4.1.1 Ex3600-5

Engine Manual
Vol No.: KM-925E-03

INTRODUCTION
This service manual is written to familiarize you with the maintenance of your S16R-Y1TAA1 Diesel Engine.
If the engine is carefully maintained it will deliver a long productive life and efficient performance marked by
power and economy.
Before you attempt to inspect, disassemble, or repair the engine, read this manual carefully to learn more about
the engine and how to care for it properly. All descriptions, illustrations, specifications, and serial numbers in
this manual are effective as of the date printing of this manual.
Pub.No. H99246H0120
What This Manual Covers
This service manual covers standard specifications for the S16R Diesel Engine, and describes
● Specifications
● Maintenance standards
● Adjustments
● Disassembly, inspection and repair
● Reassembly
In addition to the summary of Manual Contents, a short summary of contents is found on the first page of each
chapter of the manual.
Operation and periodical maintenance are described in the Operation & Maintenance Manual, component
parts and ordering of service parts are described in the Parts Catalogue. Construction and function of the
engine are described in the various training manuals.
How to Use This Manual
1. Parts in illustrations are numbered to correspond with references to these numbers in text.
2. Items or conditions to be inspected during disassembly are enclosed in a box in the disassembled views:
Clogged oil hole
3. Maintenance standards for inspection and repair are described in text where they are relevant. For a quick
summary of maintenance standards refer to chapter 2 of this manual.
4. The sequence in which parts are to be reassembled is summarized below each assembled view.
5 2 4 3 1
Such as:
➞ ➞ ➞ ➞
5. Tightening torque under wet conditions is indicated as “(wet)” in text, drawings, and tables. When so indicated
as (wet), apply engine oil to the threaded portion of the fastener. Unless indicated as such, the tightening
torque is to be assumed in the dry condition.
6. Pay attention to the special notes, cautions, and warnings.
1
WORKSHOP THEORY
Notes, Cautions, Warnings, Dangers
Notes, cautions, warnings, dangers are used in this manual to emphasize important or critical instructions or
advice.
–DANGER ............................................................. Indicates the most serious specific potential hazard

resulting in serious bodily injury or death.
–WARNING ............................................................. Indicates a specific potential hazard resulting in

bodily injury.
–CAUTION ............................................................. Indicates operating procedure, practice, etc., resulting

in personal injury or damage to or destruction of
engine.
NOTE ....................................................................... An operating procedure, condition, etc. that will help

you work more efficiently.
Terms Used in This Manual
Before you read this manual, note that the following special terms are used in dimensional and other specifications.
Assembly Standard ............................. Indicates the dimension of a part, the dimension to be attained at the
time of reassembly or the standard performance. The value is rounded
to the nearest whole number needed for inspection and is different from
the design value.
Nominal Value .................................... Indicates the standard dimension of a part.
Repair Limit ........................................ A part which has reached this limit must be repaired.
Service Limit ...................................... A part which has reached this limit must be replaced.
Standard Clearance ............................. Indicates the clearance to be obtained between mating parts at reassembly.
2
Summary of Manual Contents
Chapter Contents
1. General External views, sectional views, engine serial number location, engine
model and application codes, specifications, tips on disassembly and
reassembly.
2. Maintenance Standards Maintenance standards, tightening torque, sealants and lubricants.
3. Special Tools A list of special tools required.
4. Overhaul Instructions Determining when to overhaul the engine, testing compression pressure.
5. Adjustments, Bench Testing, Adjustment of valve clearance and fuel system priming, fuel timing
and Performance Tests adjustment, bench testing, and performance tests.
6. Engine Auxiliaries Removal Removal and installation of turbochargers, air coolers, fuel injection
and Installation pumps, alternator, staters, etc.
7. Engine Main Parts Disassembly, inspection, and reassembly of the main parts, to include
cylinder heads, valve mechanisms, cylinder liners, pistons, connecting
rods, flywheel, timing gears, camshafts, crankcase, crankshaft, main
bearings.
8. Inlet and Exhaust Systems Disassembly, inspection, and reassembly of inlet and exhaust systems,
to include exhaust manifolds and turbocharger.
9. Lubrication System Disassembly, inspection, and reassembly of lubrication system, to include

the oil strainer, oil pump, relief valve, oil cooler, and oil filters.
10.Cooling System Disassembly, inspection, and reassembly of cooling system, to include

water pump and thermostats.
11.Fuel System Disassembly, inspection, and reassembly of the fuel system, to include
fuel filters, fuel injection nozzles and injection pump.
12.Electrical System Disassembly, inspection, and reassembly of electrical system, to include

starters and alternator.
13.Workshop Tips General precautions for disassembly and reassembly of parts: oil seals,
O-rings, bearings, lock plates, and pins.
14.Adjusting Procedure of Adjustment of Actuator: PC set-up, adjustment of control link and

(Electric Governor) controller.
Actuator Controls
3
GENERAL
1. Outline ........................................................................................................................................ 1-2

1.1 External View ..................................................................................................................... 1-2
1.2 Engine Serial Number Location ......................................................................................... 1-3
1
1.3 Engine Model and Application Codes ................................................................................ 1-3
2. Specifications .............................................................................................................................. 1-4
3. Tips on Disassembly and Reassembly ........................................................................................ 1-7
3.1 Disassembly ........................................................................................................................ 1-7
3.2 Reassembly ......................................................................................................................... 1-7
GENERAL
1. Outline
1.1 External View

Fuel injection pump
Thermosat Cylinder head Rocker cover
Oil cooler Fuel feed pump
Turbochargers
Front side Rear side

(Flywheel side)
Electronic
governor
(Actuator)
Viscous Water drain

damper cock
By-pass oil filter

Starter
Oil filter Fuel filter Oil filler Oil level gauge
Left side
Fuel feed
Turbochargers pump Fuel injection
pump Fuel filter
Oil cooler
Rear side Front side
Oil pan
Timing gear case

oil drain Starter
Alternator
Water drain
cock Oil pan Right side
1-2
GENERAL
1.2 Engine Serial Number Location
The engine serial number is stamped on the

nameplate attached to the right lower side of the
16 15 14 13 12 11 10 9
engine.
Example: Model Serial No. 8 7 6 5 4 3 2 1

S16R 10012
The rated output and speed are also stamped
on the nameplate. Numbers in the illustration
show cylinder numbers.
1.3 Engine Model and Application Codes
S - Y1TAA1
1 ................ Serial No. of approved model

TAA .......... Turbocharged with air-cooled intercooler
1 ................ Primary stage
Y ............... EPA approved
Series code
No. of cylinders code
1-3
GENERAL
2. Specifications
Engine Type S16R-Y1TAA1
Main specification
Water-cooled, 4-stroke cycle, tubocharged diesel
Model
with air-cooled intercooler
No. of cylinder-arrangement 16-vertical V type
Combustion type Direct injection
Valve mechanism Overhead
Cylinder bore × stroke mm [in.] 170 × 180 [6.70 × 7.10]
Displacement l [U.S. gal] 65.37 [16.48]
Compression ratio 15.0:1
Fuel Light oil (JIS K2204 No. 1-3)
Firing order 1-9-6-14-2-10-4-12-8-16-3-11-7-15-5-13
Rotational direction Counterclockwise as viewed from flywheel
Length mm [in.] 2872 [113.1]
Dimensions Width mm [in.] 1555 [61.2]
Height mm [in.] 2266 [89.2]
Weight (Dry) kg [lb] 7400 [16314]
Engine main parts
Cylinder liner Type Wet type
Compression rings: 2
Piston ring No. of units
Oil ring (w/expander): 1
Open B.T.D.C. 63°
Inlet valve
Valve timing Close A.B.D.C. 35°
(when warm) Open B.B.D.C. 53°
Exhaust valve
Close A.T.D.C 45°
Engine support method 6 point support
Starting system Electric starter
Inlet and exhaust system
Type TD09
Turbocharger
No. of units 4
1-4
GENERAL

Oil system
Lubricating type Forced Circulation type (pressure feed by oil pump)
Standard Class CD or CF oil (API service classification)
Engine oil
Capacity (Engine) l [U.S. gal] 310 [82] approx.
Type Gear pump
Oil pump
Delivery capacity l [U.S. gal]/min. 515 (136) (at 1600 min-1; engine)
Type Piston valve type
Relief valve Valve opening pressure
MPa (kgf/cm2) [psi] 0.5±0.02 (5±0.2) [71.1±2.84]
Water-cooled, multi-plate type
Type
Oil cooler (housed in the crankcase)
Element 10 stages
Full-flow oil filter Type Paper element type (spin on)
Bypass oil filter Type Paper element type (spin on)
Type Piston valve type, built-in electric contact points
Oil filter alarm Lamp lighting and valve opening pressure +0.3 +4.27
0.15+0.03
0 (1.5 0 ) [21.3 0 ]
MPa (kgf/cm2) [psi]
Type Wax type
Oil thermostat
Valve opening temperature °C [°F] 80 to 84 [176 to 183.2]
Cooling system
Cooling type Water-cooled, forced circulation
Coolant capacity (Engine) l [U.S. gal] 170 [45] approx.
Type Centrifugal
Water pump
Delivery capacity l [U.S. gal]/min. 1600 [423] (at 1800 min-1 engine)
Type Wax
Thermostat
Valve opening temperature °C [°F] 71±2 [159.8±3.6]
1-5
GENERAL

Fuel system
Model PS8 type
Manufacturer Mitsubishi Heavy Industries, Ltd.
Injection pump Plunger outside diameter mm [in.] 17 [0.67]
Plunger lead mm [in.] Counterclockwise, left-hand 35 [1.38] lead
Cam lift mm [in.] 15 [0.59]
Model Bosch KD22Z type
Feed pump Manufacturer Bosch Automotive Systems Corporation
Cam lift mm [in.] 12 [0.47]
Governor Control system (Electrical)

Woodward PROACT-I
Model Hole type
Manufacturer Bosch Automotive Systems Corporation
No. of spray holes 10
Injection nozzles Spray hole diameter
ø0.325 [0.013] - 160°
Spray angle (deg.) mm [in.]
Injection pressure
34.32 to 34.81 (350 to 355) [4979 to 5050]
MPa (kgf/cm2) [psi]
Fuel filter Type Cartridge-type paper element, spin-on type
Electrical system
Voltage-polarity 24V- − ground
Manufacturer Nikko Electric Industry
Pinion mesh type Pinion shift (Reduction type)
Starter Out put V-kW 24-11
No. of starters 3
No. of pinion tooth/ring gear
tooth 15/193
Type 3-Phase alternating generator, Internal IC regulator

Manufacturer Mitsubishi Electric
Output V-A 24-150
Alternator
Rated output
generated min-1 5000 (at 27V, 143A)
Regulated voltage V 28.5±0.5

Alternator drive Model Ribbed V-belt (8PK875) RG1482
belt Outside circumference mm [in.] 875 [34.4]
1-6
GENERAL
3. Tips on Disassembly and Reassembly
This service manual covers recommended procedures to be followed when servicing diesel engines. It also
contains information on special tools required and basic safety precautions.
It is the responsibility of service personnel to be familiar with these requirements, precautions, and potential
hazards and to discuss these points with their foreman or supervisor.
Study this manual carefully and observe the following general precautions to prevent serious personal
injury and to avoid damage to the engine, equipment, and parts.
3.1 Disassembly
(1) Use the correct tools and instruments. Serious injury or damage to the engine can result from using the
wrong tools and instruments.
(2) Use an overhaul stand or work bench if necessary. Also, use assembly bins to keep the engine parts in
order of removal.
(3) Lay down disassembled or cleaned parts in the order in which they were removed. This will save you time
at reassembly.
(4) Pay attention to the marks on assemblies, components, and parts for positions or directions. Put on your
own marks, if necessary, to aid reassembly.
(5) Carefully check each part for faults during removal or cleaning. Signs of abnormal wear will tell if parts or
assemblies are functioning improperly.
(6) When lifting or carrying heavy parts, get someone to help you if the part is too awkward for one person to
handle. Use jacks and chain blocks when necessary.
3.2 Reassembly
(1 ) Wash all engine parts, except oil seals, O-rings, rubber seals, etc. in cleaning solvent and dry them with
compressed air.
(2) Use only the correct tools and instruments.
(3) Use only good quality lubricating oils and greases. Be sure to apply a coat of oil, grease, or sealant to parts
as specified. (Refer to section 3, of Chapter 2, “Maintenance Standards”.)
(4) Use a torque wrench to tighten parts when specified tightening torques are required.
(Refer to section 2, of Chapter 2, “Maintenance Standards”.)
(5) Replace all gaskets and packing. Apply appropriate amount of adhesive or liquid gasket when required.
1-7
MAINTENANCE STANDARDS
1. Maintenance Standards Table ..................................................................................................... 2- 2

2. Tightening Torque Table ............................................................................................................. 2-15
2.1 Important Bolts and Nuts ................................................................................................... 2-15
2.2 Standard Bolts and Nuts .................................................................................................... 2-17
2.3 Standard Eyebolts .............................................................................................................. 2-18
2.4 Standard Union Nuts .......................................................................................................... 2-18
2
2.5 High-pressure Fuel Injection Pipes .................................................................................... 2-18
3. Sealants and Lubricants Table ................................................................................................... 2-19
1. Maintenance Standards Table

Unit: mm [in.]
Assembly
Nominal Standard Repair Limit Service
Group Inspection Point Value (Standard (Clearance) Limit Remark
Clearance) (Clearance)
The rated rpm is

stamped on the
5 to 10% higher than rated Faulty if lower or 15%
Maximum rpm nameplate.
rpm higher then rated rpm
Check governor
setting.
Minimum rpm 600 to 650 min-1 –
Compression pressure 1.81 (18.5) [263] minimum Faulty if 1.27 (13) [185] Oil and water temp.
MPa (kgf/cm2) [psi] (at 120 min-1) or less 20 to 30 °C [68 to 86 °F]
0.49 to 0.59 (5 to 6) Faulty if 0.49 (5) [71]
[71 to 85] at rated rpm or less Oil temp.
Lube oil pressure
60 to 70 °C
MPa (kgf/cm2)[psi] 0.20 to 0.29 (2 to 3) Faulty if 0.10 (1) [14] [140 to 158 °F]
General
[28 to 43] minimum at idling or less

Inlet valve opens B.T.D.C. 25°
Valves are only for
Valve timing (with 2 mm Inlet valve closes A.B.D.C. 3°
checking valve timing
[0.08 in.] clearance on valve Exhaust valve opens B.B.D.C. 21°
and are different from
side, cold) Exhaust valve closes A.T.D.C. 7°
the actual ones.
±2° (crank angle)
Valve Inlet valves 0.6 [0.024]
clearance Exhaust
(cold) valves 0.8 [0.031]
Varies according to
±1° (crank specifications. Refer
Injection timing B.T.D.C.
angle) to caution plate on
No.1 rocker cover.
36.000 to
Rocker
36.040 36.090
bushing inside ø36 [1.42]
[1.41732 [1.42086]
diameter
to 1.41889]
Rockers
35.966 to
Rocker shaft 35.991 35.940
ø36 [1.42]
diameter [1.41598 [1.41496]
to 1.41697]
Engine main parts
9.940 to
Valve stem 9.960 9.910
ø10 [0.39]
diameter [0.39134 [0.39016]
The same for both
to 0.39213]
Valves inlet and exhaust
10.000 to valves.
Valve guide
10.015 10.060
inside ø10 [0.39]
[0.39370 [0.39606]
diameter
to 0.39429]
Valve seat Seat width
30°
angle
–0.2 to 0.2
Valve seats Valve sinkage 0 [–0.008 to 1.0 [0.039]
and valves 0.008] Valve
2.15 to 2.45 Valve margin
seat angle Valve
Seat width 2.3 [0.091] [0.0846 to 2.8 [0.110]
0.0965] sinkage
2-2
Unit: mm [in.]
Assembly
2.8 to 3.2 Refacing
[0.110 to permissible
Valve margin 3.0 [0.12]
0.126] up to 2.5
[0.098]
Valve seats
Cylinder head (–0.070 to
and valves
bore inside –0.130)
– (minus) indicates the
diameter and ø60 [2.36] ([–0.00276 to
interference in diameter
valve seat –0.00512])
diameter
Free length 73 [2.87] 71 [2.80]
θ
∆= 2.2
θ=1.5° [0.087]
Perpendicularity
or less at the
end
Valve
springs 66.0 [2.60]/
Set length/
289 to 319
set force
(29.45 to
mm [in.]/N
32.55) [64.9
(kgf) [lbf]
to 71.8]
Valve push 0.5 [0.020]
Deflection 0.5 [0.020]
Engine main parts
rods maximun
Flatness of
Cylinder 0.03 [0.0012] 0.07 0.50
gasket Reface if necessary.
heads or less [0.0028] [0.0197]
surface
170.000 to
Inside 170.040 170.200 170.500
ø170 [6.69]
diameter [6.69290 to [6.70079] [6.71259]
6.69447]
Roundness 0.02 [0.0008]

or less
0.02 [0.0008]
Cylindricity
or less
Perpendicularity
Cylinder of flange lower 0.03 [0.0012]
liners face to liner or less
axle
Protrusion of
cylinder liner 0.11 to 0.20
flange above [0.004 to
gasket 0.008]
surface
169.76 to
Measure diameter
Outside 169.80 169.66
ø170 [6.69] perpendicular to pin
diameter [6.6835 to [6.6795]
at pistonskirt.
6.6850]
Pistons 70.002 to
Pin bore 70.015 70.040
ø70 [2.76]
diameter [2.75598 to [2.75748]
2.75649]
2-3
Unit: mm [in.]
Assembly
0.06 to 0.65
Pistons Protrusion [0.0024 to From the crankcase
0.0256]
Cylinder 1.77 to 1.83
Thickness
head 1.8 [0.07] [0.0697 to
when tightened
gaskets 0.0720]
Clearance
Pistons and between (1.22 to 1.95)
cylinder piston top ([0.0480 to
heads and cylinder 0.0768])
head
(0.6 to 0.8) (2.0)
Top
([0.024 to 0.031]) ([0.079]) If gauge is not avail-
(0.6 to 0.8) (2.0) able, the general value
Piston rings Gaps Second
([0.024 to 0.031]) ([0.079]) can be obtained at the
(0.3 to 0.45) (2.0) cylinder bore.
Oil
([0.012 to 0.018]) ([0.079])
69.987 to
70.000 69.970
Piston pins Diameter ø70 [2.76]
[2.75539 to [2.75472]
2.75590]
70.020 to
Bushing
70.040 70.070
Engine main parts
inside ø70 [2.76]

[2.75669 to [2.75866]
diameter
2.75747]
0.05/100
Bend and
[0.0020/3.9]
twist
or less
Connecting End play (rod 60 [2.36] (0.4 to 0.9)
(1.4)
rods and crankpin ×2 ([0.016 to
([0.055])
widths) 0.035])
To be measured in
131.000 to
combination with caps.
Big end bore 131.025 131.050
ø131 [5.16] Roundness less than
diameter [5.15747 to [5.15944]
(0.1 mm [0.004 in.] -
5.15845]
service limit)
STD 3.000 2.972 to 2.985 2.930

[0.11811] [0.11701 to [0.11535]
0.11752]
– 0.25 3.125 3.097 to 3.110 3.055
[–0.0098] [0.12303] [0.12193 to [0.12028]
0.12244] Replace bearings if
Thick- – 0.50 3.250 3.222 to 3.235 3.180 worn down to service
Connecting
ness of [–0.0197] [0.12795] [0.12685 to [0.12520] limit. Regrind crank-
rod bearings
center 0.12736] pins and use under-
– 0.75 3.375 3.347 to 3.360 3.305 size bearings
[–0.0295] [0.13287] [0.13177 to [0.13012] if necessary.
0.13228]
– 1.00 3.500 3.472 to 3.485 3.430
[–0.0394] [0.13780] [0.13669 to [0.13504]
0.13720]
2-4
Unit: mm [in.]
Assembly
0.336 [0.0132]
Face runout
to less
Flywheel
0.13 [0.0051]
Radial runout
or less
89.987 to
90.022
ø90 [3.54]
[3.54279 to
Bearing bore 3.54417]
inside diameter
99.987 to
ø100 100.022
[3.94] [3.93649 to
3.93787]
Bearing 89.985 to
90.000
ø90 [3.54]
[3.54272 to
3.54331]
Outside 99.985 to
Injection diameter ø100 100.000
pump [3.94] [3.93642 to
accessory 3.93701]
drive 44.988 to
Bearing
Engine main parts
45.000
ø45 [1.77]
[1.77118 to
Inside 1.77165]
diameter 49.988 to
50.000
ø50 [1.97]
[1.96803 to
1.96850]
45.002 to
45.013
ø45 [1.77]
[1.77173 to
Drive shaft bearing 1.77216]
journal diameter 50.002 to
50.013
ø50 [1.97] [1.96858 to
1.96901]
110.000 to
Cover bearing
110.035
journal inside ø110 [4.33]
[4.33070 to
diameter
4.33208]
109.987 to
Plate bearing
Oil pump 110.022
journal inside ø110 [4.33]
drive [4.33019 to
diameter
4.33157]
Bearing 109.985 to
110.000
Outside ø110 [4.33]
[4.33012 to
diameter
4.33071]
2-5
Unit: mm [in.]
Assembly
Bearing 49.988 to
50.000
Inside ø50 [1.97]
[1.96803 to
diameter
Oil pump 1.96850]
drive Gear shaft 49.993 to
bearing 50.013
ø50 [1.97]
journal [1.96822 to
diameter 1.96901]
Radial runout 0.5 [0.020] 1.5
(at periphery) or less [0.059] Replace with new part
Damper
0.5 [0.020] 1.5 at first overhaul.
Face runout
or less [0.059]
(0.12 to 0.18) Replace gears,
(0.30) (0.50)
Backlash ([0.0047 to
([0.0118]) ([0.0197]) if necessery.
0.0071])
50.000 to
Idle gear
50.025 50.060
[1.96850 to [1.97086]
diameter
Front gears 1.96948]
49.950 to
Idle gear 49.975 49.900
ø50 [1.97]
diameter [1.96653 to [1.96456]
1.96752]
Engine main parts
(0.2 to 0.4)
Idle gear end (0.6)
([0.008 to
play ([0.024])
0.0016])
(0.12 to 0.18)
(0.30) (0.50)
Backlash ([0.0047 to
([0.0118]) ([0.0197])
0.0071])
65.000 to
Idel gear shaft
65.030 65.060
[2.55906 to [2.56142]
diameter
Timing 2.56024]
gears 64.951 to
Idle gear shaft 64.970 64.900
ø65 [2.56]
diameter [2.55713 to [2.55512]
2.55787]
(0.3 to 0.6) (1.0)
Idle gear
([0.0118 to ([0.0397])
end play
0.0236])
9.260 to
9.300 9.340 8.45
Cam lift (A-B)
[0.3661] [0.36457 to [0.3327]
0.36772]
Camshaft
Deflection at center
bushing measured
0.05 [0.0020] 0.08
Deflection with both ends sup-
or less [0.0031]
ported. Repair or
replace, if necessary.
2-6
Unit: mm [in.]
Assembly
83.92 to
Journal 83.94 83.87
ø84 [3.31]
diameter [3.3039 to [3.3020]
3.3047]
Camshaft
84.000 to
bushing inside Replace bushings and
Camshaft 84.035 84.10
diameter (as ø84 [3.31] ream them, if neces-
[3.30708 to [3.3110]
installed in sary.
3.30846]
crank case)
(0.10 to 0.25)
(0.40) Replace thrust bearing,
End play 8 [0.3] ([0.0039 to
([0.0157]) if necessary.
0.0098])
–0.050 to
Crankpin –0.070 –0.110
ø125 [4.92]
diameter [–0.00197 to [–0.00433]
–0.00276]
–0.060 to
Crankpin
–0.080 –0.110
journal ø170 [6.69]
[–0.00236 to [0.00433]
diameter
–0.00315]
Center to
center
Engine main parts
distance 90 [3.54] ±0.1

between [±0.004]
journal and
crankpin
Parallelism 0.01 [0.0004]
between or less 0.03
journals and at pin [0.0012]
crankpins length
Crankshaft
Roundness 0.01 [0.0004]
0.03
of journals and or less
[0.0012]
crankpins in diameters
Cylindricity of 0.02 [0.0008]

0.03
journals and or less
[0.0012]
crankpins in diameters
0
Fillet radius of 7.0 –0.2
7 [0.28]
crankpins 0
[0.276 –0.008 ]
0
Fillet radius of 8.5 –0.2
8.5 [0.34] 0
journals [0.335 –0.008 ]
Hardness of
journals and Hv>590
crankpins
2-7
Unit: mm [in.]
Assembly
Angularity ±0°20’
0.04 [0.0016] 0.10 Repair or replace,

Deflection
or less [0.0039] if necessary.
(0.50) Replace thrust bearings
Crankshaft ([0.0197]) if worn down to service
End play +1.18 limit. Use oversize
(0.20 to 0.40)
(width between [+0.0465] thrust bearings if worn
67 [2.64] ([0.0079 to
webs and thrust for beyond repair limit.
0.0157])
bearings) crank +0.25 [+0.0098],
shaft +0.50 [0.0197],
width +0.75 [0.0295]
STD 4.500 4.467 to 4.480 4.425
[0.17717] [0.17587 to [0.17421]
Engine main parts
0.17638]
–0.25 4.625 4.592 to 4.605 4.550
[–0.0098] [0.18209] [0.18079 to [0.17913] Replace bearings if
0.18130] worn down to service
Thick- –0.50 4.750 4.717 to 4.730 4.675 limit. Regrind
Main
ness of [–0.0197] [0.18701] [0.18571 to [0.18405] crankpins and use
bearing
center 0.18622] undersize bearings if
–0.75 4.875 4.842 to 4.855 4.800 worn beyond service
[–0.0295] [0.19193] [0.19063 to [0.18898] limit.
0.19114]
–1.00 5.000 4.967 to 4.980 4.925
[–0.0394] [0.19685] [0.19555 to [0.19390]
0.19606]
Flatness of
0.1 [0.004] 0.2
gasket Reface if necessary.
or less [0.008]
surface
Crankcase 179.000 to
Main bearing ø179 179.025 179.045
bore diameter [7.05] [7.04723 to [7.04900]
7.04821]
2-8
Unit: mm [in.]
Assembly
Inside diameter
ø22.26 22.268
of bearing-fitted
[0.876] [0.87669]
housing section
Outside 22.144
diameter [0.87181]
Inside 13.542
Bearing
diameter [0.53315]
14.440
Length
[0.56850]
Inlet and exhaust systems
ø13.5 13.496
Shaft journal
[0.531] [0.53134]
0.015
Shaft deflection
Turbo- [0.00059]
charger 0.05 to 0.15
Ring gap clearance [0.00197 to
0.00590]
Clearance between 0.29 to 0.93
shaft & turbine [0.01142 to
wheel and turbine 0.03661]
housing
0.075 to 0.135
Shaft end play [0.00295 to
0.00531]
Clearance between 0.6 to 1.2
turbine backplate [0.02362 to
and turbine wheel 0.04724]
2-9
Unit: mm [in.]
Assembly
Backlash between (0.10 to 0.20) (0.4)
drive gear and ([0.0039 to ([0.0157])
driven gear 0.0079])
Tip clear-
Clearance of (0.100 to 0.148)
ance
drive and driven ø60 [2.36] ([0.00394 to
(0.35)
gears to case 0.00583])
([0.0138])
Remove the cover
Gear end (0.040 to 0.116) packing (width of
72.5 (0.21)
clearance in ([0.00157 to 0.04 [0.0016]) for
[2.854] ([0.0083])
case 0.00457]) measurement.
Oil pump
29.887 to
Drive 29.900 29.840
shaft [1.17665 to [1.17480]
Shaft 1.17717]
dia- 29.947 to
meter Driven 29.960 29.900
shaft ø30 [1.18] [1.17901 to [1.17716]
1.17953]
Lubrication system
30.000 to
Bushing
30.021 30.055
inside diame-
(1.18110 to [1.18327]
ter
1.18193)
Valve opening 1.27±0.13
pressure, (13±1.3)
MPa (kgf/cm2) [185±18.5]
Safety [psi]
valve Spring set
65.8 [2.59] 65.8 [2.59]
length/load
/359 (36.6) /314 (32)
mm [in.]/N (kgf)
[80.7] [70.5]
[lbf]
Valve opening
0.5±0.02
Relief pressure,
(5±0.2)
valve MPa (kgf/cm2)
[71.1±2.84]
[psi]
Temperature
at which 80 to 84 °C
valve starts [176 to 183 °F]
Oil opening
thermostat Temperature
at which valve
95 °C [203 °F]
lift is more than
11 mm [0.43 in.]
2-10
Unit: mm [in.]
Assembly
Lamp lighting and
valve opening Change of oil
0.15 + 0.03
Lubrication system
pressure 0 pressure is 6.86 kPa

Oil filter (differential (1.5 + 0.3
0 ) (0.07 kgf/cm2) [1.00 psi]
alarm pressure) [21.3 + 14
0 ] with a 1 mm [0.039 in.]
MPa (kgf/cm2) shim.
[psi]
Valve opening
Piston 0.26 to 0.32
pressure,
cooling 2.7 to 3.3
MPa (kgf/cm2)
nozzle [38 to 47]
[psi]
119.987 to
120.022
ø120 [4.72] [4.72389 to
Bearing bore 4.72527]
inside
diameter 110.005 to
110.040 Same as the bearing
ø110 [4.33] [4.33090 to cover.
4.33227]
Bearing 119.985 to
120.000
ø120 [4.72] [4.72381 to
4.72441]
Outside
diameter 109.985 to
110.000
ø110 [4.33] [4.33012 to
4.33071]
Bearing 54.985 to
Water 55.000
pump ø55 [2.17] [2.16476 to
Cooling system
Inside 2.16535]
diameter 49.988 to
50.000
ø50 [1.97] [1.96803 to
1.96850]
55.011 to
55.024
ø55 [2.17] [2.16578 to
Shaft bearing 2.16629]
journal
diameter 50.011 to
50.024
ø50 [1.97] [1.96893 to
1.96944]
(0.58 to 1.5)
Vane front 1.04 [0.041] ([0.023 to
face clearance 0.059])
Temperature 71±2 °C
at which valve [159.8±
starts opening 3.6 °F]
Thermostat Temperature Check in atmospheric
at which valve pressure.
lift is 11 mm 85 °C
[0.43 in.] [185 °F]
or more
2-11
Unit: mm [in.]
Assembly
Group Inspection Point Value (Standard (Clearance) limit Remarks
34.32 to
Valve open- 34.81
ing pressure, 34.32 350 to 355
MPa (kgf/cm2) (350) [4977] [4977 to
[psi] 5048 ]
Fuel Check nozzle
injection with a hand
nozzle tester (at fuel oil
temperature 20 °C
Spray cone angle 160° [68 °F]). Replace the
nozzle tip if the spray
pattern is still bad after
washing in clean fuel
oil.
Overall
clearance at 0.2
tappet roller [0.00787]
Wear of contact
surface between 0.2
tappet and plunger [0.00787]
Outside diameter 34.963 to
at contact surface ø35 34.938 34.800
of camshaft oil [1.378] [1.37649 to [1.37001]
seal 1.37551]
Camshaft 0.05 0.15
deflection [0.00197] [0.00591]
Fuel system
▲ = 1.8
Plunger
Perpen- spring [0.071]
dicula-
Injection rity of ▲ = 0.6
pump spring Delivery
spring [0.024]
0.02 to 0.06
Camshaft thrust [0.00079 to
clearance 0.00236]
Make sure rack moves
Resistance in 500 g smoothly. Total rack
rack movement [1.102 lb] stroke should be 36 mm
[1.42 in.].
Injection start
45° ± 0.5° Camshaft angle
interval
Nozzle valve 34.3
opening pressure (350)
MPa (kgf/cm2) [psi] [4978.75]
Feed pressure 0.16 (1.6)
MPa (kgf/cm2) [psi] [22.76]
2-12
Unit: mm [in.]
Assembly
Feed pressure Discharge
(pump at start time:
100 min-1) 20 sec or less
Fuel system
No. of pumping
Feed pump Priming pump operations:
discharge start 30 strokes
or less
Feed pump feed 900 cm3
rate (pump at [54.9 cu.in.]
600 min-1) /15 sec
Diameter of
ø43 [1.69] ø42 [1.65]
commutator
Runout of 0.06 [0.0024], 0.10
commutator or less [0.0039]
0.7 to 0.9
Mica depth in 0.2
[0.028 to
commutator [0.0079]
0.035]
Height of 22 to 23
13 [0.51]
brushes [0.87 to 0.91]
Tension of 39.23 to 49.03 39.23
44.13 [4.5]
brush springs, (4.0 to 5.0) (4.0) [9],
[10]
N (kgf) [lbf] [9 to 11] maximum
13.941 to
Armature +0.25
ø10 +0.15
13.968
shaft diameter ø14 [0.55]
[0.54886 to +0.0098
[0.39 +0.0059 ]
(rear)
0.54992]
25.002 to +0.25
Armature ø25 +0.15
25.011
Electric system
shaft diameter ø25 [0.98]

