104.08 70125 | Boreto Roundness (0.04 oriess = _| oversize or replace Gyfindiity 0.08 orless = 6, #2 | Oyinderinerte-crank- | Standard 0.17 100.28 = Replace case interterence with oversize Oversize oisto021 = Replace @ Tightening torques Units Nm tkgf+m} ‘Location | Paris to be tightened Tightening torque Remarks | Balt (Gonneating rod instalation) 29 (G)+ 8 EE Wet A Lubricants and sealants Location Points of application Type ‘Guantity 7 [Bottthreads Engine ol ‘As required 2,4 _ | Connecting rod bearing inside surface Engine of ‘As required #2 [Sleeve hole in eankoase Spindle ol (ISO Vesa} ‘As required | 1-37PISTONS, CONNECTING RODS, AND CYLINDER LINERS © Special tools Unit: mm Location ‘Tool name and shape Part No. ‘Application ockat Wren Tighten connecting rod ‘Socket Wrench MH081560 ane o1se6 8 AA: Piston Guide Clamp ‘A: MHO61890 Instaling piston and con- B: Piston Guide Lever 3: MHOS 1658 necting rod assembly 6 | Cylinder Liner Installer MHos2228 Installing cylinder liners 103 oss? eO 1-38 @ Service procedure © Pre-disassembly inspection (1) Piston projection from crankcase #2 top surface NOTE The piston projections affect engine performance and must therefore be checked. ‘© Measuretthe projection of each piston at two points andcaleulatethe average of the two values. ‘A: Front of engine «Ifthe average value is out of specification, check the clearances be- tween all relevant parts. (2) Connecting rod end play ‘© Measure the end play of every connecting rod. * Ifany measurement exceeds the specified limit, replace the defec- tive parts).0x01 rd 12188 + 01907] 3 2] [4] Connecting rod bearings [installation] Install the connecting rod bearings 2, 4 by fiting the lugs A into their re- spective grooves. CAUTION /\ ‘The upper connecting rod bearing has an oil hole B. The lower connecting rod bearing has no oil hole. Take care not to confuse the upper and lower parts. [inspection] CAUTION fi, $$ + Do not attempt to manually expand a connecting rod bearing 2, 4 if its span is insufficient. + Upper and lower connecting rod bearings 2, 4 must be replaced asa set. (1) Span when free Ifthe spanis ess than the specified requirement, replace the upperand lower connecting rod bearings 2, 4 as a set. (2) Connecting rod bearing-to-crankshatt pin clearance Ifthe connecting rod bearing-to-crankshaff pin clearance exceeds the specified limit, replace the defective part(s). Ifthe connecting rod bearings 2, 4 are replaced with undersize compo- nents, grind the outside diameter A of the crankshaft pin *1 tothe spe- Cified undersize dimension. [1 P.11-60 1-39PISTONS, CONNECTING RODS, AND CYLINDER LINERS ose} oss 11-40 [5] installing piston and connecting rod assembly CAUTION A\ ‘+ Ensure that the piston ring gaps A remain in their correct pos tions. (1) P.11-47, * Take care not to damage the piston crown B (the area that forms part of the combustion chamber). Ensure that the connecting rod does not touch the oil jet + With the piston’s “A” front mark facing the front ofthe engine, install the piston and connecting rod assembly in accordance with the following procedure. D: Front of engine «* Fitthe la Piston Guide Clamp over the piston skirt. Using the bott E of the [Eb Piston Guide Lever, adjust the clamp's inside diameter such that it matches the piston’s outside diameter. Move the ja Piston Guide Clamp and [EJb Piston Guide Lever to the top of the piston, + With the piston installed, align the mating marks F on the connecting rod and connecting rod cap 3 and install the cap in accordance with the following procedure.ii Tighten the bolt 1 to the specified torque, then turn the [E) Socket Wrench by an adaltional 90° 5° © Before fitting the &) Socket Wrench overa bolt, turn the holder G count- er-clockwise to tension the builtin spring. H:Socket J: Rod K:Rod (extension) * Setthe socket wrench such that the built-in spring force forces the rod K against the orankshatt *1, ‘= On the holder G, select the inscribed line L that is easiest to see. ‘+ Using the selected line as a reference, tun the socket H 80°: 5° clock- wise. (One gradation on the scale M represents 5°.) NOTE After fitting the connecting red caps 4, inspect the following items: + Connecting rod end play ( (7) P:11-38) ‘= Piston projections ((1) P.11-38) ° osagt z © ° si 5) [6] Piston-and-connecting rod assembly and cylinder liners [Inspection] «Ifthe cylinder section inside diameter ofthe cylinder liner exceeds the specified limit, remove the cylinder liner from the crankcase and rebore it to oversize. Also replace the piston and piston rings with ones suit- able for the oversized cylinder liner inside diameter. ‘A: Measuring direction of cylinder liner bore (crankshaft axis direction) B: Measuring direction of cylinder finer bore (perpendicular to crank- shaft axis) ‘+ Evenifthecylindersection inside diameter of the cylinder liner 6 is with- in the specified limit, the piston and piston rings must be replaced ifthe piston-to-cylinder liner clearance is out of specification. [Use of oversize pistons] Pistons are avaliable in the following degrees of oversiz 4.00 mm. * To determine the necessary degree of oversize, measure the bore diameter of every cylinder and find the most worn point. ‘+ Measure the outside diameter of the oversize piston to be used. 0.50 mm and ©: Outside diameter measurement position ‘© Bore and hone-finish the cylinder liner 6 to achieve the specified piston- to-cylinder liner clearance, NOTE Even if only one cylinder liner requires boring, bore every cylin- der liner to the same oversized inside diameter. ‘+ Replace the piston rings with rings corresponding to the degree of oversize. I-41PISTONS, CONNECTING RODS, AND CYLINDER LINERS 0392 Di 2 Ds osae0] M42 Cylinder liners, [Removal] ‘+ Mount. boring machine on the crankcase *2 and centerit. Center the boring machine in the bottom of the cylinder iner6, where there should be litle eccentric wear. ‘+ Bore the cylinder liner 6 to achieve a thickness of approximately 0.5 mm. ‘= Insert an appropriately shaped tool D: (for example, a suitably machined screwdriver) between the crankcase *2 and cylinder liner 6, then lightly tap the tool so that the cylinder finer splits and can be removed, CAUTION A\ Insert the tool D with its rounded [instalation] * Before installing a oylinder ier 6, inspect the liner hole inthe crank- case *2. Ifthe hole is defective due to damage, insufficient interfer- ence, or some other problem, recy it by boring. NOTE + Ifany crankcase #2 liner hole requires boring, remove the cylin- der liners 6 from all the cylinders and bore each liner hole such that is perfectly round. * Apply spindle oil (Idemitsu DAPHNE MECHANIC #32) to the crankcase *2 liner holes before press-ftting the cylinder liners 6. Check for correct interference as follows: + Atthe positions shown in the drawing, measure the inside diameter of the crankcase #2 liner hole and the outside diameter of the cylinder liner 6. ‘+ Calculate the average of the vertical dimensions (D1, D2, and D3) and the diametrical dimensions (A and B). If the degree of interference is not up to specication, bore the crankcase *2 liner hole to oversize. + Using the Cylinder Liner Installer, press the cylinder liner 6 into the crankcase *2 such that its chamfered end goes in frst. NOTE Press in the cylinder liner 6 until its top edge is flush with the top surface of the crankcase *2. © Afterpress-fitting the cylinder liner 6, hone-finish its surface to achieve the specified inside diameter.-if interference is insufficient> ‘* Make ready a 0.5 mm oversize oylinder liner 6. ‘» Hone the crankcase to achieve the specified interference between the cylinder liner outside diameter and crankcase #2 liner hole. © Using the €] Cylinder Liner installer, press the cylinder liner 6 into the crankcase #2 such that its chamfered end goes in firs. NOTE Press in the cylinder liner 6 until its top edge is flush with the top surface of the crankcase *2. * Atterpress-fitting the cylinder liner 6, hone-finish its surface to achieve the specified inside diameter, I-45PISTONS, CONNECTING RODS, AND CYLINDER LINERS Piston and Connecting Rod Assembly Service standards @ Disassembly sequence Snap ring Piston pin Connecting rod bushing Connecting rod 4s\ compression ring 2nd compression ring Oil ring Piston ey onsene @ Assembly sequence Reverse the order of disassembly. Unit: mm Location Maintenance item (wasie diameter [) Limit | Remedy 2,3 | Piston pin-to-connecting rod small end bushing [36] 0.08 to 0.04 01 Replace clearance 2, 8 _ | Piston pinto-piston clearance 136) 0.007 to 0.021 0.05 Replace 4 | Connecting rod bend and torsion = 0.05 | Correct or replace Bt07 | Piston ing end gap | tel compression ring 0510045 7S] Replace 2nd compression ring 0.30 0.5 | Ging 0.251045 to 8 | Piston ring-to-piston ring | Yst compression ing 0.02% 0.10 02 | Replace Groove clearance ‘2nd compression ring 0.05 t0 0.08 0.15 ~ Oitring 0.0510 0.06 A Lubricants and sealants Location Points of application Type Quantity 2 __|Fiston pin outer surface Engine oi 7s required 3__| Gonneoting od bushing outer surlace Engine ol ‘As required “4___[ Bushing instalation surface of connecting rod Engine of As required 44ii © Special tools Teeaton Teal rae a shape Bane Tapa Conecting 2 [Sacer woe [Ronotng acing coment Puller Kit ings | | stor |Pitonrra seietor4 | removing ending pon ings 02170] Cr) + Service procedure 2] [3] Piston and connecting rod Ifthe clearance exceeds the specified limit, replace the detective part(s). [3] connecting rod bushing Replace the connecting rod bushing using the} Connecting Rod Bush- ing Puller Kit. This consists of the following parts: A: Base B: Bracket C:Puller D: Collar E:Plate F: Collar G:Nut [Removal] ‘+ Remove the bearing (i fitted) from the big end of the connecting rod 4 ‘+ Mount the connecting rod 4 on the base A and lock it in position with the bracket B and plate E. ‘+ Position the puller C and collar D as shown in the illustration. Then, slowly apply pressure of approximately 49 KN (5,000 kgf untithe con- noting rod bushing 3 is pressed out. U-45PISTONS, CONNECTING RODS, AND CYLINDER LINERS sar] oar7a| 46 [Installation] ‘© Apply engine ollto the small end of the connecting rod 4 and to the out- er surface of the connecting rod bushing 3. * Fitthe collar F over the puller ©, position the connecting rod bushing 3 and collar D as shown in the illustration, and lock this arrangement together with the nut G. ‘+ Align the cil holes H in the smail end of the connecting rod bushing 3 and connecting rod 4, Then, use a press to slowly apply pressure of approximately 49 KN (5,000 kaf) untilthe bushing is pressed into place. * After press-ftting the connecting rod bushing 3, ream itto achieve the specified nominal clearance between the bushing and piston pin 2. NOTE After installing the connecting rod bushing 3, insert the piston pin 2and check that it turns smoothly and without play. 2] [4] [B] Piston pin, connecting rod, and piston [Removal] Tap out the piston pin 2 using a rod and hammer. ‘© Ifthe piston pin 2 is dificult to remove, heat the piston 8 in hot water or using a piston heater. {instatltion] + Apply engine oilto the piston pin 2. With the connecting rod 4 and pis- ton 8 aligned as illustrated, insert the piston pin to hold these compo- nents together. ‘A: Front mark (A) B: Weight mark ©: Weight mark (A, B, C, D, E, FG) D: Alignment mark for connecting rod cap ‘© If the piston pin 2 is difficult to insert, heat the piston 8 in hot water or using a piston heater. CAUTION A\ * No piston 8 should differ from any other piston by a weight of more than 10 g. ‘+ The connecting rods 4 must all have the same weight mark C. © After inserting the piston pin 2, check that it turns smoothly and without play.2] [8] Piston ‘to-piston clearance canis 7 om It the clearance exceeds the specified limit, replace the defective part(s). 4] Connecting rod bend and twist * Fit the connecting rod bushing 3 and piston pin 2 in their respective positions of the connecting rod 4, ‘© Measure the extent of bending A and twisting B in the connecting rod 4. If either measurement exceeds the specified limit, replace the con- ecting rod 4 or rectify it. C: Connecting rod aligner (measurement device) NOTE ‘* Before mounting the connecting rod 4 on the connecting rod aligner C, install the upper and lower connecting rod bearings in their respective positions. © Measurements must be made with the connecting rod cap mount- ing nuts tightened to their specified torque. (1) P-11-40 3] to[B] Piston rings and piston Piston rings [Removal] {installation} Fit the piston rings 5, 6 such that the manufacturer's marks A near the {gaps face upward. Align the ring gaps as shown in the drawing. B: 1st compression ring gap ©:2nd compression ring gap D: Oil ring gap : Oil ring expander spring location tugs F Piston front mark. 1-47PISTONS, CONNECTING RODS, AND CYLINDER LINERS c c2cas| ‘U-48 [Inspection] (1) Piston ring end gap * Using the crown of a piston 8, push the piston ring 5,6 or 7 horizon- tally into a cylinder liner for measurement. ‘= Taking care not to move the piston ring measure the end gap. Re- place all the rings of a piston it any gap exceeds the specified limit. NOTE + To keep the piston ring 5, 6 or 7 horizontal, be sure to insert them into the cylinder liner using a piston 8. + Push the piston ring 5, 6 or 7 down to the bottom of cylinder lin- er; the bottom should be less worn than the top. * Piston rings 5, 6 or 7 must be replaced as a set. Never replace piston rings individually. (2) Piston ring-to-piston ring groove clearance + Itany measurement exceeds the specified limit, replace the defec- tive part(s) ‘+ Measure the 1st compression ring 5 clearance with a thickness gauge G while pressing the ring against the piston 8 with a straight edge F. NOTE + Remove any carbon deposits from the ring groove of the piston 8 and measure the clearance around the piston’s entire periph ery. + Piston rings 5, 6,7 must be replacedasaset. Never replace pis- ton rings individually.11 MEMO 49FLYWHEEL © Disassembly sequence 1 Bolt 7 Washer plate 2 Plate 8 Rear oil seal 3 Bearing 9 Flywheel housing 4 Flywheel assembly 5 Ring gear +: Crankshaft (D P.11-54 6 Flywheel A: Locating pin @ Assembly sequence Reverse the order of disassembly. Service standards Unit: rm Location Maintenance item Siandard valve Limit | Remedy @ | Fiwheet [Height of fition eurace 245 235 | Comector assombly | Friction surface distortion (005 orless 02 replace Friction surface runout (when = 02 fitted) 9 | Eecentrcy of joint = 2 | inspect or replace @ Tightening torques Unit Nom {kgf} Location Parts to be fightonod “Tightening torque Remarks | Flywheel mounting bot 39 (4) + 45" 25° Wet 4-50Q Lubricants and sealants i Location Points of application Type ‘Quantity 7 [Bot threads Engine of ‘As required @ | Rearoilsoallip Engine of ‘As required Grankcase mounting suriace of rear ol seal Thresbond 12076 p83 © Special tools Location “Tool name and shape Part No. ‘Application Socket Wrench aHios2183 ores | 1 Fting tlywheo! oars Service procedure ia eS ‘Ba [instatlation] Ps ‘* Tighten the bolts 1 to their specified torque [39 N-m (4 kgf-m)], then tighten them further in accordance with the following procedure: ‘+ Tum the holder B of the Ela Sooket Wrench counter-clockwise to ten- Dee sion the builtin spring. ©: Socket D:Rod E: Rod (extension) anos ‘ Attach the E)b Magnetic Base in the illustrated position such that i! obstructs the rod E. ‘© Set the socket wrench such that the builtin spring forces the rod E against the (Jb Magnetic Base. * On the holder B, select the inscribed line F that is easiest to see. © Using the selected line as a reference, turn the socket C 45° 5° clock wise. (One gradation on the scale G represents 10°.) U-5iFLYWHEEL 17060 fd 09351 1-52 {inspection} (1) Runout lirunoutexceeds the specifiedlimit, check that he bolts 1 are tightened correctly and inspect the crankshaft * mounting surface, Then, rectily or replace the flywheel assembly 4 as required. (2) Height of friction surface Ifthe measurement is below the specified value, rectify or replace the flywheel assembly 4. A: Height of fiction surface (8) Distortion of friction surface Hf distortion exceeds the specified ir assembly 4, NOTE. Hf any abnormality is evident on the ring gear 5, replace the ring gear before making inspections. rectify or replace the flywheel [Rectiication Grind the friction surface such that its height A remains greater than the ‘specified minimum. The friction surface must remain parallel with surface B with a tolerance of 0.1 mm, gear Inspection} Inspect the ting gear for damage and abnormal wear. any defectis evi- dnt, the ring gear must be replaced. [Removal] Heat the ring gear 5 evenly with an acetylene torch or the lke, ‘+ Remove the ring gear from the flywheel by tapping around its entire periphery.ayex op sain (heen 12970) Ge ‘Bead diameter 62 me ‘Apnly even bead slong ineribed tne e2ae2H Bieaec vi Unstattation) ‘+ Using a piston heater or the lke, heat the ring gear §to approximately 100°C for 3 minutes. + Fitthe ring gear S with the non-chamtered side of its teeth toward the flywheel 6. ‘A: Chamiered side of ring gear 3] Fitting rear oil seal + Apply engine ol tothe lip A ofthe rear ol seal 8. '* Fitthe rear oil seal 8 onto the flywheel housing 9 with its “UP” mark on its top as shown in the drawing. «Make sure the rear oil seal’s sealant application surface is free of ol! and other contamination, » Apply an even, unbroken bead of sealant, and fit the rear oil seal within three minutes ofthe sealant’s application. CAUTION /\ + When fitting the rear oil seal, make sure that tis correctly in po tion, + Apply anew bead of sealant whenever the rear oil seal’s mounting bolts have been loosened. «After fitting the rear oll seal, wait at least an hour before starting the engine. 9] Installing flywheel housing Usinga dial gauge, check or eccentricity nthe flywheel housing joint sec- tion. (Pass the dial gauge around the inside diameter) If eccentricity exceeds the specified limit, oosen the bolts and lightly strike the housing to rectly its position. 4-53CRANKSHAFT AND CRANKCASE @ Disassembly sequence 4 Bolt 10 Thrust plate 2 Lower main bearing 11 Side seal 3. No. 1 main bearing cap 42 Crankshaft assembly 4 No. 2 main bearing cap 13 Front oil seat singer 5 No. 3 main bearing cap 14 Crankshaft gear 6 No, 4 main bearing cap 15 Key 7 No. 5 main bearing cap 16 Rear oil seal slinger 8 No. 6 main bearing cap 17 Crankshaft 9 Rear main bearing cap 18 Upper main bearing CAUTION, 19 Front plate 20 Gasket 21 Crankease #41: Check valve (Gr 12, #2: Oiljet (1) Gr 12 @: Non-reusable part ‘Do not remove the crankshaft gear 14 unless defects are evident. @ Assembly sequence Reverse the order of disassembly. U-54ii Service standards Unit: mm Location ‘Maintenance item ean ene o Limit | Remedy = [ Grankshait ond play 01010028 4 | inspect 2,18 | Mainbearing [Oi clearance 7a]0.0810 008 O18 | Replace Span when free = Toss than 92.5 77 | Grankshait [Bena 0.02 orless 0.05 | Replace Pin-andjoumal [Roundness 0.07 orless 0.03 | Cone or Gylnaily 0.006 orless = replace 23 | Distortion of crankcase top surface 0.07 orless 02 | Gonestor replace @ Tightening torques Unit: N-m (kfm) Location | Parts to be tightened Tightening torque Remarks, 1 [Main bearing cap mounting bot 50 (6) + 90° 5° Wet A Lubricants and sealants Location Points of appication Kinds ‘Quantity 9 _ | Side seal mounting surfaces of rear main bearing Fivesbond 12076 [As required 2, 18 _| Main bearing inside surfaces Engine of ‘Rs required T__| Sido seal ends and grooves ‘Threebond 12076 Asrequired 1-55CRANKSHAFT AND CRANKCASE © Special tools Unit: mm Toeation "ool name and shape Pan Ne. Application 3109. | Socket Wrench vwicorsoo [Tene cmectng od cap moaning ores Bearing Cop son 9 Extractor MHo61083 ‘Removing main bearing caps we x 125 co ste 14 | cearPuter wnoste2s | Removing crankshalt gear Rear O4 Sel 16 Slinger Installer ‘MHO62677 Installing rear oll seal slinger 4-5603518! 03520] (a7) # Service procedure © Pre-disassembly inspection Crankshaft assembly end play Ifthe measurement exceeds the specified limit, replace the thrust plate 10 with an oversize type. (1) P11-59 40.18, +0.30, +0.45 mm {installation} Install the main bearings 2, 18 such that their lugs A fit into the corre- sponding grooves. CAUTION A\. ‘The upper main bearing 18 has an oil hole B. The lower main bear- ing 2has no oll hole. Take care not to confuse the upper and lower parts, {Inspection} CAUTION A\. + Donot attempt to manually expand either bearing 2, 18 if its span is insufficient. ‘+ Upper and lower bearings 2, 18 must be replaced as a set. (1) Span when free Ifeither bearing's span when free exceeds the specified limit, he bear- ings 2, 18 must be replaced. (2) Main bearing-to-crankshaft clearance Many measurement exceeds the specified limit, replace the defective part(s). HH the main bearings 2, 18 are replaced with undersize types, rectify the ‘outside diameter of the crankshaft 12 journal to the specified undersize dimension. (1) P11-60 4-57CRANKSHAFT AND CRANKCASE 3] to[S) Main bearing caps (Removal, Side seals 11 are pressed into the rear main bearing cap 8 to achieve a secure fit in the crankcase 21, Therefore, the rear bearing cap must be removed with the —) Bearing Cap Extractor. 9st [Instaliation] 3 5 ‘* Fit main bearing caps 3 to 8 with their front marks ("=") pointing toward the front of the engine. a0 « Fitthe rearmain bearing cap 9 with its embossed mark (‘R") positioned Slo ‘al as shown in the drawing. ° ° © The bolts 1 can be reused only three times. Before fing the bolts , 3 make a punch mark on the head of each one to indicate how many times ithas been reused. CAUTION A\. if any bolt already has three punch marks, it cannot be used again; replace it with a new one. * Tighten the bolts 1 to the specified torque [59 N (6 kaf-m]. Then, turn the bolts further in accordance with the following procedure: ‘Tum the holder B of the (E] Socket Wrench counter-clockwise to ten- sion the bult-in spring. E ©: Socket D:Rod E: Rod (extension) 1901 ‘© Set the socket wrench such thatthe buil-n spring force forces the rod E against the crankshaft assembly 12. © On the holder B, select the inscribed line F that is easiest to see. © Using the selectedine asareference, turnthe socket € 90° clockwise. (One gradation on the scale G represents 5°.) CAUTION A\. Since the bolts 1 utilize the plastic region tightening method, they must not be tightened further after this procedure, Ar instaling the main bearing caps: Check that the crankshalt assembly 12 can be turned easily by hand; © Check the amount of end play in the crankshaft assembly 12. mpi-s7 1-589 sea! 7 03526) ti [iq] installing thrust plates Fit a thrust plate 10 on each side of the main bearing caps 9 and at the rear end of the crankcase 21 such that the oil grooves A are on the out- side. B: Locating pin CAUTION 4, ———_ If oversize thrust plates 10 are used, they must be fitted on both sides of the bearing caps 9. Ensure that the bearing cap rear thrust plates and the rearmost thrust plate in the erankease 21 are the same size. Note, however, that the front and rear thrust plates on each bearing cap may be of different sizes. (4) instatting side seals * Fillthe sealant into the side seal mounting grooves A in the rear main bearing cap 9. ‘+ Drive side seals 11 with their ends B coated with sealant into the ‘grooves between the rear main bearing cap 9 and crankcase 21 : Rear main bearing side D: Crankcase side + Apply sealant to the main bearing cap 9 at the section E where the side seal has been installed, [14] Crankshaft gear [Removal] ‘Avoid striking the crankshaft gear 14 when itis removed. [Installation] Heat the crankshaft gear 14 with a piston heater to approx. 100°C before installation. NOTE Be sure to install the key 15 which prevents the gear from rotating on the shaft. [1g] installing rear oil seal stinger Fitthe rear ol seal slinger 16 by striking the end of the @) Oil Seal Stinger Installer until the installer section A presses firmly against the guide sec- tion B. 11-59CRANKSHAFT AND CRANKCASE [17] Crankshaft {Inspection} (1) Roundness and cylindricity of crankshaft journal and pin {f either measurement exceeds the specified limit, replace the crank: shaft 17 or grind it to undersize. (2) Bend © Support the crankshaft 17 at its No. 1 journal A and No. 7 journal B. Measure the extent of bending in the crankshaft at the centre of the No. 4 journal C. * Ifthe measurement exceeds the specified limit, replace the crank- shaft. With the dial indicator applied to the centre journal, turn the crankshaft 17 through one revolution. One-half of the dial indi- cator reading represents the extent of bending. [Rectification] NOTE Ifthe crankshaft 17 is rectified by grinding, the main bearing 2, 18 must be replaced with undersized ones. ‘+ Grind such that the centre-to-centre distance C between the journal A _| | and pin B does not change. 7 ©:57.5:£0.075 mm 2107 ‘= Grind such that the journal width D and pin width E do not change. D:95 mm (No. 1 journal $2 mm) . E41 *92) mm ‘= Finish the comer fillet smoothly and to the specified radius F. F:R4£0.2 mm + ‘Carryout magnetic inspection to check for cracks caused by grinding, ‘Also, check that the Shore hardness of the surface has not dropped be- low Hs 75. ‘= When grinding G, turn the crankshaft 17 counter-clockwise as viewed fromits front end. The grinder H should rotate in the same direction. ‘+ When finishing K the crankshaft 17 with sandpaper or a whetstone J, rotate the crankshaft clockwise. 1-60Crankshatt undersize dimensions Unit: men I Degree of undersize 025 050 078 190 Finished journal damoter 77.6910 77.70 Tras 77.45 Writ 721 76.9610 76.98 Finished pin diameter [ese106a71 | ean toes Bhi9%0 6421 69.8410 99.98 Roundness Ot orless Oylindicty 0.008 ortess < Distortion of crankcase top surface If distortion exceeds the specified limit, correct it with a surface grinder. A: Measurement positions CAUTION /\. * When grinding the: crankcase: 21, take care that the piston projec- = ¢ tions stay within specification, apr | ?) cosa 1-61GROUP 12 LUBRICATION SPECIFICATIONS 2 STRUCTURE AND OPERATION ... 3 TROUBLESHOOTING... 9 ON-VEHICLE INSPECTION AND ADJUSTMENT © Oil Filter Replacement . 10 + Engine Oil Replacement " * Oil Pressure Measurement " OIL PAN, OIL STRAINER, AND OIL JET ......-- 0 sees eee eee e ee 14 OIL PUMP .. eee eneeeenenseseeeeuneee Peers sees 16 OIL COOLER AND OIL FILTER .........00eee cece ee eeeeeeeee eee 20 (12 | 12-1SPECIFICATIONS [ item Spectcalions Tadao acon Oipimp une Oliter pe Spinon papocter pe Bypate ve pe ton vo Ol cooler ype Sha and ate ype (rat Woe) Eine a {APIOD orabove ‘Oll quantity dm? {L) Oil pan 18 (18) Outer Tae 12-2STRUCTURE AND OPERATION Lubrication System (Oil Flow) 12 7 2 — “4 W 20 22, T ant ‘8] a » Hom | | 1 Ag 27 —— — 2209| Main oil gallery Crankshaft main bearing Connecting rod bearing Connecting rod bushing Idler gear bushing Timing gear Check valve for cil jet Piston ‘Camshatt bushing 40 Rocker bushing 11 Push rod 12 Tappet 13 Injection pump 14 Automatic timer wevonsens 15 16 7 18 19 20 24 24 25 26 a7 Engine oil pressure switch Engine oll bypass alarm switch Bypass valve (Builtin within ol iter) Fullow fiter element Bypass fitter element Cit cooter Bypass valve Regulator valve Oil pump Relief valve (Built-in within oil pump) Oil strainer Turbocharger Warning lamp Oil pan 12-3STRUCTURE AND OPERATION Oil Pump 1 Crankshaft gear 2 Oil pump gear 3 Oil pump 4 Relief valve A:To oil cooler B: From oil strainer ©: To oll pan Oilpump 3isageartype. itis driven by rotation of the crankshaft via crankshaft gear 1 and oil pump gear 2. Relief valve 4 is fitted to the oil pump. When the oil pump dis- charge pressure exceeds a specified level, the relief valve re- turns some of the engine cil to the oll pan, thus protecting the lubrication system from excessive oil pressure. Oil Cooler and Oil Filter Oil pressure switch Oil cooler Regulator valve Bypass filter Ol fiter Full-flow fier Bypass valve Bypass valve Oi bypass alarm switch wovansons Coolant outlet = Coolant inlet To oll cooler To oll pan. E: To oll main gallery gomr 12-408432| 06434] “42 | ‘When the ois viscosity is high at low temperatures or when the oil cooler 2 elements clogged and resists the oils flow, the bypass valve 8 opens, thus allowing oil to flow to the oil filter § without passing through the cooler. © Bypass valve @ Regulator valve When the pressure of oil going to the main oil gallery exceeds a speci- fied level, regulator valve 3 opens, allowing some of the oil to return to the oil pan. The oil pressure is thus constantly regulated, ® Oil filter ‘The oil fiter is a spin-on fiter-paper type incorporating a fullflow filter 6 and a bypass fiter 4. A bypass valve 7 is fitted at the bottom of the fiter assembly. If the ele- ‘ments become clogged, the bypass valve opens and allows oil to flow to the main gallery E without passing through the elements. This operation prevents seizure of the engine. @ Oil pressure switch Ifthe pressure of clfed to the main oil gallery E drops below the speci- fied level, electric contacts close inside the pressure switch 1. As a result, awaming lamp illuminates in the meterclusterto alert the driver. 