Starter [0.98433 to [0.98 +0.0098
+0.0059 ]
(front)
0.98468]
Armature 0.06
shaft deflection [0.00236]
30.002 to +0.011
Pinion shaft 30.011 ø30 +0.002
ø30 [1.8]
diameter (rear) [1.18118 to +0.00043
[1.1800000]
+0.00008
1.18153]
(18.90 to –0.06
Pinion shaft 18.94) ø19 –0.10
ø19 [0.75]
diameter (front) ([0.7441 to [0.75 –0.00236
–0.00394 ]
0.7457])
Metal 19.000 to +0.033
19.033 ø19 0 0.25 Clearance between
ø19 [0.75] [0.0098] shaft and metal
Pinion [0.7480 to [0.75
+0.00130
0 ]
0.7493]
0.2 to 0.8
End play of
[0.008 to
armature
0.031]
0.2 to 0.8
End play of
[0.008 to
pinion shaft
0.031]
2-13
Unit: mm [in.]
Assembly
Output current (24 V)

1500 104 A
min-1 or higher
Rotating speed
2500 154 A
min-1 or higher
143 A
5000
min-1 or higher,
when hot
Regulator
adjusting
voltage
28.5 ± 0.5 V
(alternator at
Electric system
5000 min-1, load

at 5 A or lower)
Alternator Field coil
resistance 3.8 to 4.5 Ω
(at 20 °C [68 °F])
IC regulator
adjusting voltage
28 to 29 V
(5000 min-1,
5 A or lower)
Deflection when
pressed with thumb.
10 to 15 98 to 147 N
Drive belt
[0.4 to 0.6] (10 to 15 kgf )
tension
[22 to 33 lbf]
2-14
2. Tightening Torque Table
2.1 Important Bolts and Nuts

Thread Torque
Description Dia × Pitch Remarks
(M-thread) N·m kgf·m lbf·ft
Cylinder head 22 × 2.5 539 55 398 (Wet) 2-step tightening method
Note (a)
Cylinder head nozzle gland (studs) 14 × 2.0 69 to 78 7 to 8 51 to 58
Rocker case 12 × 1.25 108 11 80
Rocker shaft 14 × 2.0 147 15 108
Rocker arm lock nuts 12 × 1.25 64 6.5 47
Bridge lock nuts 10 × 1.25 55 5.6 40
Camshaft gear 12 × 1.25 108 11 80
Camshaft thrust plate 12 × 1.25 59 6 43
Main bearing caps 22 × 2.5 588 60 434 (Wet); Note (b)
Main bearing cap side bolts 20 × 2.5 392 40 289 (Wet); Note (b)
Hanger 12 × 1.25 392 40 289
16 × 1.5 216 22 159
Piston cooling nozzle 12 × 1.75 34 3.5 25 Note (c)
Timing gear case 16 × 1.5 255 26 188
Rear plate 12 × 1.25 108 11 80
16 × 1.5 216 22 159
Oil pan 12 × 1.25 59 6 43
Front mounting bracket 12 × 1.5 392 40 289
Center mounting bracket 20 × 1.5 392 40 289
Rear mounting bracket 20 × 1.5 392 40 289
Connecting rod metal caps 22 × 1.5 539 55 398 (Wet) 2-step tightening method
Note (d)
Balance weight 22 × 1.5 490 50 362 (Wet)
Flywheel 22 × 1.5 588 60 434 (Wet)
Ring gears 10 × 1.25 59 6 43
Viscous damper 22 × 1.5 490 50 362
Rear idler shaft 20 × 1.25 392 40 289
Rear idler shaft (nuts) 18 × 1.5 196 20 145
Front gear case 12 × 1.25 59 6 43
16 × 1.5 216 22 159
Front plate 12 × 1.25 59 6 43
Front idler shaft 12 × 1.25 108 11 80
Front idler gear thrust plate 10 × 1.25 29 3 22
Exhaust manifold V-clamp nuts 8 × 1.25 19.6 2 14.5
Exhaust manifold mounting bolts 1/4 × 28UNF 9 0.9 6.5
Exhaust pipe V-clamps 10 × 1.5 98 10 72
Oil pump and water pump 12 × 1.25 59 6 43
mounting plates
Note: (a) To tighten cylinder head bolts according to the angle method, tighten to 294 N·m (30 kgf·m) [217 lbf·ft],
then turn 60° more.
(b) Be sure to tighten main bearing caps and main bearing cap side bolts according to the specified sequence.
(1) Tighten the cap bolts to the specified torque.
(2) Tighten the side bolts on the right side of the engine.
(3) Tighten the side bolts on the left side of the engine.
(c) To tighten piston cooling nozzle check valves, be sure to use a torque wrench. Tightening without the
use of a torque wrench can result in excessive tightening force, and this can cause valve malfunctions
and lead to seizing of pistons due to insufficient lubricating oil during engine operation.
(d) To tighten connecting rod caps according to the angle method, tighten to 245 N·m (25 kgf·m) [181
lbf·ft], then turn 60° more.
(e) (Wet) indicates apply engine oil to the threads of the nuts and bolts.
2-15
Thread Torque
Description Dia × Pitch Remarks
(M-thread) N·m kgf·m lbf·ft
Bearing cover (oil pump, water pump) 12 × 1.25 108 11 80
Injection pump drive case 12 × 1.25 108 11 80
Injection pump gear (nuts) 30 × 1.5 392 40 289
Injection pump coupling shaft 14 × 1.5 167 to 17 to 123 to Tighten the slit part.
177 18 130
Oil pump 12 × 1.25 108 11 80
Oil pump cover 10 × 1.25 33 3.4 25
Oil pump safety valve 32 × 2.0 74 ± 10 7.5 ± 1 54 ± 7
Oil pump safety valve (plug) 24 × 1.5 88 ± 10 9±1 65 ± 7
Water pump 12 × 1.25 108 11 80
Water pump shaft pulley (nuts) 30 × 1.5 392 40 289 For alternator drive
Fuel filter air vent plug _ 7.8 to 0.8 to 5.8 to
9.8 1.0 7.2
Injection pump bracket 12 × 1.25 108 11 80
Injection pump 12 × 1.25 108 11 80
Injection pump laminate plate 12 × 1.25 103 to 10.5 to 76 to
113 11.5 83
Injection pump flywheel (nuts) 24 × 1.5 392 40 289
Injection pump coupling shaft 14 × 1.5 167 to 17 to 123 to
177 18 130
Injection pump plunger assembly 12 × 1.25 78 to 8 to 58 to
83 8.5 61
Injection pump delivery valve holder 30 × 1.5 235 to 24 to 174 to
255 26 188
Injection nozzle gland (nut) 14 × 1.5 98 10 72
Injection nozzle chip (nut) 28 × 1.5 177 to 18 to 130 to
196 20 145
Nozzle holder cap nuts 14 × 1.5 69 to 7 to 8 51 to
78 58
Injection nozzle set screw 10 × 1.5 34 to 3.5 to 25 to
44 4.5 33
Injection nozzle inlet connector 16 × 1.5 64 to 6.5 to 47 to
74 7.5 54
Injection pipes 18 × 1.5 49 to 5 to 7 36 to
69 51
Fuel rack control lever 8 × 1.25 25 2.5 18 2-step tightening method
Governor drive case 12 × 1.25 108 11 80
Starter 12 × 1.25 59 6 43
Underplate 20 × 1.5 392 40 289 Between gear case and
underplate
Timing gear case stay 16 × 1.5 255 26 188
Air duct clamp 6 × 1.0 4.9 0.5 3.6 T-bolt type
Note (a)
Turbocharger compressor wheel (nut) 9 × 1.0 _ _ _ Apply Moly Disulfide to
thread.
Turbocharger V-clamp _ 7.8 to 0.8 to 5.8 to Apply Moly Disulfide to
9.8 1.0 7.2 thread.
Note: (a) Tighten nut to 9.8 N·m (1.0 kgf·m) [7.2 lbf·ft] and loosen it. Retighten to 9.8 N·m (1.0 kgf·m) [7.2
lbf·ft] and turn to the angle 80 ± 3°.
2-16
2.2 Standard Bolts and Nuts
Thread Width across Strength classification

Dia × Pitch, flats, 7T 10.9
mm [in.] mm [in.] N·m kgf·m lbf·ft N·m kgf·m lbf·ft
Metric automobile screw thread
M8 × 1.25 [0.31 × 0.049] 12 [0.47] 17 1.7 12 30 3.1 22

M10× 1.25 [0.39 × 0.049] 14 [0.55] 33 3.4 25 60 6.1 44
M12× 1.25 [0.47 × 0.049] 17 [0.67] 60 6.1 44 108 11.0 80
M14× 1.5 [0.55 × 0.059] 22 [0.87] 97 9.9 72 176 17.9 129
M16× 1.5 [0.63 × 0.059] 24 [0.94] 145 14.8 107 262 26.7 193
M18× 1.5 [0.71 × 0.059] 27 [1.06] 210 21.4 155 378 38.5 278
M20× 1.5 [0.79 × 0.059] 30 [1.18] 291 29.7 215 524 53.4 386
M22× 1.5 [0.87 × 0.059] 32 [1.26] 385 39.3 284 694 70.8 512
M24× 1.5 [0.94 × 0.059] 36 [1.42] 487 49.7 359 878 89.5 647
M27× 3 [1.06 × 0.012] _ 73.8 75.3 544 1328 135.5 980
Metric course screw threads
M10× 1.5 [0.39 × 0.059] 14 [0.55] 32 3.3 24 58 5.9 43

M12× 1.75 [0.47 × 0.069] 17 [0.67] 57 5.8 42 102 10.4 75
M14× 2 [0.55 × 0.079] 22 [0.87] 93 9.5 69 167 17.0 123
M16× 2 [0.63 × 0.079] 24 [0.94] 139 14.2 103 251 25.6 185
M18× 2.5 [0.71 × 0.098] 27 [1.06] 194 19.8 143 350 35.7 258
M20× 2.5 [0.79 × 0.098] 30 [1.18] 272 27.7 200 489 49.9 361
M22× 2.5 [0.87 × 0.098] 32 [1.26] 363 37.0 268 653 66.6 482
M24× 3 [0.94 × 0.12] 36 [1.42] 468 47.7 345 843 86.0 622
M27× 3 [1.06 × 0.12] _ 686 70.0 506 1236 126.0 911
Remarks: (a) This table lists the tightening torque for the standard nuts and bolts.
(b) The numerical values in this table are for when using spring washers.
(c) This table shows the standard values with a maximum tolerance value of +10%.
(d) Except for special tables, tightening torque should be done using this table.
(e) Don’t apply oil to screws (dry).
2-17
2.3 Standard Eyebolts
Threads Width across Strength classification

Diameter × Pitch, flats, 4T
mm [in.] mm [in.] N·m kgf·m lbf·ft
M8 × 1.25 [0.31 × 0.049] 12 [0.47] 8±1 0.8±0.1 5.8±0.72
M10 × 1.25 [0.39 × 0.049] 14 [0.55] 15±2 1.5±0.2 10.8±1.45
M12 × 1.25 [0.47 × 0.049] 17 [0.67] 25±3 2.5±0.3 18.1±2.17
M14 × 1.5 [0.55 × 0.059] 19 [0.75] 34±4 3.5±0.4 25.3±2.89
M16 × 1.5 [0.63 × 0.059] 22 [0.87] 44±5 4.5±0.5 32.5±3.62
M18 × 1.5 [0.71 × 0.059] _ 74±5 7.5±0.5 54.2±3.62
M20 × 1.5 [0.79 × 0.059] 27 [1.06] 98±10 10.0±1.0 72.3±7.23
M24 × 1.5 [0.94 × 0.059] 32 [1.26] 147±15 15.0±1.5 108.5±10.8
M27 × 3 [1.06 × 0.012] _ 226±20 23.0±2.0 166.3±14.5
(Dry)
2.4 Standard Union Nuts
Width across
Nominal
Cap nut size flats N·m kgf·m lbf·ft
Diameter
mm [in.]
63 M14 × 1.5 [0.55 × 0.059] 19 [0.75] 39 4 29
80 M16 × 1.5 [0.63 × 0.059] 22 [0.87] 49 5 36
100 M20 × 1.5 [0.79 × 0.059] 27 [1.06] 78 8 58
120 M22 × 1.5 [0.87 × 0.059] 30 [1.18] 98 10 72
150 M27 × 1.5 [1.06 × 0.059] 32 [1.26] 157 16 116
180 M30 × 1.5 [1.18 × 0.059] 36 [1.42] 196 20 145
200 M30 × 1.5 [1.18 × 0.059] 36 [1.42] 196 20 145
220 M33 × 1.5 [1.30 × 0.059] 41 [1.61] 245 25 181
254 M36 × 1.5 [1.42 × 0.059] 41 [1.61] 294 30 217
(Dry; maximum tolerance valve of 10%)
2.5 High-Pressure Fuel Injection Pipes
Cap nut size N·m kgf·m lbf·ft

M12 × 1.5 [0.49 × 0.059] 39±5 4±0.5 29±3.6
M14 × 1.5 [0.55 × 0.059] 49±5 5±0.5 36±3.6
M18 × 1.5 [0.71 × 0.059] 59±1 6±1.0 43±7.2
(Dry)
2-18
3. Sealants and Lubricants Table

Group Application point Sealant or lubricant How to use
Cylinder head sealing caps Hermeseal S-2 Coat holes in crankcase
Water outlet connectors
Grease Grease O-ring joint
(Rocker case)
Cylinder liners Engine oil Grease O-ring joint
Front plate, gear case, oil pan, Coat three face-mating portions
Herdite
and crankcase only
Rear plate, gear case, oil pan, Coat three face-mating portions
Herdite
and crankcase only
Engine main parts Sealock, Loctite
Crankcase taper plugs Apply to threads
(made by Three Bond)
Coat joint portions only on
Upper and lower gaskets Herdite
both sides of packing
Underplate, crankcase, front
Three Bond 1211
gear case, timing gear case
Oil seals Engine oil Coat lip of each oil seal
Drive case Three Bond 1212 Apply to flange surface
Apply to areas around tappet
Cylinder head gasket Three Bond 1212
chambers
Lubrication system Oil pump Cover and case Three Bond 1215 Coat both sides of packing
Water Oil seal Engine oil Coat lip of inner seal
Cooling system pump Unit seal LLC solution (antifreeze) Coat floating seat
Taper plugs and cocks not
Others precoated with Three Bond Seal tape Wrap threads with 2 rounds of tape.
thread sealants.
2-19
2-20
SPECIAL TOOLS
Special Tool List ......................................................................................................................... 3-2
3
SPECIAL TOOLS
Special Tool List
Tool name Part No. Shape Use

Rocker bushing tool H3759102600 Rocker bushing installation/
removal
Eye nut H3759102400 Cylinder head lifting
Valve spring pusher H3359104500 Valve spring removal/

installation
Valve guide remover H3359104300 Valve guide removal
Valve guide and seal H3719101500 Valve guide and valve

installer stem seal installation
Valve lapper H3009108800 Valve lapping
Ring pliers H4519108400 Snap ring removal/

installation
Valve seat puller H3259104200 Valve seat removal
3-2
SPECIAL TOOLS

Cylinder liner remover H3759104100 Cylinder liner removal
Piston ring tool H3719103200 Piston ring removal/installation
Idler bushing puller H3259102500 Idler bushing removal/

installation
Piston installer H3719107100 Piston installation
Connecting rod bushing H3759101010 Connecting rod bushing

installer removal/installation
Compression gauge H3759102200 Compression pressure

adaptor measurement
Compression gauge H3339102100 Compression pressure

measurement
Socket H5830973100 For removal/installation of

injection pump gear, and water
pump shaft pulley nut.
3-3
SPECIAL TOOLS

Torque wrench H3219103100 Measuring range
0 to 539 N·m (0 to 55 kgf·m)
[0 to 398 lbf·ft]
Piston remover HMM321420 Piston lifting
Unit seal installer H3719106300 Water pump unit seal installation
Water pump pliers H3759103100 For water pump cover snap ring
Impeller remover H3759103200 Water pump impeller removal
Ring installer H3779103300 Pressurized ring insertion for

water pump unit seal
Ring remover H3779103400 Seal ring removal water pump

unit
Adjustable wrench HF961115000 Width across flats

20 mm [0.79 in.] max
Jack-bolt H6436268500 Oil-pump and water-pump plate

removal, flywheel removal
M12 × 1.25 [0.47 × 0.049] -

95 [3.74]
Unit: mm [in.]
3-4
SPECIAL TOOLS

Nozzle tester H4109101500 Nozzle connection pipe Nozzle opening pressure
M18 × 1.5 [0.71 × 0.059] (Tester side) measurement
M18 × 1.5 [0.71 × 0.059]

(Nozzle fitting side) Unit: mm [in.]
Pliers H4916090101 Snap ring (H4916023100)
removal / installation


Tool box H4916090501 75 × 203 × 360 mm

[2.95 × 7.99 × 14.17 in.]
Injection coupling H3759106100 Injection pump coupling

gauge connection
Front seal installer H3759105010 Front oil seal installation

assembly
Rear seal installer H3779106010 Rear oil seal installation

assembly
3-5
SPECIAL TOOLS

Valve seat cutter shaft H3759106400 Valve seat contact surface
adjustment
Valve seat cutter H3759106430
Liner pusher H3759106200 Liner retainment
Bolt H3759106300
Head bolt spacer H3759809100 Spacer used for tightening liner

pusher with head bolt
Projection plate H3759809201 Crankcase counter bore depth

measurement
Head bolt plate H3759808900 Head-bolt tightening through

an angle
Interface box H3786300700 Governor adjuster
3-6
SPECIAL TOOLS
For injection pump

Cable 3093944 Adjustment of governor
Pump assembly stand H4829100100 Pump assembly and

disassembly
Plunger spring H4829100200 Installation and removal of

compressing jig plunger spring
Plunger spring H4829100301 Installation and removal of

retaining jig plunger spring
(8 pieces required)
Cam thrust ejector H4829100400 Measurement of camshaft

thrust clearance
Stopper plate H4829100500 t: 11 mm [0.43 in.] Prevention of pinion and

rack damage during barrel
installation
Rack setting jig H4829100600 M8 [0.31 in.] bolt Assembly of control rack
57 mm
ø 18 mm
[2.24 in.]
[0.71 in.]
Sleeve installer H4820209301 For installation of oversized
sleeve on camshaft
Fuel injection nozzle H3756199000 Adjusting injection volume of

fuel injection pump
3-7
OVERHAUL INSTRUCTIONS
1. Determination of Overhaul Timing ............................................................................................ 4-2

2. Testing the Compression Pressure .............................................................................................. 4-3
4
1. Determination of Overhaul Timing

In most cases the engine should be overhauled when the engine’s compression pressure is low. Other factors
that indicate the necessity of engine overhaul are as follows:
(a) Decreased power
(b) Increased fuel consumption
(c) Increased engine oil consumption
(d) Increased blow-by gas volume through the breather due to abrasion at the cylinder liner and the piston ring
(e) Gas leakage due to poor seating of the inlet and the exhaust valves
(f) Starting problems
(g) Increased noise from engine parts
(h) Abnormal color of exhaust gas from engine after warm-up
Any one or a combination of these symptoms may indicate that engine overhaul is required. Of the items listed
above some are not directly related to the necessity of engine overhaul. Items (b) and (f) are more likely to be
affected substantially by
• Injection volume of the fuel injection pump
• Fuel injection timing
• Wear of injection-pump plunger
• Fitting of the injection nozzle
• Condition of electrical equipment: battery, starter, or alternator
Item (d) above, however, requires special consideration because decreased pressure due to wear at the cylinder
liner and the piston ring is one of the most obvious signs that the engine requires overhauling.
The most effective way to make a decision is by testing the compression pressure; other factors are to be
considered secondarily.
4-2
2. Testing the Compression Pressure
(1) Remove the injection nozzle from the cylinder

head where the compression pressure is to be
B
measured.
(2) Attach the Compression gauge adapter A

(H3759102200) to the adapter and connect
Compression gauge B (H3339102100) .
A
(3) Crank the engine with the starter, then read the
compression gauge indication while the engine
is running at the specified speed.
(4) If the compression pressure is lower than the

repair limit, overhaul the engine.
–CAUTION
(a) Measure the compression pressure on all
cylinders. It is not a good practice to measure
the compression pressure on only few
cylinders, and presume the compression on
the remaining cylinders.
(b) Compression pressure varies with engine

speed. Check engine speed when measuring
the compression pressure.
Unit: MPa (kgf/cm2) [psi]

Item Assembly Standard Repair Limit
Compression 1.81 (18.5) [263] 1.27 (13) [185]
pressure min. max.
NOTE
Measure the compression pressure with the
engine running at 120 min-1.
–CAUTION
(a) Measure the compression pressure at regular
intervals to obtain correct data.
(b) The compression pressure will be slightly
higher in a new or overhauled engine due to
new piston rings, valve seats, etc. Pressure
will drop gradually by the wear of parts.
4-3
ADJUSTMENTS, BENCH TESTING, AND PERFORMANCE TESTS
1. Adjustments ............................................................................................................................... 5- 2
1.1 Valve Clearance ................................................................................................................. 5- 2
1.2 Fuel System Bleeding ........................................................................................................ 5- 5
1.3 Fuel Injection Timing Adjustment ..................................................................................... 5- 7
1.4 Idling Speed and Maximum Speed Setting Inspection and Adjustment ............................ 5- 9
1.5 Inspecting and Adjusting Alternator Drive Belt ................................................................ 5- 9
2. Bench Testing ............................................................................................................................ 5-10
2.1 Starting Up ......................................................................................................................... 5-10
2.2 Inspection after Starting Up ............................................................................................... 5-10
2.3 Bench Testing (Dynamometer) Conditions ....................................................................... 5-10
2.4 Inspection and Adjustments after Bench Testing ............................................................... 5-10
3. Performance Tests ...................................................................................................................... 5-11
3.1 Engine Equipment Condition ............................................................................................ 5-11
3.2 Tests and Their Purposes ................................................................................................... 5-11
5
3.3 Other Inspection ................................................................................................................. 5-11
3.4 Adjustment Engine Output ................................................................................................ 5-11
4. Engine Bench Testing Procedures ............................................................................................. 5-13
4.1 Main Specifications ........................................................................................................... 5-13
4.2 Test/inspection Items ......................................................................................................... 5-13
4.3 Test Methods and Judgment Criteria ................................................................................. 5-14
1. Adjustments
1.1 Valve Clearance A
Valve clearance should be inspected and adjusted

B
when the engine is cold.
Unit: mm [in.]
Item Assembly Standard
Valve clearance Inlet valves 0.6 [0.024]
(A) Exhaust
0.8 [0.031]
valves
NOTE
(a) The bridge-to-valve rotator clearance (B)
should be more than 1.5 mm [0.059 in.] after
the front and rear valve heights have been
adjusted. If the clearance is too small, grind
the bridge to obtain the specified clearance.
(b) Looking toward the cylinder head, the inlet
valves are on the left, the exhaust valves on
the right.
(c) The specified clearances for the valves are
indicated on the caution plate fitted to the
No.1 cylinder rocker cover.
(1) Inspecting valve clearance

Running Turning
(a) Inspect the valve clearance in the firing order
by turning the crankshaft in the direction of
normal rotation to bring the piston to top dead
center of the compression stroke.
4 1 5
Firing order
2
Cylinder no.: 1-9-6-14-2-10-4-12-8-16-3-11-7-15-5-13 3
6
Injection and 0° –60° –90° –150° –180° –240° –270°
ignition –330° –360° –420° –450° –510° –540°
intervals: –600° –630° –690°
NOTE
1 2
Note these points when using the turning gear
3 4
(a) Loosen bolts and . Remove the plate
4
from the slot of the shaft .
Push the shaft until it reaches its limit.
5-2
4
5 6
(b) Make the shaft turn by rotating it with
6
the socket and the ratchet handle .
Push down the ratchet handle to turn the
crankshaft in the normal direction.
4 3
(c) After completing the turn, pull out the shaft
4 1 2
. Insert the plate into the slot of the
3
shaft . Tighten the bolts and .
4
Check and be sure the plate is inserted
into the slot of the shaft .
–CAUTION
Make sure that the turning gear at the running
position before you start the engine.
(b) The top dead center on the compression stroke

of the piston is identified by the timing mark
1
(provided on the viscous damper), aligned •
with the pointer. With the piston so located, 8
the inlet and exhaust valve rocker arms are
not pushed up by their push rods.
(c) Insert feeler gauges in between the rocker arm

and bridge cap, and inspect the valve
clearance.
(2) Adjusting front and rear valve heights by the

valve bridge
(a) Before adjusting the valve clearance, adjust

the bridge to the front and rear valve tops with Screwing for 10°
the bridge adjusting screw (bring the bridge 55 N·m
(5.6 kgf·m)
into contact with the valves). If the valve seats [40 lbf·ft]
are worn, valve heights will differ, causing
gap between stem top and bridge.
(b) To adjust valve height, loosen the lock nut,

then back off the adjusting screw.
(c) Push down the rocker arm with your fingers,

slowly screw in the adjusting screw until it
touches the valve stem top. After looking into
the inspection hole of the bridge to check that
the screw is in contact with the stem top, turn
the screw about 10° more, and tighten the lock
nut.
5-3
–CAUTION
If the valve clearance between the bridge and
valve rotator is less than specified, the valve
cotters may come off. Be sure to maintain the
clearance specified value or more.
(3) Adjusting valve clearance
(a) Insert the feeler gauge of specified thickness

between the rocker arm and bridge cap, then
adjust the clearance by turning the screw in
either direction to the extent that the gauge is
gripped softly between the rocker arm and
bridge cap.
64 N·m
(b) After adjusting the clearance, tighten the lock (6.5 kgf·m)
[47.0 lbf·ft]
nut. Inspect the clearance again and make sure
that it is correct.
5-4
1.2 Fuel System Bleeding
To bleed the fuel system, start from the part closest

1
to the fuel tank in the following sequence: water
separator → fuel filter → injection pump.
(1) Water separator
1
(a) Loosen air vent plug of the water separator
(by rotating about 2 full turns).
2
(b) Loosen the mounting bolt of protector until
the protector can be freely moved. Turn the Water separator
protector 90 degrees, and tighten the mounting
bolt to secure the protector in that position.
3
(c) Turn priming pump cap counterclockwise
to loosen, then move the priming pump cap
up and down.
(d) When fuel flowing out of the air vent no

longer contains air bubbles, close the air vent
plug.
Injection pump
Priming pump
(2) Fuel filter
(a) Loosen the vent plug 1 by turning it about

1.5 rotations. 1
(b) Unlock the priming pump cap by turning it
counterclockwise. Operate the priming pump
by moving the cap up and down.
(c) Tighten the air vent plug when fuel flows from
the vent hole without bubbles.
(d) Follow the same procedure for both right and

left fuel filters. Fuel filter
5-5
(3) Fuel injection pumps
(a) Loosen the air vent cock 1 by turning it about

2 rotations.
(b) Operate the priming pump cap.
(c) Tighten the air vent cock when fuel flows from
the vent hole without bubbles. Lock the
priming pump by turning its cap clockwise
while pushing it down before tightening the
last vent cock.
(d) Follow the same procedure for both the right
and left injection pumps.
NOTE
(a) If the vent plugs and cock are tightened
before the priming pump cap is locked, fuel
pressure acts on the feed pump, making it
impossible to restore the cap.
(b) Wipe off fuel spilled from the vent holes with
rag.
2
(e) Turn protector to the original position, and
tighten the mounting bolt.
(4) Tightening priming pump cap

θ = 120 to 150°
Position where
(a) Tighten the priming pump cap 1
by hand,
becomes 1
hand-tightening
and stop turning immediately after the
suddenly heavy.
tightening force suddenly increases. Head section may
become damaged
NOTE when
Mark the priming pump cap in this position to overtightened
facilitate the following procedure. (θ = 240° or more).
(b) After step (a), further turn the priming pump

cap by 120 to 150° using a wrench.
NOTE
After step (a), the priming pump cap should be
loose enough to rotate 70 to 90° more when
turned forcibly by hand.
–CAUTION
Be sure to tighten the priming pump cap according
to the specified angle (θ =120 to 150°).
If the priming pump cap is not tightened firmly,
engine operations can result in the wear of internal
threads. This can cause the priming pump cap to
eject and fuel to flow out.
If the priming pump cap is tightened with
excessive force (θ = 240° or more), the head
section of the priming pump can become damaged.
5-6
1.3 Fuel Injection Timing Adjustment
Right-hand Injection Pump
(1) Fuel injection timing and indication
The injection timing is stamped on the caution plate

fitted to the No. 1 rocker cover. Be sure to verify the
timing by referring to this caution plate. The injection
timing for each engine model varies according to its
output, speed, and specifications.
(2) Confirming the No. 1 piston’s top dead center Running Turning
on the compression stroke
(a) Use the ratchet handle to turn the crankshaft.

Push down the ratchet handle to turn in the
normal direction.
(b) Stop turning when the timing mark (1•8) on

the viscous damper is aligned with the pointer.
1
•
(c) Move the No. 1 cylinder inlet and exhaust 8
valve rocker arms up and down to make sure
that they are not being pushed up by their push
rods.
–CAUTION
Do not confuse the top dead center on the
compression stroke for No. 1 cylinder with that
for the No. 8 cylinder.
1
(3) Inspecting fuel injection timing
(a) Turn the crankshaft once about 60° in the

reverse direction. Turn it a little at a time in 2
2
the normal direction to align the timing mark
1
on the pump drive coupling with the
pointer on the pump case.
5-7
(b) Read the degree angle (injection timing) scale

on the damper, indicated by the pointer minus
(-) mark on the scale.
BTDC on the caution plate means “Before
Top Dead Center.”
(4) Adjusting fuel injection timing
(a) Make sure that the timing mark for No. 1

cylinder on the damper is aligned with the
pointer.
1 2
2
(b) Loosen the coupling bolts , then turn the
injection pump shaft to align the pointer
on the pump case with the timing mark on 3 3
the coupling. Tighten one bolt to the specified
torque. After turning the crankshaft, tighten
the other bolt.
(c) Inspect the timing again by turning the engine

103 to 113 N·m
by one more rotation.
(10.5 to 11.5 kgf·m)
[76 to 83 lbf·ft]
1
Left-hand Fuel Injection Pump
On this pump, the position where the pointer is

aligned with the index numbers “9•16” on the damper
is top dead center on the compression stroke of the
No. 9 cylinder piston. At this position, both inlet
and exhaust valves of that cylinder should have the
specified clearance.
For subsequent steps, follow the same procedure
outlined for the right-hand injection pump.
5-8
1.4 Idling Speed and Maximum Speed

Setting Inspection and Adjustment
–CAUTION
(a) The idling speed (no-load) and maximum
speed are set for each engine at factory bench
testing, then the set bolts are sealed. These
settings are to be inspected and adjusted at
Mitsubishi service shops only.
(b) After adjusting the governor be sure to seal

the stopper.
(c) The stoppers are specified to be sealed.

Whether the seals are intact or not has
importance bearing on the validity of claims
under the warranty.
(d) When inspecting and adjusting these settings,

be ready to operate the engine stop lever
manually against the engine overrunning.
NOTE
Prior to inspection and adjustment, warm up the
engine until coolant and oil temperature rise to
70 °C [158 °F] or higher.
1.5 Inspecting and Adjusting Alternator

Drive Belt Approx. 10 mm
(0.4 in.)
With your thumb apply pressure (98 to 147 N (10 to
15 kgf) [22 to 33 lbf] approx.) to the belt midway
between the pulleys to inspect the belt tension. If the A
tension is incorrect, adjust it with the turnbuckle A.
Unit: mm (in.)
Item Assembly Standard Retaining bolt
Belt tension 10 to 15 (0.4 to 0.6)
–CAUTION
Be sure the drive belt tension is not excessively
tight.
5-9
2. Bench Testing 2.3 Bench Testing (Dynamometer)

Conditions
An overhauled engine should be tested for
performance on a dynamometer. This test is also for Here is a summary table of bench testing conditions.
breaking in the major running parts of the engine.
Step Speed Load (kW(PS)) Time (min.)
To test the engine, follow the procedures described (rpm)
below.
1 Idling No load 5
2.1 Starting Up 2 1000 No load 5
3 1200 No load 10
(1) Inspect the levels in the radiator, oil pan, and fuel 4 Rated 25% 10
tank. Prime the fuel and cooling systems to bleed (Varies
air out. depending on
specifications)
(2) Crank the engine with the starter for about 10 5 ˝ 50% 10
seconds to permit lubricating oil to circulate 6 ˝ 75% 30
through the engine. For this cranking, do not 7 ˝ 100% 20
supply fuel to the engine, placing the stop lever
in stop position. Rated speed: Varies according to specifications.
(3) Move the speed control lever slightly in the 2.4 Inspection and Adjustments after
direction of increasing fuel injection, then turn Bench Testing
the starter switch to START to start the engine.
Do not move the control lever to the “full fuel (a) Adjusting valve clearance
injection” position.
(b) Adjusting injection timing
(4) After the engine starts, let it idle under no load by
operating the speed control lever. (c) Re-tightening external bolts and nuts
2.2 Inspection after Starting Up
After starting up the engine, check the following

points. If you find anything wrong, immediately stop
the engine, then investigate the cause.
(1) Lubricating oil pressure should be 0.49 to 0.64

MPa (5 to 6.5 kgf/cm2) [71 to 92 psi] at rated
speed or over 0.20 to 0.29 MPa (2 to 3 kgf/cm2)
[28 to 43 psi] at idling speed.
(2) Coolant temperature should be 70-90 °C [158-

194 °F].
(3) Lubricating oil temperature should be in the range

of 70-110 °C [158-230 °F] when measured in the
oil pan.
(4) Check for leakage of oil, coolant, fuel, especially

oil leakage from oil pipe connections for
turbocharger lubrication.
(5) Knocking should die away as coolant temperature

rises. No other defective noise should be heard.
(6) Check for exhaust color and abnormal odors.
5-10
3. Performance Tests
There are various performance test procedures, and here the procedures for “Earth moving machinery
Engines, Part 1 : Test code of net power (JIS D 0006-1)” and “Earth moving machinery Engines, Part 2 :
standard format of specifications and tests methods of diesel engines (JIS D 0006-2)” are described. Other
test items may be required on application. Engine performance is judged with integrated test results.
3.1 Engine Equipment Condition
Engine must be equipped with such standard auxiliaries as cooling fan, air cleaner and alternator.
3.2 Tests and Their Purposes
(1) Operation load test
Conduct this test to evaluate engine output, torque, fuel consumption rate and governor performance under
various load conditions.
(2) Continuous load test
Operate the engine continuously for 10 hours at 90% load (continuous load application) of nominal net
brake power while engine speed is maintained at revolutions corresponding to the nominal brake power. In
this test, evaluate fuel consumption rate and operating condition and confirm continuous engine operation.
(3) No-load minimum idle speed test
Conduct this test to confirm that the engine can operate stably at the specified no-load minimum idle
speeds.
3.3 Other Inspections
During performance testing, inspect for leakage of gases, coolant, lubricating oil, or fuel, and for noise or
hunting. Make adjustment, as needed.
3.4 Adjustment Engine Output
Diesel engine output is affected by atmospheric pressure, temperature, and humidity. Therefore, the engine
output should be set for standard atmospheric conditions.
(1) Standard atmospheric conditions

Base temperature 298 K (25°C) [77°F]
Atmospheric pressure 100 kPa [750 mmHg]
Atmospheric vapor pressure 99 kPa [743 mmHg]
5-11
(2) Calculation of corrected power
Multiply the measured brake power or torque by the calculated diesel engine correction factor (see below)
to obtained a corrected value.
Corrected output = Correction factor (αc) × Measured brake power
• Atmospheric conditions for test

Temperature (T): 283 K (10ºC) [50ºF] =< T =
< 313 K (40ºC) [104ºF]
< Pd < 110 kPa (825 mmHg)
Dry atmospheric pressure (Pd): 80 kPa (600 mmHg) = =
(3) Calculation of correction factor (αc)
αc = (fa)fm fa: Atmospheric factor fm: Engine factor
(a) Calculation of atmospheric factor (fa)
➀ Natural aspiration engine and engine with mechanically driven air charger
fa = ( 99 ) • ( T ) 0.7
Pd 298
➁ Turbocharged engine without air cooler (after cooler) or with air-to-air cooler
T 1.2
fa = ( 99 ) 0.7 • ( )
Pd 298
➂ Turbocharged engine with air-to-liquid cooler
T 0.7
fa = ( 99 ) 0.7 • ( )
Pd 298
(b) Calculation of engine factor (fm)
fm = 0.036 qc – 1.14
➀ qc (Corrected fuel supply volume) = q

–
r
(z) × (Fuel flow rate g/s)
q = ———————————————————————–1—
(Stroke volume l) × (Engine idle speed min )
z = 120000 (4-cycle engine)
r: Ratio of pressure at turbocharger or air cooler to atmospheric pressure
(r = 1 for natural aspiration engine)
➁ Applicable range of engine factor (fm)

< qc <
37.2 = = 65 mg/(l-cycle)
< 37.2 mg/(l-cycle) : fm = 0.2 (Constant)
• qc =
< qc : fm = 1.2 (Constant)
• 65 mg/(l-cycle) =
(c) Range of correction equation use

The range of correction factor (αc) use is as follows: 0.9 =< αc =
< 1.1.
If this range is exceeded, indicate the corrected value and record the test conditions on the test record sheet.
5-12
4. Engine Bench Testing Procedures
4.1. Main Specifications
Rated output
(in dismounted condition) 1400 kW/1600 min-1
Injection timing 21° BTDC

Fuel Diesel fuel
4.2. Test/inspection Items
To test an engine dismounted from the vehicle, use a hydraulic dynamometer as the load.
Rotation Operating No. of
Output
No. Test item speed time measure- Remarks
kW min–1 min. ments
1 Starting test 0 800±50 Approx. 5 —
2 Stopping test 0 800±50 Approx. 5 —
3 (1) No-load test 0 5 1
1. To be conducted after setting
(2) 50%-load test 50% of rated torque 5 1
the rack and governor.
(3) 80%-load test 80% of rated torque 5 1 2. Tests must be conducted with
(4) 90%-load test 90% of rated torque 5 1 suction air resistance of
(5) 100%-load test 1400 1600 60 2 approx. 2.94 kPa [300
(6) Full-load test 1450 5 1 mmAq] and exhaust resist-
1300 5 1 ance of approx. 5.39 kPa
[550 mmAq], both at rated
1200 5 1
output.
4 No-load minimum 0 800 5 1 3. Use a correction factor in
speed test operating the engine.
5 Protection device —
operation check
Output settings (1) Mechanical rack setting:1368 kW±68 kW/1300 min–1 (under standard atmospheric condition)
(2) Controller rack setting: 1400 kW±70 kW/1600 min–1 (under standard atmospheric condition)
1400 kW/1450 min–1 Reference value
1199 kW±60 kW/1200 min–1 (under standard atmospheric condition)
(3) Governor setting: 0 kW/1750±30 min–1
(Rate of fluctuation should be
between 7.5 and 11.25%)
In this step, make sure that the actuator opening is 44±2%.
If not, change the Min. Act%.
(4) Low-idle setting: 800±30 min–1
(5) Auto idling: 1400±30 min–1
NOTE
(a) Make an adjustment without using the personal computer for governor setting adjustment. The
adjustment procedure is as follows:
(1) Adjust the temperature of the right and left exhaust systems under 100%-load operation
by using the link on the fuel injection pump side. Then, check the exhaust temperature
under no-load operation.
(2) Adjust the length of the link between governor and rack. Check the rated output, maximum
torque point, and output at 1200 min-1. Then, adjust the output to the maximum torque
point, and adjust the mechanical rack so that it makes a light contact.
(b) If the controller setting value is changed, indicate in the test record.
5-13
4.3. Test Methods and Judgment Criteria
No. Test/inspection Item Testing Method Judgment Criterion

1 Starting test Set the engine at low-idle position (850±30 min–1). Engine should start normally.
Operate the starter switch and make sure that the
engine starts.
2 Stopping test After the engine starts, stop the engine and make Engine should stop normally.
sure it stops without a problem.
3 Load test Set the rack and governor to specified values, Rated output:
then hold the governor lever at the position for 1400 kW±5%/1600min–1
rated rotation speed and rated output. Start the Rated fuel consumption:
dynamometer from “no load,” and increase the 211±10.6 g/kWh
load sequentially to 50% of rated load, to 80%, (Lower-limit value as reference
to 90% and to 100%. information.)
Then, increase the braking force of the Lubricating oil pressure at rated
dynamometer to reduce the speed to 1450 min-1, operation:
to 1300 min-1, and to 1200 min-1. At each of 0.4 to 0.65 MPa
these speeds, operate the engine for a specified (4 to 6.6 kgf/cm2) [58 to 87 psi]
time length to measure the following items. Exhaust temperature at rated
(Rotation speed, shaft output, fuel consumption, operation:
exhaust temperature, cooling water temperature 550°C [1022°F] or lower
at inlet and outlet, lubricating oil temperature and
Smoke at rated operation:
pressure, air supply temperature and pressure, Bosch 1.5 or lower
suction air temperature, smoke, room temperature, Cooling water temperature
atmospheric pressure) (at outlet):
96°C [205°F] or lower
NOTE Lubricating oil temperature:
110°C [230°F] or lower
(a) Maintain the air supply temperature Maximum rotation speed under no-
at 50±10°C [122±50°F] when engine load operation:
is operating at rated output and when 1750±30 min–1
setting the rack. Maximum torque:
(b) Record the actuator output (value 10051 N·m (1024 kgf·m)
displayed on PC) during operation. [2260 lbf·ft]/1350 min–1
Minimum fuel consumption:
200 g/kWh or lower
Smoke in all operating range:
Bosch 3.0 or lower
Leaks:
There should be no leak.
4 No-load minimum Operate the engine at low idling (0 kW/800 min-1) Engine should operate stably.
speed test for 5 minutes, then check performance.
5 Protection device Check the following switches. Indications should be accurate.
operation check (1) Oil pressure decrease: 0.15±0.02 MPa
(1.5±0.2 kgf/cm2)
[22±3 psi]
0.3±0.02 MPa
(3 to 0.2 kgf/cm2)
[44±3 psi]
(2) High water temperature: 99 to 101°C
[210 to 214°F]
5-14
ENGINE AUXILIARIES REMOVAL AND INSTALLATION
1. Preparation ................................................................................................................................. 6- 2
2. Engine Auxiliaries Removal ...................................................................................................... 6- 3
3. Engine Auxiliaries Installation .................................................................................................. 6- 17
6
This section explains procedures and tips for removal

and installation of the auxiliaries, the preliminary
procedures before overhauling the engine.
1. Preparation
(a) Shut off the fuel supply, and disconnect the

starting system (electrical connection).
(b) Loosen the drain plugs of both sides of the

crank case and drain the coolant.
(c) Loosen the oil drain plug, and drain the engine
oil.
Oil capacity: approx. 260 l (68.7 U.S. gal)
–WARNING
Hot engine oil can cause serious burns. Use
caution when you drain the oil.
6-2
2. Engine Auxiliaries Removal
(1) Removing air ducts (between turbocharger and

air cooler)
2 3 1 Turbocharger
5 A
1 3
4
7
A
6 2
F 8 9 4 G 3 A
6
9
H
8 H
F
1 Air duct 5 Air duct 9 Air duct

2 Air duct 6 Rubber hose F Air duct
3 Connector 7 Air duct G Air duct stay
4 Rubber hose 8 Rubber hose H Air duct stay
(2) Removing water pipes (between thermostat and

radiator)
5 4
1 Water pipe stay 4
2 Rubber hose
3 Water pipe 2 2
4 Water pipe 1
5 Water pipe stay
6 Air duct stay
3
13 1 6 1
6-3
(3) Removing insulators (exhaust manifolds,

turbocharger)
I
4 J H
3 7 G
L
F 5 K
1
3 9
6
F 2
F
8
F
(a) Remove insulators from the exhaust manifolds. (b) Remove insulators from the turbocharger.
1 Insulator H Turbocharger insulator

2 Insulator I Turbocharger insulator
3 Insulator J Turbocharger insulator
4 Insulator K Insulator stay
5 Insulator L Plate
6 Insulator
7 Insulator
8 Insulator
9 Insulator
F Long insulator
G Insulator
6-4
(4) Removing exhaust manifolds
1
1 2
1
2 3 6
1
2 3 2
1 3
2 3 2 1
1 3
2 3 2
1 3 3 1
4 2 2
3 3 1 6
2 2
3 1
5 2
3 1
2
4 1
1
5
1, then remove flexible

2
(a) Loosen V-clamps
joints .
(b) Remove exhaust manifolds 3.

(c) Remove exhaust manifolds 4.
(d) Remove exhaust connectors 5.
(e) Remove exhaust manifolds 6.
NOTE
When reinstalling manifold gaskets, make sure
the MANIFOLD indication on each gasket faces
the manifold side.
6-5
(5) Removing the turbocharger and exhaust pipe
1
(a) Remove the turbocharger oil pipes.
1 Oil pipe 2
2 Oil pipe 5
3 Oil pipe
4 1
4 Stay
5 Drain pipe 3
5
8 H
7 8
9 7
F
K 7
9
L
6 J F
G I
G 6
6
7
(b) Remove mounting bolts , and dismount the
8 9
turbochargers .
F G
(c) Remove exhaust joints and .
H
(d) Remove turbocharger brackets and .
I J
(e) Remove the exhaust pipe .
K L
(f) Remove exhaust pipe brackets and and
exhaust pipe stays and .
6-6
(6) Removing air ducts (between air cooler and

crankcase)
9
8
7
4 4 8
6
5 4
1 1
F
G
3 IH
2
1
1
1 Rubber case 6 Air duct G Duct stay

2 Air duct 7 Air box H Air duct stay
3 Air duct 8 Air duct stay I Air duct stay
4 Rubber hose 9 Air box
5 Air duct F Duct stay
NOTE
I, remove
J
Before dismounting air duct stay
breather pipes .
6-7
(7) Removing breathers (front and rear) 3

(a) Remove breathers 1 on the front side. 4 43
1 5
Remove breather case 2.
(b)
5
Disconnect breather pipes 3 on the rear side,
and remove breathers 4.
(c)
(d) Remove breather pipes 5. 2

(8) Removing thermostats
8
(a) Remove water pipe 1. 6
Remove couplings 2, and remove bypass 8 7
pipes 3, 4, 5. 2 42
(b)
Remove thermostat brackets 6, 7, then 1 3

remove thermostats 8.
(c)
5
(9) Removing the alternator 2

(a) Remove the belt covers 1,2. 5
3, and 6
4
(b) Loosen belt adjustment turnbuckle
remove V-belt .
4 3
Remove bracket 5, and dismount alternator
6.
(c)
(10) Removing the water pump
(a) Remove the nut 1

at the end of the water
2
pump shaft. Remove the alternator driving
pulley .
2
(b) Remove the water pump 3 by unscrewing 3
the bolts and nuts. 1
Weight: approx. 33 kg (73 lb)
6-8
(11) Removing the oil pump

2
(a) Remove the connection stay 1 from the oil
1
pipe located under the oil pump.
1
2
(b) Unscrew the oil pump mounting bolts, then
remove the oil pump .
6-9
(12) Removing the injection pipes
7 6
1
2 JK 5
1 HI
G
9 F
2 8
S
3
R
5 Q 1
P 2
MN O 1
L 3
1 1 2
2 4 2
5
(a) Remove pipe clamps, and dismount injection pipes.

1 9 M
2
Pipe clamp
F N
No. 2 injection pipe No. 10 injection pipe
3
Pipe clamp
G O
4
Pipe seat
H P
5
Pipe clamp
I Q
6
Pipe clamp
J R
7
Pipe seat
K
No. 7 injection pipe
S
Clamp
8 No. 1 injection pipe L
–CAUTION
Cover the openings of the injection pump, the
nozzle inlet connector, and the injection pipe to
prevent dust from entering the fuel line.
6-10
(13) Removing fuel leak-off pipes
7
Cylinder head
Injection pump R.H.
3
5 6
Cylinder head
4 Injection pump L.H.
Oil pan 2
1
(a) Remove clips, and dismount fuel leak-off pipes.

1 4 7 Fuel leak-off pipe
2 5
Fuel pipe Fuel leak-off pipe
Fuel pipe Fuel pipe
3 Fuel leak-off pipe 6 Fuel leak-off pipe
6-11
(14) Removing the fuel filter and fuel pipes
G
5 F Front side
➪
6 7
F
L.H.
G
8
2
9 R.H.
3 1 1
(a) Remove clamps and clips, and dismount fuel

pipes.
1
2
Clamp
3
Fuel pipe
4
Fuel pipe
5
Fuel pipe
6
Clamp
7
Fuel pipe
8
Fuel pipe
Fuel pipe
9 Fuel pipe
F, and
G
(b) Remove the fuel filter brackets
dismount the fuel filters .
6-12
(15) Removing oil pipes (for injection pump)
6
Oil filter
Front side
8
Drive case
Oil cooler
5 7 4
Crankcase 2
Crankcase
3
Drive case 1
(a) Remove clips, and dismount oil pipes.
1
2
Oil pipe
3
Oil pipe
4
Rubber hose
5
Connector
6
Oil pipe
Oil pipe
7
8
Rubber hose
Connector
6-13
(16) Removing injection pumps (right and left)
(a) Remove the ball joint 1 to disconnect the 5

fuel rack control.
(b) Remove the coupling cover 2. 1 4

3.
(c) Remove two coupling connecting bolts 3 2
Remove pump mounting bolts 4 and 5.
With the coupling attached to the injection
pump (leave the laminated plate on the drive
shaft), lift the injection pump to dismount.
(17) Removing the left and right injection pump

brackets
1
(a) Unscrew the bracket mounting bolts, and
remove bracket . 1
(18) Removing the stop solenoid
1 2
2 3
(a) Remove bolts , then remove the stop
solenoid and solenoid plate . 6
4 5
2 3
(b) Remove bolts , and dismount the solenoid
from the solenoid plate . 7 3
5
5 and spacers 1 4
6
(c) Dismount the rubber cushions
.
(d) Remove the solenoid bracket 7.

Rubber Replace at Maximum load:
cushion major overhaul 226 N (23 kgf) [0.517 lbf]
6-14
(19) Removing the actuator 1

(a) Remove the ball joint 1 to disconnect the 8
fuel control. 3
2 3
4
(b) Remove bolts , and remove the actuator
and actuator plate .
6 4
5 and spacers 5
6 5
(c) Dismount the cushion mount
. 2 7
7, and dismount the actuator
3
(d) Remove bolts
.
(e) Remove the actuator bracket 8.

(20) Removing the right oil cooler
5
(a) Remove oil pipes 1 and 2.
3
(b) Remove the clip, and dismount the oil pipe
.
4
4 2
(c) After unscrewing the oil cooler inlet connector
mounting bolts, disconnect connector .
6 3 1
(d) Pull out the oil thermostat 5 from the oil
cooler.
6
(e) Unscrew the oil cooler mounting bolts, then
remove the oil cooler .
Cushion Replace at Maximum load:

mount major overhaul 686 N (70 kgf) [1.596 lbf]
6
1
(21) Removing the left oil filter and oil cooler 3
1 and one 2 5
2
(a) Remove four oil filter elements
by-pass filter element .
3
(b) Disconnect the oil pipes 3. 3 4 3
4
(c) Unscrew the oil cooler inlet connector mounting
bolts, and disconnect the connector .
(d) Remove the oil thermostat 5.

6
(e) After unscrewing the oil filter bracket
mounting bolts, remove the filter bracket
complete with the oil cooler.

6-15
(22) Removing the oil filler
Remove oil filler 1 by unscrewing mounting bolts.
(23) Removing the starter
Remove starters 1 by unscrewing the starter

mounting bolts.
1
6-16
3. Engine Auxiliaries Installation
To install the engine auxiliaries, follow the removal

procedures in reverse. After installation, service them
as follows.
(a) Refill the engine with the recommended oil

up to the specified level.
(b) Refill the cooling system with coolant.
(c) Check each pipe connection for oil or coolant

leaks.
(d) Prime the fuel system.
(e) Installation of the fuel injection pump is

described below. After installing the fuel
injection pumps, be sure to inspect and adjust
the injection timing. (Refer to Section 1.3 of
Chapter 5, “Adjustments, Bench Testing, and
Performance Tests.”
Fuel Injection Pump Installation:

Right Injection Pump
(1) Right injection pump installation
(a) Turn the crankshaft in the normal direction to

align the timing marks “1•8” on the viscous
damper with the pointer.
(b) Move the No. 1 cylinder inlet and exhaust

valve rocker arms to make sure that they are
not being pushed up by their push rods.
(c) Turn the crankshaft once about 60° in reverse.

Turn it a little at a time in the normal direction
to align the timing mark on the damper with
the pointer.
6-17
NOTE
Verify the injection timing by referring to the
caution plate attached to the No. 1 rocker cover.
1
2
1
(d) Install the coupling to the injection pump, then
2
align the pointer on the pump case with
mark on the coupling.
(e) Connect the pump drive coupling 3

to the
drive shaft. Loosen the coupling mounting
bolts enough.
3
4
(f) Put the pump case on the pump bracket, then 108 (11) Unit: N·m (kgf·m) [lbf·ft]
tighten the mounting bolts temporarily. [80]
(g) Connect the fuel pipe and the oil pipe to the 4 5
injection pump.
5
(h) Tighten the two coupling bolts temporarily. 167 to 177
(17 to 18)
Using the Injection coupling gauge A 103 to 113
5 6
(10.5 to 11.5) [123 to 130]
(H3759106100), adjust the clearance between [76 to 83]
the flywheel and coupling.
1) Insert the side of the gauge marked with “GO”

to determine clearance B between the
flywheel and coupling, then tighten the bolt.
Bolt
2) Make sure the side of the gauge marked with B
“NO GO” does not enter the gap. Only the
side marked with “GO” should fit into the gap.
(Clearance between flywheel and coupling:
49±0.25 mm [1.93±0.010 in.])
3) If the inspection in step 2) shows that the

clearance is not 49±0.25 mm [1.93±0.010 in.], A
loosen the bolt and readjust the clearance.
6-18
4
2
(i) Tighten the pump mounting bolt firmly. Be
1
sure that the coupling mark aligns with the
5
pump case pointer . Tighten the two connect-
ing nuts as specified.
(j) Tighten the shaft tightening bolt 6 of the

coupling as specified.
–CAUTION
Apply equal and specified torques on each
coupling bolt. Coupling damage or wrong
injection timing can be caused by improper
tightening of bolts.
Left Injection Pump
(2) Left injection pump installation
(a) To install this pump, align the timing marks

“9•16” on the viscous damper with the pointer.
At this position make sure that both inlet and
exhaust valves of the No. 9 cylinder piston is
at top dead center of the compression stroke.
(b) For subsequent steps, follow the procedures

described for the right injection pump above.
(3) Installing actuator link

55°
(a) Check to make sure the output shaft of the
actuator is positioned on the side marked with
“0” (no-injection side).
1
(b) Install throttle lever at an angle of 55° from 1
the vertical position.
(c) Install adjusting bolt 2to the Pro Act plate.

2
1
When the tip of the adjusting bolt contacts
the throttle lever , further tighten the
adjusting bolt (about 3 full turns), making sure
that the angled face of the throttle lever is
horizontal.
6-19
(d) Install links 3

on the right- and left-hand
3
banks, making sure that the installation length
is 62 mm [2.44 in.].
62 mm [2.44 in.]
(e) Install link 4 on the right-hand bank.

NOTE 239 mm
Link 4 has a fixed length of 239 mm [9.4 in.]. [9.4 in.]
(f) Install link4 on the left-hand bank, making

sure that the length is 239 mm [9.4 in.] (same
as for the right-hand bank). 4
239 mm
[9.4 in.]
6-20
8 6
7
1
68 to 72 mm
[2.68 to 2.83 in.]
7 1
6 7
(g) Connect link to throttle lever and lever
. Adjust link to achieve a distance of 68
to 72 mm [2.68 to 2.83 in.] between the edge
of the injection pump rack and the end surface
of the pump case.
NOTE
Make sure more than 8 mm [0.315 in.] of threads
of the rod and ball joint are engaged on both ends.
(h) Check to make sure the rack stroke is
8
approximately 2 mm [0.08 in.] when stopper
lever is pulled fully to the STOP side.
6-21
(4) Adjusting and inspecting stop solenoid

4 1
[RUN-ON solenoid]
3
1
0.5 to 1.0 mm
< Adjustment > [0.020 to 0.039 in.]
(a) Cut off electric current to solenoid
(extended condition).
(b) Loosen bolts 2. 2

(c) Move solenoid 1 to adjust the clearance
between adapter 3 and follower 4 to be
68 to 72 mm
[2.68 to 2.83 in.]
from 0.5 to 1.0 mm [0.020 to 0.039 in.].
(d) Tighten bolts 2.

RUN-ON solenoid
1
< Inspection >
(e) Supply electric current to solenoid
(contracted condition).
(f) After adjusting the exhaust temperature for

the right- and left-hand banks, operate the
engine at high idling speed.
(g) Cut off electric current to solenoid 1

(extended condition).
(h) After the engine stops completely, check to

make sure the distance between the rack end
surface and pump case end surface is 68 to
72 mm [2.68 to 2.83 in.] on both banks.
–CAUTION
When adjusting actuator, refer to Chapter 14
“Adjusting Procedure of Actuator Controls
(Electric Governor)”.
(5) Readjustment of the adjusting bolt 1

4
1
(a) After adjusting the stop solenoid , a space
2
will be created between adjusting bolt and
1 2
throttle lever . Retighten the adjusting bolt
until it contacts the throttle lever .
2
6-22
ENGINE MAIN PARTS
1. Cylinder Heads and Valve Mechanism ...................................................................................... 7- 2

1.1 Disassembly ....................................................................................................................... 7- 2
1.2 Inspection and Repair ........................................................................................................ 7- 5
1.3 Reassembly ........................................................................................................................ 7-13
2. Cylinder Liners, Pistons, and Connecting Rods ........................................................................ 7-17
2.1 Disassembly ....................................................................................................................... 7-17
2.2 Inspection and Repair ........................................................................................................ 7-22
2.3 Reassembly ........................................................................................................................ 7-34
3. Viscous Damper and Front Gears .............................................................................................. 7-39
3.1 Disassembly ....................................................................................................................... 7-39
3.3 Reassembly ........................................................................................................................ 7-44
4. Oil Pan and Oil Strainer ............................................................................................................. 7-47
4.1 Disassembly ....................................................................................................................... 7-47
4.2 Reassembly ........................................................................................................................ 7-48
5. Flywheel, Timing Gears, and Camshafts ................................................................................... 7-49
5.1 Disassembly ....................................................................................................................... 7-49
5.3 Reassembly ........................................................................................................................ 7-58
7
6. Crankcase, Crankshaft, and Main Bearings ............................................................................... 7-64
6.1 Disassenbly ........................................................................................................................ 7-64
6.3 Reassembly ........................................................................................................................ 7-74
ENGINE MAIN PARTS
1. Cylinder Heads and Valve Mechanism
1.1 Disassembly
1
M
Cracks, oil leaks,
deterioration
L 3
Cracks, damage, Q N
carbon and scale
deposits
4
Wear 5
2
O 6
9
Damaged threads P
7
Wear, clogged oil
hole
K
H Matching, wear
V
Worn ends,
Wear
G distortion
X
F Worn stem or Worn cam
R 8 face, corrosion, contact face or
JI
sliding surface
S
damaged, or
carbon deposits
T
Replace gasket
U
Cracks,damage,
W
Distortion,
cracks deterioration,
rubber parts
cracked
1 Rocker cover I Bridge cap U Stem seal

2 Fuel inlet connector J Valve bridge V Valve
3 Nut, washer K Push rod W Cylinder head gasket
4 Injection nozzle gland L Rocker case X Tappet
5 Injection nozzle M Water outlet connector
6 Gasket N Cylinder head bolt
7 O-ring O Cylinder head
8 Adjusting screw P Inlet port packing
9 Bolt Q Exhaust connector
F Rocker R Valve cotter
G Spacer S Valve rotator
H Rockershaft T Valve spring
7-2
ENGINE MAIN PARTS
(1) Removing fuel injection nozzle assemblies

2 A
1 and the
2
(a) Remove the fuel inlet connector
nozzle gland .
(b) Use the Nozzle remover Â (H3359110101), 3

3
to remove the nozzle assembly. Take out the
gasket if it is left behind in the cylinder
head.
1
(c) Store the nozzle and the inlet connector as a
set to avoid swapping. Pay attention not
damage the nozzle tip.
(2) Removing the rockershaft assemblies
(a) Loosen the adjusting screw 1 of each rocker.