12-5STRUCTURE AND OPERATION © Engine oil bypass alarm switch * Ifthe oil filter elements become clogged, the flow of engine oil decreases. The engine oil bypass alarm switch 9s fited to prevent engine seizure if this happens. + Clogging of the oi fiter elements causes a valve to open inside the cil bypass alarm switch 9. Thus, engine oilflows directly to the main oll gallery E without passing through the full‘low fiter element 6. ‘When the engine oil bypass alarm switch operates, a warning lamp luminates to alert the driver. @ Main bearing and connecting rod bearing 1 Oilmain galery 2 Main bearing 3 Crankshaft 4 Connecting rod bearing ‘A: Connecting rod oll passage Ol supplied via the oil passage in the crankshaft flows through the oil passage B in the connecting rod to jubricate the connecting rod's small end. © Timing gear ‘Thrust plate ‘Camshaft Idler gear bushing Automatic timer Timing gear case Idler gear Idler shatt Camshaft gear Camshaft bushing No. 1 Main bearing Oilpipe evousens A: From main oil gallery Oil jet odbat Engine oil from the main oil gallery passes through the camshaft 2 and idler shaft 7 to lubricate the gears. Also, an oil jet B is provided in the timing gear case 5 to provide constant, forced lubrication of the automatic timer 4, 12-6© Valve mechanism 1 Crankcase Cylinder head Rocker shatt Rocker shaft bracket Rocker bushing Rocker Push rod Tappet ‘Camshatt bushing No. 1 worvoasen : Rocker oil hole il main gallery ©:To oll pan © Oil jet 1 Piston 2 Oiljet 3 Check valve A: Main oll gallery An il jet 2s fitted in the lower part of the main oil gallery A for each piston. These oil jets cool the pistons 1 by injecting oll into them. Each oil jet is fited with a check valve 3 that opens and closes at specified oll pressure levels. At low oil pressures, these check valves close to maintain the re- ‘quired volume of oil in the lubrication system and prevent reductions in oi pressure, @ Turbocharger 1 Bearing housing 2 Piston ring 3 Bearing A: From main oll gallery B:To oil pan Via an oil pipe, engine oit is delivered from the main oil gallery to the bear- inghousing 1 to lubricate bearing 3. Ateach end of the turbine wheel shaft, piston ring 2 acts as an oil seal. 127STRUCTURE AND OPERATION | 4 Injection pump 2 Governor 3 Oilpipe 4 Bearing cover | 5 Automatic timer A: From main oil gallery B:Tooil pan 1 B2282F 12-8TROUBLESHOCTING 12 Symptoms = . E Remarcs 3] j3[8 Bee sl/sl=|a 515\2/8 Possible causes G|6/3]o Oi coco element nstaled Fooly SI Gackot defective Ofoto ‘Oring defective ofolo i cooler (Oi cooler element clogged Slot Gileoverelment damaged o[o[o Fatigue in bypass valve sping o Fatigue in regustor valve spring o (i pump matuneoning oo ctpump Tren botoen al pnpaserantalmame eee || | 9 Fatigue rll valve spaing ott Oifiterfited pooty e oi iter Zioment cogued ofS Gasket defective 3 Oi sivainer insted poor andlor dogged oto Crankshaft of seal defective o|men Grankehal rear of eal defective [ect Timing goer caso installed pooty Often Piston cooing ols) detective 3 il workng ts way up nto combustion chamber) 3 ‘i werking te way down into combustion chamber) © Givisosty too high 3S ‘Unslabie of quality 3 Deteioratonin ol ° Ft ed tho ot 12-9ON-VEHICLE INSPECTION AND ADJUSTMENT Oil Filter Replacement © Special tools Unit nm Location “Tool name and shape Part No. ‘Application enes59s wea t ‘MHO63200 — |} oiltiter wrench 01503 {Removall 17866 [instattation] + Clean the surface on the oil cooler body 1 that makes contact with the oil fter 2. ‘+ Apply a film of engine oil to the gasket area A of the fter 2. + Serewon the oilfiter until the gasket area A touches the cil cooler body 1. Then, give the oil fiter another three-quarters of a tum to tighten it completely. ‘+ Start the engine and check that no oil leaks from gasket area A. ‘+ Check the engine oil level and add oil necessary. 7 2 0818 12-10Engine Oil Replacement @ Tightening torques 12] Unit: N-m {kgf-m) Cocation’ Parts to be tightened Tightening torque Remarks 2 Gilpan drain plug 7) = $7969 [Draining) Warm up the engine and remove the oil filler cap 1. Then, remove the oil pan drain plug 2 and allow the engine oil to drain out. (Filing) Tighten the oil pan drain plug 2to the specified torque. Then, pour the spe- ified amount of new engine oil into the engine. Engine oil API classification: Class CD or better Quantity: Oil pan: 18 dm? (18 L} Oil filter: 1.1 dm? {1.1 L} WARNING A\ ‘+ Wipe up any spilled engine oil since it can cause a fire. ‘+ Donot touch oll when the engine is hot since it can inflict severe burns. CAUTION A\. When pouring oil into the engine, take care not to spill any on the V-belts. Contact with oil could make the V-belts slip, rendering the cooling system less effective.ON-VEHICLE INSPECTION AND ADJUSTMENT Oil Pressure Measurement Service standards Unit : kPa {kgtfemn®) Location Maintenance item Standard value Limit | Remedy = [Oiipressure (at [At neload minimum speed 147 (15) a9(08) Adjust ciltemperature S010 90°C) [Atno-load maximum speed 294 to 490 (810 5} 196 (2) @ Tightening torque Unit: N-m fkgf-m} Location | Paris to be tightened Tightening torque Remarks 2 | Engine oll pressure svtch 7201.2) = A Sealant ovation Points of application Type Quantity 2 [Wrap around thread of engine il pressure switch Thresbond 1271 As required sear’ 12-12 ‘+ Remove the engine oil pressure switch 2 from the oil cooler 1. ‘= Mount the oil pressure gauge after installing adaptor 3 onto oll cooler 1. ‘+ Warm up the engine until the oll temperature reaches 70 to 90°C. ‘+ Measure the oil pressure at the engine's no-load minimum speed and no-load maximum speed. If the measurements are below specifica- tion, overhaul the lubrication system. * After taking measurements, refit the engine oll pressure switch 2 and tighten it to the specified torque. Inspection of engine oll pressure switch (1) P.12-21MEMO 12-13OIL PAN, OIL STRAINER, AND OIL JET @ Tightening torques @ Disassembly sequence Drain plug Bolt Oil pan Oil strainer O-ring Check valve Oiljet Engine oll level sensor O-ring waransens +: Crankcase (2) Gr 11 ©: Non-reusable part @ Assembly sequence Reverse the order of disassembly. Unit: Nom fkgf-m} [Location Parts to be tightened Tightening torque Remarks 1 Drain plug 63 {7) = 6 | Check valve 2813) Wer A Lubricant and sealant Location Points of application Type Quantity 3 __| Grankease mounting sure ot ol pan "Taroebond 1207 ‘As required 3 __| Entre dreumferene of Oving Engine of As required | Gheck valve thread Engine ot Ae required 10746) 12-14 © Service procedure 3] Fitting oll pan ‘© Apply sealant A to the mounting surface of oil pan3 asilustrated. Apply the sealant evenly and without breaks. © Within three minutes of applying sealant A foil pan Sonto the crank caset, CAUTION A\, * Clean the oii pan mounting surface and ensure it is free of oily substances before applying sealant A. ‘© Carefully mount oil pan 3 exactly in the correct position. Ensure that sealant A:does not spread to other areas. © After fitting olf pan 3, wait at least one hour before starting the en- gine. ‘+ Apply a new bead of sealant A whenever the oil pan mounting bolts 2 have been loosened or removed,TL 10s T OFF A mr 12 Engine oil level sensor ‘© Check for electrical continuity as shown below. Co @ ON one OFF O—O Terminalto-terminal continuity * Replace the engine oil level sensor 8 if it appears defective. : Float 12-15OIL PUMP 2 Bot 3 Split pin 4 Seat 5 Spring 6 Ralief valve 7 Oil pump cover 10 O-ring #2: Crankshatt gear +3: Drive gear @: Non-reusable part @ Disassembly sequence 1 Oil pump assembly 8 Driven gear assembly 9 Oil pump case assembly #4: Crankcase (1) Gr 11 © Assembly sequence Reverse the order of disassembly. 88220(1.0202) 10728 Service standards Unit: mm 5 ‘Siandard value Location Maintenance item eae ee ry um | Remedy [Backlash between oll pump gear and crankshaft 0.0910 0.18, 3 | Replace gear (1 Gr tt © __|Reliet valve opening pressure THEO KPa (11.0 kolfeme) = = 5 __| Relief valve spring load (installed length = 38) 28:18%9 = Replace 7,*3 _ | Clearance between drive gear shaft and ol pump 120] 0.0410 007 015 | Replace cover 3,9 | Clearance between driven gear shaft and driven (20) 0.0410 0.07 0.15 | Replace gear assombly 8,8, *3 | Diflerence between height of each gear and depth 0011007 018 | Replace ofcase Clearance between case and tooth tips of each 0.10100.18 02 gear @ Tightening torque Unit: N-m (kgf-m} Location Paris to be tightened “Tightening torque Remarks 2 [Oiipump cover mounting bolt ‘A Lubricants Unit: N-m {kgf-m} Location Point of application Type. Quantity 70 Entire crcumferenoe of O-ring Engine of ‘As required 12-16OIL PUMP 10727 12 Service procedure 4] Installation of seat ‘A: Oil pump assembly side [i] t0[] inspection of cover, driven gear assembly, and gear and case assembly Measure the clearance between each gear shaft and the internal diame- ters of the cover and case, 7] [3] Installing oif pump cover and oil pump case assembly ‘+ Position the oil pump cover 7 on oil pump case assembly 9 using two 49 mm pins A. ‘+ Fit the bolts 2 and tighten them to the specified torque. 12-17OIL PUMP 0729. 12-18 ‘© Remove the pins A, then fit the other bolts 2 and tighten them to the specified torque. NOTE After assembly, turn the oil pump gear B by hand and check that itrotates smoothly. if the gear does not rotate smoothly, disas- semble and reassemble the components. 8] [3] inspection of driven gear assembly and of gear and case as- sembly (1) Differences between gear heights and case depth Replace any component whose measurement is out of specification, (@) Clearance between gear teeth and case Replace any component whose measurement is out of specification.12 MEMO 12-19OIL COOLER AND OIL FILTER 17965 @ Disassembly sequence 1 Oilfiter (P1210 12 Plug 2 Oil cooler assembly 13 Oxting 3 Nut 14 Spring 4 O-ring 15 Bypass valve 5 Oil cooler element 16 Oil bypass alarm switch 6 Engine oil pressure switch 17 Oil cooler body 7 Plug 18 Gasket 8 O-ring 9 Spring +: Crankcase ([i Gr tt 40 Regulator valve @: Non-reusable part 11 Drain plug @ Assembly sequence Reverse the order of disassembly. Service standards Unit: KPa tkaffem2} Location Maintenance item Standard value Limit | Remedy 6 _| Engine oil pressure switch activating pressure 494 10(0520.1) = Replace JO _| Regulator valve opening pressure 440229 (8520.3) = Replace 75 _| Bypass valve opening pressure 1390+29 (4020.3) = Replace 46 _ | Oilbypass alarm switch activating pressure 137 £20 (1420.3) = Replace 12-20@ Tightening torques [12] Unit: Nom {kgf-m) Location’ Paris to be tightened Tightening torque Remarks 3 _| Nat(0ll cooler element mounting) 19.525 (20205) = 6 _| Engine oll pressure switch 12 (1.2) When engine is cold 7__| Plug (Regulator valve spring mounting) 79525120205) = 11__ [Drain plug (Oil coolen 348.5) = 12 __| Plug (Bypass vaive spring mounting) 18526 (202035) = 16 __| Engine oll bypass alarm switch 1210 16(1.2 10 1.8) 1 = A Lubricant and sealant Location | Points of application Type Quantity 1 __| Apply sparingly to oil fiter gasket (1) P.12-10 Engine ol! ‘As required 4 _| Apply to O-rings Engine ofl ‘As required | 6 __| Apply to thread of engine oit pressure switch Threebond 1211 ‘As required 04240] Service procedure @ Cleaning + Check whether carbon deposits or sludge have accumulated in the oil passages ofoilcooler element 5 and oll cooler body 17 orinthe oilcool- er's bypass arrangement. Remove any deposits with cleaning sealant. + Clean out any water scale or fur that has accumulated inthe oil cooler clement 5 or ol cooler body 17. n of oil cooler element 5] inspec ‘+ Seal the outlet A ofthe oll cooler element 5 and connect a hose to the engine oil inlet B. Then, immerse the oll cooler element in a tank of water. «Apply air pressure of 980 kPa (10 kgticm®} via the hose and check whether air leaks out of the oil cooler element 5. + Hany airleaks, replace the oll cooler element. [6] inspection of engine oil pressure switch Perform the following inspections and replace the engine oil pressure switch 6 if any defect is apparent. * Withno air pressure applied to the engine oil pressure switch 6, check that there is continuity between the terminal © and body ®. ‘* Starting from 0 kPa {0 kgticm?}, apply and gradually increase the air pressure A. Check that the air pressure is within the specified range when the continuity disappears between the terminal © and body @. : Air pressure gauge 12-21Li3 | GROUP 13 FUEL AND ENGINE CONTROL SPECIFICATIONS .........000eeeeeeeeee 2 STRUCTURE AND OPERATION 3 TROUBLESHOOTING .... 2.2... 0s cess eee eect teen eee near eee 10 ON-VEHICLE INSPECTION AND ADJUSTMENT = Checking and Adjusting Injection Timing 14 ‘+ Checking and Adjusting Minimum and Maximum No-load Speeds 7 FUEL FILTER ...cccsscrscccseccccsescccccsccseccrronsssccnese 18 INJECTION PUMP ....... 00. ce cence cere eee eeeeeeeeeeeeeeennee 20 I INJECTION NOZZLE ....... 2. ce eeeeee cence eeee ee eeeeneeeneeee 24 13-1SPECIFICATIONS Injection Pump Engine model e0aaT ter Manufacturer Zexel Model Bosch A Govemar ype iSViype alt speed mechanical govemor Feed pump type KS ‘Automatic timer ype = Injection Nozzle Engine mace eDaeT tem Manuiacturer Zexel Model Hole-ype (epring) No. of holes 3 Hole diameter (rm) 90.31 x2 I 90.29 x3) Fuel filter item Specifications Fuel filter ype 13-2 Spin-on type (paper fiter)STRUCTURE AND OPERATION 13 Fuel System (Fuel flow) 19008] 1 Fuel feed hose & Fuel suction pipe 2 Fuel fter 9 Feed pump 9 Injection nozzle 10 Injection pump 4 Fuel feed pipe 11 Overflow valve 5 Fuel return pipe 42 Leakotf pipe 6 Fuel tank 13 injection pipe 7 Governor Fuel from the fuel tank 6 is drawn up by the feed pump 9 and strained by the fue! fier 2. The feed pump is driven by a ‘cam in the injection pump 10. Ar filtration, fuel is fed to the injection purnp 10. From there, iis fed under high pressure to the injection nozzles 3. The injection nozzles spray the fuel into the combustion chambers. ‘Surplus fue! from the injection nozzles 3 returns to the fuel tank 6 via the fuel return pipe 5. Ifthe fuel pressure in the injection pump 10 exceeds a preset level, the overflow valve 11 opens to allow excess fuel to return to the fuel tank 6, 13-3STRUCTURE AND OPERATION Fuel Filter o1822| ora2a| 13-4 1 t 1 Fuel filter element 2 Fuel filter head ‘A: From feed pump B:To injection pump ‘The fuel filter separates any water content out of fuel fed from the injection pump’s feed pump, and fuel filter element 1 re- moves any impurities. Delivery valve holder Delivery valve spring Delivery valve Plunger barrel ‘Control pinion Plunger Control rack Control sleeve Plunger spring “Tappet ‘Camshaft weavonaens ‘The injection pump feeds fuel to the injection nozzles under high pressure and incorporates a mechanism for increasing and de- ‘creasing the fuel flow.13 ° 10} " @ Fuel feed action ‘A: Fuel drawn in B: Start of pressure feed C:End of pressure feed InleVoutiet hole E:Lead © opens eas ore27| ‘As the plunger 6 rises and its lead E meets the fuel inletoutiet hole D, fuel flows through the center of the plunger and is expelled from the inlet/outlet hole. Regardless of how much further the plunger rises, no fuel feed takes place thereatter. ‘The stroke length F ofthe plunger during which pressure feed takes place |s known as the “effective stroke.” @ Injection volume adjustment mechanism ‘To match changes in engine loading, an adjustment mechanism controls ‘the amount of fuel injected. This mechanism turns the plunger 6 by a given angle, thereby altering the point at which the fue! inleoutlet hole D meets the lead E. Simply stated, the effective stroke is made longer or shorter, single controlrack7 is used to rotate every plunger in the engine, so the plungers rotate simultaneously and by the same angle. @ Delivery valve G: Pressurization starts H: Injection J: Pressurization ends (Starting suction) K: Suction ends L:Suction stroke Fuel highly pressurized by plunger pushes up delivery valve 3 for injec tion, and when delivery of pressurized fuel ends, delivery valve returns by the force of delivery valve spring 2 to close fuel passage, thus avoiding reverse flow of fuel. Delivery valve lowers further to rest at its seat, and for this stroke L, residual pressure between delivery valve and injection nozzle is for an instant lowered. This return suction makes fuel-cutting at nozzles effective and avoids post-injection dripping. 