(b) Store the shaft assembly and mounting bolts
together as a set.
(3) Disassembling rockershaft assemblies
Arrange the disassembled rockers in the order

removed, so you can install them in that order at
reassembly. This will ensure the same rockershaft
clearance as before.
(4) Removing the valve bridge
Remove the valve bridge and bridge cap.
NOTE
Do not drop the bridge cap or other parts into the
crankcase through the push rod hole.
7-3
ENGINE MAIN PARTS
(5) Removing the rocker cases
1 2 1
2 2
(a) Remove the snap ring of the water outlet
3
connector . Slide the connector towards
the snap ring.
3
(b) Unscrew the rocker case mounting bolts, then
remove the rocker case from the cylinder
head.
(6) Removing cylinder head assemblies

A
(a) Each cylinder head is located relative to the

crankcase with dowel pins. Use the Eye nut
A(H3759102400) to lift the head off the
crankcase at a slant.
Cylinder head weight: approx. 35 kg (77 lb)
(b) Remove the cylinder head gasket.
–CAUTION
Do not damage the cylinder head or crankcase
surfaces when you remove the gasket with a
screwdriver or other tool.
(7) Removing valves and valve springs

A
Use the Valve spring pusher A (H3359104500) to
compress the valve spring squarely, then remove the
valve cotters.
NOTE
If the valves are to be reused, do not change the
combination of the valve seat and valve guide.
2
(8) Removing studs, guides, etc.
1 1
2
Do not remove the nozzle gland mounting studs
or the bridge guide from the cylinder head unless
absolutely necessary. If any of these parts have been
removed, apply thread adhesive to the threads when
installing it or a new part to the cylinder head.
7-4
ENGINE MAIN PARTS
1.2 Inspection and Repair Measuring Measuring

directions points Measuring
directions
Rocker Bushings and Rockershaft
(1) Measuring rocker bushing inside diameter and

rockershaft diameter
If the measurement exceeds the service limit, replace

the bushing or shaft.
Unit: mm [in.]
Nominal Assembly Service
Item Value Standard Limit Measuring rocker bushing and rockershaft
36.000 to 36.040
Rocker bushing ø36 36.090
[1.41732 to
inside diameter [1.42] [1.42086]
1.41889]
35.966 to 35.991
Rockershaft ø36 35.940
[1.41598 to
diameter [1.42] [1.41496]
1.41697]
(2) Replacing rocker bushings Bushing joint mark 45°

Use the Rocker bushing tool A (H3759102600) to A
remove the rocker bushings for replacement.
Align holes
NOTE Chamfered side
(a) Press a new bushing into the rocker from the
chamfered side of the bore.
(b) Align the oil holes in the bushing and rocker. Removal Installation
Replacing the rocker bushing

(c) After installing the bushing, measure its
+0.04
inside diameter to make sure that it is ø36000
0
+0.002
mm [1.42 0 in.]. If the diameter is not within
this tolerance, refinish to standard tolerance
+0.04 +0.002
by reaming (ø360000mm
0 [1.420000in.]
0 0.8 Ra).
7-5
ENGINE MAIN PARTS
Valve Guide and Valve Stems

Measuring
(1) Measuring valve stem diameter and valve guide directions
inside diameter
The valve guide wears more rapidly at its ends than

at any other location. Measure the inside diameter of
the guide at its ends in two directions. If the service Measuring
points
limitis exceeded, replace the guide.
Unit: mm [in.]
Measuring valve stems
Item Value Standard Limit
9.940 to 9.960
Valve stem ø10 9.910 Measuring
[0.39134 to directions
diameter [0.39] [0.39016]
0.39213]
10.000 to 10.015
Valve guide ø10 10.060
[0.39370 to Measuring
inside diameter [0.39] [0.39606]
0.39429] points
Measuring valve guide inside diameter
(2) Replacing valve guides and stem seals

A
(a) Use the Valve guide remover A (H3359
104300) to remove the valve guide for
replacement.
Removing valve guide
7-6
ENGINE MAIN PARTS
(b) Use the Valve guide seal installer B (H37191

01500) to install slowly a new guide with a
press.
B
32 mm [1.26 in.]
–CAUTION
(a) The installation depth for the valve guide is Valve guide Stem seal
specified, so use the Valve guide seal
installer to secure the correct depth. Cylinder head
(b) Do not apply any oil or sealant to the surface
of the stem seal that comes in contact with
the valve guide. When installing the stem Installing valve guide and stem seal
seal, apply lub oil to valve stem to ensure
initial lubrication of the stem seal lip.
(c) Use a new stem seal whenever removed.
Valves and Valve Seats
(1) Inspecting the valve face
Coat the valve face lightly with red lead. Use the
Valve lapper A (H3009108800) to inspect the valve
contact with its seat. If the contact is not uniform, A
or if the valve is defective, or if the repair limit is
exceeded, repair or replace the valve and valve seat.
Red lead
NOTE
(a) Inspect the valve face after the inspection or
replacement of the valve guide.
(b) When you press the valve coated with red
lead into the valve seat, do not rotate the Inspecting a valve face
valve.
Good Bad
Valve contact with its seat
7-7
ENGINE MAIN PARTS
Unit: mm [in.]
Assembly Repair Valve seat width
Item Standard Limit
Angle 30°
Valve -0.2 to 0.2 1.0
Valve seat sinkage [-0.008 to 0.008] [0.039]
Valve seat angle
2.15 to 2.45 2.8
Width
[0.0846 to 0.0965] [0.110] Valve margin
Valve 2.8 to 3.2 2.5 [0.098] Valve sinkage
margin [0.110 to 0.126] by refacing
(2) Refacing the valve face
If the valve face is badly worn, reface it with a valve

refacer.
NOTE
(a) Set a valve refacer at an angle of 30°.
(b) Grind the valve as little as possible. If the
margin seems to exceed the repair limit as a
result of grinding, replace the valve.
(3) Refacing valve seats
(a) Use the Valve seat cutter A (H3759106400,

H3759106430) or valve seat grinder to reface
the valve seat. After refacing, grind the seat
lightly using #400 grade sandpaper inserted A
between the cutter and valve seat.
(b) Lap the valve in the valve seat.
NOTE Refacing a valve seat

(a) Cut or grind the valve seat only as needed
for refacing.
(b) Replace the valve seat if the seat width is
more than the repair limit as a result of wear
or cutting.
(c) Replace the valve seat if the valve sinkage
exceeds the repair limit after refacing.
7-8
ENGINE MAIN PARTS
(4) Replacing valve seats
(a) (i) Weld a stud to the valve seat. Insert a

Weld
shaft into the valve guide holder from
the upper side of the cylinder head. Drive Shaft
the seat off the head as shown.
Valve seat
NOTE
When you weld the stud, do not permit splatter Stud, etc.
to come in contact with the machined surfaces
of the cylinder head. Removing a valve seat
(ii) Use the valve seat puller (H32591

04200) to remove valve seats. Valve seat puller
Removing a valve seat (Using valve seat puller)
[0.457 + 00.0039 ]
(b) Before inserting a new valve seat, measure
[0.142] [0.31] + 0.1
11.6 0
the inside diameter of the cylinder head bore
and the outside diameter of the seat to make
8
sure that clearance (fit) is within clearance

standards.
3.6
Unit: mm [in.] Bore outside

60° diameter
Nominal Standard
Item ø60 + 0.030 [ø2.36 ++ 0.00512
0.00394 ]
Value Clearance 0
Seat outside diameter
Cylinder head ø60 ++ 0.130 + 0.00512
0.100 [ø2.36 + 0.00394 ]
Apply same dimensions
bore inside –0.070 to –0.130 Unit: mm [in.]
for inlet and exhaust
diameter and ø60 [2.36] [–0.00276 to
valve seat –0.00512] Valve seat dimensions
outside diameter
NOTE
A minus (-) indicates interference.
(c) Chill the valve seat in liquid nitrogen

(about –170 °C [–274 °F]) for more than 4
minutes with the cylinder head kept at normal
temperature, or heat the cylinder head to 80
to 100 °C [176 to 212 °F] with the valve seat
chilled in ether or alcohol containing dry ice.
(d) Use the Installer to install the valve seat.

Installing a valve seat
7-9
ENGINE MAIN PARTS
(5) Lapping valves in valve seats
Be sure to lap the valves in the valve s seats after the

seats has been replaced.
(a) Coat the valve face lightly with a lapping

compound.
Lapping compound
NOTE
(a) Do not permit the compound to come in
contact with the valve stem. Coating valve with lapping compound
(b) Use a compound of 120 to 150 mesh for
initial lapping and a compound finer than
200 mesh for finish lapping.
(c) Mixing the compound with a small amount
of engine oil will facilitate coating.
(b) Use the Valve lapper A (H3009108800) to

lap the valve in the seat. To lap, raise the valve
off the seat, then rotate the valve only a partial
A
turn and strike it against the seat.
(c) Wash off the compound with diesel fuel.
(d) Coat the valve face with engine oil, then lap
the valve again.
(e) Check the valve face for contact.

Lapping a valve in its valve seat
7-10
ENGINE MAIN PARTS
(6) Measuring valve spring perpendicularity

(clearance) and free length
Perpendicularity
Measure the free length and clearance of each valve (clearance)
spring. If the free length or perpendicularity exceeds
the service limit, replace the spring.
Unit: mm [in.]
Item Assembly Standard Service Limit Free length
Free length 73 [2.87] 71 [2.80]

Perpendicularity θ=1.5° max. ∆=2.2 [0.087]
at the end Measuring a valve spring
Length under test 66.0 [2.6]/

force/test forces 289 to 319
mm [in.]/N (29.45 to 32.55)
(kgf) [lbf] [65 to 72]
(7) Checking bridge-to-rotator clearance
(a) If the clearance is less than 1.5 mm [0.059

in.], check the valve stem top for cupping.
When the stem top is badly cupped, replace
the valve to obtain more than 1.5 mm [0.059
in.] clearance.
(b) Check the condition of the bridge cap.

Replace it if it is badly worn.
Checking bridge-to-rotator clearance
7-11
ENGINE MAIN PARTS
Tappets and Push Rods
(1) Inspecting cam contact faces of tappets
Replace the tappets if their cam contact faces are

abnormaly worn.
Good Bad Bad
Tappet cam contact face
(2) Measuring valve pushrod deflection
If the deflection exceeds the assembly standard,

replace the push rods.
Unit: mm [in.]
Push rod deflection Less than 0.5 [0.020] max.
Measuring valve pushrod deflection
Cylinder Head
Measuring head gasket flatness of surface
Use a straight edge and feeler gauges to measure

warping on each cylinder head. If warping exceeds
the repair limit, reface the gasket surface with a
surface grinder.
Unit: mm [in.]
Assembly Repair Service
Item Standard Limit Limit
< 0.03 0.07 0.50 Measuring head gasket flatness
Flatness
[0.0012] [0.0028] [0.0197]
7-12
ENGINE MAIN PARTS
1.3 Reassembly
To reassemble, follow the reverse of dissasembly
procedure
(1) Installing tappets
Insert tappets coated with engine oil into the tappet

holes and make them seat softly on the camshaft.
Coat with engine oil
(2) Installing cylinder head gaskets

Replace gasket
(a) Clean the gasketed surfaces of the cylinder
head and crankcase thoroughly with a solvent
or degreasing solution.
(b) Place the gaskets on the crankcase, making

sure that the dowel pins enter their holes in
the gaskets.
Dowel pin
• Application of liquid gasket

Apply a thin coat of ThreeBond 1211 (H37594
01300) around tappet holes and oil passage holes Do not allow
on both sides of the head gasket. Install the gasket 10 mm
[0.394 in.] liquid gasket in
before the liquid gasket dries. this area.
Do not apply an excessive amount of liquid

gasket, since it can press the head gasket O-ring A
and cause deformation. Do not allow liquid gasket 5 to 8 mm
[0.197 to
to adhere around the bore; otherwise, gas leakage 0.315 in.]
can occur.
Before installation, be sure to wipe off oil and
grease from the bottom face of the cylinder head, Application of liquid gasket on head-facing side
the top face of the crankcase and the head gasket,
and make sure they are clean.
The drawing on the right shows the areas and
Do not allow liquid
amounts of liquid gasket application. gasket in this area.
10 mm
NOTE [0.394 in.]
(a) Apply liquid gasket (H3759401300) to areas

5 to 8 mm [0.197 to 0.315 in.] from the
periphery of the head gasket.
(b) Liquid gasket should be applied to areas B
indicated in the diagram on the right.
(c) Apply liquid gasket to both sides of the head
gasket. Spread the liquid gasket with a finger
to a thickness of 0.2 to 0.5 mm [0.008 to Application of liquid gasket on crankcase-facing side
0.020 in.].
(d) Sections (A) and (B) are very close to O-
rings. Make sure that there is no large amount
of liquid gasket on the edge at these sections.
(c) Install the cylinder head gasket by aligning

holes with the dowel pins.
7-13
ENGINE MAIN PARTS
(3) Reassembling the cylinder heads

A
(a) Coat the valve stems with engine oil, then
insert them into the valve guides.
(b) Install the valve springs and rotators to the

valve guides. Compress each valve spring
with the Valve spring pusher A (H33591
04500), then install the valve cotters on the
valve stem. Coat with engine oil
(c) Lightly tap on the top of each valve stem with

a soft-faced mallet to maker sure that the valve
spring and cotters are properly installed.
(4) Installing cylinder head assemblies

1
–CAUTION
Before you install the cylinder head assembly, A
measure the protrusion of each piston. Make sure
that the protrusion is correct. (Refer to (4),
“PISTONS”, 2.2, of this chapter.)
1
(a) Install the exhaust connector to the cylinder
Coat with
engine oil
head, while pushing down the exhaust connector
so it touches the edge of the bolt hole.
NOTE
Place the gasket so its “MANIFOLD” printed
side aligns with the connector side.
(b) Install the Eye nut A (H3759102400) to the

stud bolt, and lift up the cylinder head
assembly. Locate the head aligning its holes
with the the dowel pins, and keep the head
being slightly separated from the cylinder.
Apply engine oil to the threads and bearing
surfaces of head bolts, then wipe off the
excessive oil before tightening.
–CAUTION
The cylinder head bolts should be screwed down
after wiping off the coating of engine oil.
7-14
ENGINE MAIN PARTS
(c) Tighten the cylinder head bolts with the specified

2
539 N·m (55 kgf·m) [398 lbf·ft] [wet]
4
torque in the order shown in the drawing.
• Tightening cylinder head bolts based on angle-

of-turn procedure
5
(a) Place the Head bolt plate A (H3759808900) 6
on the cylinder head.
(b) Tighten each head bolt to 294 N·m (30 kgf·m)
[217 lbf·ft] torque (initial torque).
1 3
(c) The head bolt plate has graduations at 30°
intervals. Place a reference point mark on each Head bolt tightening sequence
head bolt.
(d) Turn each head bolt by 30°. After tightening A
all bolts, turn each bolt again by 30° (total of
60° turn).
Coat with
engine oil
(threads and
seating sur-
face)
Head bolt tightening by turn angle method
(5) Installing the rocker case 108 N·m

(11 kgf·m)
(a) Insert the water outlet connector fully into the [80 lbf·ft]
rocker case.
(b) Install the rocker case so it meets the dowel
pins.
(c) Tighten the rocker case mounting bolts to the
specified torque.
(d) Insert the water outlet connector by sliding it
from the next rocker case after coating the O- Coat with
grease
ring with grease. Install the snap ring.
(6) Installing valve bridges and caps
(a) Coat the bridge guides with engine oil, then

install the bridges to the guides with the
adjusting screws positioned on the exhaust
manifold side. Coat with engine oil
(b) Coat the bridge contact face of the bridge caps

with engine oil. Install the caps in position,
being careful not to let them fall into the
crankcase through the push rod holes.
7-15
ENGINE MAIN PARTS
(7) Installing rockershaft assemblies 147 N·m (15 kgf·m)

[108 lbf·ft] Spacer
(a) Install the spacer to the rocker shaft and mount
the rockers on both sides.
(b) Align the pin hole of the rocket shaft with the
positioning pin, and install the rocker shaft
assembly to the rocker case.
–CAUTION
(a) Move the rocker arm up and down to make
sure that the arm is free.
(b) While tightening the bracket mounting bolts
temporarily, install the bracket in place so
the rocker tip comes in contact with the
bridge caps evenly.
(c) Tighten the long bolt securing the head and
rocker bracket first, then tighten the short
bolt to the specified torque.
(8) Installing injection nozzle assemblies Unit: N·m (kgf·m) [lbf·ft]

98.0 (10)
[72] O-ring
(a) Disconnect the fuel inlet connector from the (Coat with grease)
Down side
nozzle assembly.
(b) Install three O-rings to the nozzle and coat Gasket

with grease. (Coat with grease)
64 to 74
(6.5 to 7.5)
(c) Coat the gasket with grease then install the [47 to 54]
gasket to the nozzle. Insert the nozzle
assembly into the cylinder head. Aligning its
connector hole with the rocker case hole.
(d) Tighten the fuel inlet connector to the

specified torque.
(e) Tighten nozzle gland mounting nut to the

specified torque.
NOTE
(a) Maintain equal distances between the fuel
inlet connector and the cylinder head before
tightening the gland to the specified torque.
(b) Be sure to install the gasket when installing
the nozzle assemblies.
(9) Adjusting valve clearance
Refer to section 1.1, Chapter 5, “Adjustments, Bench

Testing, and Performance Tests.”
7-16
ENGINE MAIN PARTS
2. Cylinder Liners, Pistons, and Connecting Rods
2.1 Disassembly
Wear, scratches, damage
4 Fatigue
5 8
6
Scratches, cracks,
9 damage, wear, carbon
deposits on outside
surface
7
F
Cracks, clogged oil hole
Scratches, wear on
G inside surface, rust on
outside surface
Wear, scratches,
discoloration on inside
surface
Damage
Scratches, seizure,
wiping out of overlay
on both sides
H
3
2
1
Damaged threads
1 Bolt 5 Second compression ring 9 Piston

2 Connecting rod cap 6 Oil ring F Connecting rod
3 Connecting rod bearing (lower shell) 7 Snap ring G Connecting rod bushing
4 Top compression ring 8 Piston pin H Connecting rod bearing
(upper shell)
7-17
ENGINE MAIN PARTS
(1) Removing connecting rod caps
Unscrew the cap bolts from the inspection window,

then remove the cap.
NOTE
(a) Do not damage the bearings or drop them
into the oil pan.
(b) Mark the removed connecting rod bearings
for identification of cylinder numbers and
for upper and lower shells.
(2) Preparation before removing pistons
Use a cloth or oil paper to remove all carbon deposits

from the upper areas of the cylinder liner. If any
carbon deposits are present, this will make it difficult
to pull a piston up.
(3) Removing pistons in right bank cylinders
(a) Turn the crankshaft to bring the piston

assembly (from which the connecting rod cap Cylinder number
has been removed ) to top dead center.
Pointer
(b) Turn the crankshaft in reverse until the crank

pin comes off the connecting rod and the bolt
hole of the rod is visible through the inspection
hole on the side of the crankcase.
Crankpin
7-18
ENGINE MAIN PARTS
(c) Cover a bar A with a cloth for protection.

Put the tip of the bar under the bottom of the Cloth-protected bar
large end of the connecting rod, then pry up
the piston assembly a small amount. Make use
of the crank pin as a fulcrum.
NOTE 10 to 20 mm
A
[0.39 to 0.79 in.]
If you put the turning bar too much, you may not
be able to pry up the piston assembly. Insert the
bar so it protrudes about 10 to 20 mm [0.39 to
0.79 in.] from the bottom end of the large end.
(d) Turn the crankshaft in the normal direction

just a little at a time to raise the crank pin
(fulcrum) while pushing down on the outer
end of the bar to raise the piston assembly.
NOTE
Raise the piston assembly carefully so that the
connecting rod will not interfere with the oil jet
nozzle for piston cooling. Raised fulcrum
(e) When the oil ring of the piston comes out of

the cylinder liner, lower the piston a little and Oil ring
carefully rest the oil ring on the edge of the
liner.
–CAUTION
To avoid damage to the oil ring, lower the piston
slowly and carefully. Do not rotate the piston.
(f) While holding the compression ring portion

of the piston with your hands, carefully pull
the piston from the cylinder liner, then rest its
skirt on the top of the crankcase.
(g) With your hands hold the piston pin portion

of the piston, and lift the piston assembly off
the liner.
7-19
ENGINE MAIN PARTS
(4) Removing pistons in left bank cylinders
Removal procedure is the same as that for removing

pistons in right bank cylinders. The only difference Pointer
is that the position of the crank pin and the direction
of the crankshaft rotation for removal are reversed.
Cylinder number Crankpin
(5) Using the Piston remover

A
(a) Turn the crankshaft to bring the piston
assembly to be removed to 50° after top dead
center for the left bank.
(b) Attach the Piston remover A (HMM321420)

to the top of the piston. Grip the handle of the
remover, then lift the piston and the
connecting rod off the liner.
–CAUTION
(a) Do not damage the piston when you pull it
out from the cylinder liner. Do not let it hit
the connecting rod with its skirt.
(b) Support the connecting rod to avoid the
cylinder liner bore from scratching.
(6) Removing the piston ring

A
Use the Piston ring tool A (H3719103200) to remove

the piston rings.
7-20
ENGINE MAIN PARTS
(7) Removing piston pins
(a) Use the Ring pliers A (H4519108400) to A

remove the snap rings.
(b) Remove the piston pin to separate the piston

from the connecting rod.
(c) If it is difficult to pull out the pin, heat the

piston with a piston heater or in hot water to
expand the pin bore.
7-21
ENGINE MAIN PARTS
2.2 Inspection and Repair
Cylinder Liners
(1) Measuring cylinder liner inside diameter
Measure the inside diameter of each liner in two

directions, parallel and transverse to the piston pin,
at three positions, top (weared position), middle and
low. If measurements exceed the service limit, replace
the liner.
Unit: mm [in.] Measuring cylinder liner
Unit: mm [in.] Measuring Measuring directions
170.000 to points
Cylinder Transverse to
30 [1.18]
ø170 170.040 170.500 piston pin
140 [5.51]
liner inside Parallel to
[ø6.69] [6.69290 to [6.71259]
diameter piston pin
6.69447]
250 [9.84]
Cylinder liner measuring diagram
(2) Measuring cylinder liner protrusion
Measure the protrusion of each liner at its flange with A

dial gauge as shown.
NOTE
The method of measuring the protrusion of an B
used liner differs from that of newly installed one.
Measuring cylinder liner protrusion

Unit: mm [in.]
Cylinder liner protrusion 0.11 to 0.20
at flange [0.0043 to 0.0079]
–CAUTION
If the protrusion is less than the assembly
standard, the gasket will fail to seal the bore
resulting in gas leakage.
7-22
ENGINE MAIN PARTS
• When cylinder head has just been removed
(a) Clean the gasketed surface of the crankcase

and the top of the liners.
(b) Secure the top of the liner uniformly at four

places with the Liner pusher A (H37591
06200) and the Bolts B (H3759106300). C
NOTE
Use the Head bolt spacers C (H3759809100)
when tightening the Line pushers using head bolts.
(c) Set up the dial gauge at the top face of the

crankcase, then set the gauge pointer to zero
(0).
(d) Measure the protrusion at four places at the

flange of the liner. Take the average of the
four measurements.
(e) If the average is less than the assembly

standard, insert a shim under the collar of the
cylinder liner.
• When cylinder liner is to be replaced

A
(See section (3).)
D
(a) Remove the cylinder liner, and observe the
cylinder liner contacting surface to the
crankcase. B
C
Rotary grinder
(b) If the cylinder liner contacts the crankcase
only on one side, use a rotary grinder to grind
the surface to keep the differences of depth in
four directions A, B, C and D within 0.05 mm
[0.0020 in.].
7-23
ENGINE MAIN PARTS
(c) Measure the counter bore depth of the crankcase.

Since the top surface of the crankcase may
be slightly distorted, use the Projection plate
D (H3759809201) to obtain accurate D
measure-ments. Counter bore depth
(d) Measure at four locations A, B, C and D, and

obtain the average.
(e) Measure the thickness (standard value: 15 mm

[0.59 in.]) of the Projection plate using a
micrometer. Subtract the Projection plate
thickness from the measured counter bore
depth to obtain the actual counter bore depth
from the top surface of the crankcase.
Unit: mm [in.]
Crankcase counter bore +0.05 +0.0020
14 +0 [0.55 +0 ]
depth
(f) Measure the thickness of the cylinder liner

collar.
Unit: mm [in.]
Thickness of cylinder +0.20 +0.0079 05
14+0.16 [0.55 +0.0063]
liner collar +0.05
(g) Subtract the crankcase ridge depth from the

cylinder liner collar thickness. This value is
the cylinder liner protrusion.
(h) If the value is less than the assembly standard,

insert a shim under the collar of the cylinder
liner.
7-24
ENGINE MAIN PARTS
• Measuring step height of cylinder liner collar
(a) Place a dial gauge on the rim of the liner collar,

and set the indicator to 0 (zero).
(b) Measure the cylinder liner step as shown at

four locations, and obtain the average.
Unit: mm [in.]
Cylinder liner step height 0.2±0.04 [0.008±0.002]
Measuring height of liner collar
(c) If the average is less than the assembly

standard or if the step has sectional chipping,
replace the cylinder liner.
(See section (3).)
• Inserting cylinder liner shim
Remove the cylinder liner. Insert a shim between

the cylinder liner and crankcase.
NOTE
From the table below, select the appropriate shim
thickness that achieves the largest protrusion Shim
within the assembly standard range.
Inserting cylinder liner shim
Thickness of shim Part No.

0.05 mm [0.0020 in.] H3750702510
0.10 mm [0.0039 in.] H3750702500
0.15 mm [0.0059 in.] H3750702520
7-25
ENGINE MAIN PARTS
(3) Replacing cylinder liners
(a) Use the Cylinder liner remover A

(H3759104100) to remove the cylinder liner A
from the crankcase for replacement.
(b) Attach O-rings to the new cylinder liner, then

carefully insert the liner into the bore of the
crankcase.
–CAUTION
Before inserting the liner, coat the O-rings with Coat with O-ring (black)
engine oil to prevent them from twisting. engine oil
O-ring (black)
O-ring (red)
(c) After inserting the liner into the bore, lightly

tap it on the top with the Installer so it rests
on its flange on the counterbore in the
crankcase. After seating the liner, tap on it
several times more to secure the proper
seating.
NOTE
(a) After installing the liners on all bores, test
the liner fitting for water tightness by
applying water under pressure.
(b) Check each liner to be sure its protrusion is
within assembly standards.
7-26
ENGINE MAIN PARTS
Pistons
(1) Inspecting the piston outside surfaces
Check the combustion surfaces and inside surfaces

of the pin bosses. Replace the piston if any defects
are found.
(2) Measuring piston diameter 30 mm

[1.18 in.]
(a) Using a micrometer, measure the diameter of
each piston perpendicular to the piston pin (at
the position shown). If the diameter exceeds
Measuring
the service limit, replace with new pistons. points
Unit: mm [in.]
Piston ø170 169.76 to 169.80 169.66
diameter [6.69] [6.6835 to 6.6850] [6.6795] Measuring piston diameter
(b) Part number of the piston is stamped on the

top of each piston. Part No.
Engine front side mark

Piston weight
Piston part number stamp location
(3) Inspecting piston ring grooves
Check the piston ring grooves for wear and damage,

then replace the piston if necessary. Check the Ni- Ni-resist insert
resist insert for cracks. Replace the piston if the insert Top ring groove
is cracked.
Second ring groove
Oil ring groove
Inspecting piston ring grooves
7-27
ENGINE MAIN PARTS
(4) Measuring piston pin bore diameter
Using calipers or a cylinder gauge, measure the piston

pin bore diameter. If the diameter exceeds the service
limit, replace the piston.
Unit: mm [in.]
Piston pin 70.002 to 70.015
ø 70 70.040
bore [2.75598 to
[2.76] [2.75749]
diameter 2.75649]
(5) Measuring piston protrusion
Measure the protrusion of each piston. If it is not

within standards for piston protrusion measurement,
inspect the clearance of the parts.
(a) Measure the top dead center of the pistons

with a dial gauge.
(b) Set up the dial gauge at the top of the

crankcase. Set the gauge pointer to zero (0).
Measuring piston protrusion
(c) Measure the protrusion at four places on the
piston head. Average the four measurements
to determine the protrusion. Subtract the
piston protrusion from the thickness of the
cylinder head gasket (as installed) to
determine the clearance between the clearance
between the piston top and cylinder head.
Unit: mm [in.]
0.06 to 0.65
Piston protrusion
[0.0024 to 0.0256]
Installed thickness of 1.77 to 1.83
cylinder head gasket [0.0697 to 0.0720]
Clearance between piston 1.22 to 1.95
top and cylinder head [0.0480 to 0.0768]
–CAUTION
Keep the piston protrusion with assembly
standard range to maintain high engine
performance and to prevent the valves from
stamping on the piston.
7-28
ENGINE MAIN PARTS
Piston Rings
(1) Measuring piston ring gaps
Place the rings in the new or master cylinder liner,

then measure the gap of each ring. If the gap of any
ring exceeds the service limit, replace all the rings as
a set.
Master cylinder liner inside diameter: 170 ± 0 mm

[6.69 ± 0 in.]
Measuring piston ring gap
NOTE
Use a piston to place the piston ring in the liner
by pushing it squarely.
Unit: mm [in.]
Standard Service
Item Clearance Limit
0.6 to 0.8
Top
[0.024 to 0.031]
Piston ring 0.6 to 0.8
Second 2.0 [0.079]
gaps [0.024 to 0.031]
0.3 to 0.45
Oil
[0.012 to 0.018]
(2) Measuring piston pin diameter Measuring

directions
Using a micrometer, measure the outside diameter
of each piston pin. If the outside diameter exceeds
the service limit, replace the pin.
Unit: mm [in.]
Measuring
Piston pin 69.987 to 70.000 points
ø70 69.970
outside [2.75539 to
[2.76] [2.75472]
diameter 2.75590]
Measuring piston pin diameter
7-29
ENGINE MAIN PARTS
Connecting Rods, Connecting

Rod Bearings, and Bushings Measuring
directions
(1) Measuring connecting rod bushing inside Measuring
diameter points
Using a cylinder gauge, measure the inside diameter

of each bushing. If the inside diameter exceeds the
service limit, replace the bushing.
Unit: mm [in.]
Item Value Standard Limit Measuring connecting rod bushing inside diameter
Connecting
70.020 to 70.040
rod bushing ø70 70.070
[2.75669 to
inside [2.76] [2.75866]
2.75747]
diameter
(2) Replacing connecting rod bushings
(a) Use the Connecting rod bushing installer A Installation

(H3759101010) to remove the bushing for Removal
replacement as shown. A
(b) When installing a new bushing, align the oil

holes in the bushing and connecting rod.
Replacing connecting rod bushing
(c) After installing the bushing, insert the piston

pin, and make sure that the pin rotates freely
without rattling.
7-30
ENGINE MAIN PARTS
(3) Inspecting connecting rods for bend and twist

C < 0.05 [0.0020]
l 100 [3.9]
(a) Measure C and l. If the measurement at C is C
larger than 0.05 mm [0.0020 in.] per 100 mm l
l
[3.9 in.] of l, straighten the rod with a press. Piston pin
C < 0.05 [0.0020] C
l 100 [3.9]
Connecting rod twist
NOTE
Connecting rod bend
To inspect for bend, install the cap to the
connecting rod, then tighten the cap bolts to the
specified torque. Unit: mm [in.]
Inspecting connecting rod
(b) To inspect the rod assembled with the piston,

D
place the piston on a surface plate, insert a
round bar the same diameter as the crank pin C
into the large end bore, then measure heights
(A) and (B) of the bar.
Unit: mm [in.]
Item Assembly Standard A B
Connecting rod bend and 0.05/100 max.

twist (C/D) [0.0020/3.9]
Inspecting connecting rod installed on piston
(4) Inspecting connecting rod large-end bearings
Inspect each bearing shell for flaking, scratching,

seizure, pitting, and other defects. If any defect is
found, replace the shell. Scratching
Flaking
Seizure
(5) Measuring connecting rod end play
Install the connecting rod to its crank pin, then tighten

its cap bolts to the specified torque. Use feeler gauges
to measure the end play. If the end play exceeds the
service limit, replace the connecting rod.
Unit: mm [in.]
Nominal Standard Service
Item Value Clearance Limit
Connecting 0.4 to 0.9
rod end 60 × 2 [0.016 to 1.4
play* [2.36 × 2] 0.035] [0.055] Measuring connecting rod end play
*Widths of connecting rod and crank pin
7-31
ENGINE MAIN PARTS
(6) Replacing connecting rods
When replacing connecting rods, use replacement

parts of the same weight ranking.
Weight ranking table

Weight ranking Weight (g) [oz]
A 14300 [504 oz] Weight ranking
stamp location
B 14400 [508 oz]
C 14500 [511 oz]
Replacing connecting rods
D 14600 [515 oz]
E 14700 [519 oz]
F 14800 [522 oz]
G 14900 [526 oz]
(7) Measuring connecting rod large-end bore

diameter
A
Measure the connecting rod big-end bore diameter B
12
1 2
in directions A, B and C and at front and rear positions C Front Rear
and , as shown in the drawing. To obtain the
roundness value, subtract the smallest measured value Measuring
from the largest measured value. Measuring points
If the diameter exceeds the service limit, replace the directions
connecting rod.
Unit: mm [in.] Measuring connecting rod large-bore diameter

Roundness
Item Nominal Assembly Service Service
Value Standard Limit Limit
Connecting
131.000 to
rod
ø131 131.025 131.050 0.100
large-end
[5.16] [5.15747 to [5.15944] [0.0039]
bore
5.15845]
diameter
(8) Inspecting serration on connecting rod big-end
Inspect the serration on connecting rod big-end by

conducting a Magnaflux (magnetic particle) test. If
cracking or damage is found, replace the connecting
rod.
7-32
ENGINE MAIN PARTS
(9) Measuring connecting rod bearing thickness
Use a ball-point micrometer to measure the center of

each bearing shell. If the thickness exceeds the
service limit on the upper or lower shell, replace both
shells as a set.
Unit: mm [in.]
STD 3.000 2.972 to 2.985 2.930
[0.11811] [0.11701 to [0.11535]
0.11752] Measuring connecting rod bearing thickness
-0.25 3.125 3.097 to 3.110 3.055
[-0.0098] [0.12303] [0.12193 to [0.12028]
0.12244]
Connecting -0.50 3.250 3.222 to 3.235 3.180
rod bearing [-0.0197] [0.12795] [0.12685 to [0.12520]
thickness 0.12736]
-0.75 3.375 3.347 to 3.360 3.305
[-0.0295] [0.13287] [0.13177 to [0.13012]
0.13228]
-1.00 3.500 3.472 to 3.485 3.430
[-0.0394] [0.13780] [0.13669 to [0.13504]
0.13720]
NOTE
Four sizes are available for the connecting rod
bearings (see column 2 of the table above).
7-33
ENGINE MAIN PARTS
2.3 Reassembly
Piston weight
Reassembly is done in the reverse order of

disassembly.
(1) Reassembling pistons and connecting rods
(a) The piston pin is clearance-fitted to the piston.

To facilitate pin insertion, heat the piston with Part No.
a piston heater or in hot water. View A
(b) Coat the piston pin with engine oil, then insert Matching marks on connecting rod
it in position through the connecting rod.
(c) Install the connecting rod to the piston with

the matching marks on the large end on the
camshaft side.
(d) Use the Ring pliers A (H4519108400) to

install the snap rings in the grooves of the A
piston. Make sure that the rings are not
fatigued and that they fit in the grooves
properly.
NOTE
Position the ends of both snap rings at the bottom
of the pin bore.
(2) Installing piston rings
(a) Use the Piston ring tool (H3719103200) to Up mark

install the piston rings on the piston.
Top ring
–CAUTION
Second ring
The top piston ring and second piston ring are
marked “RH”, and the oil ring is marked “R” Oil ring
near the gap on the side. Install the rings with
Coil spring
these marks upside. If not, excessive oil
consumption and overheating will result. Piston and piston ring arrangement
7-34
ENGINE MAIN PARTS
(b) Install the oil ring with its gap positioned at

180° to the coil spring joint.
Coil spring joint
180°
Oil ring gap
(3) Preparation before installing pistons

Stamped cylinder number
(a) Pistons for right bank cylinders
Turn the crankshaft in the normal direction until the 1

number (stamped on the damper) of the cylinder to 8
which the piston is to be installed is at the position of 50°
approximately 50° before top dead center.
(b) Pistons for left bank cylinders
Turn the crankshaft in the normal direction until the Stamped

number of the cylinder to which the piston is to be cylinder
installed is at the position of about 50° after top dead number
center.
50°
9
16
(c) Clean the cylinder liner bore surface and crank

pin by wiping with a cloth, then coat it with
engine oil.
7-35
ENGINE MAIN PARTS
(4) Installing connecting rod bearing upper shells

Lug groove
Install the upper shell of the bearing in the rod by
fitting its locating lug in the lug groove provided in
the rod. Coat the inside surface of the shell with
engine oil. Make sure the oil holes in the rod and
bearing are aligned.
(5) Inserting pistons

CAM ↓ (arrow mark)
(a) Put the connecting rod in the cylinder liner,

and carefully rest the piston on top of the
crankcase.
–CAUTION
(a) Make sure the arrow mark above the “CAM Camshaft
↓ (arrow mark)” on top of the piston points
forward.
(b) When placing the connecting rod in the liner,
have another service man to observe the rod
through the inspection hole to keep it away
from the oil cooling nozzle. Do not rotate
the piston.
(b) Coat the piston rings with engine oil, then

Gap of top compression ring
position the ring gaps as shown. Joint of coil spring
Gap of second compression ring Gap of oil ring
(c) With your hands, hold the compression ring

portion of the piston, then carefully insert the
piston into the cylinder liner.
NOTE
Do not pinch your finger between the oil ring
and cylinder liner.
Slowly insert the piston to avoid damaging the
oil ring.
7-36
ENGINE MAIN PARTS
(d) After making sure that the piston ring gaps A

are positioned properly, coat the rings with
engine oil, then clamp them, using the Piston
installer A (H3719107100). At this time, coat
the inside surface of the installer with engine
oil.
(e) Lightly tap on the piston head with a soft-head

mallet to insert the piston into the cylinder
liner. If the piston will not go into the liner,
move the large end of the connecting rod back
and forth through the crankcase inspection
hole.
(f) By inserting your hand through the crankcase

inspection hole, make sure that the upper shell
of the bearing is properly positioned in the
large end of the connecting rod.
(6) Installing connecting rod cap bolts
Place the connecting rod bearing on the connecting Lug groove

rod fitting its lug in the lug groove.
(a) Coat the threads of the cap bolts and the inside
surface of the lower shells of the connecting
rod bearing with engine oil.
7-37
ENGINE MAIN PARTS
(b) Install each cap in position. With your hand,

hold the upper end of the cap, then tighten
the bolt at the lower end first. This will help
prevent the cap from dropping into the oil pan.
Coat the threads and bearing surfaces of the
bolts with engine oil, then tighten the bolts
temporarily.
(c) With the cap bolts tightened temporarily,
touch the joint between the cap and rod. Make
sure that the cap is fit in place, and tighten
the bolts to the specified torque.
–CAUTION
Make sure that the matching marks on the cap
and rod are on the same side and show the same
number.
(d) Install the other connecting rod to the crank

pin. Temporarily tighten the cap bolts of the
rod installed later, then press it squarely
toward the rod already installed by tapping.
Move the large end of this rod in the thrust
direction. Make sure that the rod has correct
end play.
(e) Tighten the cap bolts to the specified torque.
NOTE
To tighten connecting rod cap bolts according to
the angle method, tighten to 245 N·m (25 kgf·m)
[181 lbf·ft], then turn 60° more.
539 N·m (55 kgf·m)

[398 lbf·ft] [wet]
(f) Use feeler gauges to measure the end play of

the connecting rod. Make sure that the end
play is equal on both top and bottom sides of
the crank pin.
–CAUTION
Before installing the cylinder head, measure the
protrusion of the piston. Make sure that the
measurement is correct. (refer to (5), “Pistons”,
2.2 of this chapter.)
7-38
ENGINE MAIN PARTS
3. Viscous Damper and Front Gears
3.1 Disassembly
Worn seal lip

5
6
7
Wear, nicking, chipping, 3
defective splines
F G
Roughness in 8 9 5
rotation Wear
4
Clogged oil
hole,wear
Wear, nicking, chipping,
abnormally worn bushing
Cracking, defective
dowel pin hole 2
1 Cracking, defective
dowel pin hole
1
Worn, lip, nicking,
deterioration
Cracking, oil leakage
1 Viscous damper, damper spacer 5 Water coupling 9 Idler gear

2 Plate 6 Water pump bearing cover F Idler shaft
3 Oil pump gear 7 Oil pump bearing cover G Front plate
4 Front gear case 8 Thrust plate
7-39
ENGINE MAIN PARTS
(1) Removing the viscous damper
(a) Attach a sling to the viscous damper.

Unscrew the mounting bolts.
(b) Screw the jack-bolts (M14 × 1.5-40 mm [0.55

× 0.059-1.57 in.]) into the threads evenly, then
remove the viscous damper.
Weight: Approx. 50 kg (110 lb)
(2) Removing the oil pump and water pump

mounting plate A
Unscrew the mounting bolts of the plate.

Remove the plate by screwing the two jack-bolts A
(H6436268500: M12 × 1.25 mm [0.47 × 0.049 in.])
evenly into the plate.
(3) Removing the oil pump gear
Remove the oil pump gear with the bearing.
(4) Removing the front gear case
(a) Attach a sling to the front gear case.
(b) Unscrew the front gear case mounting bolts.

Remove the lifted gear case by sliding it until
the gear case comes apart from the positioning
dowel pin. Be careful not to damage the oil
seal, or bend the pointer by hitting it.
7-40
ENGINE MAIN PARTS
(5) Removing the oil pump and water pump bearing

cover
Unscrew the bearing cover mounting bolts, and

remove the bearing cover.
(6) Measuring backlash and end play of the idler gear
Measure the backlash and end play of the idler gear

to obtain the data for replacement. (Refer to 3.2 of
this chapter.)
(7) Removing the idler gear
Unscrew the thrust plate mounting bolt and remove

the idler gear.
(8) Removing the idler shaft
Do not remove the idler shaft unless it is needed.

When needed, remove it by unscrewing the mounting
bolts and screwing the two jack-bolts A (M10 × 1.25
mm [0.39 × 0.049 in.]) evenly.
7-41
ENGINE MAIN PARTS
(1) Viscous damper inspection
Check the viscous damper for cracks, deformations

or cracks in the mirror plate, leakage of silicone oil,
discolored or peeling paint due to excessive heat.
Replace it with a new one at first overhaul, even when
no defect is observed.
Mirror
Viscous damper inspection
(2) Measuring backlash
Set up a dial gauge so that it contacts with the pitch

circle of the gear to measure the backlash between
the gears. If the dial gauge is not available, measure
the backlash by inserting feeler gauges between the
teeth of the gears. If the backlash exceeds the service
limit, replace the worn gear.
Unit: mm [in.]
Standard Service
Item Clearance Limit Measuring gear backlash
0.12 to 0.18 0.50
Backlash
[0.0047 to 0.0071] [0.0197]
Oil Pump Drive: Bearing Bore Diameters
• Inside and outside diameters of bearing-fitted

sections of oil pump drive
Rotate the bearing, and replace it if it is not smooth.

Check the fittings of following items and replace
them if they show any evidence of excessive wear.
• Drive shaft and bearing

• Drive case and bearing
• Drive shaft and oil seal
Unit: mm [in.]
Nominal Assembly
Item Value Standard
Cover ø110 110.000 to 110.035
bearing bore [4.33] [4.33070 to 4.33208]
Plate ø110 109.987 to 110.022
bearing bore [4.33] [4.33019 to 4.33157]
Outside ø110 109.985 to 110.000
diameter [4.33] [4.33012 to 4.33071]
Bearing
Inside ø50 49.988 to 50.000
diameter [1.97] [1.96803 to 1.96850]
Gear shaft ø50 49.993 to 50.013
bearing bore [1.97] [1.96822 to 1.96901]
7-42
ENGINE MAIN PARTS
Idler Gears, Idler Gear Bushings, and Idler

Gear Shafts
(1) Measuring idler gear bushing inside diameter and

idler gear shaft diameter Measuring
directions
If the diameter exceeds the service limit, replace the Measuring
bushing or shaft (whichever is worn). points
Unit: mm [in.]
Norminal Assembly Service
Idler gear
50.000 to 50.025
bushing ø50 50.060
[1.96850 to Measuring inside diameters
inside [1.97] [1.97086]
1.96948] for idler bushing and shaft
diameter
Idler gear 49.950 to 49.975
ø50 49.900
shaft [1.96653 to
[1.97] [1.96456]
diameter 1.96752]
(2) Measuring idler gear end play
Measure the end play with feeler gauges or dial

gauge. If the idler gear end play exceeds the service
limit, replace the thrust plate.
Unit: mm [in.]
Item Standard Clearance Service Limit
0.2 to 0.4 0.6
Idler gear end play
[0.008 to 0.016] [0.024]
Measuring idler gear end play
(3) Replacing idler bushing
(a) Use the Idler bushing puller (H3259102500)

to remove the bushing.
(b) Install a new bushing to the gear by pressing 1 mm 1 mm

it until the end face of the bushing is 1 mm (0.04 in.) [0.04 in.]
[0.04 in.] recessed from that of the gear boss.
(c) After installing the bushing, make sure that

its inside diameter is within the assembly
standard. If it is less than the standard, ream Replacing idler bushing
the bushing to the inside diameter of
ø50+0.025
0 mm [1.97 +0.0010
0 in.] 0.4 Ra.
7-43
ENGINE MAIN PARTS
3.3 Reassembly
Reassembly is the reverse procedure of disassembly.
(1) Installing the front plate
(a) Apply sealant (HERDITE) to the front plate

mounting surface of the crankcase, then place
the packing in position. Apply the same
sealant to the packing, then install the front
plate. 59 N·m (6 kgf·m) [43 lbf·ft]
(b) Replace the dowel pins if worn, or if the front

plate has been replaced.
(c) Make sure that the lower end of the front plate
is flush with the bottom of the crankcase. Cut
off the excess of the packing neatly along the
edge of the plate.
(2) Installing the idler shaft
(a) Insert the idler shaft using the guide bolts.
(b) Tighten the shaft mounting bolts to the

specified torque.
108 N·m
(11 kgf·m) [80 lbf·ft]
(3) Installing the idler gear
(a) Insert the idler gear into the shaft, and install
the thrust plate.
(b) Install the thrust plate, then tighten the

mounting bolts to the specified torque.
29 N·m (3 kgf·m) [22 lbf·ft]
7-44
ENGINE MAIN PARTS
(4) Installing the oil pump and water pump drive

bearing cover
(a) Insert the bearing cover into the front plate,

then tighten the cover mounting bolts to the
specified torque.
108 N·m
(11 kgf·m)
[80 lbf·ft]
(5) Installing the front gear case and pointer Coat with grease Unit: N·m
(kgf·m)
(a) Apply a sealant (HERDITE) to the front gear [lbf·ft]
case packing mounting surface, then place the
packing in position. Apply sealant in the same
manner to the packing, then install the front
gear case.
M12: 59 (6)
(b) Now mount the water coupling of the front [43] Coat with grease
plate and the gear case to the crankcase. Apply M16: 216 (22) [159]
grease to the O-rings and O-ring grooves.
Do not damage the O-rings when installing
the gear case.
16±0.3 mm [0.6±0.012 in.]
(c) Replace the dowel pins if worn, or if the front Front gear case
cover has been replaced.
(d) Tighten the front cover mounting bolts evenly Oil seal
to the specified torque.
(e) Make sure that the lower end of the front cover Slinger
is flush with the bottom of the front plate. Cut
off the excess packing neatly along the edge
of the cover.
(f) Install the oil seal to the front gear case.
(g) Apply engine oil to the lip of the oil seal.
(h) Insert the oil seal to the slinger using the

special tool [Front seal installer assembly
(H3759105010)].
7-45
ENGINE MAIN PARTS
When the Pointer is Out of Place

Timing gear case
To determine the top dead center on the compression
stroke of No. 1.8 cylinder, for example, bring the
mark on the flywheel to where it is at an equal
distance between the marks stamped on the timing
gear case.
Flywheel
(6) Installing the oil pump gear and mounting plate

for the oil pump and water pump
(a) Insert the oil pump gear.
(b) Install the plate, then tighten the bolts to the

specified torque.
59 N·m
(6 kgf·m)
[43 lbf·ft]
(7) Installing the viscous damper
Tighten the damper mounting bolts to the specified

torque.
490 N·m (50 kgf·m) [362 lbf·ft]
7-46
ENGINE MAIN PARTS
4. Oil Pan and Oil Strainer
4.1 Disassembly
Damage, cracks
9 4
8 Clogs
6
Replace
Cracks
3
Replace
Cracks 2
1 Oil level sensor 4 Timing gear case stay 7 Underplate

2 Lower oil pan 5 Upper oil pan 8 Oil strainer
3 Lower gasket 6 Upper gasket 9 Oil pipe
7-47
ENGINE MAIN PARTS
4.2 Reassembly
6 locations
To assemble, follow the disassembly procedures in
reverse.
(1) Installing the upper and lower gaskets
The upper and lower gaskets are multi-piece gaskets.

Apply HERDITE to the joined sections of the gaskets
to prevent leakage.
Joints in upper gasket
4 locations
Joints in lower gasket
(2) Apply Three Bond 1211 to the upper mounting

surface of the underplate when assembling.
7-48
ENGINE MAIN PARTS
5. Flywheel, Timing Gears, and Camshaft
5.1 Disassembly
9 4
8
F
7
Clogged
G
oil hole
Damage, wear
6 Flaking or worn
7 6
4 5
Rough bearing
rotation,
damaged seal Oil hole
2
clogged, wear
5
H
Worn, damaged,
or deteriorated lip
3 Damaged threads
Cracks, damaged
dowel holes
Cracks, defective
1
dowel holes,
worn ring gear
1 Flywheel 5 Idler gear 9 Camshaft

2 Idler shaft thrust collar 6 Idler shaft F Rear plate
3 Timing gear case, oil seal 7 Camshaft gear G Nozzle plate
4 Injection pump drive 8 Thrust plate H Cover
7-49
ENGINE MAIN PARTS
(1) Removing the flywheel
(a) Attach a sling to the flywheel.
(b) Unscrew the mounting bolts.
(c) Screw the two jack-bolts A (H6436268500:

M12 × 1.25 mm [0.47 × 0.049 in.]) into the
holes in the flywheel evenly, then remove the
flywheel. A
–CAUTION
(a) When you remove the flywheel, do not drop
it or bump it against a hard object.
(b) The ring gear is bolt mounted to the flywheel.

Do not remove the gear except when it has
to be replaced.
(2) Removing the idler shaft collar
(a) Unscrew the cover mounting bolts, then

remove the cover.
(b) Unscrew the idler shaft thrust collar mounting

nuts. Mark the collar at its position. Right and left
identification
(c) Screw the bolts (M6 × 1.0 mm [0.24 × 0.039 marks
in.]) through the thrust collar removing bolt
holes and pull the thrust collar from the gear 404298
case.
NOTE
Place marks to identify the right and left collars
to ensure proper backlash and end play in
reinstallation.
(3) Removing the timing gear case
(a) Attach slings to the timing gear case.
(b) Unscrew the timing gear case mounting bolts.
(c) Remove the timing gear case by lifting it up 404299

until it separates from the dowel pin. Do not
damage the oil seal.
7-50
ENGINE MAIN PARTS
(4) Measuring backlash and end play
Measure the backlash and end play of each gear to

obtain the data for parts replacement.
(5) Removing the fuel injection pump drive gears

(left and right)
Unscrew the injection pump drive case mounting

bolts, then remove the pump drive. Do not damage
the gear teeth.
NOTE
Remove the No. 16 cylinder cam cover before
removing the pump drive case of the left side.
(6) Removing idler gears
(a) Remove the slinger of the crankshaft.
NOTE
When the slinger is removed, install a new slinger
during reassembly.
(b) Remove the idler gears (left and right).
(7) Removing the idler shaft
Do not remove the idler shaft unless you need to

repair it. To remove, install the sliding hammer to
the idler shaft removing screw hole (M22 × 1.5 mm
[0.87 × 0.059 in.]).
7-51
ENGINE MAIN PARTS
(8) Removing camshaft gears
Unscrew the camshaft gear mounting bolts, then

remove the camshaft gear.
(9) Removing camshafts
Unscrew the thrust plate mounting bolts, then pull

out the camshaft from the crankcase.
–CAUTION
When pulling out the camshaft, support it with a
bar inserted through the camshaft inspection hole
of the crankcase to prevent damage to the cam
surfaces and bushings.
7-52
ENGINE MAIN PARTS
Flywheel and Ring Gear
• Measuring the flywheel face and radial runouts
Measure the runouts of the flywheel installed on the

crankshaft. If the runouts exceed the assembly
standard, check for loose bolts or obstacles lodged
between the mounting faces of the flywheel and
crankshaft.
Unit: mm [in.] Measuring flywheel runout
Assembly
Item Standard
Flywheel Face runout 0.336 [0.0132] max.
Radial runout 0.13 [0.0051] max.
Injection Pump Drive Diameter and Inside

Diameter of Bearings
(1) Inside and outside diameters of bearing-fitted

sections of injection pump drive
Check the bearing for smooth rotation.

Replace the bearing if its rotation is not smooth.
Check the fit of the drive shaft in the bearing. Replace
excessively worn parts.
Check the fit of the bearing in the drive case. Replace
excessively worn parts.
Check the drive shaft and oil seal. Replace any
defective parts.
Unit: mm [in.]
Nominal Assembly
Item Value Standard
89.985 to 90.000
ø90 [3.54]
Outside [3.54272 to 3.54331]
dia. 99.985 to 100.000
ø100 [3.94]
[3.93642 to 3.93701]
Bearing
44.988 to 45.000
ø45 [1.77]
Inside [1.77118 to 1.77165]
dia. 49.988 to 50.000
ø50 [1.97]
[1.96803 to 1.96850]
45.002 to 45.013
ø45 [1.77]
Drive shaft [1.77173 to 1.77216]
bearing dia. 50.002 to 50.013
ø50 [1.97]
[1.96858 to 1.96901]
7-53
ENGINE MAIN PARTS
(2) Measuring timing gear backlash
To measure the backlash between the gears, set up a

dial gauge so that it contacts the pitch circle of the
gear to measure. If a dial gauge is not available,
measure the backlash by inserting feeler gauges
between the gear teeth. If the backlash exceeds the
service limit, replace the worn gears.
Unit: mm [in.]
Standard Repair Service
Item Clearance Limit Limit
Timing 0.12 to 0.18 Measuring timing gear backlash
0.30 0.50
gear [0.0047 to
[0.0118] [0.0197]
backlash 0.0071]
Idler Gear, Idler Gear Bushing, and Idler

Gear Shaft
(1) Measuring the idler gear bushing inside diameter

and idler gear shaft diameter
Measuring
directions
If the diameter exceeds the service limit, replace the
Measuring
bushing or shaft if either is worn. points
Unit: mm [in.]
Norminal Assembly Service
Idler gear, 65.000 to 65.030
ø65 65.060
bushing [2.55906 to
[2.56] [2.56142]
inside dia. 2.56024]
64.951 to 64.970 Measuring idler gear bushing and shaft
Idler gear ø65 64.900
[2.55713 to
shaft dia. [2.56] [2.55512]
2.55787]
(2) Measuring idler gear end play
Measure the end play with feeler gauges or a dial

gauge. If the end play exceeds the repair limit, replace
the thrust plate.
Unit: mm [in.]
Idler gear end 0.3 to 0.6 1.0
play [0.0118 to 0.0236] [0.0397]
Measuring idler gear end play
7-54
ENGINE MAIN PARTS
(3) Replacing idler bushings

A
(a) Use the Idler bushing puller A to remove the
bushing.
(b) Install a new bushing to the gear by pressing

it until the end face of the bushing 1 mm [0.04
in.] recessed from that of the gear boss.
(c) After installing the bushing, be sure its inside

diameter is within the assembly standard. If it
is less than assembly standard, ream the bush- Replacing the idler gear bushing
ing to the inside diameter of ø65 +0.0300 mm
+0.012
[2.56 0 in.] 0.4 Ra.
Camshafts and Camshaft Bushings
(1) Measuring cam lift

A
Use a micrometer to measure the diameters of “A”
B
and “B” on each cam to determine the reduction in
cam lift. If the cam lift is less than the service limit,
replace the camshaft.
Unit: mm [in.]
Item Assembly standard Service Limit
Cam lift (A-B) 9.260 to 9.340 8.45 Measuring cam lift
[0.36457 to [0.3327]
0.36772]
(2) Measuring camshaft deflection
If the deflection exceeds the repair limit, straighten

the camshaft with a press, or replace it with a new
one.
–CAUTION
Set up a dial gauge on the camshaft, then turn
the camshaft. Take one-half of the gauge
indication as the deflection.
Measuring camshaft deflection
Unit: mm [in.]
Camshaft deflection 0.05 [0.0020] max. 0.08 [0.0031]
7-55
ENGINE MAIN PARTS
(3) Measuring camshaft journal diameters

Measuring
directions
Use a micrometer to measure each camshaft journal
in two directions at right angles to each other. If the
diameter exceeds the service limit, replace the
camshaft.
Unit: mm [in.]
83.92 to 83.94
Camshaft ø84 83.87
[3.3039 to
journal dia. [3.31] [3.3020] Measuring camshaft journal diameter
3.3047]
(4) Measuring camshaft bushing inside diameter

Measuring
directions
Use a cylinder gauge to measure the inside diameter
of the camshaft bushings fitted to the crankcase. If
the inside diameter exceeds the service limit, replace
the bushings.
Unit: mm [in.]
Camshaft 84.000 to 84.035
ø84 84.10
bushing [3.30708 to
[3.31] [3.3110] Measuring cam shaft inside diameter
inside dia. 3.30846]
(5) Measuring camshaft end play
Use a dial gauge to measure the end play of the

camshaft to which the camshaft gear is installed. If
the end play exceeds the service limit, replace the
thrust plate.
Unit: mm [in.]
Camshaft end 0.10 to 0.25 0.40
play [0.0039 to 0.0098] [0.0157]
Measuring camshaft end play
7-56
ENGINE MAIN PARTS
(6) Replacing camshaft bushings
Install the bushings in the crankcase, then secure them

in place with the set screws.
Before tightening the screws, be sure that the screw
holes in the bushings and crankcase are aligned and
that the oil holes in the bushings are aligned with
Sealing
those leading to the oil gallery in the crankcase.
washer
Use a wide bushing as the bearing for the rear section,
and insert it in the correct attitude.
Replacing a cam shaft bushing
Shorter Longer
Crankcase
rear end
Set screw
7-57
ENGINE MAIN PARTS
5.3 Reassembly M12 : 108 N·m (11 kgf·m)

[0.47 in.] [80 lbf·ft]
M16 : 216 N·m (22 kgf·m)
(1) Installing the rear plate [0.63 in.] [159 lbf·ft]
(a) Apply sealant (HERDITE) to the rear plate

mounting surface of the crankcase, then place
the packing in position. Apply the same
sealant to the packing, then install the rear
plate.
Replace packing
(b) Replace the dowel pins if worn, or if the rear
plate has been replaced.
(c) Make sure that the lower end of the rear plate
is flush with the bottom of the crankcase. Cut
edge of the plate.
(2) Cranking the engine
(a) Install the bolts (M22 × 1.5 mm [0.87 × 0.059

in.]) to the viscous damper mounting holes.
(b) Using these bolts, turn the crankshaft with a

bar to bring the No. 1 cylinder piston to the
top dead center.
(3) Installing idler gear shafts
Fit the O-ring to the idler shaft. Apply grease to the

O-ring to insert the idler shaft into the crankcase. At
this time. In this step, make sure the “TOP” mark on Apply O-ring
the shaft is located at the top (oil passage in vertical grease
direction). Oil feed hole
(vertical direction)
7-58
ENGINE MAIN PARTS
(4) Installing the camshafts (left and right)
(a) Insert the camshaft into the crankcase, then

install the thrust plate.
59 N·m
(b) Tighten the thrust plate mounting bolts to the
(6 kgf·m)
specified torque. [43 lbf·ft]
(c) Check and make sure that the camshaft turns

smoothly.
NOTE
Do not mix the two different camshafts when you
reassemble the engine.
(5) Installing camshaft gears
(a) Install the camshaft gears to meet the dowel

pin.
(b) Tighten the camshaft gear mounting bolts to

the specified torque.
108 N·m
(c) After installing the camshaft gear, check that (11 kgf·m)
the gear rotates smoothly. [80 lbf·ft]
(6) Installing idler gears
(a) Install the idler gear by aligning its matching

mark with that on the crankshaft gear and 392 N·m
camshaft gear. Tighten the idler gear mounting (40 kgf·m)
bolts to the specified torque. [289 lbf·ft]
(b) Insert the slinger to the crankshaft. (Refer to

section 5.2, of this chapter.)
(c) Confirm that the matching marks of the timing Camshaft gear
gears are as the drawing shown on the right.
Idler gear
Injection pump gear Injection pump gear

Crankshaft gear
Timing gear train
7-59
ENGINE MAIN PARTS
(7) Installing the injection pump drive
(a) Install the injection pump gear to the drive

shaft, then tighten it to the specified torque.
392 N·m (40 kgf·m)

[289 lbf·ft]
(b) Fit the O-ring to the installation surface of

108N·m
the drive case. Apply a thin coat of ThreeBond (11 kgf·m)
1212 on the flange surface. [80 lbf·ft]
(c) Install the injection pump drive to the rear

plate by aligning its matching mark to that of
the idler gear.
(d) Tighten the drive case mounting bolts to the Coat 1212
specified torque. O-ring
(8) Inspecting and adjusting timing gears after

installation
After installing the timing gears, be sure to inspect

and adjust them as follows.
7-60
ENGINE MAIN PARTS
Inspecting Timing Gear

Backlash and End Play
After installing the timing gears, inspect the backlash

between the gears in mesh, and the end play of each
gear.
Inspecting Valve Timing

TDC
It is not necessary to inspect the valve timing, 4 45° 63°

1
provided that all match marks on the timing gears Direction of
are aligned. Inspect the timing for verification as rotation 1 Inlet valve opens
2 Inlet valve closes
3 Exhaust valve opens
explained below.
4 Exhaust valve closes

Using a feeler gauge 2 mm [0.08 in.] thick, add 2 mm
[0.08 in.] clearance to the inlet and exhaust valves of
3 53° 35° 2
the No. 1 cylinder. Then insert a feeler gauge 0.05 mm
BDC
[0.020 in.] thick between the bridge cap and rocker.
Slowly turn the crankshaft to find the position where Valve timing diagram
the feeler gauge is firmly gripped (the valve starts
opening) and the position where the gauge is released
(the valve starts closing). Check that these positions
coincide with the angular positions shown in the valve
TDC
4 25° 1
7°
timing diagram with 2 mm [0.08 in.] clearance added Direction of rotation
to the valves.
3 21° 23°
BDC
Valve timing diagram with 2 mm [0.08 in.]
clearance added to valves
7-61
ENGINE MAIN PARTS
(9) Installing the timing gear case 18±0.3 mm

Timing gear case [0.7±0.012 in.]
(a) Apply sealant (HERDITE) to the timing gear
case surface. Place the packing in position. Oil seal
Apply the sealant on the placed packing. Cut
bottom surface of the crankcase.
(b) Replace the dowel pins if worn, or if the gear Slinger

case has been replaced.
(c) Tighten the gear case mounting bolts evenly

to the specified torque.
(d) Apply engine oil to the oil seal lip. Insert the
oil seal into the timing gear case.
(e) Fit the oil seal to the slinger using the Rear
seal installer (H3779106010) in the position
as shown.
255 N·m
(26 kgf·m)
[188 lbf·ft]
(10) Installing the idler shaft thrust collars
(a) Apply grease to the thrust collars, and insert

the collars in the timing gear case.
In this step, make sure the “TOP” mark is
located at the top and the right and left collars
are installed in their original positions by Right and left identi-
checking the identification marks placed fication marks
during removal.
196 N·m (20 kgf·m)
[145 lbf·ft]
(b) Tighten the thrust collar mounting nuts to the
specified torque.
(c) Install the cover, and tighten the mounting

bolts to the specified torque.
7-62
ENGINE MAIN PARTS
(11) Installing the flywheel
(a) Install the flywheel. Check that all dowel pins

enter their holes.
(b) Coat the threads and the bolt bearing surface

of the flywheel mounting bolts with engine
588 N·m
oil, then tighten the bolts to the specified (60 kgf·m)
torque. [434 lbf·ft]
Inspect the face and radial runouts of the [wet]
flywheel.
(12) Installing the pickup