13-5STRUCTURE AND OPERATION © Overflow valve u When the fuel pressure in the injection pump exceeds a preset level, the steel ball Uis pushed up, allowing fuel to flow out from the injection pump and return to the fuel tank. This stabilizes the fuel temperature and tem- A perature distribution in the injection pump and keeps the injection rate A constant in each cylinder. ( Boras Governor sisal 4. Governor housing 40 Idling subspring 2 Supporting lever shatt 41 Ungleich spring 3 Guide lever 42 Fultload stopper bolt 4 Tension lever 13 Flyweight 5 Start spring 14 Stop lever 6 Shackle 15 Adjusting lever 7 Governor cover 46 Camshaft 8 Floating lever 17 Swivel lever 8 Governor spring 18 Control rack ‘The governor is an all-speed type that utilizes the centrifugal force of a flyweight arrangement. In addition to controlling the ‘maximum and minimum speeds, the governor automatically controls the engine speed at any intermediate speed position. 13-6Feed Pump (i3 1. Priming pump 2 Inlet check valve 3 Feed pump housing 4 Gauze filter 5 Outlet check valve From fuel tank B:To fuel filter ‘The feed pump is driven by the camshattin the injection pump. The priming pump 1 enables fuel tobe drawn upmanually when the injection pumpis stationary. Itis particularly useful for air bleeding. ‘The gauze filter 4 removes large impurities {rom fuel drawn up from the fuel tank and thus, prevents clogging ofthe feed pump. It must be washed regularly in gas oll, asa 01835] 626) orss7! @ Suction stroke ‘When the injection purnp camshaft 6 forces up the push rod 7, fuel in the suction chamber C is compressed and opens the outlet check valve 8, Most ofthe fuel forced out is drawn into the pressure chamber D below the piston. © Pressure feed stroke ‘As the camshaft 6 turns and the cam loses its lit, the piston 9 is pushed down by the piston spring 8. The fuel in the pressure chamber D is thus forced out and fed toward the fue! fiter 8, ‘Atthe same time, the outlet check valve § closes and the inlet check valve 2 opens. AS a result, fuel is again drawn into the suction chamber ©. @ Stoppage When pressurein the pressure chamber D exceeds a preset level, thepis- ton spring 8 cannot push back the piston 9. The pump therefore stops op- erating, preventing pressure in the fuel filter from rising more than neces- sary. 13-7STRUCTURE AND OPERATION Injection Nozzles 13-8 1 Washer 2 Spring 8 Nozzle tip 4 Needle valve ‘A: From injection pump B:To fuel tank When pressurized fuel fed from the injection pump over- comes the spring 2, it pushes up the needle valve 4 and ‘prays out ofthe orifice at the end of the nozzle. “The injection pressure is adjusted by increasing or decreas- ing the thickness of the washer 1.MEMOTROUBLESHOOTING ‘Symptoms Engine maximum speed too high Engine dificult to start Engine knocks Unstable engine output Possible causes insufficient engine output Engine stops soon affer starting Engine does not reach maximum speed Unstable engine idling ‘Accelerator pedal too stif Defective fuel supply Injection pump [Sticky plunger proper Sick contol rack Sticky delivery valve ‘Worn tappet Worn camshaft 00] O[OfO} Engine wil not start Poorly adjusted injection timing o| fo ° ‘Worn plunger o| fo Defective delivery valve seat ° Excessively advanced injection timing ° Insufficient plunger side stroke Broken plunger spring Defective sliding action in control rack ° “Tappet wom or not siding correct Broken delivery valve spring L Poor aitighiness due to loose delivery valve holder ojofofofofolo Defective delivery valve operation ‘Loose control pinion Plunger spring not seating correctly Dalivery valve halder too tight Uneven injection volume to cyinders ° ofofojolo| Fuslfeed pump | Gauze fier clogged ‘Ghedk valve not operating Sticky piston Sticky push rod) ofofofofo! ‘Wom tappet Defective check valve operation of fo i) Piston wom of fo ° 13-1013 Sympioms 3 al lelg 2) |s/8 3/2/8)o/5/E| |2 s/e] (S/clEg|2/8l ei sie Ble] sl 8ls/s/els|s| se 2/318) 81g |elalel2| 21s slE\s/s/elsie|S|2| als elev Seige lgialelals Possible causes 6/5/05) 2/a)5|ala|a<|é Governor Trace oad stopper poston Weak governor sping o Inconel adjusted conoliever o 6 Fiji na operating eecively 3 Weak idiing spring ° Bont ks o Excasve Won oF play ks 3 Tooso round nat Te Poory adjusted ding sat bok 5 Defective sliding action in control lever ° ‘Stop mechanism damaged 3 Injestion nozzles | Sicky need valve o Valve opening pressure oo ow 8 a Blocked injection orifice oO 9° oO ° o Poor airtightness in nozzle oO oO oO ) oO Vato opering pressure too Figh 5 ‘Broken spring o[o Defecve sling acon innesdie vale o Defective vaive opening pressure ° Weakness/deterioration in spring oO Fuel fiter | Fite (andor secondary fier) logged 3° ° oo Fueltankempiy 5 Fuel pipes booked andor fol lealng Kom connodtons o Air or water in fuel system ° ° o}o Low-quality fuel in use ole} fol jo Cracked fuel pipe ° eal uel tank 6 Incorrect oll viscosity Gr. 12 O° Incorrect vatve clearance OG. 11 ° o Detective head gasket mew! [o o CI Wear and/or carbon deposits on valve and valve seat Gr. 1 ° 9° Weakness/deterioration in valve spring Gr. 11 ° 3° ‘Womidamaged piston ring(s) Meri] [o oO 13-1TROUBLESHOOTING ‘Aiddns jany an709}80, {mis 001 fepad 10}819]800y doje tou jy euibuS, poeds wnuipeus yoee: jou seop eujbua | Burejs seye uoos sdoys eursua Buypl euibue eiqesun ‘UBy 00) paads wnuurrew euj6u3 yndino eujBue wueroqynsuy vadino euBue erqeisun ‘syo0uy aujbuR yeIs O} yNOWWIP EUIBUS, o ° o ° ° wes 10u jum eUjBUR ‘Symptoms Possible causes Mert Mor 11 Worn/damaged piston ring groove(®) Wom piston and cylinder liner Mon 14 Mar 54 Cooling system malfunctioning Detective starter switch Defective glow relay Gr 54 13-1213 MEMO 13-13ON-VEHICLE INSPECTION AND ADJUSTMENT Checking and Adjusting Injection Timing Service standards Location Maintenance item Standard value Limit | Remedy —__ | Fustinjscion ining (TOO) 7 = ‘Adjust @ Tightening torques Unit: N-m {kgf} ‘Location | Parts to be tightened “Tightening torque Remarks 7 _[Union nat 2425) = 2 [beckplate Tato 108 (O80 i) = 3 [Delivery valve noider 291044 (4.01045) = 72, 13 | Injection pump mounting nak 291039 (01040) = &) Special tools 13-14 [fozaton Tatra aap ane Tapieaon | fC 2,19 |rberet wsstoes | secon an assent these tn an scree flat: 14 5103 [Inspection} ‘= From the injection pump's No. 1 cylinder, remove the union nut 1 of injection pipe, lock plate 2, delivery valve holder 3, stopper 4, delivery valve spring 5, and delivery valve 6. + Fit the delivery valve holder 3, CAUTION /A\. Place all parts in gas oil after removal to keep them free of dust.(is | 0790e. Painter 16436 ‘© Fit an injection pipe 7 onto cylinder No. 1. Point the pipe's other end downward such that fuel flowing out can be seen clearly. ‘© Rotate the crankshaft pulley clockwise (as seen from the front of engine) by at least 180° and bring cylinder No. 1 to approximately 30° BTDC on its compression stroke, + Feed fue into the injection pump using the priming pump 8. With fuel flowing out of the injection pipe 7, crank the engine slowly clockwise (as seen from the front of engine). CAUTION 4, A Make sure the stop lever 9 on top of the governor is in its engine starting position A. ‘© When the flow of fuel from the injection pipe 7 diminishes, crank the en- gine more stowly. When the low of fuel stops completely, stop cranking the engine. ‘+ Check that the pointer on the flywheel housing indicates a value approximately 1° before the specified fuel injection timing, NOTE + The injection timing is advanced by approximately 1° from the specified timing because the delivery valve spring applies no valve opening pressure. + The specified injection timing is shown on the caution plate attached to the rocker cover. 13-15ON-VEHICLE INSPECTION AND ADJUSTMENT 13-16 * Ifthe fuel injection timing is out of specification, make adjustments in accordance with the following procedure. [Adjustment] «Loosen the injection pump mounting nuts 12, 13. 12: Nut (4-olf; on flange) 43: Nut (1-off) ‘© Ifthe fue! injection timing is overty retarded, incline the injection pump 114 toward the crankcase B. «Ifthe fuel injection timing is overly advanced, incline the injection pump +14 away from the crankcase C. ‘© Turing the injection pump by one of the gradations inscribed on the timer case flange 15 causes a 4° change in the injection timing. 18: Pointer ‘Tighten the nuts 12, 13 tothe specified torque then check the fuel injec- tion timing again. ‘* After checking that the fuel injection timing is up to specification, fit the delivery vale 6, delivery valve spring 5, and stopper 4, and then the delivery valve holder 3, lock plate 2 and union nut 1. © Tighten each part to its specified torque.13 Checking and Adjusting Minimum and Maximum No-load Speeds Service standards Location Maintenance item ‘Standard value Limit_[ Remedy —_ | No-ioad minimum speed (idling speed) 975 1pm, = Adjust —__[No-ioad maximum speed 72320 pm = Adjust s7122 Before making inspections and adjustments, warm up the engine untilthe coolant reaches 80 to 90°C. (1) No-load minimum speed [Inspection} Confirm that the adjust lever 4 is touching the idling set bolt 2. Then ccheck that the minimum speed is up to specification, [Adjustment] Ifthe minimum speed is out of specttication, adjust it using the idling set bott 2. (2) No-load maximum speed LUnspection) Confirm that the adjusting lever 1 is touching the full-speed set bolt 3. ‘Then, check that the maximum speed is up to specification. B:Fullspeed position {Adjustment} If the maximum speed is out of specification, adjust it using the full- speed set bolt 3. NOTE Check that the engine does not stall and that no hunting occurs when the adjusting lever 1is moved quickly from the full-speed position to the idling position. if any abnormality is apparent, make adjustments within the specified range. 13-17FUEL FILTER @ Tightening torques © Disassembly sequence 1 Eyebolt 2 Fuel feed hose 3 Fuel filter element 4 Airvent plug 5 Fuel fter head @ Assembly sequence Reverse the order of disassembly. Unit: N-m {kgf-m) Location Parts to be tightened Tightening torque Remarks 1 | Eyebon 34 (3.5) = 4__|Airvent plug B12 (08212) = A Lubricants ores. Location Points of application Type. ‘Quantity | (3 [aster between fuel iter and uel fiter head Engine of = © Special tools Location Too! name and shape Part No. Application 0 3 Fier MHO061509_ Removing fuel filter ‘Wrench 0 13-18ee 13220 13 Service procedure [3] Fuel titer [Removal] WARNING /i, + Fuel is highly flammable; keep it away from flames and sources of heat. 2 To minimize the $k of fire, wipe up any spilled fuel. [Installation] WARNING /\, Use of an unsuitable fuel filter 3 can lead to fuel leaks and fires. Be sure to use a genuine Mitsubishi filter. * Toft the fuel fitter 3, turn it until the gasket C touches surface B of the fuel fiterhead 5. Then, tighten the fter by 3/4 to 1 turn. Be sure to turn the fiter by hand. ‘© Start the engine and check for fuel leaks. 13-19INJECTION PUMP 8 e $7970 s7071 @ Disassembly sequence 1 Eyebott 6 Eyebolt 11 Injection pump assembly 2 Fuelfeed hose” 7 Leak-off hose 42 O-ring 3 Eyebolt 8 Eyebott 4 Fuel feed hose 9 Oilpipe @: Non-reusable part 5 Injection pipe 10 Injection pump stay @ Assembly sequence Reverse the order of disassembly. WARNING A\ «Fuel is highly flammable; keep it away from flames and sources of heat. + To minimize the risk of fire, wipe up any spilled tuel. CAUTION /\. © Dirt particles in the injection pump assembly 11 can seriously detract from engine performance. To prevent the \gress of dirt, cover all pipes, hoses, and other parts after removal. ‘* Do not hold the injection pump assembly's 11 control levers and allow the assembly to hang from them; when picking up the assembly, always hold its main body. Also, do not remove the levers since this would mal pump malfunction. ‘the 13-20@ Tightening torques Unit: N-m {kfm} Location Paris to be tightoned Tightening torque Remarks © _| Fuolloak-of pipe eye bot 1910 29 (2163) = 7,3 _| Fuethose eye bot W775) = Tnjeaton pipe union nut 24 25) = [8 [ooitine eye bait Bio 1 (OBI0 18) = A Lubricant Location Points of application Type Quantity 12 [Oxrng Engine ol = ©)Special tools Unit: mm Location Tool name and shape ]_ PartNo. Application 19 | Sceket Wrench 12 siaat-tatoo | Remove! and fing of ejection pump o 08876 Service procedure ig [Removal] Installing injection pump assembly 13-21INJECTION PUMP {instalation} ‘= Crank the engine unti the “1 -6* mark on the flywheel is aligned with the pointer A in the flywheel housing inspection window. With the engine in this condition, piston No. 1 is at the top-dead-center (TDC) position of its compression stroke. + Ifthe inlet and exhaust valves of cylinder No. 1 are not pushed up by their push rods with the engine in this condtion, piston No. 1 is at the ‘TDC position ofits compression stroke. I the inlet and exhaust valves are pushed up, turn the crankshatt by 360°. areear| © Align the alignment mark B on the timer case with the notch € on the injection pump gear. aor © Insertthe timer case guide bar D into the front plate quide hole E. Using the bar as a guide, push the injection pump until the injection pump gear almost reaches the idler gear. 07800 ‘© Make sure the notch C on the injection pump gear is aligned with the | alignment mark B on the timer case, then push the injection pump. As c the gears mesh and the injection pump gear tumns, the gear notch C will move in the "F" direction. 17130] 13-22Lis MEMO 13-23INJECTION NOZZLE © Disassembly sequence Injection pipe Fuel leak-oft pipe Bolt Bridge O-ring Injection nozzle assembly Retaining nut Tip packing Straight pin Ee 13) 40 Needle valve @— 12] 11 Nozzle 12 Pressure pin e-—s 30-9) 13 Spring 40] 14 Adjusting shim 41] 15 Nozzle holder 16 Nozzle gasket Z| #:Oylinder head (1) Gr 11 8) @:Non-reusabie part woroasene © Assembly sequence Reverse the order of disassembly. WARNING /\ ‘To minimize the risk of fire, wipe up any spilled fuel, CAUTION A\. + Clean off any carbon deposits before disassembling, reassembling, or adjusting the injection nozzle assembly 6. Before disassembly, check the pressure and shape of the spray and inspect the assembly for fuel leaks. no abnormality is apparent, do not commence disassembly. * Donottouch the sliding part of the needle valve 10. Ifthe sliding partis touched, it could suffer damage or corro- sion, causing the nozzle 11 to lose its air-tightness. © Under no circumstances change the needle valve 10 and nozzle 11 combination used on each cylinder. © Dirt particles in the injection nozzle assembly 6 can seriously detract from engine performance. To prevent the ingress of dirt, cover all mounting points after removal. Service standards Unit: kPa (kgtom?) Location Maintenance item Standard value Limit | Remedy © [Injection pressure(valve opening pressure) BAST (20) Adjust @ Tightening torques Unit: Nom (kgf) Location Parts to be tightened Tightening torque Remarks 1__| Injection pipe union nut 24 (2.5) = ‘3__| Bridge mounting bot 2412.5) = 7 [Retaining nut 29 1039 (804) = 13-24© Special tools Location | Toolname and shape Part No. ‘Application — Nessie caring Toot *105789-0010 _| Cleaning injection nozzle assembly i *Zexel part number Service procedure @ Pre-disassembly inspection Fitthe injection nozzle assembly 6 onto the nozzle tester A ready for in- ‘spection. NOTE Before commencing inspection, operate the lever on the nozzle tester A two or three times to bleed all air out of the arrangement. (1) Checking valve opening pressure ‘Slowly press down the lever on the nozzle tester A. The pressure gauge reading wil gradually rise, then the needle will suddenly deflect. Note the pressure when the needle starts to deflect. * Ifthe measurement is out of specification, disassemble the nozzle, clean it, and make adjustments using the adjusting shim 14. + Every 0.05 min change inthickness of shim 14 correspondstoa 735 kPa {7.5 kgt/om?} change in nozzle opening pressure. (A 1 kgficm? change in nozzle opening pressure requires an approx. 0.0067 mm change in shim thickness.) * Ifthe measurement is stil out of specification after adjustment, re- place the injection nozzle assembly 6. (2) Inspecting spray condition ‘+ Pump the lever on the nozzle tester A at a rate of about 4-6 times per second, and maintain a continuous spray. ‘A: Even spray from all five injection orifices (Good) ven and symmetrical spray (Good) : Asymmetrical spray (Bad) D: Branched spray (Bad) E: Thin spray (Bad) : Irregular spray (Bad) ‘If the spray is unsatisfactory, disassemble and clean the injection nozzle assembly 6, then inspect the spray again. If the spray is still unsatisfactory, replace the injection nozzle assembly 5. ‘+ Check that no fuel drips from the nozzle after the spray is complete. WARNING A\ Do not touch the spray that comes out of the nozzie 11. 13-25INJECTION NOZZLE [oy i Bad Good a \ 05388] (3) Inspecting for leaks © Slowly increase the nozzle pressure to 1.96 MPa {20 kt/em?} below the specified vaive opening pressure. Maintain this pressure for 10 seconds and check that no fuel drips irom the end of the nozzie, «Ifthe injection nozzle assembly 5 appears defective, disassemble and clean it, then inspect it again. If the injection nozzle assembly 5 siill appears defective, it must be replaced. {GJ injection nozzle assembly {Disassembly} CAUTION A\. * Do not touch the sliding parts A of the needle valve 10. * Donot change the needle valve 10 and nozzle 11 combination on each cylinder. 06832] aoe 13-26 [Cleaning] Wash the needle valve 10 and nozzle 11 in gas ol, then use the )Clean- Ing Tool Setto remove any carbon deposits in accordance with the follow- ing procedure. + Remove carbon from the end ofthe needle valve 10 using the Cleaning Bar B of the {E} Cleaning Too! Set. CAUTION /\, Do not use a re brush or any hard metallic object for cleaning. * Remove carbon from the injection orifice of the nozzle 11 using the Needle Cleaner Cof the E) Cleaning Tool Set. Insert the Neadie Clean- er and rotate it to dislodge the carbon. Cleaning needle diameter: $0.25 mm or less * Clean the seat of the nozzle 11 using the Cleaning Needle D of the Cleaning Too! Set. + Toremove burned and hardened carbon, use FUSO Carbon Remover.10 oro 13 {inspection} + Wash the needle valve 10nd nozzle 11 in gas il, then fit them togeth- er. © Pull up the needle vaive 10 by approximately 1/3 of its entire stroke, then check that it drops under its own weight. Repeat this test several times, turning the needle vaive each time. + Ifthe needle valve 10 does not drop as required, wash itin gas oil and carry out this test again. Ifthe needle valve'is still defective, replace the needle valve and nozzle 11 asa set. 13-2314 GROUP 14 COOLING SPECIFICATIONS sete ec ee ee ee eeneeeeseeeeneeseeeeeeteeneenes 2 STRUCTURE AND OPERATION .........ecceeeeeeeeeeeeeeeeeee. 2 TROUBLESHOOTING 4 ON-VEHICLE INSPECTION AND ADJUSTMENT + Replacing Coolant and Cleaning Cooling System . * Air Bleeding of Cooling System + Gas Leak Testing .. COOLING FAN, V-BELT, AND WATER PUMP THERMOSTAT 14-1SPECIFICATIONS / STRUCTURE AND OPERATION SPECIFICATIONS tem Specifications Cooling system Forced water circulation type Water pump type Baltdriven involute type ‘Thermostat type Coolant capacity am (L) Wax pale, bottom bypass typ (with jiggle valve) {engine main body oniy) STRUCTURE AND OPERATION Cooling System (Coolant Flow) 95 (9.5) 1 Radiator 2 Thermostat 8 Oil cooler 14-2 4 Water pump 5 Cooling fan 6 Pressure cap e2006Hcr) Water Pump yea s7972| Thermostat 1 Case 2 Unit seal 3 Impeller 4 Unit bearing 5 Flange 1 Thermostat cover 2 Thermostat 3 Thermostat case A:To radiator ‘rom cylinder head fo water pump ‘Thermostat2isa bottom bypass type that uses wax-charged pellets as its regulating element. As the wax changes from solid toliquidin line with teriperature increases, the total wax volume changes. As a result, the position of the valve, changed by the coolant temperature, regulates the flow of coolant to the radiator and water pump (bypass side) and controls the coolant temperature. 143TROUBLESHOOTING Symptoms 3 z é a Remarks g| |3|s ARE SIRI El3 Poesble causes 8/6 [2 |5 V-belt. Loose or damaged ° oO Sessa sin 3 Grenbak 3 Waar pimp | Water pop Ried poor ol tot6 Unit bearing defective oO oO impel deecve Ofte Unit seal defective © | Tooseftbetweenunbeatrg an lange andlor da and impeller ° ° Themmawat [Ease ited pooty OCS Tal oping para Wo GR TaN TS closed ° ‘Valve opening temperature too low; valve remains open oO Oil cooler Oil cooler fitted poorly: oO O|M@ert2 eset eco Sto Cylinder head Cylinder head fitted poorly ° o|men Gasket defective ° ° Cost ean aint 3 Coola passages dy anor 3 Tose te por of 16 Anbiet tonperatue een low SCE 144MEMOON-VEHICLE INSPECTION AND ADJUSTMENT Replacing Coolant and Cleaning Cooling System 4 Pressure cap 2 Radiator drain cock 3 Crankease drain plug @ Tightening torques Unit: Nem {kgf +m) ‘Location Paris tobe lightened Tightening torque Remarks | 2 | Grankease drain plug 115 (12) = 1 Using the radiator for extended periods without cleaning the cooling system will cause overheating since rust and scale de- posits will accumulate, The cooling system must be cleaned periodically. © Draining coolant Before draining the coolant, loosen pressure cap 4 to reduce the pressure in the cooling system. WARNING /\ + To avoid being scalded, ensure that the coolant has cooled sutficiently before draining it out, * Unless care is exercised, opening pressure cap 1 when the coolant is hot can cause the coolant to spray out. Cover the pressure cap with acloth, and loosen the cap slowly to bleed off the pressure before opening it fully. © Cleaning procedure * Run the engine and keep the coolant at a temperature of approximately 90°C so that the thermostat valve remains open and the coolant continues to circulate in the radiator. + Toincrease the coolant temperature quickly, cover the front of the radiator with cardboard or a similar material. + If cleaning is carried out after a large amount of rust has accumulated, the radiator may start to leak. Carefully examine the radiator for leaks alter cleaning the cooling system. + Soft water to be used should have the folowing properties. CAUTION A, Do not use hard water as it causes scale and rust. Required properties of soft water Total hardness '300 ppm or less ‘Total dissolved solids 500 ppm ores: Sulfate SOF 100 ppm or less pH ei08 ‘Chloride Gr 400 ppm or less = = 14-6Method of cleaning the cooling system depends on its condition. @ Ordinary condition @ Extremely dirty coolant @ Clogged radiator Cleaning using water Cleaning using Rladipet 7 or equivalent (Work procedure) rs Bane oa i ‘Mako @ solution of FUSO Radiator Gleaner (Racipet 7 or equivalent) at a rate of 5 to 10% to the total volume of coolant. 1 Fl the radiator with the solution, ‘Keep the solution temperature at 90°C andiet the engine idle for 30 minutes. CAUTION AY Be sure to allow the engine to idle for 30 min- utes only. Circulating the solution in the sys- tem for more than an hour might cause the system to breakdown, ch Drain the water and the solution. =I F Fl with soft water (boiled preferably). | 10 minutes. ‘Keep the water temperature at 90°C and let engine idle for tod Drain the water, To is stil muddy, repeat the procedure. NOTE If the drained water is clear, clearing has been successtul ‘+ After cleaning with solution, fill with coolant as quickly as possible. To prevent freezing of the coolant and corrosion of the cooling system, use specified coolant solution of FUSO Diesel Long Life Coolant, FUSO Antifreeze or Radiator Antirust (Ra of these materials.) et 9). (See the Owner's Handbook for use 14-7ON-VEHICLE INSPECTION AND ADJUSTMENT Air Bleeding of Cooling System ‘Remove the pressure cap. Keeping the coolant temperature at 90°C, let the engine idie until the cooling system is com- pletely bled of ai. While the engine is idling, keep the heater controller's adjustment lever at its maximum-temperature Position so that coolant flows freely in the heater piping. «After bleeding the cooling system of at, add coolant tothe radiator and reservoir tank as required. Gas Leak Testing ‘The presence of air or exhaust gas in the coolantincreases corrosion and rust in the cooling system. Check for air or exhaust gas in the coolant using the following procedure: + Flemove pressure cap 1. WARNING A, ———————__$_______—_ Make sure the coolant is sufficiently cool before loosening the pressure cap. If the coolant is hot, it will spray out, ‘+ Run the engine until the coolant temperature reaches approximately s0°c. + bubbles A appear continuously, theres air or exhaust gasinthe cool- ant, ‘Ifthe coolant contains air, the cylinder head bolts, water pump mount- ing bolts, or hose connections may be loose. Alternatively, the hoses may be damaged. + Ifthe coolant contains exhaust gas, itis possible that the cylinder head gasket is damaged or that the cylinder head is cracked, 14-8MEMOCOOLING FAN, V-BELT, AND WATER PUMP +7074 @ Disassembly sequence 8 Water pump assembly (0 P.14-13 4 Bolt 9 O-ring 2 Washer 3 Cooling fan +#:Timing gear case (1) Gr 11 4 V-belt @:Non-reusable part 5 Bolt 6 Spacer @ Assembly sequence 7 Water pump pulley Reverse the order of disassembly. CAUTION A\, © The V-belts 4 must be replaced together as a set. Never replace either V-belt individually. © Apply soap suds to the O-ring 9 before fitting It. Do not apply engine oil to the O-ring since this would make It swell, Service standards Unit: mm Location Maintenance lam I Standard value Limit | Remedy 4 _|Vabeitension I Tow is ‘ajust © Special tools Location | ‘Tool name and shape Part No. Application | Bolt Tension e jpetTe ioc224s | v.bett tension measurement ooor2 14-10s7975! 03613: osste 03615: Service procedure 4| V-belt {inspection} Apply force of approximately 98 N (10 kgf} tothe center of the V-belt 4 and measure the extent of V-belt deflection A. B: Akternator pulley ‘C: Water pump pulley D:Crankshatt pulley © Use of belt tension gauge + Set upper Oxing'H of ] Belt Tension Gauge to 98 N (10 kgf} (push load) on scale J + SetlowerO-ring K of &) Belt Tension Gauge tothe V-belt's correct max- imum deflection value on scale L. ‘+ Apply the) Belt Tension Gaugeto the center of V-belt 4 and push until ‘O-ring H reaches the flange Nv. * Measure the extent of V-belt 4 deflection A. If the measurement does not conform with the standard value, adjust the V-belt as shown below. d4-LCOOLING FAN, V-BELT, AND WATER PUMP (Adjustment) Adjust the V-belt tension as follows: ¢ Loosen alternator mounting bolts Q (2 places) and adjust the V-belt 4 tension by moving alternator P to the left or right. «When the adjustment is complete, tighten the bolts and nuts securely. CAUTION A\, A © Excessive tension in V-belt 4 may damage the belt and related bearings. © Be sure to replace the V-belts 4 as a set to maintain even ten- sion between them. ‘© Keep V-belt 4 free of oil. if the belt becomes oily, it will slip, re= sulting in overheating of the engine and insufficient charging of the battery. 14-12Water Pump Assembly @ Disassembly sequence 1 Impeller 2 Flange 3 Snap ring 4 Bearing 5 Spacer 6 Bearing 7 Washer 8 Water pump shaft 9 Unit seal 0 1 Grease nipple 1 ‘11 Water pump case @ Assembly sequence B76 54 jones ons 10 Service standards Units mam Siandard value Location Maintenance iter (eacedanetsret) Limit | Remedy 7,8 _ | impollerto-water pump shaft inererence [13] 0.08 to 0.05, =| Reassem- bly allowed only twice 2,8 _ | Flange-to-waler pump shatt interference {2510.05 to 0.08 = | Reassen bi allowed only twice - Lubricants and sealant Tosation Pins of appcaion Kinds [ouanity 4,6 | Bearings Whee! bearing grease ‘As required INUGI No, 2 (Li soap)] 9 | Uritseal outer periphery ‘Threebond 1102 ‘As required 70 | Grease ripple ‘Wheel bearing grease 609 INLGINo. 2 (Li s02p)} © Special tools Unit: mm Location ‘Tool name and shape Part No. Application 1 | impotior Puter MHos1417_ | Removing impeller | no Lee 16027 14-13COOLING FAN, V-BELT, AND WATER PUMP 17980 Service procedure © inspection atter assembly + Aiterassembly, rotate flange 2 by hand and check that ittums smoothly ihout hindrance. * lithe flange does not turn smoothly, disassemble and inspect the water pump again. 17981 21.34 20.46 7] impeller [Removal] © Tap threads (MB x 1.25) into the two holes (6 mn) in the impeller 1. = Fit the &) Impeller Puller onto the impelier and use it to remove the impeller, [installation Press-fit the impeller until the outer edges of its blades are the specified distance (see the drawing) fromthe end surface B of the water pump case 1" C: Press (8825 N {900 kgf} or more) D: Cylindrical jig CAUTION fi, ——$_______________ Press-fit the impeller such that flange side E of water pump shaft is the load receiving surface. 