Timing gear case
(a) Rotate the engine using the turning gear until
a tooth of the ring gear is positioned at the
center of the pickup mounting hole.
Lock nut
(b) Screw the pickup gently into the hole. When Approx. 1 mm
the tip of the pickup contacts the tooth surface Ring gear [0.04 in.]
of the ring gear, loosen the pickup by a 3/4 (number of
rotation, then tighten the lock nut to secure teeth: 193)
the pickup in place.
7-63
ENGINE MAIN PARTS
6. Crankcase, Crankshaft, and Main Bearings
6.1 Disassembly
K
Scale damage, cracks,
clogged oil holes
Wear scratching,
pitting, scoring
2
Stripped
threads
Wear
8 G
H
J
Clogged
oil hole
I
Check valve
movement
7 6 Wear,
chipping,
Scoring, pitting, flaking,

4 abnormal
tooth contact
5
chipping, cracking, corrosion
Wear
Cracking
F
9
Stripped
threads
3 1
1 Main bearing cap bolt 6 Crankshaft G Slinger (rear)

2 Side bolt 7 Main bearing (upper) H Crankshaft gear (rear)
3 Main bearing cap 8 Thrust bearing I Check valve
4 Main bearing (lower) 9 Slinger (front) J Piston cooling nozzle
5 Thrust bearing F Crankshaft gear (front) K Crankcase
7-64
ENGINE MAIN PARTS
(1) Turning the crankcase upside down
Use such lifting tool as a chain block and shackles to

lay the crankcase on its side. Then add slings to the
crankcase, and turn it upside down.
Crankcase and crankshaft weight: approx. 2500 kg

(5512 lb)
(2) Removing the main bearing caps
(a) Unscrew the cap bolts and side bolts. Remove

the main bearing cap using cap removers or a
chain block (use 2 eye bolts, M27 × 1.5 mm
[1.06 × 0.059 in.]). Cap bolt
(b) Remove the thrust bearings from the No. 9

bearing cap. Do not damage the thrust bearings. Side bolt
(3) Removing the crankshaft
(a) Remove the front upper halves of the thrust

bearings by rotating them slowly.
(b) Carefully lift the crankshaft off the crankcase,

keeping it horizontal.
(c) Remove the rear upper halves of the thrust

bearings on the crankcase.
(4) Removing the piston cooling nozzles

34 N·m
Do not remove the nozzles unless such defects as (3.5 kgf·m)
clogging are observed. [25 lbf·ft]
NOTE
Tighten the piston cooling nozzle to the specified
torque when reassembling.
7-65
ENGINE MAIN PARTS
6.2 Inspection and Repair Measuring Measuring

directions points
Crankshaft
(1) Measuring crank pin and journal diameters
(a) Using a micrometer, measure the crank pin

and journal diameters. If the diameter exceeds
the repair limit, grind them to the next lower
size: -0.25 mm [-0.0098 in.], -0.50 mm
[-0.0197 in.], -0.75 mm [-0.0295 in.], or
Measuring crank pin diameter
-1.00 mm [-0.0394 in.].
(b) Measure the crank pins and journals to

determine the and cylindricity.
(c) If the -1.00 mm [0.0394 in.] undersize journals

and crank pins exceed the repair limit, replace
the crankshaft.
Measuring Measuring
directions points
Unit: mm [in.]
Nominal Assembly Repair
Crank pin diameter ø125 –0.050 to –0.110
[4.92] –0.070 [–0.00433]
[–0.00197 to
–0.00276]
Journal diameter ø170 –0.060 to –0.110
[6.69] –0.080 [–0.00433]
[–0.00236 to Measuring crank journal diameter
–0.00315]
Pin, Roundness Dia. 0.03
journal difference [0.0012]
0.01 [0.0004]
max.
Cylindricity Dia. 0.03
difference [0.0012]
0.02 [0.0008]
max.
0
Fillet Pin 7 7.000
– 0.2
0
radius [0.28] [0.276 – 0.008 ]
0
Journal 8.5 8.500
– 0.2
0
[0.33] [0.335 – 0.008 ]
Hardness Hv >590
7-66
ENGINE MAIN PARTS
Grinding dimensions for an undersize

crankshaft
Unit: mm [in.]
Finishing Roundness Cylindricity
Undersize Dimension
Crankpin 0.25 124.68 to 124.70
dia. [0.0098] [4.9087 to
4.9094]
0.50 124.43 to 124.45 Dia. Dia
[0.0197] [4.8988 to difference difference
4.8996] 0.01 0.02
0.75 124.18 to 124.20 [0.0004] [0.0008]
[0.0295] [4.8890 to max. max.
4.8898]
1.00 123.93 to 123.95
[0.0394] [4.8791 to
4.8799]
Journal 0.25 169 67 to 169.69
dia. [0.0098] [6.6799 to
6.6807]
0.50 169.42 to 169.44 Dia. Dia.
[0.0197] [6.6701 to difference difference
6.6709] 0.01 0.02
0.75 169.17 to 169.19 [0.0004] [0.0008]
[0.0295] [6.6602 to max. max.
6.6610]
1.00 168.92 to 168.94
[0.0394] [6.6504 to
6.6512]
(2) Grinding the crankshaft
Refinish the crankshaft according to the dimensions

of the undersize main bearing and connecting rod
bearing.
When grinding the crank pins and journals, be sure

to produce the same fillet radius as the original. They
should have a hardness of 590 (Vickers Hardness
Number). If necessary, re-harden the crank pins and
journals, and inspect them for cracks by conducting
a Magnaflux (magnetic particle) test. After grinding,
finish the journals and crank pins to 0.2 Ra.
7-67
ENGINE MAIN PARTS
(3) Measuring crankshaft end play Unit: mm [in.] 7 [0.28]R 67 0

+0.030
+0.001181
[2.64 0 ]
(a) Install the thrust bearings in position, then
secure the bearing cap. Under this condition,
measure the end play. If the end play exceeds
the standard clearance, replace the thrust
bearings.
(b) If the end play still exceeds the repair limit

even after the new thrust bearings have been
8.5 [0.335]R
installed, replace the bearings with the next
oversize bearings. There are three sizes for Measuring thrust bearing journal length
the thrust bearings:
+ 0.25 mm [+0.0098 in.]
+ 0.50 mm [+0.0197 in.]
+ 0.75 mm [+0.0295 in.]
Generally the rear journal is likely to wear more

rapidly than the front journal. This means that
replacement of the rear thrust bearings will generally
be sufficient.
Unit: mm [in.]
Measuring crankshaft end play
Crankshaft end 0.20 to 0.40 0.50
play [0.0079 to 0.0157] [0.0197]
Crankshaft Journal Grinding Dimensions for

Oversize Thrust Bearings
Unit: mm [in.]
Oversizes
for Journal Oversizes for
Item or Thrust Journal and Tolerance
Bearings Thrust Bearings
+0.25 67.25 67.50

[0.0098] O.S [2.6476] [2.6575]
+ 0.03
+0.50 67.50 68.00 0
[0.0197] O.S [2.6575] [2.6772] + 0.0012
[ 0 ]
+0.75 67.75 68.50
[0.0295] O.S [2.6673] [2.6968]
7-68
ENGINE MAIN PARTS
(4) Measuring crankshaft deflection
Support the crankshaft on its journals in V-blocks,

then measure the deflection at the center journal with
a dial gauge. Depending on the amount of deflection,
repair the crankshaft by grinding or straightening with
a press. If the deflection exceeds the repair limit,
replace the crankshaft.
Unit: mm [in.]
Crankshaft deflection 0.04 [0.0016] max. 0.10 [0.0039] Measuring crankshaft deflection
(5) Replacing the oil seal slinger Timing gear case
Replace the slinger if it is pitted, scratched, or Front cover

distorted enough to cause oil leaks. Oil seal slinger
Oil seal Oil seal
Front Rear
Removing the Slinger
Use a gear puller to remove the slinger from the

crankshaft.
7-69
ENGINE MAIN PARTS
Installing the Slinger Identification Identification

(H37425-08200) (H37411-04200)
(a) Identify the front slinger and the rear slinger,
and pay attention to their attitudes.
Attach to gear Attach to gear
Front view Rear view
(b) Use a slinger installer to install the slinger

heated above 110 °C [230 °F] to the crankshaft
until it contacts the gear.
If the slinger has stopped before it touches
the gear, tap the center or shoulder of the
installer with a copper hammer.
(6) Replacing the crankshaft gear
Removing the Gear
Use a gear puller to remove the gear from the

crankshaft.
NOTE
Do not remove the gear by hitting it with a
hammer.
7-70
ENGINE MAIN PARTS
Installing the Gear Align dowel pin and notch
(a) Before installing the crankshaft gear, measure

the inside diameter of the crankshaft gear to
be sure that the fit is within the specified value.
Front side: 0.106 to 0.171 mm [0.00417 to 0.00673 in.]

Rear side: 0.274 to 0.358 mm [0.01079 to 0.01409 in.]
(b) Heat the gear to the range 180 to 200 °C [356

to 392 °F].
(Do not heat the gear above 200 °C [392 °F].)
(c) Drive the rear crankshaft gear onto the

crankshaft by tapping the end face of the gear Drive direction Drive direction
lightly with a copper hammer. Be sure the
crankshaft dowel pin enters the notch in the
gear.
(d) The rotational position of front gear is
discretionaly.
–CAUTION
Front Rear
(a) Install the gear to the crankshaft until it
contacts the collar.
(b) Do not mistake the direction of gear
installation.
Main Bearing
(1) Inspecting the main bearing surfaces
Inspect each bearing shell for abnormal contact such Scratches, corrosion,
as scratching, corrosion, flaking, etc. Also check for flaking
signs of poor seating in the bore of the crankcase or
bearing cap.
7-71
ENGINE MAIN PARTS
(2) Measuring bearing thickness
Use a ball point micrometer to measure the center of

each bearing shell. If the thickness exceeds the service
limit on any of the upper or lower shells, replace the
upper and lower shells as a set.
Unit: mm [in.]
Main STD 4.500 4.467 to 4.480 4.425
bearing [0.17717] [0.17587 to [0.17421] Measuring main bearings thickness
thickness 0.17638]
(center) -0.25 4.625 4.592 to 4.605 4.550
[0.0098] [0.18209] [0.18079 to [0.17913]
0.18130]
-0.50 4.750 4.717 to 4.730 4.675
[0.0197] [0.18701] [0.18571 to [0.18405]
0.18622]
-0.75 4.875 4.842 to 4.855 4.800
[0.0295] [0.19193] [0.19063 to [0.18898]
0.19114]
-1.00 5.000 4.967 to 4.980 4.925
[0.0394] [0.19685] [0.19555 to [0.19390]
0.19606]
NOTE
Four undersizes are available for the main
bearings; namely, -0.25 mm [-0.0098 in.], -0.50
mm [-0.0197 in.], -0.75 mm [-0.0295 in.] and
-1.00 mm [-0.0394 in.].
(3) Replacing main bearings
If the thickness exceeds the service limit, either

replace the main bearings as above, or refinish the
crankshaft and use undersize bearings.
Crankcase
(1) Measuring flatness of gasket surface
Measure flatness with a straight edge and feeler

gauges. If the warpage exceeds the assembly
standard, reface the gasketed surfaces with a surface
grinder.
Unit: mm [in.]
Crankcase Measuring crankcase gasketed surfaces
gasket surface 0.1 [0.004] max. 0.2 [0.008]
flatness
7-72
ENGINE MAIN PARTS
NOTE
Do not grind the crankcase more than necessary
to remove warpage. Excessive grinding can cause
the piston protrusion to exceed assembly
standard.
(2) Measuring main bearing bore diameter 588 N·m (60 kgf·m)
[434 lbf·ft] [wet]
Secure the end bearing cap to the specified torque,
and measure the bore diameter in the three directions.
Unit: mm [in.]
Nominal Assembly Service 392 N·m (40 kgf·m)
Item Value Standard Limit [289 lbf·ft] [wet]
179.000 to
Main
ø179 179.025 179.045
bearing
[7.05] [7.04723 to [7.04900]
bore dia.
7.04821] Measuring main bearing bore diameter
7-73
ENGINE MAIN PARTS
6.3 Reassembly
(1) Installing the main bearing

Lug groove
(a) Install each upper shell of the main bearing
in the crankcase by fitting its locating lug in
the lug groove. The oil holes in the bearings
and crankcase will be aligned when the
bearings are installed in this way.
(b) Lightly coat the inside surface of the shells

with engine oil.
(2) Installing thrust bearings
(a) Install the thrust bearings to the No. 9 bearing

seat of the crankcase, with the oil groove side
of the bearings facing out.
(b) After installing the crankshaft, install the inner

thrust bearing with the oil groove facing inside Oil
the crankcase. grooves
(3) Installing the crankshaft
(a) Wash the crankshaft with cleaning solvent,

and dry it by air blow.
NOTE
After washing the crankshaft, make sure that the
oil holes are clean and not clogged.
(b) Hold the crankshaft horizontally with a hoist,

then carefully put it on the crankcase.
(c) Lightly coat the journals with engine oil.
7-74
ENGINE MAIN PARTS
(4) Installing main bearing caps “FRONT” mark
(a) Fit the lower shell of the bearing to each

bearing cap.
B Bearings
(b) Install the thrust bearings to the No. 9 bearing No. 1-9
cap, with the oil groove side of the bearing
facing out.
(c) From the front side of the crankcase, bearings

No. 1 to No. 9 are stamped on the caps. Install
the caps with these numbers and “FRONT”
mark on the front of the crankcase.
(d) Coat the threads of the bearing cap bolts with

engine oil, then temporarily tighten the bolts.
(e) Use a soft-head mallet to drive in the bearing

caps evenly.
(5) Installing bearing cap bolts
(a) Temporarily tighten the bearing cap coated

with engine oil. Tighten the four bolts 588 N·m
(60 kgf·m)
progressively and evenly to the specified [434 lbf·ft]
torque. 392 N·m [wet]
(40 kgf·m)
[289 lbf·ft]
(b) Tighten the left and right side bolts [wet]
progressively and evenly to the specified
torque. O-ring
(c) Make sure that the crankshaft rotates

smoothly.
(6) Measuring crankshaft end play
(a) Tighten No. 1 through No. 8 bearing cap bolts

and side bolts to the specified torque, with
the No. 9 cap bolt temporarily tightened, then
measure the end play.
(b) After tightening the No. 9 cap bolts, make sure

that the end play is correct.
(c) Confirm that all cap bolts and side bolts are
tightened to the specified torque.
7-75
INLET AND EXHAUST SYSTEMS
1. Description .................................................................................................................................. 8- 2
2. Air Heater ................................................................................................................................... 8- 3
Disassembly ................................................................................................................................ 8- 3
3. Turbocharger ............................................................................................................................... 8- 4
3.1 Disassembly ........................................................................................................................ 8- 4
3.2 Inspection ............................................................................................................................ 8- 8
3.3 Reassembly ......................................................................................................................... 8-10
8
1. Description
Exhaust pipe
Turbocharger
Turbochager
Inlet air from air cleaner Inlet air from air cleanr
Air cooler
Cylinder
Inlet
Exhaust
8-2
2. Air Heater
Disassembly
5
3
2
1
1 Flange terminal 3 Air heater assembly 5 Air heater

2 Harness 4 Air heater bracket
8-3
3. Turbocharger
3.1 Disassembly
Wear of thrust seating
F
surface
6
59
Wear
34
Wear
O P
1 H I
8 G
Chafing with 2 7 Chafing with turbine
compressor wheel wheel, cracks, defor-
mation
Bent vanes, damage,
back-side chafing,
corrosion
K
Chafing with turbine
wheel, damage
J
L
RM Bent vanes, damage, back-side chafing,
NQ
corrosion, ring groove damage
S
Damaged bearing hole, corrosion by
gas, deformed flange on turbine side
1 V-clamp 9 O-ring M Piston ring

2 Compressor cover F Oil deflector N Turbine backplate
3 Lock nut G Thrust ring (compressor side) O Bearing
4 Compressor wheel H Thrust bearing P Snap ring
5 Snap ring I Thrust ring (turbine side) Q Snap ring
6 Insert J V-clamp R Bearing
7 Piston ring K Turbine housing S Bearing housing
8 Flinger sleeve L Shaft & turbine wheel
–CAUTION
Carefully handle the compressor wheel and
turbine wheel during disassembly and assembly,
since vanes can easily bend when dropped or hit.
8-4
(1) Preparing for disassembly
Mount the turbine housing K on a vice by clamping

at the flange.
K
–CAUTION
Clamp the flange securely to prevent the turbine
housing from loosening or moving during work.
(2) Removing the compressor cover
–CAUTION
2 S
K
The compressor cover , bearing housing
and turbine housing must be re-assembled in
correct orientation. Therefore, put alignment
2
marks with a punch or marker. 1
Pay attention not to hit or pry the vanes of the
compressor when removing the compressor
cover, since vanes can easily bend.
(a) Loosen the V-clamp 1 using a socket wrench.

(b) Remove the compressor cover 2.
(3) Removing the compressor wheel

4
L 3
(a) While holding the boss of the shaft & turbine
4
wheel , remove the lock nut fastening
the compressor wheel .
8-5
4
(b) While holding the turbine wheel with one
hand, turn the compressor wheel lightly
with the other hand and remove.
4
(4) Removing the snap ring
–CAUTION A
Put a thumb on the snap ring to prevent it from

flying out in case the pliers lose grip.
Using the snap ring pliers A (H4916090101), remove

5
5
the snap ring .
8
7
(5) Removing the insert and oil deflector
6
6 S 9
(a) Using two screwdrivers, gently pry out the
insert from the bearing housing .
F
8 G
7
(b) Separate the flinger sleeve together with
the piston ring from the insert. H
I
S
(c) Remove the following parts from the bearing
9
housing .
F
O-ring
G
Oil deflector
H
Thrust ring (compressor side)
I
Thrust bearing
Thrust ring (turbine side)
(6) Removing the V-clamp
Loosen the V-clamp J with a socket wrench, and

dislodge the V-clamp from its clamping position.
8-6
(7) Removing the shaft & turbine wheel

L
L
(a) While gripping the shaft of the shaft & turbine
S
S
wheel with one hand, hold the bearing
housing with the other hand and slowly
K
remove the shaft & turbine wheel from the
turbine housing .
K
(b) Turn over the bearing housing S(so the

L
turbine wheel faces up), and place it on the
compressor cover. Then, remove the
L
following parts.
S M
M
Shaft & turbine wheel
N
Piston ring
N
O
Turbine backplate
Bearing (compressor side)
O
(8) Removing the snap ring and bearing

P
Q
–CAUTION
R
(a) Use the Snap ring pliers (H4916090201) to
remove the snap ring.
(b) Carefully remove the snap ring, making sure
not to damage the inside surface of the S
bearing house or the seal (turbine side) of
the piston ring.
Place the bearing housing S on a workbench with

the compressor side facing up. Then, remove the
P
following parts.
Q
Snap ring (compressor side)
Snap ring 
R Bearing 
 (turbine side)
8-7
3.2 Inspection
Bearing housing
Measuring inside diameter of bearing-fitted
section
If the measured diameter exceeds the service limit,
replace the bearing housing.
Unit: mm [in.]
Service
Item Limit
Inside diameter of bearing-fitted
22.268 [0.87669]
section of housing
Bearing
(1) Measuring bearing outside diameter
If the measured diameter is less than the service limit,

replace the bearing.
Unit: mm [in.]
Service
Item Limit
Bearing outside diameter 22.144 [0.87181]
(2) Measuring bearing inside diameter
If the measured diameter exceeds the service limit,

Unit: mm [in.]
Service
Item Limit
Bearing inside diameter 13.542 [0.53315]
(3) Measuring bearing length
If the measured length is less than the service limit,

Unit: mm [in.]
Service
Item Limit
Bearing length 14.440 [0.56850]
8-8
Shaft & turbine wheel

(1) Measuring journal diameter of the shaft & turbine
wheel
If the measured diameter is less than the service limit,

replace the shaft & turbine wheel.
Unit: mm [in.]
Service
Item Limit
Shaft journal diameter 13.496 [0.53134]
(2) Measuring shaft deflection
(a) Set a dial gauge at a location next to the

threaded section of the shaft, and measure
shaft deflection.
–CAUTION
If the shaft is bent, replace. Do not attempt to
correct the bend.
If the deviation indicated by the dial gauge

exceeds the service limit, replace the shaft &
turbine wheel.
(b) If the surface of the shaft journal is rough,

mount the shaft on a lathe, and gently polish
the surface using #400 sandpaper and engine
oil while rotating at 300-600 min-1.
Unit: mm [in.]
Service
Item Limit
Shaft deflection 0.015 [0.00059]
Insert
Insert
Measuring piston ring end gap Ring end gap
Piston ring
Install a new piston ring squarely in the insert, then
measure the piston ring end gap.
If the end gap deviates from the assembly standard,
replace the insert.
Unit: mm [in.]
Assembly
Item Standard
0.05 to 0.15
Ring end gap
[0.00197 to 0.00590]
8-9
3.3 Reassembly
4 1 S P M N L
7 5 6 9 H
8 G I F
2 3 O Q J R K
Reassembly Sequence
S➔Q➔R➔P➔N
➔O➔I➔H➔9➔G➔F
M➔L ➔5➔4➔3➔K➔J➔1➔2
8➔7➔6
–CAUTION –CAUTION
(1) Replace the following parts once If vanes are damaged or cracked, do not reuse
7
disassembled. the part.
M
Piston ring If only one vane is slightly bent or scratched, the
9
Piston ring part can be reused. However, do not attempt to
O-ring correct the bend.
(b) After installing the overhauled turbocharger
on the engine, crank the engine with the
starter to send lubricating oil to the moving
parts in the turbocharger.
8-10
(1) Installing the shaft & turbine wheel and bearing

PQ R S
S
(a) Install the following parts.
R
Bearing housing

Q
Bearing
 (turbine side)
P
Snap ring 
Snap ring (compressor side)
–CAUTION
(a) Use the Snap ring pliers (H4916090201) to
install the snap ring. After installing the snap
ring, rotate the ring with a finger to make
sure it rotates smoothly.
(b) Apply engine oil to the outside and inside
surfaces of the bearing before installation.
S
2 N
(b) Place the bearing housing on the compressor
cover , and install the turbine backplate . Large space
M into the groove on the

L.
(c) Insert the piston ring Small space
shaft & turbine wheel
When installing the shaft & turbine wheel L

L
Ring end gap
(d)
housing S, position the ring on the shaft as

mounted with the piston ring in the bearing
N
shown in the drawing, and insert the shaft & S
turbine wheel while rotating.
8-11
–CAUTION
O
(a) Do not expand the piston ring excessively
or twist the ends when installing on the shaft
& turbine wheel.
S
(b) After installing the piston ring in the ring
groove, apply Moly Disulfide to the ring J
before assembly.
(c) The piston rings on the turbine side and
K
compressor side are identical.
(d) Do not apply excessive force without
centering the shaft properly during the
installation of the shaft & turbine wheel.
(e) After installing the shaft & turbine wheel , L

hold the shaft end and turn over the assembly
O
so the compressor side faces up.
Then, install the bearing on the compressor
side.
S K
After the assembly is completed, mount the
J
bearing housing on the turbine housing
and fasten the V-clamp temporarily.
(2) Installing the thrust bearing
I
H
Apply engine oil to both sides of the thrust ring
H
and thrust bearing .
To install the thrust bearing, align the notch to the
groove pin.
(3) Installing the O-ring
Apply grease to the O-ring 9, and install.
8-12
(4) Installing the oil deflector
G
F
Apply engine oil to both sides of the thrust ring ,
and install. Then, install the oil deflector with the
baffle facing down.
F
(5) Assembling the insert sub-assembly

6
6. 7
8
(a) Install the following parts to the insert
7
Flinger sleeve
8
6
Piston ring
Insert
–CAUTION
(a) Do not expand the piston ring excessively
or twist the ends when installing on the
flinger sleeve.
(b) Apply Moly Disulfide to the piston ring
installed on the flinger sleeve, then install
on the insert carefully so as to avoid piston
ring damage.
S
(b) After installing the above parts, install the sub-
assembly in the bearing housing .
8-13
(6) Installing the snap ring

S
5 S
With the tapered face facing up, install the snap ring
in the bearing housing using the Snap ring
pliers (H4916090101).
–CAUTION
(a) Be sure to install the snap ring in the correct
attitude.
(b) Lightly drive both ends of the snap ring using
a screwdriver and hammer to securely insert
the ring into the groove on the bearing
housing.
(c) Make sure the screwdriver does not hit the
bearing housing when driving the snap ring
with the screwdriver and hammer.
S 5
(7) Measuring clearance between the turbine wheel

and turbine housing
L
Set a dial gauge on the end face of the shaft & turbine
wheel . Read the dial gauge indication while
L
moving the shaft & turbine wheel in the axial
direction.
If the dial gauge indication deviates from the
assembly standard, disassemble and locate the cause
of the problem.
Unit: mm [in.]
Standard
Item Clearance
Clearance between turbine 0.29 to 0.93
wheel and turbine housing [0.01142 to 0.03661]
(8) Installing the compressor wheel
4 4
3
Install the compressor wheel . Apply Moly
Disulfide to the threads of the lock nut , and tighten Left-handed thread
the nut to the specified torque.
• Lock nut tightening method
Tighten nut to 9.8 N·m (1.0 kgf·m) [7.2 lbf·ft]
Cylindrical
section 3
and loosen it.
Retighten to 9.8 N·m (1.0 kgf·m) [7.2 lbf·ft]
Compressor
and turn to the angle 80° ± 3°. wheel side
8-14
(9) Measuring play of the shaft & turbine wheel in

the axial direction
L
L
Set a dial gauge on the end face of the shaft & turbine
wheel .
4
Measure the amount of play while moving the
compressor wheel in the axial direction.
If the measured amount of play deviates from the
4
standard value, disassemble and locate the cause of
the problem.
Unit: mm [in.]
Assembly
Item Standard
Play of shaft & turbine wheel 0.075 to 0.135
in axial direction [0.00295 to 0.00531]
(10) Measuring clearance between the turbine

backplate and the back side of the turbine wheel
S 2
Remove the turbine housing from the bearing housing
. Install the compressor cover , and conduct the
following measurement. S
8 2
Using feeler gauges, measure clearance between the
turbine backplate and the back side of the turbine
wheel.
–CAUTION
Be sure to use two feeler gauges, and take the
measurement at vane tips.
If the measured clearance deviates from the assembly

standard, disassemble and locate the cause of the
problem.
Unit: mm [in.]
Standard
Item Clearance
Clearance between turbine
0.6 to 1.2
backplate and back side of
[0.02362 to 0.04724]
turbine wheel
(11) Installing the turbine housing
K
(a) Check the mounting direction of the turbine
S
housing , then install on the bearing housing
J
.
J
(b) Apply Moly Disulfide to the threads of the V-
K
clamp , and tighten to the specified torque.
7.8 to 9.8 N·m
(0.8 to 1.0 kgf·m)
[5.8 to 7.2 lbf·ft]
8-15
2
(12) Installing the compressor cover
2
Check the mounting direction of the compressor
cover , then install.
(13) Installing the V-clamp or snap ring 7.8 to 9.8 N·m

(0.8 to 1.0 kgf·m)
[5.8 to 7.2 lbf·ft]
1
Apply Moly Disulfide to the threads of the V-clamp
, and tighten to the specified torque.
2
1
8-16
LUBRICATION SYSTEM
1. Description ................................................................................................................................. 9- 2
2. Oil Pump and Safety Valve ........................................................................................................ 9- 3
2.1 Disassembly ....................................................................................................................... 9- 3
2.2 Inspection ........................................................................................................................... 9- 4
2.3 Reassembly ........................................................................................................................ 9- 7
3. Oil Filter, Oil Filter Alarm, Relief Valve, Left Side Oil Cooler and Oil Thermostat ................ 9- 8
3.1 Disassembly ....................................................................................................................... 9- 8
3.2 Inspection ........................................................................................................................... 9- 9
3.3 Reassembly ........................................................................................................................ 9-12
4. Right Side Oil Cooler and Oil Thermostat ................................................................................ 9-13
4.1 Disassembly ....................................................................................................................... 9-13
4.2 Inspection ........................................................................................................................... 9-13
4.3 Reassembly ........................................................................................................................ 9-13
9
LUBRICATION SYSTEM
1. Description
Camshaft Piston
Main gallery
Rockershaft
Turbocharger
Piston cooling
nozzle
Relief valve
Timing gear
Oil cooler
Fuel injection
Water pump pump
Oil thermostat
Crankshaft
Safety valve
Oil pump
Filter bypass valve
Bypass oil filter Oil filter
Oil strainer
9-2
LUBRICATION SYSTEM
2. Oil Pump and Safety Valve
2.1 Disassembly
Fatigue, break, wear
Cracks, other damage
Worn, broken spline

3 4
Damage, wear
5 8
Replace packing Damage,
wear
7
6
6
Damage, wear
1 7
1
Cracks, other damage
1 Oil pump cover 4 Drive gear 7 Bushing

2 Safety valve assy. 5 Driven gear 8 Oil pump case
3 Bushing 6 Driven gear
9-3
LUBRICATION SYSTEM
2.2 Inspection
(1) Measuring drive gear and driven gear backlash
If the backlash exceeds the service limit, replace the

gears.
Unit: mm [in.]
Drive gear and
0.10 to 0.20 0.4
driven gear
[0.039 to 0.0079] [0.0157]
backlash
(2) Measuring drive gear and driven gear clearance
Use feeler gauges to measure the clearance. If the

clearance exceeds the service limit, replace the gears
or case, whichever is badly worn.
Unit: mm [in]
Drive gear Tip
0.100 to 0.148
and driven ø60 clearance:
[0.00394 to
gear [2.36] 0.35
0.00583]
clearance [0.0138] Measuring drive gear tip clearance
(3) Measuring pump gear end clearance
Use a dial gauge to measure the clearance. If the

clearance exceeds the service limit, replace the gears
or case, whichever is badly worn.
Unit: mm [in.]
Pump gear 0.040 to 0.116
72.5 0.21
end [0.00157 to
[2.854] [0.0083]
clearance 0.00457]
Measuring drive gear end clearance
NOTE
Remove the cover mounting packing (0.04 mm
[0.0016 in.] thick) when measuring.
9-4
LUBRICATION SYSTEM
(4) Measuring drive and driven gear shaft and

bushing diameters
(a) Check the gear teeth. Replace gears if they

are defective.
(b) Measure the gear shafts and bushings using a

dial gauge. If the diameter exceeds the service
limit, replace the parts.
Unit: mm [in.]
Drive 29.887 to 29.900
29.840
shaft [1.17665 to
[1.17480]
diameter 1.17717] A
Driven ø30 29.947 to 29.960
29.900
shaft [1.18] [1.17901 to
[1.17716]
diameter 1.17953]
Bushing 30.000 to 30.021
30.055
inside [1.18110 to
[1.18327] Pump case
diameter 1.18193] Pump cover
(5) Replacing oil pump bushings Oil pump bushing match mark positions
(a) Remove the oil pump bushing as needed. If

the oil pump busing insertion is too tight to
remove it, replace it with the case or cover Pump cover Pump case
assembly.
Drive gear
Drive gear
(b) When you install the pump cover bushing, position position
place the bushing joint positions as shown in
the right drawing. (Do not align with the
lubrication oil groove.)
Bushing joint positions
(c) Using the oil pump bushing installer A, insert

the bushing to the position shown in the right
drawing.
(d) After you press a new bushing into

Bushing Bushing
position, finish its inside diameter to
ø30H7 +0.021
0 mm [1.18+0.0008
0 in.] 0.8 Ra. 1 mm 1 mm
[0.04 in.] [0.04 in.]
deep deep
Installing oil pump bushing
9-5
LUBRICATION SYSTEM
(6) Inspecting the safety valve
(a) Check the valve spring of the oil pump safety

valve for fatigue. If excessive fatigue, wear
or break is found, replace the valve spring.
Shims
(b) Measure the valve opening pressure. If the
pressure is higher or lower than the assembly
standard, increase or decrease the thickness of
shim inserted between the spring and spring
cap nut. For the thickness of a shim, 1 mm
[0.04 in.] corresponds to a change in pressure
of 0.10 MPa (1 kgf/cm2) [14.2 psi].
Assembly Service
Item Standard Limit
1.27±0.13 MPa
Safety valve
(13±1.3 kgf/cm2)
opening pressure
[185±18.5 psi]
Safety valve
65.8 [2.59]/ 65.8 [2.59]/
spring set length
359 (36.6) 314 (32)
/set force
[80.7] [70.5]
mm [in.]/N (kgf) [lbf]
9-6
LUBRICATION SYSTEM
2.3 Reassembly
8
33 N·m (3.4 kgf·m)
3 [25 lbf·ft] 4 7 88±10 N·m (9±1 kgf·m) 2
[65±7 lbf·ft]
5
74±10 N·m
6 (7.5±1kgf·m)
[54±7 lbf·ft]
Apply Three Bond No. 1215

to both cover and case
Reassembly Sequence
1➔3
8➔7➔4➔5➔6➔2
➔
NOTE
During reassembly, apply Moly Disulfide to all
sliding surfaces. When installing valve
assemblies, apply engine oil to O-rings.
9-7
LUBRICATION SYSTEM
3. Oil Filter, Oil Filter Alarm, Relief Valve, Left Side Oil Cooler and Oil Thermostat
3.1 Disassembly
7
Holes clogging, cracks
Replace packing
3
Replace
O-rings
6
4
Replace O-rings
4 1
5 1 8
H
Replace every 250
hours
Fatigue, break, wear
G G
of spring
2 F Deterioration,
wear, cracks
9
Wear, cracks
Replace every 250 hours
1 Full flow oil filter element 5 Adaptor A assy. 9 Connector

2 Bypass oil filter element 6 Adaptor B assy. F Oil thermostat
3 Oil filter alarm 7 Air cooler element G Thermostat seal
4 Filter bracket assy. 8 Relief valve assy. H Bracket
9-8
LUBRICATION SYSTEM
3.2 Inspection
(1) Inspecting the oil filter
When you replace the paper element, sample about

500 cm3 [30.5 in3.] of oil and check for metal particles.
If any metal particles are found, unfold the pleats of
element and check the color and shape of the particles
trapped in the pleats to identify the cause.
(2) Inspecting the oil filter alarm
(a) Use a tester to check the alarm for insulation

and continuity. If the alarm is found defective,
disassemble and repair it. Replace the alarm
if the bakelite or rubber insulators are
deteriorated or damaged.
(b) If the alarm pressure is not within the Shim

assembly standard, adjust it by inserting
shims. For the thickness of a shim, 1 mm
[0.04 in.] corresponds to a change in pressure
of 6.86 kPa (0.07 kgf/cm2) [1.00 psi].