14-14 [71 impetier-to-water pump shatt interference {the measurement does not conform wih the standard value, replace the defective part(s). CAUTION A\. Even if the standard value is satisfied, reassembly must not be carried out more than twice.+e oN 17978 [2] Fiange [Removal] A: Gear puller (Press-fiting) Press-it the flange until it touches the bearing 4. B: Cyiindical jig 2940 mm D:20 mm or more : Press (7354 N (750 kgf] or more) 2] [B] Flange-to-water pump shaft interference lithe measurement does not conform with the standard value, replace the defective part(s), CAUTION A\. Even if the standard value is satisfied, reassembly must not be carried out more than twice. 14-15THERMOSTAT CAUTION A\. Apply soap suds to the O-rings 7 before fitting them. Do not apply engine oil to the O-rings since this would make them swell, @ Disassembly sequence Thermostat cover ‘Thermostat cover gasket ‘Thermostat Thermostat case ‘Thermostat case gasket Bypass pipe O-ring ‘Thermo switch +: Oylinder head (D) Get @: Non-reusable part © Assembly sequence Reverse the order of disassembly. Service standards Location Maintenance fem Standard value Lint | Remedy Valve opening 7526 = = temperature 3 | Thermostat rermosta Valve titiemperaiure Tomm ormore = = (o0rc) Operating Terese =] Replace temperature 7 8 | Termo-switch ON-OFF tempera: FC orless = ture ference @ Tightening torque Unit: N-m (kgf) Location Parts to be tightened Tightening torque [__ Remarks 8 _[ Thermo switch 23239 (23204) C= A Lubricant and sealant Location Points of application Kinds Quantity 7_ [Periphery of Oving Soapy water As required 14-16(14) Service procedure [2] Thermostat cover gasket installation Install the thermostat cover gasket 2 with the sealant application surface A toward the thermostat case 4. [B] Thermostat inspection Place the thermostat in a container of water. While stiring the water with 0d B to ensure thatitis heated evenly, carryout the following inspection procedure, Ithe measurements do net conform withthe standard values, replace the thermostat 3. (1) Valve opening temperature © Support thermostat 3 with wire F to keep It away from heat source E. ‘+ Gradually heat the water untilit reaches the valve opening tempere- ture. + Maintain this temperature for § minutes and check that valve C is open ‘+ When the water temperature drops below 65°C, cheok that valve C is completely closed. D: Thermometer (2) Valve ttt Heat the water to slightly higher than the valve opening temperature. With vaive C fully open, maintain this water temperature for 5 minutes. Measure the extent of valve lift G. ‘Thermo switch + Connect circuit tester A set for resistance measurement tothe termi- nals of thermo switch 8, and dip the thermo switch in test liquid B (glyc- cin) as deep as its threaded section. «After checking that there is no continuity between the terminals, heat the liquid B. NOTE Stir the li uid while heating to ensure that it is heated evenly. + With a mercury thermometer, measure the temperature at the moment when the switch operates and continuity is established between both terminals. 14-17THERMOSTAT CAUTION A ________________ Gradually heat the liquid when the temperature rises near to the switch’s normal operating range. (When the liquid is heated toa temperature 5°C lower than the operating temperature, maintain itfor 5 minutes and then raise the temperature at a rate of 1°C in every 2 to 3 minutes.) Continue heating the liquid for a while after the switch operating tem- perature has reached, and then stop heating to let the liquid cool down. Read the liquid temperature at the moment when the circuit tester does notindicate continuity any more, and check the difference between that temperature and the temperature when continuity was established. ‘= Ifthe difference between these temperatures (ON-OFF temperature difference) is out of the standard range, replace the thermo switch 8. 14-18GROUP 15 INTAKE AND EXHAUST SPECIFICATIONS feet eae see eeeceeeeseeeeeeeteeseesseneaeee 2 STRUCTURE AND OPERATION .......... 2-0 seseeeeeee cere eee 2 TROUBLESHOOTING ....... 0020s cece cece e cree tence eeeeeeeee 3 TURBOCHARGER... 4 INTAKE MANIFOLD 8 EXHAUST MANIFOLD . 9 INTERCOOLER IS-1SPECIFICATIONS / STRUCTURE AND OPERATION SPECIFICATIONS Turbocharger tem Specifications ype TFOSH [Manufacturer ‘Mitsabishi Heavy Industiios STRUCTURE AND OPERATION ‘Turbo Charger Assembly (3 15-2 1. Compressor whee! 2 Thrust sieeve 3 Thrust bearing 4 Bearing 5 Bearing housing 6 Turbine back plate 7 Turbine housing 8 Shaft & turbine wheel 9 Piston ring 40 Thrust ring 11 Oil deflector 12 Insert 18 Compressor cover 1-6, 8-12: Cartridge assemblyTROUBLESHOOTING 15 Possible causes. ‘Symptoms Engine hard to start Black exhaust gas White exhaust gas Insufficient engine output ‘Strange sound or vibration i Excessive oll consumption exhaust system Remarks ‘Air | Clogged air cleaner element cleaner ° Furbo- | Ganvidge | Detective bearing charger | assembly | Carbon deposited on shaft and turbine wheel ‘Shaft and turbine wheel interfering with turbine back plate “Turbine wheel interfering with turbine housing Bent shaft and turbine wheel ‘Damaged shaft and turbine whee! ‘Compressor wheal interfering with compressor housing “Thrust sleeve and thrust bearing selzure o| 0 fofolo| o [ojo] o Damaged compressor wheel ofo} o fofofo| o fofo] o Cilleaks due to wom piston ring and inset ojo Improperly mounted piston ring Unsmooth siding of internal parts duo to clogged lubrication oll pipe and eyebolt L ° ‘Damaged oll seals duo to clogged olf return Pipe Improperly mounted compressor housing Improperly mounted tubine housing Deformed front pipe, muller, tailpipe Improperly mounted front pipe, mul, tall pipe olojojo Incorrect vaive clearance Mert Defective head gasket Mert Worn valve and valve seat and deposited carbon ‘Sagging vaive spring MGrtt Merit ‘Worn or damaged piston ring men [Worn or damaged piston ring groove of piston Mert ‘Maifunctioning cooling equioment Maw Excessive engine of olofofofofofofofo Mare ‘Seizure of major moving parts fern 15-3TURBOCHARGER @ Removal sequence Eyebott Oil inlet pipe it return pipe onnens g ‘Turbocharger assembly CoRiss 7 Gasket *: Exhaust manifold (opts ©: Non-reusable part @ Installation sequence Reverse the order of removal. @ Tightening torque Unit: Nm {kgf} Location Paris to be tightened Tightening torque Remarks 1_| Eyebot (or mounting oft pipe) { Brea) 5 | Nut (lor mounting turbocharger assembly) | ar 142) A Lubricant Location Points of application Kinds ‘Quantity a __[Ovne Engine of ‘As required [77S [Suppiy when instaling wbocharger assembly Engine ol 7s required ¢ Service procedure [Ey Installation of turbocharger assembly ‘When the turbocharger assembly 6 is installed, supply engine ol from the oil hole A to make sure that all the parts operate smoothly, 15-4(45 ] Turbocharger Assembly © Disassembly sequence Bott Coupling Turbine housing ‘Snap ring ‘Compressor housing ‘Orting Cartridge assembly Noasene @:Non-reusable part ‘@ Reassembly sequence Reverse the order of disassembly. NOTE ‘The cartridge assembly 7 cannot be disassembled. Replace the entire assembly ifthe turbine wheel or compres- sor wheel becomes damaged or if the assembly does not rotate smoothly or is otherwise defective. Service standards Unit: mm Location Maintenance tem ‘Standard value Limit | Remedy 7 | Caridge [Asda playin shat 0.05 160.08 01 | Replace assembly [Biay at right Turbine wheel 0.40 100.53 058 Replace angie to axial | side sirection ‘Compressor 0.85 to 0.66 072 wheel side | @ Tightening torque Unit: Nem {kgf-ra} Location Parts tobe tightened Tightening torque Remarks 1 Bolt (for mounting cartridge) 8 to 9 (0.8 to 0.9) = A Lubricant Location Paints of application Kinds Quantity 7___ [Apply o threads and Bearing sutace of bal MOLYKOTE As required 6 __ [Apply tall ofthe O-ring Engine of ‘As required Service procedure © Operations before disassembly ‘Make alignment marks A on the coupling 2, turbine housing 8, compres ‘sor housing 5 and cartridge assembly 7. 155TURBOCHARGER 17987 +7908 orss2! 15-6 01599) @ Inspection after reassembly After reassembling the turbocharger assembly, turn the wheels by hand and check that they rotate smoothly. [3] Removal of turbine housing CAUTION A\. * While using care to prevent damage to the turbine housing 3, lightly strike its entire circumference with a rubber hammer or similar tool. * Since the blades of the turbine wheel are readily bent, use careto make sure that they do not hit the turbine housing 3. '3][5] Cleaning turbine housing and compressor cover + Before cleaning the components, check them visually for scorching, abrasion, and other defects. (Such problems may be impossible to see after cleaning.) Replace any item that appears defective. + Remove any hard deposits with a plastic scraper or siif brush. Then, immerse the disassembled components in non-flammable solvent A (Paido Chemical Industry DAI CLEANER 730). After removing the components from the solvent, blow them clean with compressed air B. If there is deposit of dit on the removed parts, remove it with a plastic scraper or bristle brush € before cleaning. [2] instatting snap ring ‘© Fitthe snap ring 4 onto the compressor cover 5 with its tapered surface Afecing upward. WARNING /\ ‘When fitting the snap ring 4, hold it down to prevent it from flying off. 5] Removal of compressor cover CAUTION A\ ‘* While using care to prevent damage to the compressor cover 5, lightly strike its entire circumference with a rubber hammer or similar tool. © Since the blades of the compressor wheel are readily bent, use care to make sure that they do not hit the compressor cover.06175 ‘oarr6| iy oat77| inspection of cartridge assembly (1) Axial play in shaft and turbine wheel assembly ithe measurement exceeds the specified limi, replace the cartridge assembly 7. (2) Play at assembly Play on turbine whee! side If the measurement exceeds the specified limit, replace the car- ‘ridge assembly 7. nt angle to shaft dire shaft and turbine wheel + Play on compressor wheel side If the measurement exceeds the specified limit, replace the car- tridge assembly 7. 15-7INTAKE MANIFOLD @ Tightening torque @ Disassembly sequence Earth plate Air inlet pipe Rubber hose Gasket Air heater Gasket Bott Intake manifold Gasket wean sene @: Non-reusable part @ Reassembly sequence Reverse the order of removal. : Turbo charger assembly (1) P.15-5 Unit: N-m {kgf-m} Location Parts to be tightened Tightening torque Remarks 7__ | Bolt for mounting intake manifold) 171025 (1.7 102.6), 15-8EXHAUST MANIFOLD @ Tightening torque $7990 @ Disassembly sequence 1 Nut 2 Exhaust manifold 3 Gasket #: Cylinder head (0.Gr.11 @: Non-reusable part @ Reassembly sequence Reverse the order of disassembly. Unit: N-m {kgf-m) Location Parts to be tightened Tightening torque Remarks 1_[ Nut (for mounting exhaust manifold) 41 10 84 (4.21055), = ores, Service procedure 3 &) Install the gasket 3 with the grommet fold-back portion A toward the cylin- der head. Installation of gasket 15-9INTERCOOLER <6D34-TL> @ Disassembly sequence or ly seq 3 2 ° 1 Clamp 2 Rubber hose | 3 ocouee ¢ neesoenblyseqsence ® Revere he order cf deassemoy 10 \ 2 Service standards {Location Maintenance item _ Standard value Limit | Remedy 3 |Trterobotar air loak at the ar pressure of 150 KPa | en (Omt) = replace (1.5 koler) I @ Tightening torque Nem kgi+m) Location Parts to be tightened 1 Tightening torque [Remarks 1 __[Giamp (lor mounting rubber hose) 431059 (051006) CL - Service procedure 3] Inspection of intercooler Puta cap A on either ofthe air ports of the intercooler 3.and connect a hose tothe other, immerse the intercooler 3 ina water tank, and apply the standard pressure from the hose side to check for air leaks. It there are air leaks, replace the intercooler. 18949 15-10GROUP 54 ELECTRICAL SYSTEM SPECIFICATIONS .........- 220 eeeeee eee ee eeee ee ee eeeeeeee ees 2 STRUCTURE AND OPERATION ........2..eeeeeeeeeeeeeeeeeee 3 TROUBLESHOOTING ....... 00s eeceeeee eee eee esse teen eeeeee 8 ON-VEHICLE INSPECTION AND ADJUSTMENT + Inspection of Alternator 10 + Inspection of Regulator n ALTERNATOR 2.2.0... s cece cece cence eee ee ener eeeeeeeeeeeees 12 STARTER... see eeeee ee eeee cece eee ee cece eeeeeeeeeereeeeneees 20 PREHEATER CIRCUIT ..........0.0.seceeeeeeeeeeeeeeeee seers 34 ENGINE STARTER CIRCUIT ..........0.0000cceeceeseee eee ee ee 35 54-1SPECIFICATIONS tem i Specifications Numbers in (_) show parts No, Aliermator — | Manulacturer MITSUBISHI ELECTRIC CORP. Type ‘Allemator wih builtin regulator with brush, Fan inlernally provided | 7 _ ‘With brush Model ‘AOOSTNSSBE_(MET50693) ‘Output (V=A) 24-35 |Staner | Manutacturer MITSUBISHI ELECTRIC CORR, | Moder ‘MoosTa7i71 (ME049303) Output (v=) 24-5 Magnet switch operating voltage (V) Gores ‘Staner relay | Model {WOOTXS5075 (ME701597) Excling current (VA) 24-2. Closed magnetic voltage (V). 16 or less [Opened magnetic voltage (V) Aorless ‘Allowable breaking voltage (V) 200 Rated voltage (V=A) 24-23 Glow plug | Type ‘Sheathed type [Vottage — current (V=A) 23-3 Glow relay | Modet ‘wootT31389 (MEO72600), Voltage ~ current (VA) [ 2-23 Safety relay | Model t ROTS0173 (MEO77148) 54-2STRUCTURE AND OPERATION Alternator 54 1 Rectifier 2 Rear bracket 3 Stator assembly 4 Front bracket 5 Front bearing 6 Pulley 7 Rotor assembly 8 Fan 9. Brush spring 10 Brush 11 Regulator & brush holder 12 Rear bearing B: Terminal B L: Terminal L R: Terminal R P: Terminal P 543STRUCTURE AND OPERATION Charging Circuit 1 Battery 2 Alternator 3. Charge warning lamp 4 Starter switch B: Terminal B E: Terminal E L: Terminal L R: Terminal R ferrinal P Battery + Tum the starter switch ON. ‘Slarterswitch } + Safety relay or charge I Jamp (ON) Alternator ‘Riemator(Terminal)] [Aliemator (feminai)] { Earth |+——________ 54-4Aerator (lerminal 5) 525424 t Starter switch Battory Earth In this manner, the electrical system starts tocharge the battery. The charge lamp (i fited) illuminates at this time. 4 Batiory 2 Alternator 3. Charge warming lamp 4 Starter switch B: Terminal B E: Terminal E L: Terminal L R: Terminal R P: Terminal P ® Ifthe voltage at alternator terminal B exceeds the battery voltage (when the engine is started and the alternator starts to generate), current flows as shown in the flow chart. S48STRUCTURE AND OPERATION Satety Relay ‘The safety relay detects the rotating speed of the alternator. When the rotating speed exceeds the reference value, the safely relay keeps the starter inoperative even i the starter switch is accidentally set to ON while the engine is running. P: Terminal P R: Terminal R. L: Terminal L S:Terminal $ E:Terminal E 17531 1 Alternator 6 Safety relay 2 Starter switch 7 IC regulator 3 Battery switch 4 Battery A:To starter 5 Starter relay When the starter switch 2 is set to ON, current flows from the starter relay 5 through terminal S of the safety relay 6 to terminal E, and contact P, closes. ‘When rotation of the starter causes the engine to start running, pulses with a frequency of a tenth of the altemator speed are generated at terminal P of the alternator 1. ‘When the pulse frequency at terminal P of the alternator 1 exceeds the reference value, the continuity between terminals S and E fs lost, and the starter remains inoperative even if the starter switch 2 is set to ON while the engine is running. 54-6Starter 17 16 15 44 13 woranaens Rear bracket Brush holder Brush Brush spring Magnet switch Ball Lever Front bracket Spring +7962) 10 Pinion stopper 18 Packing 41 Pinion 19 Yoke assembly 12 Front bearing 20 Armature assembly 43 Overrunning clutch 21 Rear bearing 14 Washer 22 Starter relay 15 Gearshaft assembly 16 Intemal gear assembly 17 Planetary gear Terminal B Terminal M zo This starter uses planetary gear 17 in the reduction gear mechanism. 54-7TROUBLESHOOTING ‘Sagging brush spring (brush is provided) Alternator Delective conditions z 28 B| |8)Se |= %) |2\E5 |2 El-|2|ee |4 glBl2\28 |3 B\e\s\25 .\5 Remarks 3/8) 5/e22|S2 B/E E|508 ee ele) 228 2\ 5 glzlgiees\28 Probable causes &|8|8|3 28 \=6 Connector incorecty connected, hamess open-cruled, defective grounding ° © Biown fuse oO O° ° ‘Weak tension of V belt ° Oo [Marta Broken Vek ° o [mers Detestve battery 3 ° ‘Aerator Siator coll open-crouted a Stator coil and core short-circuited oO Field col defective o Reciier dofeaive © Regulator defective ofo}_o Brush wom (it brush is provided) oO 10| ° Defective wiring 54-8Starter Defective condition Slarterstarts | but engine does fot start 2 | z js |g $) | « [30/2 2 8 \ B|E |#2)3 |/g|/S]e]s| Fema eis |Es/e |2lsisls §)88 [58/22 8) a/sls ! 2/55 |S |e || S| Sis | Possible causes oles |a8 8 |5)5/5/8 “Gonneciorincarecly connected, hamess oper cruled, delec tive grounding ° oO jojaljojo Blown fuse o o Insufficient capacity of battery fe] o [) Starter Contact of magne! switch binding or deposed [O Goll of magnel wich oper-ciculed © Ovemunaing clth n defective operation o Worn or damaged pinion oO | Detective starter relay oO Detective starter switch oO o Worn or damaged rng goar of fyaheal © men Detective glow plug o|o Defective glow relay | ofo Delestve temperature sensor ofofe Connecing plate incorrectly connected O[o, [men 54-9ON-VEHICLE INSPECTION AND ADJUSTMENT Inspection of Alternator sons 54-10 Performance test ‘* Connect the alternator as shown in the drawing. ‘A: Ammeter (50A range) B: Alternator terminal B Switch D: Terminal V:Volimeter WARNING A, —————_—____—_— Before connecting the test circuit, disconnect the battery's © ter- minal and cover it with insulating tape. Unless the battery's G ter- minal is disconnected, the battery voltage will be applied constantly to the B terminal. This could be dangerou: + When the switch Cis tured ON, the voltmeter wilingicate the battery voltage. + Start the engine. + immediately tun ON al the vehicle's ight switches. + Observe the ammeter reading when the engine speed reaches 2,500 om. «Ifthe ammeter reading is 70% of more of the allerato’s rated output and the charge warning lamp E5)iluminates, the alternator can be considered serviceable. Rated alternator output ‘Alternator model Voltage ‘Output ‘ADOSTNESBG 24V. 3A NOTE On-vehicle testing provides only a rough indication of alternator performance. For more accurate results, perform inspections on atest bench. (1) P54-13Inspection of Regulator Service standards Location | ‘Maintenance item Standard value Limit | Remedy [Regulated votage from regulator [24V 265 208V = Replace “| Connect the alternator as shown in the drawing. ‘A: Ammeter (50A range) B: Alternator terminal B ©: Switch 1D: Terminal (chassis hamess) V: Voltmeter WARNING (XA __—_—_—___— * Before connecting the test circuit, disconnect the battery's © ter- minal and cover it with insulating tape. Unless the battery's © ter- minal is disconnected, the battery voltage will be applied constantly to the B terminal, This could be dangerous. + The cable connected to the switch C must be as thick (or thicker) than the battery cables. » To prevent electrical loading during the inspection, turn OFF the vehicle's heater, lights, and other electrical devices. © Tum ON switch C, then start the engine. SAUTION A, $$$ Ifthe engine is started with the switch OFF, the starter current will flow through the ammeter A and damage «Ifthe charging current is 5A or less at an engine speed of 2,500 rpm, observe the voltage at terminal B. «Ifthe charging current exceeds 5A, take either of the following steps: ‘ Increase the engine speed and allow the battery to charge; ‘+ Replace the battery with a fully charged one. * ifthe measurement is out of specification, perform checks on a test bench 54-1ALTERNATOR 2 Alternator ([. P.54-14 $ Spee 4 Adjust plate +: Timing gear case WARNING /\ Before removing the alternator 2, be sure to disconnect the negative © terminal of the battery and insulate it with tape or something else. If the negative © terminal is not disconnected, the battery voltage is always available at terminal B and is dangerous. @ Installation sequence Reverse the order of removal. @ Adjustment after installation ‘Adjust the tension of the V-belt 1. 1] Gr 14 Service standards Location Maintenance item ‘Standard value [Umit Remedy 2 [Altemator output current 1500 pm 20A oF more = Check (When hot, when 27 is gen- (or more = une [35a [2500 rem 298 ‘5000 rpm ‘3A or more, = Regulator regulated voltage 2852050 = Replace (6000 rpm, loads 5A or less) *:"When hot" refers othe state of the engine after 30 minutes of maximum cutput operation at 6000 rpm at anormal ambient temperature, 54-1254 Service procedure [2] inspection of alternator (1) Inspection of performance of alternator (Inspection by test bench) + Wire the altemator 2 as shown, Ammeter Alternator terminal 8 Switch Switch : Alternator terminal E : Load resistance (variable resistance) : Alternator drive motor Alternator terminal Voltmeter <297moOm> ‘= Increase the load resistance F to a maximum (where practically no load current flows). + Sel the switch C and switch D to ON. + Let the alternator 2 warm up at 5000 rpm for 30 minutes. + Adjust the load resistance F so that the current will have the nominal value, Nominal value of alternator current Model Output “AQOSTNS386 24V-35A + Measure the current with the alternator 2 at each of the specilied speeds. * Ifthe reading is out of the standard value, disassemble and check the alternator 2. (1) P.54-14 (2) Inspection of performance of regulator (laspection by test bench) ‘+ Wire the alternator 2 as shown, Ammeter + Alternator terminal B Switch : Alternator terminal E Alternator drive motor Alternator terminal L Alternator terminal R, :Volimeter <2romoapr Set the switch € to ON. + Let the alternator 2 rotate at a low speed, ‘+ Increase the rotating speed of the alternator 2 to 5000 rpmand mea- sure the voltage (regulated voltage). At the same time, check to ‘ensure that the current value is SA or less. + Ifthe readings are out of the standard values, proceed as described below. * Ifthe readings exceed the standard values, replace the regulator, ‘+ Ifthe readings are below the standard values, checkall the parts of the alternator before replacing the regulator. 54-13ALTERNATOR Alternator Assembly 16197 @ Disassembly sequence 1 Rotorandtrontbracketassembly 7 Front bearing 12 Brush 2 Nut 8 Front bracket 13. Regulator and brush holder 3 Pulley 9 Statorandrearbracketassembly 14 Slinger 4 Rear bearing 10 Stator assembly 15 Rectifier 5 Rotor assembly 11 Cover 16 Rear bracket 6 Cover NOTE Do not remove parts 4, 7, 10 and 12 unless they are found to be defecti @ Reassembly sequence oot s. [ woo mon 1: [eorse {ob eo10 POS Tb ase 54-144 Service standards Unit: mm Location Maintenance tem Standard valve Limit | Remedy | Rolorassembly | Field col resistance (at 20°) 3101058 =| Replace [Siping outside diameter aT Bat 72_[Brushiength 28 3 Replace @ Tightening torques +m (kgf-m} Location Parts to be tightened Tightening torque [Remarks 2 _ [Nut to mount pulley) Fa to 162 (195 0 18.5) = Service procedure T] Rotor & front bracket assembly [Removal] * Insert a plain screwdriver A between the front bracket 8 and stator assembly 10. 6199] 6190! * While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 1 from the stator & roar bracket assembly 8. CAUTION /\. Ifthe plain screwdriver Ais inserted too far, the coll B of the stator assembly 10 might be damaged and short-circuited. [installation] Ifthe brush 121s protruding from the regulator & brush holder 13, the rotor assembly 5 cannot be mounted on the rear bracket 16, Therefore, per- form the following steps. + Push the brush 12 into the regulator & brush holder 13. Insert the pin C from the rear of the rear bracket 16 and press the pin C against the pin hole D to hold the brush 12. Ifthe brush 12s worn and the pin hole D gone, hold the end of the brush ‘12 with the pin C. ‘+ After installation, slowly remove the pin C. 54-15ALTERNATOR [Disassembiy) CAUTION A, $$ When the rotor assembly 5 is held in a vice, make sure that the base E of the lugs of the core is held. If the lugs F of the core are held, they will be broken or damaged. 4757] «758! 0759) 54-16 [@] Removal of rear bearing CAUTION A, AA _______ When the bearing puller is installed, use care to prevent damage to the slip ring A. Ifthe slip ring is damaged, the brush will fai to make good con- tact. [B] inspection of rotor assembly (1) Resistance of field coil ‘¢ Measure the resistance across the slip ring A. «= Ifthe readingis out of the standard value, replace the rotor assembly 5, (2) Continuity between slip ring and core '* Check to ensure that there is no continuity between slip ring A and core B. ‘If there is continuity, it means a short circult. Therefore, replace the rotor assembly 5. * If the outside diameter of the slip ring A is below the limit, replace the rotor assembly 5. * Ifthe surface of the slip ring A is rough or unevenly worn, correct by finding with emery paper or a lathe, CAUTION A, $$$ Do corrective grinding within the extent that the outside diame- ter of the slip ring A does not exceed the limit.16200 02396) 16225 02837 [5a] [10] stator assembly (Removal » Disconnect the leads A and remove the stator assembly 10 from the rectifier 15. The leads are soldered to the diode leads B of the rectifier. (Three places) CAUTION 2§ AA De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time. © For installation, reverse the order of removal. [Inspection] (1) Continuity between leads ‘Check to ensure that there is continuity between each lead. ‘+ If there is no continuity, the leads are open-circuited. Replace the stator assembly 10. (2) Continuity between each lead and core * Check to ensure that there is no continuity between each lead and the core. ‘= If there is continuity, it means a short circuit. Replace the stator assembly 10. [3] Brush [Removal] Aiter removing the cover A, de-solder the leads of the brush 12 and remove the brush from the regulator & brush holder 13. 54-17ALTERNATOR 16231 ores 1516202 54-18 Unstalation} ‘+ Install the brush 12 in the regulator & brush holder 13 in the direction shown. + After installation, solder the leads of the brush 12 to the regulator & brush holder 13. ‘Thereafter, ft the cover A as before. LInspection} Ifthe length of the brush 12 is near the wear limit B, replace. [13] Removal of regulator & brush holder ‘+ Remove the regulator & brush holder 13 by de-soldering the two ilus- trated points A. + For installation, reverse the order of removal. CAUTION A\. Make sure that you desolder within five seconds because thereg- lator is heat sensitive. [33] inspection of recttier + Checkthe continuity of each dlode inthe rect. any dle is detec- tive, replace the rectifier. Resistance infinite in both cases....Open Resistance close to 0 2 in both cases...Short A, C, D: Leads of stator coil connected E, G: Heat sink portion F: Regulator connected ‘+ Exchange the @ and © sides of the tester and perform checks in both cases. NOTE When a tester is used for the checks, the current that flows out from the tester is feebler than the current that normally flows through the rectifier 15, 50 the tester may indicate a questionable resistance value. In a low range, this tendency will be stronger. ‘Therefore, it is advisable to use the highest possible range.[54 | MEMO 54-19STARTER [ 54-20 @ Removal sequence 1 Earth strap 2 Starter assembly (1° P54.22 3 Starter relay (f° PS4-35 B: Terminal B CAUTION A, ——____—_—_ the starter relay 3, the battery volt- age is constantly applied to terminal B. To prevent a dangerous short cir cuit when removing the harness from terminal B, make sure the tool does not touch the starter or its surround- ings. * Before removing the harness from ter- minal B, disconnect the battery's S terminal and cover it with insulating tape. @ Installation sequence Reverse the order of removal.54 MEMO 54-21STARTER Starter Assembly @ Disassembly sequence Stopper ring Pinion stopper Pinion Spring Magnet switch Shim Rear bracket Conical washer Yoke & brush holder assembly 10 Brush spring 11 Brush S 42 Brush holder assembly 13 Yoke assembly wovousons 54-22 4 15 16 7 18 19 20 2t 23 24 25 26 Brush @ Yoke Armature assembly Rear bearing Washer Armature Ball Front bracket assembly Cover Rubber packing Planetary gear Rubber packing Plate 27 Lever 28 Bushing 29 Gearshaft & overrunning clutch assembly 30 E-ting 31 Internal gear assembly 32 Gearshaft 83 Washer 34 Intemal gear 35 Overrunning clutch 36 Front bearing 37 Dust seal 88 Front bracketCa) CAUTION /\. ‘* Do not remove the bearings 17 and 36 unless they are found to be defective. ‘+ When the armature assembly 16 is removed, the ball 20 may simultaneously come out. Be careful not to lose it, NOTE * When the motor section only is to be disassembled and checked like when the brushes and surrounding areas are to be checked, the pi A 3 need not be removed. + Except in the above case, the pinion 3 must be removed before disassembly of the individual portions. @ Reassembly sequence Reverse the order of disassembly. NOTE ‘When the magnet switch 5 was replaced, be sure to adjust the pinion gap. @ Inspection after reassembly P5424 Service standards Unit: mam Location Maintenance item Standard value Limit | Remedy. —_ [Pinion gap a5 1020 = ‘Adjust = |Noload During 2aVSKW [Current 5A or oss = Check | character- | supply Rotating ‘3750 rpm or more = istes speed 10 _| Spring pressure of brush spring 291039N (Sto 4kaH) [BON erat | Repco Ti, 14 [Brush length 18 i Roplace 16 | Outside diameter of commutator 2 ‘ia __| Replace ‘Gommutator outer circumferential runout = Oi er mare ‘Depth of mica between segments ‘Ozarless | Repair or replace A Lubricants Location Points of application Kinds Quantity 8 | Apply to conical washer ‘Multipurpose grease As required INLGINo. 