Pressure difference 0.15 + 00.03
+ 0.3
across oil filter alarm (1.5 0 )
that makes its valve open [21.3+ 04.27 ]
9-9
LUBRICATION SYSTEM
(3) Measuring relief valve pressure
(a) Remove the taper plug (PT 1/8) on the upper

side of the filter bracket, and attach a pressure
gauge.
(b) Warm up the engine until the oil temperature

rises to 70-90 °C [158-194 °F].
(c) Measure oil pressure at idling speed and

maximum speed.
(d) If the measured oil pressure is lower than the

specified value, adjust the valve opening
pressure by inserting shims. For shim
thickness, 5 mm [0.2 in.] corresponds to a
change in pressure of approximately
0.1 MPa (1 kgf/cm2) [14 psi].
Shims
0.49 to 0.64
Set pressure (max. speed) (5 to 6.5)
[71.12 to 92.46]
0.5 ± 0.02
Relief valve opening
(5 ± 0.2)
pressure
[71.1 ± 2.84]
NOTE
The measured oil pressure might be above the
set pressure when oil temperature is low, but it
returns to the set pressure when oil temperature
rises.
(e) If adjustment with shims is not effective,

replace the relief valve and spring.
(4) Inspecting the left side oil cooler
Test the oil path with compressed air of 1.47 MPa

(15 kgf/cm2) [213 psi] for damage or cracks in the
element. If there is any leakage, replace the element.
9-10
LUBRICATION SYSTEM
(5) Inspection the left side thermostat
(a) Inspect the oil thermostat seal for deterioration Installing direction
and cracks. If any are found, replace the seal.
(b) Refer to the drawing on the right that shows

the correct direction for seal installation.
Thermostat
Installing seal for thermostat
(c) Operation testing
Immerse the thermostat in engine oil, then measure

the temperature where the valve opens, then measure
it again when the valve lift is 11 mm [0.43 in.].
Replace the thermostat if temperatures are not within
standard.

Temperature for valve 80 to 84 °C
opening [176 to 183.2 °F]
Temperature for 11 mm 95 °C
[0.43 in.] valve lift [203 °F]
–CAUTION
(a) Stir the oil to maintain even temperatures
during the test.
(b) At reassembly, confirm the valve opening
temperature stamped on its mounting flange.
9-11
LUBRICATION SYSTEM
3.3 Reassembly
(1) Replace packing and O-rings for reassembly.
(2) Before reassembly, clean the oil paths of the oil

filter bracket, etc. by flushing them with oil and
blowing them with air.
(3) Install the oil filter element with its bracket.
9-12
LUBRICATION SYSTEM
4. Right Side Oil Cooler and Oil Thermostat
4.1 Disassembly
Holes clogged,
cracking 4 Deterioration, wear, cracks
5
2
Wear, cracks
3 1
Replace packing
1 4
2 5
Connector Oil cooler element
3
Oil thermostat Thermostat
Oil cooler
4.2 Inspection
Follow the same inspection procedure as that for the

left side oil cooler and oil thermostat. If any
deterioration is found, replace them.
4.3 Reassembly
(1) Replace packing and O-rings for reassembly.
(2) Before reassembly, clean the oil paths of the oil

cooler cover, etc. by flushing them with oil then
blowing them with compressed air.
9-13
LUBRICATION SYSTEM
9-14
COOLING SYSTEM
1. Cooling System with a Radiator ................................................................................................ 10- 2

2. Water Pump ............................................................................................................................... 10- 3
2.1 Disassembly ....................................................................................................................... 10- 3
2.2 Inspection ........................................................................................................................... 10- 6
2.3 Reassembly ........................................................................................................................ 10- 7
3. Thermostats ............................................................................................................................... 10- 10
3.1 Disassembly ....................................................................................................................... 10- 10
3.2 Inspection ........................................................................................................................... 10- 10
10
COOLING SYSTEM
1. Cooling System with a Radiator
Water pump
Water jacket
Oil cooler
Radiator
Water
outlet
(rocker
Thermostat cases)
Water
outlet
(rocker
cases)
Bypass pipe Oil cooler Water jacket
10-2
COOLING SYSTEM
2. Water Pump
2.1 Disassembly
9 G
F
Wear, deterioration
8 of lip
Rotation
7
6
2 1
3
4
H 5
Corrosion, chafing
Crack, damage
Wear, damage
1 Snap ring 6 Oil seal sleeve G Oil seal

2 Cover 7 Bearing H Pump case
3 Water pump impeller 8 Water pump gear
4 Ring 9 Bearing
5 Unit seal F Water pump shaft
10-3
COOLING SYSTEM
(1) Inspecting the wear pump on the engine
Touch the drain port located at the bottom of the pump

with your finger. If the port is leaking water, check
the condition of the unit seal. If it is leaking oil, the
oil seal is defective.
(2) Removing the impeller

A
(a) Remove the snap ring the Water pump pliers
A (H3759103100), then remove the cover.
Cover
Snap ring
(b) Remove the impeller with the Impeller Impeller

remover B (H3759103200).
B
Shaft
Removing the impeller
10-4
COOLING SYSTEM
(3) Removing the water pump shaft
(a) Remove the oil seal sleeve.
(b) Remove the gear, and the bearing with the

gear puller.
(c) Remove the snap ring of the impeller side ball

bearing.
Removing the gear
(d) Inset the two half rings C of the Ring remover

Press
(H3779103400) between the unit seal and the
pump case as shown in the drawing.
(e) Fit the outer ring D to the outside of the half C

C
rings to prevent them from falling down. D
(f) Support the pump case and push out the end
face the shaft impeller side by pushing with a
hand press in the direction of the arrow mark
as shown in the drawing.
10-5
COOLING SYSTEM
2.2 Inspection
Water pump
Measure the inside diameter of the pump case bore

to which the bearing outer race is fitted. Measure the
diameter of the pump shaft on which the bearing inner
race is fitted. If the bearing, case, or shaft is worn,
replace it.
Unit: mm [in.]
Item Nominal Value Assembly Standard
Inside diameter of pump case ø120 119.987 to 120.022
bearing [4.72] [4.72389 to 4.72527]
Inside diameter of cover to which ø110 110.005 to 110.040
the bearing outer race is fitted [4.33] [4.33090 to 4.33227]
Bearing Diameter ø120 119.985 to 120.000
[4.72] [4.72381 to 4.72441]
ø110 109.985 to 110.000
[4.33] [4.33012 to 4.33071]
Inside diameter ø55 54.985 to 55.000
[2.17] [2.16476 to 2.16535]
ø50 49.988 to 50.000
[1.97] [1.96803 to 1.96850]
Diameter of pump shaft on which ø55 55.011 to 55.024
bearing inner race is fitted [2.17] [2.16578 to 2.16629]
ø50 50.011 to 50.024
[1.97] [1.96893 to 1.96944]
10-6
COOLING SYSTEM
2.3 Reassembly
H
1 7
6
2
392 N·m
40 kgf·m
[289 lbf·ft]
3
F
4 5 G 9 8
Coat with sealant (Three Coat oil seal lip with Coat floating parts with
bond 1102) to unit seal engine oil anti-freeze LLC (2 locations)
outer cylinder before installing unit seal
floating seal to ring
Reassembly Sequence
H➔G➔5
➔ ➔7➔6➔4➔3➔2➔1
F➔9 8
–CAUTION
Replace all O-rings, unit seal and oil seals for
reassembly.
10-7
COOLING SYSTEM
(1) With the Oil seal installer, drive in the oil seal.
Apply engine oil to the oil seal lip.
Apply engine oil
(2) Use the Unit seal installer A (H3719106300) to Apply sealant

drive in the unit seal.
Replace the unit seal once disturbed.
A
NOTE
Install the unit seal after coating with sealant
(Three-Bond 1102) to seal the outer ring.
(3) Use a press to press in the impeller-side pump

shaft, complete with ball bearings into the case.
Install the snap ring with its gap down.
(4) With a press, press in the unit seal ring with the
Floating seat
unit seal floating seat using the Ring installer Shaft
(H3779103300).
NOTE
Before installation, coat with LLC solution (anti-
freeze) to the floating seat at two locations.
80±0.15 mm
[3.15±0.0059 in.]
Unit sealing ring
10-8
COOLING SYSTEM
(5) Insert the gear into the shaft by aligning the key.
Press in the ball bearing on the nut side.
(6) Press in the impeller to the depth where impeller’s

Flat
boss end face is flush with the shaft end.
Shaft
Impeller
(7) Mount the cover on the impeller side, and secure

it in place with the snap ring.
(8) After installing the water pump assembly, install

the alternator pulley and tighten the nut to the
specified torque.
392 N·m
(40 kgf·m)
[289 lbf·ft]
10-9
COOLING SYSTEM
3. Thermostats
3.1 Disassembly
1
2 Deteriorated, worn,
3 cracked
4
5
6
Replace packing
Worn, cracked
1 Thermostat cover 3 Snap ring 5 Thermostat seal

2 Packing 4 Thermostat 6 Thermostat case
3.2 Inspection
Immerse the thermostat in water, then measure the

temperature where the valve opens, then measure it
again when the valve lift is 11 mm [0.43 in.]. Replace
the thermostat if temperatures are not within standard.

71 ± 2 °C
Temperature for opening
[159.8 ± 3.6 °F]
Temperature for 11 mm
85 °C [185 °F]
[0.43 in.] valve lift
–CAUTION
(a) Stir the hot water to maintain even
temperatures during the test.
(b) At reassembly, confirm the valve opening
temperature stamped on its mounting flange.
10-10
FUEL SYSTEM
1. Description ................................................................................................................................. 11- 2

2. Fuel Filters ................................................................................................................................. 11- 2
2.1 Disassembly and Inspection .............................................................................................. 11- 2
2.2 Reassembly ........................................................................................................................ 11- 3
3. Fuel Injection Nozzles ............................................................................................................... 11- 4
3.1 Disassembly ....................................................................................................................... 11- 4
3.2 Inspection and Adjustment ................................................................................................ 11- 5
3.3 Reassembly ........................................................................................................................ 11- 7
4. Injection Pump ........................................................................................................................... 11- 8
4.1 Disassembly ....................................................................................................................... 11- 8
4.2 Inspection ........................................................................................................................... 11- 12
4.3 Reassembly ........................................................................................................................ 11- 16
4.4 Adjustment ......................................................................................................................... 11- 23
5. Feed Pump ................................................................................................................................. 11- 25
5.2 Reassembly ........................................................................................................................ 11- 26
5.3 Testing ................................................................................................................................ 11- 26
6. Water Separator ......................................................................................................................... 11- 28
6.2 Reassembly ........................................................................................................................ 11- 28
11
FUEL SYSTEM
1. Description
Leak-off pipe
Injection nozzle
Injection pipe Injection pump
Feed pump
To fuel
<
<
From fuel tank tank
From engine right side

Fuel filter
To engine right side
2. Fuel Filters
2.1 Disassembly and Inspection
2
Cracks, damaged threads
Change every 1,000

1 hours
1 Element 2 Fuel filter bracket
11-2
FUEL SYSTEM
2.2 Reassembly
Air vent plug

7.8 to 9.8 N·m
(0.8 to 1.0 kgf·m)
[5.8 to 7.2 lbf·ft]
2 Apply fuel oil
Reassembly Sequence
2 ➔1
To install the cartridge, clean the mounting surface and apply fuel oil to the gasket. After bringing the gasket
into contact with the sealing surface of the bracket, tighten the cartridge with your hand about one-half to three
quarters of a full turn.
–CAUTION
After installing the fuel filter on the engine, start the engine, then confirm that the fuel is not leaking.
11-3
FUEL SYSTEM
3. Fuel Injection Nozzles
3.1 Disassembly
9
F
8 1
7 Fatigue, damage
2
6 Wear, damage
5
Carbon deposits,
4 clogged spray hole,
sticking needle valve
3
1 Cap nut, gasket 5 Nozzle tip 8 O-ring
2 Adjusting screw 6 Spacer 9 Nozzle holder
3 O-ring 7 Pushrod, nozzle spring, F Fuel inlet connector
4 Retaining nut spring seat
11-4
FUEL SYSTEM
3.2 Inspection and Adjustment
(1) Injection pressure A
(a) Install the nozzle on the Tester A (H41091

01500). Operate the handle of the tester at a
rate of about 1 stroke per second to observe
the pressure at which fuel is being injected.
If the pressure is out of standard, adjust the
pressure of the nozzle.
34.32 to 34.81
Injection pressue
(350 to 355)
(Valve opening pressure)
[4979 to 5050]
–CAUTION
During injection testing, never attempt to touch
the spray hole of the injection nozzle.
(b) To adjust the injection pressure, remove the

69 to 78 N·m
1 2
set screw from the nozzle holder, loosen the
(7 to 8 kgf·m)
cap nut , then turn the adjusting screw
1
[51 to 58 lbf·ft]
in either direction with a screwdriver.
Decrease Increase
injection injection
(c) After completing the adjustment, tighten the pressure pressure
set screw and the cap nut to the specified
torque. 2
(d) Re-check the injection pressure to be sure that
it is correct.
(2) Spray pattern
(a) When you are testing the injection pressure,

inspect each nozzle for clogged spray holes
and fuel leaks from the holes.
Also examine the spray pattern. If the nozzle
is faulty, wash or replace the nozzle tip. Good Large After Inter- Whirling
spray angle dribble mittent spray
(b) When tested on the nozzle tester, the nozzle spray spray
should spray fuel from its ten holes at the same
time in a straight cone of 160 degrees. The
spray should consist of finely atomized fuel Spray patterns
particles without any large droplets. The spray
should terminate with no dripping at the top.
11-5
FUEL SYSTEM
(3) Washing or replacing the nozzle tip
(a) The nozzle tip is spring loaded. Remove the

set screw and with a screwdriver, loosen the
adjusting screw until it can be loosened by
hand.
1
(b) Loosen the retaining nut , remove the
nozzle tip and wash the needle valve and body.
A
–CAUTION
When pulling out the nozzle tip, do not damage
1
the tip A.
(c) Wash the nozzle tip in clean diesel fuel oil.

After washing, assemble the needle valve and
body in clean diesel fuel.
NOTE
Needle
The needle valve and body are finely finished. valve
Body
Do not swap the combination of the valve and
body.
(d) Tighten the retaining nut to the specified

torque.
(e) If the spray pattern is still bad after the nozzle

has been adjusted and cleaned, replace the
nozzle tip.
NOTE
New nozzle tips are coated with vaseline to
preserve them. Wash them in diesel fuel before
you inslall them.
11-6
FUEL SYSTEM
3.3 Reassembly
34 to 44 N·m
(3.5 to 4.5 kgf·m)
[25 to 33 lbf·ft]
69 to 78 N·m 1
(7 to 8 kgf·m)
[51 to 58 lbf·ft]
2
64 to 74 N·m
(6.5 to 7.5 kgf·m)
[47 to 54 lbf·ft]
8
9
F 8
7
6
3
177 to 196 N·m
4
(18 to 20 kgf·m)
[130 to 145 lbf·ft]
5
Reassembly Sequence
9➔3➔8➔7➔6➔5➔4➔F➔2➔1
–CAUTION
4
Tighten the retaining nut to the specified torque. Excessive torque on the retaining nut will cause sticky
movement of the needle and will result in eshaust smoke or the needle stick.
11-7
FUEL SYSTEM
4. Injection Pump
4.1 Disassembly
5 Fatigue
67 Wear of teeth, cracks, wear 2
Damage and
cracks on bushing
Seat contacting
F 8
of sliding surface contacting surface
surface
Z X 3
H G W
Contact Fatigue
surface
GY V
Ridges caused be abrasion, cracks
Wear, scratches
U T Damage
S
Cracks
Wear, scratches, L 9
discoloration,
corrosion, erosion J
Wear
K\ R
Wear of teeth I
Rotating condition
SR series
1 4
O [ P
Q M
N Scratches, wear
Rotating condition
1 Drain plug H Barrel shim S Shim

2 Coupling I Bellows T Lower spring seat
3 Flywheel J Set screw U Plunger
4 Feed pump K Rack V Plunger spring
5 Valve holder L Tappet W Upper spring seat
6 Stopper M Bolt X Pinion
7 Delivery valve spring N Front cover, bearing outer race Y O-ring
8 Delivery valve assembly O Camshaft Z Barrel
9 Deflector bolt P Center bearing [ Pump case
F Barrel bolt, washer Q Bearing inner race \ Rack bushing
G Plunger assembly R Rear cover, oil seal, bearing outer race
11-8
FUEL SYSTEM
(1) Preparing for disassembly

(a) Clean the outer surface of the injection pump,
and mount the pump on the Pump assembly
stand (H4829100100).
(b) Remove the drain plug from the bottom of

the pump and drain oil from the case.
(c) Remove the coupling, flywheel and feed

pump.
(2) Removing delivery valves
Remove delivery valve holders. Remove the stopper,

delivery valve spring, delivery valve and valve seat
from each valve holder.
–CAUTION
Place each pair of delivery valve and valve seat
in clean diesel fuel. Do not swap the original
combinations of delivery valves and valve seats.
(3) Removing plunger assemblies

Deflector bolt
(a) Position the cam at the bottom dead center in
the cylinder from which the plunger assembly
is removed.
(b) Remove the deflector bolt located on the back

side of the pump case.
–CAUTION
Be sure to remove the deflector before removing
the plunger assembly. If the plunger assembly is
removed without removing the deflector bolt
first, damage results in the deflector bolt and
plunger assembly.
(c) Screw the Plunger spring retaining jig

(H4829100301) in the threaded hole on the
upper end of the plunger.
(d) Loosen two barrel bolts alternately, and lift

the plunger assembly and remove.
11-9
FUEL SYSTEM
(4) Removing the rack
(a) Dislodge the bellows from the grooves of the

rack and rack bushing installed in the pump
case, and remove the bellows.
(b) Remove the set screw from the back side of

the pump case, and pull out the rack.
(5) Removing tappets
Hook a wire to two small holes (4-mm (0.16 in.) dia.)

on the upper side of the tappet, and pull out the tappet.
(6) Removing the camshaft
Remove two center bearing mounting bolts. Remove

four front cover mounting bolts, and dismount the
front cover. Tap the camshaft end on the drive side
with a soft-head mallet to remove the camshaft and
front cover.
(7) Removing the rear cover
Remove the rear cover mounting bolts. Insert the tips

of screwdrivers into the notch located on the side of
the rear cover, and pry out. Remove the shim.
11-10
FUEL SYSTEM
(8) Disassembling plunger assemblies
(a) Compress the plunger assembly using the

Plunger spring compression jig (H48291
00200), then remove the plunger spring
compression jig.
(b) Remove the lower spring seat, plunger and

plunger spring from the barrel.
–CAUTION
(a) Handle plungers carefully to prevent damage
and scratches.
(b) Place the removed plungers in a tray with
clean diesel fuel in it, making sure to arrange
them in order to ensure correct reassembly.
(c) Do not swap the original combinations of
plungers and barrels.
11-11
FUEL SYSTEM
4.2 Inspection
15°
After disassembly, wash each part with clean diesel
oil. Replace defective or damaged parts.
(1) Plungers and barrels
(a) Inspect the lead section and tip of each plunger

for wear, scratches, discoloration, and erosion.
(b) After washing with clean diesel fuel, check
each plunger by tilting approximately 15° and
lifting it approximately 30 to 35 mm [1.18 to Inspecting plunger for smooth movement
1.38 in.], as shown in the diagram. The plunger
must fall smoothly on its own weight. Change
the plunger position by turning it slightly and
check again. Repeat this test two or three times
for each plunger.
(c) If the plunger falls too quickly or sticks before

it reaches the bottom, replace the plunger and
barrel as a set.
(2) Delivery valves
(a) In each delivery valve, inspect the valve seat

and sliding surfaces for scratches and check
contacting surface to the barrel.
(b) Wash parts with clean diesel oil. Lift the valve
and let it fall, making sure that it slides down
smoothly to the valve seat.
(c) If the valve sticks, replace the delivery valve Inspecting delivery valve for smooth movement
and valve seat as a set.
(3) Tappets
(a) Check each tappet roller, roller bearing and

tappet pin for flaking, local wear and scratches.
(b) Check overall clearance of tappet, taper roller,

roller bearing and tappet pin. If the mea-
surement exceeds the service limit, replace
with a new assembly.
Unit: mm [in.]
Service
Item Limit Measuring overall clearance of tappet
Overall clearance of tappet roller 0.2 [0.00787]
(c) Inspect the plunger contact surface of each tappet.
If the amount of wear exceeds the service limit,

replace with a new assembly.
Unit: mm [in.]
Service
Item Limit
Wear of plunger contacting
0.2 [0.00787]
surface of tappet.
Inspecting wear of tappet
11-12
FUEL SYSTEM
(4) Camshaft
(a) Check the key and key groove for excessive

play. Also check the tapered section for
Oil seal contacting surface
scratches, and the cam surfaces for flaking,
local wear and scratches. If damage is found,
replace the camshaft.
Key groove
(b) Check the oil seal contacting surface for wear.
If the amount of wear exceeds the service
limit, replace with a new part.
Unit: mm [in.] Inspecting camshaft outer surfaces
Assembly Service
Item Standard Limit
34.963 to
Outside diameter of
34.938 34.800
camshaft at oil seal
[1.37649 to [1.37001]
contacting section
1.37551]
[Installation of oversized sleeve]

● Cautions in installation Apply engine oil
Flange Section to
• Clean the seal contacting surface, and remove section Tapered section
be cut off
burrs from the camshaft before inserting an of camshaft
oversized sleeve.
• If the camshaft has deep grooves due to abrasion,
fill the grooves with metal-powder-containing
epoxy filler (ThreeBond 2084B main agent +
hardening agent, or equivalent), and insert the
oversized sleeve before the filler hardens. Cross-sectional diagram of oversized sleeve
• Install the oversized sleeve so that it covers the
grooves, and make sure it does not extend to the
tapered section.
• Apply engine oil to the end section of the
oversized sleeve when installing the oil seal. Sleeve installer
● Procedure for inserting oversized sleeve on
camshaft
1. Hold the camshaft with a vice.
2. Apply ThreeBond No. 1215 to the
oversized sleeve installation surface on Oversized sleeve
the camshaft, and insert the oversized
sleeve, with the flange section facing the
camshaft, onto the camshaft. Driving jig and oversized sleeve
3. Using the sleeve installer (special tool)
and a drive tool, strike the oversized
sleeve with a soft hammer.
Name of special tool Part No.

Sleeve installer H4820209301
NOTE
Use a wooden hammer or soft hammer to strike
the drive tool.
Driving oversized sleeve

11-13
FUEL SYSTEM
4. After the installation, remove the flange

section of the oversized sleeve at the cut
line on the flange section.
Removing flange from oversized sleeve
(c) Support the camshaft with V blocks, and

measure runout at the center bearing section
using a dial gauge. If the amount of runout
exceeds the repair limit, correct with a press
or replace with a new part.
Unit: mm (in.)
Assembly Repair
Item Standard Limit
0.05 0.15
Camshaft deflection
[0.00197] [0.00591]
(5) Bearing Measuring camshaft deflection
Check the bearing for flaking, abnormal abrasion and

noise. If damage is found, replace with a new part.
(6) Plunger springs and delivery valve springs
(a) Check the surface of each spring for scratches

and rust.
Perpendicularity (gap)
(b) Using a square, measure the perpendicularity
(gap) at the upper end of the spring.
If the measurement exceeds the service limit,
replace the spring. Free length
Measuring spring inclination and free length
11-14
FUEL SYSTEM
Plunger spring Unit: mm [in.]

Assembly Service
Item Standard Limit
Free length 70.8 [2.787]
▲ = 1.8
Perpendicularity
[0.071]
Set length/set load 60.0 [2.36]/299 to 366

(mm [in.] /N (kgf) [30.5 to 37.3]
[lbf]) [67.2 to 82.2]
Delivery valve spring Unit: mm [in.]

Assembly Service
Item Standard Limit
Free length 18 [0.71]
▲ = 0.6
Perpendicularity
[0.024]
Set length/set load 14.15 [0.56]/51.6 to 61.4

(mm [in.] /N (kgf) (5.26 to 6.26)
[lbf]) [11.60 to 13.80]
(7) Valve holders
(a) Check the contacting surfaces of injection

pipe and delivery valve on each valve holder
for scratches.
(b) If the contact surfaces are scratched, replace

the valve holder since surface scratches can
cause fuel leakage.
(8) Pump case
Check the pump case for surface scratches, dents,

cracks and damage. If critical flaws are found, replace
with a new part.
(9) O-rings, gaskets and bellow
Replace O-rings, gaskets and below with new ones

once disturbed.
11-15
FUEL SYSTEM
4.3 Reassembly
F
5
Z 67 9
H 8 I
YX
K
G WV
U J
T
L
[ N
M P 1 4 O QSR 3 2
Reassembly Sequence
[➔N➔O➔P➔Q➔M➔S➔R➔L➔K➔J➔G➔H➔F➔9➔8➔7➔6➔5➔I➔4➔3➔2➔1
Z➔Y➔X➔W➔V➔U➔T
11-16
FUEL SYSTEM
(1) Assembling the bearing and front cover
(a) Install the oil seal, O-ring and bearing outer

race on the front cover.
(b) Install the front cover on the pump case by

striking with a hammer.
(c) Tighten the front cover mounting bolts.
(2) Assembling the center bearing on the camshaft
(a) Install the bearing inner race on the camshaft

by striking with a hammer.
(b) Lay the pump case on its side.
(c) Place the center bearing on the camshaft, and

insert the shaft into the pump case.
(d) Slowly rotate the camshaft and align the bolt

hole in the center bearing with the bolt hole
in the pump case, then tighten the mounting
bolt.
11-17
FUEL SYSTEM
(3) Assembling the rear cover
(a) Install the bearing outer race on the rear cover.
(b) Install the O-ring and shim on the rear cover,

and install the rear cover on the pump case.
(4) Measuring thrust clearance of the camshaft
(a) Set a dial gauge on the end surface of the

camshaft, and measure end play using the
Cam thrust ejector A (H4829100400).
Unit: mm [in.]
Assembly
Item Standard
A
Camshaft thrust end play 0.02 to 0.06
[0.00079 to 0.00236]
(b) If the measured clearance deviates from the

assembly standard, increase or decrease the
shim thickness to make adjustment.
(c) Turn the camshaft to make sure if it rotates

smoothly. Shims
Part No. Thickness (mm [in.])
H4820214100 0.5 [0.020]
H4820214200 0.1 [0.0039]
H4820214300 0.15 [0.0059]
H4820214400 0.3 [0.0118]
(5) Assembling tappets
(a) Install the tappet roller, roller bearing and

tappet pin in each tappet.
(b) Apply lubricating oil to each part.
(c) After assembly, make sure the roller rotates

smoothly without squeeze.
11-18
FUEL SYSTEM
(d) Install tappets in the pump case by positioning

each tappet so the falt faces of the tappet
engages securely with the stopper pin.
(6) Assembling plunger assemblies
–CAUTION C
(a) Wash each part with clean diesel fuel before B
assembly. A
(b) Use new O-rings.
(c) Apply grease to the O-rings to prevent
damage during assembly. Install the O-rings
in the sequence of A, B and C.
(a) Install three O-rings on each barrel.
(b) Install the pinion and upper spring seat on

each barrel by tapping with a hammer. Make
sure the pin inserted in the barrel is positioned
at the notch of the upper spring seat. Alignment mark
(punched dot)
(c) On the Plunger spring compressing jig

(H4829100200), place the assembly
consisting of barrel, pinion and upper spring
seat, then install the plunger spring, plunger
and lower spring seat.
11-19
FUEL SYSTEM
(d) Align the flange section of the plunger

properly with the plunger seating section of
the pinion using a screwdriver.
(e) Press down the handle of the spring

compression jig to insert the plunger into the
plunger seating section of the pinion, then
screw the Plunger spring retaining jig
(H48291-00310) into the upper end of the
plunger.
(7) Installing the rack
(a) Insert the rack in the pump case, making sure

the “F” mark on the end surface of the rack is
on the counter-drive end, then install the set
screw.
(b) Install the Rack setting jig (H4829100600) in

the threaded hole at the tip of the counter-drive
side of the rack. In this step, visually check
and make sure the wide tooth (three times
wider than other teeth, provided for correct
meshing with the pinion) on the rack is
positioned at the center of the pump case
cylinder.
Wide tooth section
on rack
11-20
FUEL SYSTEM
(8) Installing plunger assemblies
(a) Position the cam at the bottom dead center in

the cylinder to which the plunger assembly is
installed.
(b) Place the Stopper plate (H4829100500) on top

of the pump case to prevent damage to the
pinion and rack during the installation of the
plunger assembly.
NOTE
If the stopper plate is not used during plunger
assembly installation, the teeth on the pinion hit
the teeth on the rack, causing rough edges that
hinder smooth rack movement.
(c) Hold the flange of the barrel with both hands

and press down the plunger assembly until
the bottom side of the flange contacts the
stopper plate.
(d) Remove the stopper plate, and lower the

plunger assembly by serching the correct
meshing slowly. Do not apply excessive force
to press down the plunger assembly. If the
plunger assembly is jammed, turn the flange
by jiggling back and forth, then press down.
(e) Insert standard barrel shims (thickness: 1.0

mm [0.04 in.] ) under each barrel flange, and
align the reference mark on the barrel flange
with the alignment mark (1.5-mm [0.06 in.]- Reference mark
diameter hole) on the pump case.
Barrel shim
–CAUTION Alignment mark