2 Lisoap)) 20 [Apply to batt MOLYGOAT @ AGESO ‘As required 19, 24 _| Apply to teeth of gears of armature and planetary gears MOLYGOAT ® AGESO ‘As required 27 | Apply to overrunning cuich siding surfaces of lover Mutipurpose grease ‘As required INUGI No. 2 (Lisoap)) ‘33_ [Apply to washer MOLYGOAT ® AGESO As required 32, 35 | Apply to siding surfaces of gearshafl assembly and overcunning | Multipurpose grease ‘As required clutch assembly INLGI No, 2 (Lisoap)] ‘34 [Apply to slicing surtaces of intemal gear and armature assembly _| MOLYCOAT @ AG650 ‘As required 35. | Apply to splined portion of overrunning clutch Multipurpose grease ‘As required INUGI No. 2 (Lisoap) 54-23STARTER Service procedure @ Inspection after reassembly itor reassembly, check the starter by supplying current WARNING /\, $$ + When current is supplied to the starter, the pinion 3 will spring out and rotate. Be careful not to touch it by hand. ‘+ The magnet switch 5 may be very hot after the end of inspection. Be careful when you touch it. 14288] 14257 54-24 CAUTION A, $$ + The time during which currentis supplied to the starter should be limited to 10 seconds or less on the pull-in coil P side and 30 seconds or less on the holding coil H side. If current is supplied to the coils for a longer period, the coils will be overheated and baked. + When current is supplied to the starter, a large current that ‘exceeds 100A will flow. When the starter is inspected, therefore, use thick cables like booster cables. Check to ensure that all the connections are tight and secure. (1) Performance test © Wire the starter as shown, A: Ammeter D:DC power supply B: Starter terminal B S: Starter terminal S ¢:Switeh V:Volimeter * Set the voltage at 23V DC. CAUTION A\ ‘The voltage that is applied should be limited to 24V maximum. ‘The following operations are performed by supplying current to the starter. Itis therefore necessary that the series of operations ranging from measuring the current that flows through the startertomeasur- ing the rotating speed are completed in less than 90 seconds. ‘¢ Sethe switch C to ON to supply current tothe starter. Atthe time, the pinion 3 will spring out and rotate. CAUTION A\. When the switch Cis set to ON, current is supplied to both the pullin coil P and holding coil H. When the large current from. the DC power supply Dis supplied from terminal of the starter to terminal M, the current to the pull-in coil is interrupted, and current flows to the holding coil only. ‘To prevent baking the holding coil, therefore, all the operations must be completed in less than 30 seconds. ‘Measure the current and rotating speed of the starter. Measure the rotating speed of the starter by illuminating the pinion 3 with a stroboscope. ‘© Set the switch C to OFF to stop supplying current to the starter. «Ifthe reading is out of the standard value, disassemble and check the starter.(2) Pinion gap [laspection} ‘= Wire the starter as shown, ©: Switch D:DC 24 E: Switch starter terminal M. : Starter terminal S © The following operations are performed by supplying current to the starter. Itis therefore necessary that the series of operations up to ‘completion of measurement of the pinion gap is completed in less than 30 seconds. * Set the switch © and switch E to ON to supply current to the starter. At the time, the pinion 3 will spring out and rotate. ‘= Immediately (in less than 5 seconds) after the pinion has started rotation, set the switch E to OFF stop rotation ofthe pinion. CAUTION A, _______________ When the switch C and switch E are set to ON, current is sup- plied to both the pull-in coll P and holding coil H. Since wiring is such that no voltage is applied to terminal B of the starter, current flows to the pull-in coll during rotation of the pinion 3. Topreventbaking the pull-in coil, therefore, itisnecessary that the switch Eis set to OFF immediately (in less than 5 seconds) after the pinion has started rotating. Lightly push the end of the overrunning clutch 35 in and measure the amount G the clutch moves in the axial direction (pinion gap). ‘= Sot the switch C to OFF to stop supplying current to the starter. ‘= Ifthe readingis out of the standard value, adjust by the following pro- cedures. [Adjustment] «Remove the magnet switch § from the front bracket assembly 21 + Adjust by changing the thickness of shim 6, Increasing the number of shims reduces the pinion gap G. 54.25STARTER 4257] 54-26 Pinion [Removal] ‘To remove the pinion3, itis necessary to supply current othe starter and let the pinion spring out, WARNING /\, $$ » When currentis supplied to the starter, the pinion 3 will spring out and rotate. Be careful not to touch it by hand. «+ The magnet switch § may be very hot after the end of inspection. Be careful when you touch it, CAUTION /\ « The time during which currentis supplied to the starter should be limited to 10 seconds or less on the pull-in coil P side and 30 seconds or less on the holding coil H side. If current is supplied to the coils for a longer period, the coils will be overheated and baked. © Make sure that the pinion 3 is made to spring out by supplying current to the starter. If the pinion is forced out by pulling the lever 27 without supplying current to the starter, the front bracket 38 and lever could be damaged by the impact produced when the stopper ring 1 is removed. + When current is supplied to the starter, a large current that exceeds 100A will low. When the starter is inspected, therefore, use thick cables like booster cables. Check to ensure that all the connections are tight and secure. '» Wire the starter as shown, A: Switch B:DC 24v C: Switch D: Cable M: Starter terminal M S: Starter terminal S ‘* The following operations are performed by supplying current to the startet. itis therefore necessary that the series of operations up to removal of the pinion 3 is completed in less than 30 seconds. * Setthe switch A and switch C to ON to supply current tothe starter. At the time, the pinion 3 will spring out and rotate.19219} 3007) 17900] ‘+ Immediately (in less than 5 seconds) atter the pinion 3 has started rotating, set the switch © to OFF to stop rotation ofthe pinion. CAUTION A\ ‘When the switch A and switch C are set to ON, currentis supplied to both the pull-in coil P and holding coil H. Since wiring is such thatno voltage is applied to terminal B ofthe starter, current flows to the pullin coil during rotation of the pinion 3. To prevent baking the pullin coil, therefore, itis necessary that the switch Cis set to OFF immediately (in less than 5 seconds) after the pinion has started rotating. + Set the pipesike tool E on the pinion stopper 2. «Lightly strike the too! E with ahammerto remove the stopper ring 4 from the ring groove F of the pinion stopper 2. ‘+ Remove the stopper ring 1 and remove the pinion 3. ‘* Set the switch A to OFF to stop supplying current to the starter. NOTE ‘When the power supply to the starter is stopped, the pinion 3 may move in and the stopper ring 1 may fit in the ring groove F of the pinion stopper 2 again. In this case, repeat the operations by supplying current to the starter. {installation} ‘To install the pinion 3, it is not necessary to supply current to the starter. «Install the pinion stopper 2 and pinion 3 on the overunning clutch 35 in the direction shown, ‘+ Sethe stopper ring 1 in the ring groove G of the overrunning clutch 35. ‘© Pullthe pinion 3 strongly to make sure that the stopper ring 1 securely fits in the ring groove F of the pinion stopper 2. 54-27STARTER +7300 13310 +7909 33021 54-28 [B] Magnet switch {Installation} Install the magnet switch 5 on the lever 27 with terminal S in the direction shown. inspection} (1) Open circuit test on coi ‘= Check to ensure that there is continuity between terminals S and M. ‘= If there is no continuity, replace the magnet switch 5. ‘© Check to ensure that there is continuity between terminal M and body A. ‘If there is no continuity, replace the magnet switch 5. (2) Contact fusion check ‘© Check to ensure that there is no continuity between terminals B and M. - ‘If there is continuity, replace the magnet switch 5. (2) Contact contacting check © Push the end of the magnet switch § in o close the internal contact. In this state, check to ensure that there is continuity between termi- nals B and M. © Ifthere is no continuity, replace the magnet switch 5.10768 0 ‘ PPA he vs 7] Installation of rear bracket : Alignment marks [8] installation of conical washer Install the conical washer 8 in the illustrated direction in the rear bracket 7. Removal of yoke & brush holder assembly ‘To remove the yoke & brush holder assembly 9, proceed as described below, while using care to prevent damage to the commutator A of the armature assembly 16 by the brushes 11 and 14, ‘+ Keep the brushes 11 and 14 apart from the commutator A and hold the brush spring 10 alongside the brushes. » Remove the yoke & brush holder assembly 9 from the front bracket assembly 21 CAUTION A\. ‘When the yoke & brush holder assembly 9 is removed, do not titt itdownward, Otherwise, the armature assembly 16 may fall down, © For installation, reverse the order of removal, [id] inspection of brush spring ‘* Use new brushes 11 and 14 and measure the load at the moment the brush spring 10 leaves the brushes as shown, ‘= Ifthe reading is more than the limit, replace the brush spring 10. 54-29STARTER 02465] o2ss7 o2e77| c2e7e| 54-30 [4] [4 inspection of brush (1) Length of brush It the reading is less than the limit, replace the brushes 11 and 14, CAUTION /\, © Toreplace the brush ® 14, replace the yoke holder assembly 13. + Toreplace the brush © 14, replace the brush holder assembly 12. (2) Commutator contacting surfaces If the contacting surfaces are rough or unevenly worn, repair with ‘emery paper (#300 to 00). Inspection of brush holder assembly > Check to ensure that there is no continuity between the @ side brush holder and side holder plate. © Ifthere is continuity, it means a short circuit. Replace the brush holder assembly 12. [13] Inspection of yoke assembly (1) Open circuit test on coil ‘+ Check to ensure that there is continuity between cable A and brush e. ‘= Ifthere is no continuity, it means an open circuit. Replace the brush yoke assembly 13, (2) Earth test on colt ‘= Checkto ensure that there is no continuity between the yokeassem- bly 13 and brush @ 14. ‘+ If there is continuity, it means @ short circuit, Check the insulation, It sepair is Impossible, replace the yoke assembly 13. [ig] inspection of armature assembly (1) Short circuit test on coil + Bring the ion piece B close to the armature assembly 16, keeping itin paratie A: Growier tester # Slowly rotate the armature assembly 16 by hand. + Ifthe iron piece B is attracted or vibrates, it means a short circuit. Replace the armature assembly 16.19929 19990 c2are is 207s} 2076: [54 ] (2) Earth test on coil © Check to ensure that there is no continuity between the commutator C and core D (or shaft portion E). © If there is continuity, it means a short circuit. Replace the armature assembly 16. (3) Runout of commutator the reading is more than the limit, repair the outside diameter of the commutator portion C within the limit (4) Rough of commutator surtace + Ifthe surface is rough or unevenly wom, repair with emery paper (#300 to 500). © After the repair, be sure to check the runout of the commutator por- tion ©. (6) Outside diameter of commutator Ifthe reading is more than the limit, replace the armature assembly 16. (6) Depth of mold between segments * Ifthe reading is less than the limit, repair or replace the armature assembly 16. F: Depth of mold ‘ If the mold portion is as shown, repair or replace the armature assembly 16. 54-31STARTER 27) instalation of lever a» tol Ina ve2 nthe aon onthe overning hh y Je \ J o 15140 [34] Removal of gear shaft and internal gear assembly at ‘Take off the E-rings 30, then remove the gear shaft and internal gear assembly 31 from the overrunning clutch 35. Ifthe splines A on the gear shaft 82 bind against the inside of the overrunning clutch 35 and prevent removal, take the following steps: 8 f + Push the gear shaft 32 against the overrunning clutch 35. + Change the position of the splines A by giving the gear shaft 32 approx- imately one-eighth of a turn. 16917] Inspection of overrunning clutch Perform the following checks. there is anything wrong, replace the over- running olutch 35. © Check'o ensure that when the shaft A is made to rotate in the direction B, it rotates smoothly. = Checkto ensure that when the shaft A is made to rotate in the direction , itis locked. 13908 {BG tnstatation of front bearing © Before the front bearing 36 is press-fitted, install the dust seal 37. © Press-fitthe front bearing 36 in the front bracket 38 with a press, using the pipe-tike tool A. 54-3254 © Stake the front bracket 38 side. NOTE Avoid staking the previously staked points B. ‘A: Staking points (4 places) 54-33PREHEATER CIRCUIT Starter switch Glow plug indicator Glow plug Glow relay Battery switch Battery Airheater 8019 Service standards Location | Maintenance item Standard valve Gat | Remedy 3 [ Resistance of glow plug at normal temperate 38 (relerence valve) —__| Replace o2sia! Service procedure [3] inspection of glow plug ‘© Measure the resistance of the glow plug 3 as shown. ‘+ Ifthe reading is out of the standard value, replace the glow plug 3. Mer 4] Inspection glow relay (1) Inspection of heater Ifthe fuse A is blown, replace it with one having the same amperage stamped on the fuse, (2) Inspection of main body ‘+ Perform continuity checks according to the following table. © ® | @ | @ | @ | oy earth) ‘When no currents soppied o [When curent is supplied S O—O There is continuity between terminal. @—] Terminals to which 24V DC is applied AsFuse © If there is anything wrong, replace the glow relay 4.ENGINE STARTER CIRCUIT 54 Alternator (f P54-12 Starter relay Starter (C PS4-20 Battery switch Battery Starter switch Safety relay Noonens Service standards Location | Maintenance item Standard value Limit Remedy 4 _|Salety relay ‘Approx. 2008 = Replace Service procedure [2] Inspection of starter relay * Perform continuity checks according to the following table. B s sw ‘When no current is supplied of When current is supplied oo O—O There is continuity between terminals. @—O Terminais to which 24V DC is applied ge If there is anything wrong, replace the starter relay 2. 4] inspection of safety relay Measure the resistance value between terminals P-L. Ifthe reading is out of the standard value, replace the safety relay 4, 54-35os,