In each cylinder, insert barrel shims of the same
thickness, one in front and one in back. (Do not
use two or more shims at one location.) If the
shim thickness varies in the front and back of a
cylinder, the rack may not move smoothly,
causing hunting and other problems.
(f) Install washers on the barrel bolts, and screw

the bolts snug. Then, using a torque wrench,
tighten the bolts progressively and evenly to
the specified torque.
11-21
FUEL SYSTEM
(g) Remove the Plunger spring retaining jig

(H4829100301) and the Rack setting jig
(H4829100600). Check to make sure the rack
Total stroke 36 mm
slides and strokes smoothly.
[1.42 in.]
–CAUTION
Move the rack after installing each plunger
assembly to make sure it moves smoothly (sliding
resistance: 4.9 N (0.5 kgf) [1.10 lbf] or less). At
the same time, check to make sure the total rack
stroke is 36 mm [1.42 in.].
(9) Measuring rack sliding resistance
(a) After the pump assembly is completed, attach

a spring balancer to the rack and make sure
the rack moves smoothly over the entire
stroke.
Unit: N (kgf) [lbf]
Assembly
Item Standard
Rack sliding resistance 4.9 (0.5) [1.10] or less
(b) After making sure the rack sliding resistance

is lower than the standard value, install the
deflector bolts on the pump case and tighten.
(10) Assembling delivery valves
(a) In each barrel, install delivery valve, valve

spring, stopper and valve holder in that order.
(b) Apply grease to a new O-ring to prevent O-

ring from damage, then install the O-ring on
each valve holder.
(c) Using a torque wrench, tighten the valve

holders to 235 to 255 N·m (24 to 26 kgf·m)
[174 to 188 lbf·ft].
(11) Installing the bellows
Insert the protrusions on the bellows into the grooves

on the rack and rack bushing and install the bellows.
11-22
FUEL SYSTEM
4.4 Adjustment
After the pump assembly is completed, place it on

an injection pump tester, and make the following
adjustments.
Adjustment of Injection Timing
(1) Adjusting the prestroke
(a) Remove the deflector bolt from the back side

of the pump case.
(b) Remove the valve holder from cylinder No. 1

(counter-drive side), then remove the stopper,
valve spring and delivery valve.
(c) Set the measuring tip of a dial depth gauge

on the head of the plunger. Rotate the camshaft
by hand to bring the plunger to the bottom
dead center by reading the indication on the
depth gauge. Set the depth gauge indicator to
“0.”
(d) Turn the camshaft in the normal operating

direction until the dial depth gauge indicates
5 mm [0.2 in.].
(e) With the camshaft in this position, check to

make sure the pointer located on the pump
case end surface aligns with the stamped line Point
on the flywheel. If they are not aligned, stamp
a new line on the flywheel at the pointer
position. Stamped line
on flywheel
(f) Point a flashlight from the top of the pump

Suction hole Flashlight
case, and look through the deflector bolt hole
and check the position of the upper end of the
plunger.
Plunger
11-23
FUEL SYSTEM
(g) Rotate the camshaft until the upper end of the

plunger closes the barrel suction hole. With
the camshaft in this position, the pointer
should align with the stamped line on the
flywheel. If not, change the shims so the
pointer aligns with the line.
Increase of shim thickness → Retards
injection timing
Decrease of shim thickness → Advances
injection timing–
CAUTION
Use one shim of the same thickness in each side
of a cylinder. Do not use two or more shims to
adjust the thickness.
(2) Adjusting injection intervals

Barrel shims
(a) For cylinder No. 2 and subsequent cylinders, Part No. Thickness (mm [in.])
use the injection start timing of cylinder No.
1 as the reference point and check the injection H4820204500 0.8 ± 0.02 [0.031 ± 0.00079]
start intervals on the angle scale on the pump H4820204600 0.9 ± 0.02 [0.035 ± 0.00079]
tester according to the injection sequence. H4820204700 1.0 ± 0.02 [0.039 ± 0.00079]
H4820204800 1.1 ± 0.02 [0.043 ± 0.00079]
(b) If the injection intervals deviate from the
specification, make adjustment by adjusting H4820204900 1.2 ± 0.02 (0.047 ± 0.00079]
the thickness of the barrel shims in the same
way for prestroke adjustment.
Injection start intervals 45° ± 0.5°
Adjustment of Injection Volume
(1) Install a fuel hose and the specified fuel pipe to

the fuel injection pipe.
Increase
(2) Make adjustment with the following conditions.
Decrease
H3756199000
Nozzle (nozzle holes:
10- ø0.325 mm [0.013 in.])
Nozzle opening 34.32 MPa (350 kgf/cm2)
pressure [4979 psi]
0.3±0.05 MPa
Feed pressure
(3±0.5 kgf/cm2)[43±7 psi]
H3756112700
Fuel pipe
(ø7 × ø2.8 – 817 mm)
(O.D. × I.D. – Length)
[ø0.28 × ø0.11 – 32.17 in.]
Test fuel JIS Class 2 diesel fuel
Test fuel pressure 40±10°C [104±18°F]
(3) Check the control rack “0” position.
(4) Set the pump to the specified rotation speed, and

secure the control rack at the specified position.
11-24
FUEL SYSTEM
5. Feed Pump
Scuffing, rust on piston

Fatigue and cylinder
1
GH654 Fatigue
Wear of seat 2 3I
Dust particles
Gauze filter: Wash with
diesel fuel
Cracks, damage of threads

Fatigue
I J F9 8 7
1 Priming pump 8 Spring
2 Spring 9 Piston
3 Valve F Push rod
4 Plug G Snap ring
5 Spring H Tappet
6 Valve I Adapter
7 Plug J Pump housing
–CAUTION
Do not disassemble the gauge filter if it is
clogged; otherwise the filter becomes twisted and
damage results. Remove as much dust as possible
through small holes, then disassemble the gauge
filter with a screwdriver.
11-25
FUEL SYSTEM
5.2 Reassembly
1 G
4 J H
5 2 F
6 3
I I 7 8 9
Reassembly Sequence
J➔I➔H➔G➔F➔9➔8➔7➔6➔5➔4➔3➔2➔1
5.3 Testing Air pressure: 0.2 MPa
(2 kgf/cm2) [28.4 psi]
(1) Airtightness test a
Plug the discharge port. Apply air pressure of 0.2 MPa

(2 kgf/cm2) [28.4 psi] to the suction port, immerse b
the pump in diesel fuel, and check for air leakage d
(air bubbles).
c
a Measuring cylinder c Plug

b Tappet d Diesel fuel
(2) Feed pump test
Fuel pipe: Outside diameter 15 mm [0.59 in.], Inside

diameter 13 mm [0.51 in.], Length 2000 mm [78.7
in.]
Cam lift: 12 mm [0.47 in]/revolution
Drive the pump in the above testing condition, and
measure the discharge start time. 2000 mm [78.7 in.]
Assembly
Item Standard
Feed pump discharge start Discharge start time:
(pump at 100 rpm) 20 sec or less
11-26
FUEL SYSTEM
(3) Priming pump suction capacity test
Discharge fuel completely from the feed pump in the

testing conditions described in (2). Then, operate the
priming pump at a rate of 60 to 100 strokes per
minute, and count the number of pumping operations
required for fuel to reach the pump.
Unit: st/min
Assembly
Item Standard
No. of pumping
Priming pump discharge start operations
30 strokes or less
(4) Feed rate test
Open the valve on the discharge side in the testing

conditions described in (2). Then, operate the pump
and measure the amount of oil fed during the first 15
seconds.
Unit: cm3 [cu.in.]/15 sec
Assembly
Item Standard
Feed pump feed rate
900 [54.9] or more
(pump at 600 min-1)
11-27
FUEL SYSTEM
6. Water Separator
3 2
Replace: Every
1,000 hours
1 Lid (upper cover) 2 Element 3 Outer cylinder
6.2 Reassembly
Reassembly Sequence
1 If suction of air cannot
3➔2➔1 be stopped by tighten-

ing, replace the gasket
3
and O-ring.
–CAUTION 2
Inspect the fastened sections for tightness, and
wipe leaked fuel.
After the installation, start the engine and check
for fuel leakage.
11-28
ELECTRICAL SYSTEM
1. Locations of Electrical Devices ................................................................................................. 12- 2

2. Starter......................................................................................................................................... 12- 3
2.1 Disassembly ....................................................................................................................... 12- 3
2.3 Reassembly ........................................................................................................................ 12- 10
3. Alternator ................................................................................................................................... 12- 14
3.1 Disassembly ....................................................................................................................... 12- 14
3.3 Reassembly ........................................................................................................................ 12- 19
3.4 Inspection and Adjustment during Installation .................................................................. 12- 21
12
ELECTRICAL SYSTEM
1. Locations of Electrical Devices

Oil pressure switch (H) Oil pressure switch (L)
0.29 MPa (3.0 kgf/cm2) [42.7 psi] 0.15 MPa (1.5 kgf/cm2) [21.3 psi]
Pulse sensor
Intake air (L.H.) for
temp. ECM
semsor controler
(L.H.)
No. 2 Starter
(L.H.UP)
11kW
No. 3 Starter
(L.H.LOW)
11kW
Oil by-pass
Oil level sensor
alarm terminal
Water temp. sensor

for Fan radiator control
Water temp.
sensor
for Water
temp. meter
Thermo switch
for Eng. Over
Stop heat 101 °C
solenoid (374.2 K)
Pulse sensor Intake air temp.
(R.H.) sensor [R.H.]
Tachometer
No. 1 Starter
(R.H.) 11kW
Alternator
24V-150A
12-2
ELECTRICAL SYSTEM
2. Starter
2.1 Disassembly
9 Adhesion of brush particles,

irregular wear, brush movement
F 7 1 in holder
Rotation
Wear of gear, damage Wear of gear 6 4 3 2
Rotation
8 Surface roughness,
5
seizure, step wear teeth,
wear and damage
1 Magnetic switch assy. 5 Armature assy. 9 Pinion case

2 Rear bracket 6 Center bracket F Pinion clutch assy.
3 Brush holder assy. 7 Shift lever assembly
4 Yoke assy. 8 Front bracket
12-3
ELECTRICAL SYSTEM
(1) After removing the safety switch, remove the lead

wire, and then the magnetic switch assembly.
(2) Unscrew the through bolts and the brush holder

mounting screws, then remove the rear bracket.
(3) Remove the brushes from the brush holder

assembly, then remove the yoke.
(4) Pull out the armature assembly.
12-4
ELECTRICAL SYSTEM
(5) Remove the center bracket.
(6) Remove the lever pin, inner housing, and shift

lever from the pinion case.
(7) Using a jig, remove the pinion stopper, then Unit: mm [in.]
remove the overrunning clutch from the pinion
shaft. Pipe
ø24
[0.94]
ø19.1
[0.752]
NOTE M5 - 40 mm
Push [0.20 - 1.57 in.] 20 mm [0.79 in.]
To remove the shaft bearing for replacement, use t=7 mm
[0.28 in.]
a bearing puller as shown in the drawing.
37 mm [1.46 in.]
10 mm
120 mm [4.72 in.]
[0.39 in.]
Support
5 mm
[0.20 in.]
tap
Pinion shaft bearing puller
12-5
ELECTRICAL SYSTEM
Magnetic Switch
(1) Testing the magnetic switch coil
(a) Test the pressure coil and holding coil for an

open ciruit. The coils are open-circuited if
there is no continuity between the M terminal
of the magnetic switch and the case.
Resistance: 1.16 ohms (approx.)
(b) Apply voltage of 24 volts between the M

terminal of the magnetic switch and the case.
Now push in the plunger by hand. When you
release your hand, the plunger should not be
attracted.
(2) Testing magnetic switch contact points
Measure the load current flowing through the starter.

If the voltage drop between terminals B and M
exceeds 0.3 volts per 100 amperes, clean or replace
the contact points.
If the starter switch is turned to OFF during voltage
measurement, the battery voltage is directly applied
to the voltmeter. This can damage the voltmeter.
Always turn the starter switch to ON before
measuring the voltage, then turn it OFF after
measuring the voltage.
–CAUTION
Do not apply 24 V on terminals to test the
magnetic switch movement.
12-6
ELECTRICAL SYSTEM
Armature
(1) Measuring the armature deflection
Measure the deflection with a dial gauge. If the

deflection exceeds the assembly standard, repair
or replace the armature.
Unit: mm [in.]
Armature deflection 0.06 [0.00236]
(2) Inspecting the commutator
(a) Check the condition of the commutator

surface. If it is rough, polish it with #400 to
#600 sandpaper.
Check the commutator for runout with a dial
gauge. Replace the commutator if the
deflection exceeds the service limit.
Unit: mm [in.]
Item Assembly Standard Service Limit
Commutator 0.06 0.10
deflection [0.0024] maximum [0.0039]
(b) Measuring the mica depth
Use a depth gauge to measure the depth of Improper undercutting

each mica undercut. If the depth exceeds the Good
repair limit, re-condition the mica. Bad
Unit: mm [in.]
0.7 to 0.9 mm
Item Assembly Standard Repair Limit [0.028 to 0.035 in.]
Commutator mica 0.7 to 0.9 0.2
depth [0.028 to 0.035] [0.0079]
12-7
ELECTRICAL SYSTEM
(3) Testing the armature
(a) Use a growler to test the armature for short

circuits. If the hacksaw blade vibrates against
the core, replace the armature.
(b) If there is continuity between the commutator

and shaft, replace the armature.
Field coil
(1) Testing for open circuits
If there is no continuity between the M terminal

of the field coil and the lead wire on the brush
side, replace the field coil.
Overruning Clutch
The clutch is in good condition if it rotates freely in

one direction when turned by hand.
Check the pinion teeth for wear or damage. If they
are damaged, replace the pinion.
–CAUTION
Do not immerse the overruning clutch in cleaning
solvent to clean it. Immersion in cleaning solvent
will cause grease inside the clutch to run out,
causing clutch parts to seize when operating.
12-8
ELECTRICAL SYSTEM
Brushes
(1) Inspecting for wear
[0.87 to 0.91 in.]

Unit: mm [in.]
22 to 23 mm
[0.5 in.]
13 mm
Item Assembly Standard Service Limit
Brush height 22 to 23 [0.87 to 0.91] 13 [0.51]
(2) Testing brush spring tension

Unit: N (kgf) [lbf]
Assembly Service
Item Standard Limit
39.23 to 49.03 39.23
Brush spring tension (4.0 to 5.0) (4.0) [9]
[9 to 11] maximum
Safety Switch
Connect the safety switch as shown, and check the Switch

starter and safety switch operations. B C SR (+)
Battery
(1) Connect the R terminal to the battery minus (–)
side. Safety relay (–)
Earth (E)
(2) Turn the switch on, and check that the starter Connection to starter
turns. body
(3) After step (2) above is completed, if you remove

the R terminal from the battery minus (–) side,
or if you connect the terminal to the battery plus
(+) side after removal, make sure you stop the
starter operation.
–CAUTION
When you are making connections, pay special
attention to the battery’s polarity (+) (–).
12-9
ELECTRICAL SYSTEM
2.3 Reassembly
7 9 1 45
3
8 F 2
Coat with oil
Coat with grease

6
Reassembly Sequence
9➔8➔F➔7➔6➔5➔4➔3➔2➔1
12-10
ELECTRICAL SYSTEM
(1) Install the center bracket, overrunning clutch, and

pinion stopper to the pinion shaft. Insert the shaft
in position by tapping it with a soft-head mallet.
(2) Install the shift lever and pinion shaft to the front
bracket by aligning the matching mark on the
shift lever.
(3) Install the armature and yoke to the center

bracket, making sure that the dowel pin enters
its hole.
(4) Install the brushes and brush holders.
12-11
ELECTRICAL SYSTEM
NOTE
Install the positive (+) side brush and negative
(–) side brush as shown.
êbrush ëbrush
(5) Install the rear bracket to the yoke by aligning

the matching marks. Secure the brush holders
with bolts, then tighten the through bolts.
(6) Measure the end play of the armature. If the end

play exceeds the assembly standard, adjust it on
the rear side.
Unit: mm [in.]
Armature end play 0.2 to 0.8 [0.008 to 0.031]
(7) Liberally coat the internal gear with grease, then

install the pinion shaft to the gear.
12-12
ELECTRICAL SYSTEM
(8) Measure the end play of the pinion shaft. If the

end play exceeds the assembly standard, adjust
it on the internal gear side.
Unit: mm [in.]
Pinion shaft end play 0.2 to 0.8 [0.008 to 0.031]
(9) Install the magnetic switch. Apply a voltage of

24 volts between the C and E terminals. Connect
the lead wire and energize the circuit between
the M and E terminals (within 1 second). After
the pinion has shifted, measure retraction length
of the pinion. If the measurement is not within
2.5 to 5.5 mm [0.098 to 0.22 in.], use the magnetic
switch adjusting screw to make adjustments.
2.5 to 5.5 mm
[0.098 to 0.22 in.]
(10) Secure the lead wire.
(11) Install the safety switch.
12-13
ELECTRICAL SYSTEM
3. Alternator
3.1 Disassembly
Rotation
7 P
6 8
G 9 O
F
Rotation
4 5
H
3
2
N
M
I J
1
L
K
1 Front bracket assembly 8 Rear bearing K Plate

2 Nut set 9 Front bearing L Rectifier
3 Pulley F Oil seal M Rear bracket
4 Fan G Front bracket N Stator coil
5 Nut H Rear bracket assembly O Screw
6 Cover I Field coil P Screw
7 Rotor J Regulator
(1) Removing the front bracket assembly and rear
bracket assembly 1
H
Remove four through bolts A. Dismount the front
bracket assembly1 and rear bracket assembly H
by prying with a screwdriver at section B in the A
drawing.
B
NOTE
Do not remove parts 3 and 4 unless they need
repair.
12-14
ELECTRICAL SYSTEM
(2) Removing the pulley and rotor

(a) Hold the rotor 7 with a vice. 3 B
NOTE
When holding the rotor with a vice, be sure to
clamp the rotor at sections A in the drawing. A A
(Do not apply excess force on the rotor when
using a vice.)
B: Do not clamp at these sections.
6
(b) Remove four cover mounting screws to loosen
the cover .
5 7 5
G
Remove the nut to separate the rotor
from the front bracket .
7
G
(3) Removing the rear bearing

8
8
Use the bearing puller to pull out the rear bearing Front bearing
.
Narrow
7
(4) Replacing the front bearing
9
Since the gap between the rotor and front
Bearing remover
bearing is narrow (3.4 mm) [0.13 in.], the front
bearing cannot be removed with the bearing
puller. Use a bearing remover and a press for the
removal of the front bearing.
12-15
ELECTRICAL SYSTEM
(5) Removing the stator coil
N
Disconnect eight soldered connections at location
B on the stator coil and location A on the
L
rectifier .
B
A: Rectifier diodes
B: Stator coil lead wires
NOTE L A
N
Disconnect each soldered connection quickly by
placing the soldering iron tip for less than 5
seconds.
(6) Removing the field coil

P
(a) Remove two screws P.
NOTE
P O O
I
Be sure to remove screws first. If screws are
removed first, the field coil becomes loose
J
and its weight will be applied to the connecting
section of the regulator , and this can damage
the joint section.
(b) Remove three screws O.

NOTE
O I
Support the field coil by hand, since removal of
screws dismounts the field coil .
(c) Remove the field coil I.

NOTE
I
J
When removing the field coil , the section
connected to the regulator may become caught
by the stator coil. To prevent damage, do not
apply excessive force when removing the field
coil.
12-16
ELECTRICAL SYSTEM
(1) Field coil

I
I
Measure resistance between the terminals of the field
coil . If the measured value deviates from the
standard value, replace the field coil.
Item Asembly Service

Standard Limit
Field coil resistance
3.8 to 4.5 Ω —
(at 20 °C [68 °F])
(2) Rectifier
L
(a) Check to make sure the diodes in the rectifier E
function properly. If a diode shows open-
circuit or short-circuit, replace the rectifier. A
B
Infinite resistance indicated in both tests — C F
Open circuit D
0 Ω indicated in both tests — Short circuit
A, B, C, D: Stator coil lead wire connections
E, G: Heat sink G
F: Regulator connection
E B F
(b) Conduct two tests by switching the positive
ê and negative ë sides.
NOTE
The current that flows during the test is much
L
lower than the current that normally flows in the A C G D
rectifier . Therefore, the tester may not indicate
resistance accurately in some cases. When the
measuring range is narrow, this tendency
becomes larger. Use the largest measuring range.
12-17
ELECTRICAL SYSTEM
(3) Diode trio
Take measurement between regulator connection E

plate F and lead wire connections (A, C and D only).
If abnormalities are found, replace the rectifier. A
B
C F
NOTE D
When the rectifier does not have regulator
connection plate F, it is not equipped with a diode G
trio. If that is the case, the above test is not
necessary. E B F
A C G D
(4) Stator coil
(a) Checking continuity between lead wires

The stator has two pairs of coils, each with
four lead wires.
• There must be continuity between all four
lead wires of each coil pair.
• There must not be continuity between the
lead wires of different coil pairs.
If abnormalities are found, replace the
stator.
(b) Checking continuity between lead wires and

core
Check to make sure that there is no continuity

between the lead wires and core. If there is continuity,
the circuit is grounded. Replace the stator. (It is not
possible to replace the core only.)
12-18
ELECTRICAL SYSTEM
3.3 Reassembly
O
G
I 4
J M
L
J 5 3
2
8
L
F
9
L 6
K N 1
H
7
Reassembly Sequence
M➔L➔K➔J➔N➔I➔O➔P➔H
G➔F➔9➔6
➔
➔5➔4➔3➔2➔1
7➔8
12-19
ELECTRICAL SYSTEM
(1) Using a press, press down the rear bearing 8 in

direction A until it stops. A
8
–CAUTION
Make sure the bearing outer race is free of oil.
Oil, if applied to the inner surface, can flow out.
(2) Using a press, install the oil seal F in direction

C.
C
6
9
6
Press until the face of the front bearing is flush
with the mounting face of the cover .
F
Apply an adequate amount of grease (Idemitsu
Autorex) to the lip of the oil seal before press-
G
9
fitting the front bearing.
(3) Install the cover 6.

Secure the cover 6 with four bolts.
6
(4) Follow the disassembly sequence in reverse and

complete the assembly.
12-20
ELECTRICAL SYSTEM
3.4 Inspection and Adjustment during

Installation
(1) Inspecting the alternator
Performance test V
• Connect the wires of the alternator as shown in
the drawing. A
A: Ammeter (200-A class)

B: Alternator terminal B
C: Switch C
D: Terminal B D
V: Voltmeter
–CAUTION
• Before connecting wires, disconnect the
cable from the negative − terminal of the
battery and insulate the cable end with tape.
If the cable is not disconnected from the
battery’s negative − terminal, battery voltage
continues to flow to terminal B, and it will
cause a serious hazard.
• The wire connected to the switch C must
have a diameter equal to or larger than that
of the harness wire on the chassis side.
• Turn on the switch C, and make sure the voltmeter

C indicates the battery voltage.
• Start the engine.
• Turn on the vehicle lamp switches immediately.
• Increase the engine speed to high idling at
approximately 1750 min -1 and measure the
maximum amperage.
• If the measured value is 70% of the nominal
output current or higher, the alternator is in good
condition.
Alternator nominal output

Alternator Voltage Output current
150 A 24 V 150 A
–CAUTION
Only simplified inspection can be conducted on
the alternator mounted on the engine. For more
accurate testing, remove the alternator and use a
test bench.
12-21
ELECTRICAL SYSTEM
(2) Inspecting the regulator

V
• Connect the wires of the alternator as shown in
the diagram.
A
A: Ammeter (200-A class)
B: Alternator terminal B
C: Switch
D: Terminal C
V: Voltmeter B D
–CAUTION
• Before connecting wires, disconnect the
cable from the negative − terminal of the
battery and insulate the cable end with tape.
If the cable is not disconnected from the
battery’s negative − terminal, battery voltage
continues to flow to terminal B, and it will
cause a serious hazard.
• The wire connected to the switch C must
have a diameter equal to or larger than that
of the harness on the chassis side.
• Turn off the lamp and heater switches to minimize

drain during the test.
• Turn on the switch C, and start the engine.
• If the output current is 5 A or lower when the
engine is operating with low idling at
approximately 800 min-1, measure voltage at
terminal B.
–CAUTION
If the output current is more than 5 A and less
than 15 A, the measured value (regulated voltage)
becomes slightly lower. However, this does not
denote a malfunction as long as it is within the
standard range.
• If the output current exceeds 5 A, take one of the

following measures.
• Operate the engine for a while to charge the
battery.
• Replace with a fully charged battery.
• If the measured value deviates from the standard
value, conduct a test using a test bench.
Inspection Assembly Service

Location Standard Limit
Regulated
28.5 ± 0.5 V —
voltage
12-22
WORKSHOP TIPS
1. Precautions for Disassembly and Reassembly ........................................................................... 13-2

1.1 Oil Seals .............................................................................................................................. 13-2
1.2 O-rings ................................................................................................................................ 13-3
1.3 Bearings .............................................................................................................................. 13-3
1.4 Lock Plates .......................................................................................................................... 13-4
1.5 Split Pins and Spring Pins ................................................................................................... 13-4
13
WORKSHOP TIPS
1. Precautions for Disassembly and Reassembly
1.1 Oil Seals
When installing oil seals, carefully observe the

following points.
Driving oil seals into housings
(a) Check the seal lip for damage, and be sure to

position correctly in the housing.
(b) Apply a smear of grease to the surface of the

oil seal (to be fitted into the housing bore).
(c) Use an oil seal driver shown to guide the seal

lip and drive the outer diameter squarely. To
avoid damage to the oil seal and leaking, never
hammer on it directly.
400247
Oil seal driver
Driving oil seals onto shafts
(a) Apply a smear of grease to the oil seal lip.
(b) Use an oil seal guide of the type shown when

driving the oil seal over the stepped portion,
splines, threads, or key way to prevent damage
to the oil seal lip.
400248
Oil seal guide
13-2
WORKSHOP TIPS
1.2 O-rings
Use an O-ring guide to install an O-ring over stepped

parts, splines, threads, or key way to prevent damage
to the ring. Apply a smear of grease to the O-ring
before installation.
400249
O-ring guide
1.3 Bearings
(1) When installing a rolling bearing, be sure to

push the inner or outer race by which the bearing
is fitted. Be sure to use a bearing driver like the
one shown.
400250
Bearing driver
(2) Whenever possible, use a press to minimize shock

to the bearing and to assure proper installation.
400251
Bearing installation with a press
13-3
WORKSHOP TIPS
1.4 Lock Plates
Bend lock plates against the flats of the nuts or bolt

heads as shown.
Good Good Bad
Bad
Good Bad Good
Bending lock plates
1.5 Split Pins and Spring Pins
Generally, split pins are to be replaced once disturbed.

Insert the pin fully and spread it properly. Drive each
spring pin into position to hold it in place after later
installation of parts has been completed.
13-4
ADJUSTING PROCEDURE OF (ELECTRIC GOVERNOR) ACTUATOR CONTROLS
1. Foreword .................................................................................................................................. 14- 2

1.1 Adjustment Procedure ...................................................................................................... 14- 2
1.2 Order of Adjustment ......................................................................................................... 14- 2
2. Preparation before Adjustment ................................................................................................ 14- 3
2.1 Required Equipment ......................................................................................................... 14- 3
2.2 Controller Installing Location and Part No. Location ...................................................... 14- 4
3. Connection of PC and Actuator Controller .............................................................................. 14- 5
4. Service Program Start-up ......................................................................................................... 14- 6
4.1 Normal Start-up Procedures.............................................................................................. 14- 6
4.2 Starting from DOS Mode .................................................................................................. 14- 9
4.3 Instructions for Tunable Operation of Governor .............................................................. 14-11
5. Setting Items List ..................................................................................................................... 14-15
6. Checks before Parts and/or Controller Setting Change ........................................................... 14-17
6.1 Procedure for Checking before Part and/or Controller Setting Change ........................... 14-17
7. Parts and/or Controller Setting Change ................................................................................... 14-18
8. Input for Releasing Protection ................................................................................................. 14-18
9. Control Link/Controller Setting ............................................................................................... 14-19
9.1 Setting Procedures ............................................................................................................ 14-19
10. Resetting of Protection ............................................................................................................ 14-22
11. Disconnection of PC and Actuator Controller ......................................................................... 14-22
12. PC Set-up (Confirmation of Faulty PC Start-up) .................................................................... 14-23
12.1 Confirmation of Serial Port Setting in IBM PC (WINDOWS98) .................................... 14-23
13. Malfunction Display ................................................................................................................ 14-24
14. Tunable List (for Reference) .................................................................................................... 14-25
14
1. Foreword
1.1 Adjustment Procedure
When replacing fuel injection pumps, an actuator or

control linkages, the injection pumps shall be adjusted
to have full control rack at the maximum fuel position
of actuator on the control set by using the PC and
control software.
Prior to the adjustment, use the direct control function
on the controller in order to move the lever of the
actuator for adjustment.
–CAUTION
When the engine is replaced, be sure to use the
new controller provided with the new engine.
Do not reuse the controller used with the previous
engine.
1.2 Order of Adjustment
Adjusting order is as follows:
(1) Preparation before Adjustment
(2) Connection of PC and Actuator Controller
(3) Service Program Start-up
(4) Checks before Parts and / or Controller Setting

Change
(5) Parts and / or Controller Setting Change
(6) Input for Releasing Protection
(7) Control Link / Controller Setting
(8) Resetting of Protection
(9) Disconnection of PC and Actuator Controller
(10) PC Set-up
14-2
2. Preparation before Adjustment
2.1 Required Equipment
(1) Prepare the fuel injection pumps that the injection

amount are adjusted with control rack setting,
when the injection pump shall be changed.
(2) In order to adjust the controller, prepare the PC,

harnesses and software.
(a) Interface box for governor adjustment (c) You may also need an adapter like D-SUB 9-
(H3786300700) pin to 25-pin adapter or an RS-232 cable
depending on the situation.
(b) IBM-PC or IBM-PC fully compatible
computer with 486 or higher processor. (d) IBM PC-DOS Version 3.3 or higher
The PC also must have an RS-232 port and a (CANNOT run correctly under Windows 98
3.5 inch floppy drive. DOS mode).
Color display recommended.
(e) PC service program “PCSVC.EXE”.
(3) Matching Part No. of controller / software

(floppy).
S16R Controller Floppy
Serial No. Part No. Part No.
10847 H3786300100 H3786300111
10892 ↑ ↑
11004 H3786310100 H3786310111
11017 ↑ ↑
11056 ↑ ↑
11111 ~ H3786320100 H3786320111
NOTE
The integrated adjustment software (floppy disc)
is compatible with three engine models (S6R,
S12A2 and S16R). Use this software for engine
adjustment.
Integrated Adjustment Software Engine Model Controller Version Controller Part No.
09500 H3756309500
S6R 19500 H3756319500
29500 H3756329500
02100 H3266302100
Ver. 1.01 (March 18, 2002) S12A2
22100 H3266322100
00100 H3786300100
S16R 10100 H3786310100
20100 H3786320100
14-3
2.2 Controller Installing Location and Part

No. Location
(1) Controller is installed in the rear side of the box Controller

under the driver’s seat.
Controller Installing Location (1)
(2) Open the door of the box to expose the controller

part number. Controller Door
Controller Installing Location (2)
(3) Controller part No. is stamped at the front upper

left side.
Part No.
Controller Part No. Location
14-4
3. Connection of PC and Actuator Controller
6-pin Deutsch-DB25F
Serial link adapter data connector
18” DB9F-DB9H cable
Cable
(Part no. 3093944)
→ To data link connector

→ To 12V DC
PC/Laptop
Connection of PC and Actuator Controller
(1) Connect interface box (H3786300700) for

governor adjustment, then connect cable
(3093944).
NOTE Data link

Use changeable adaptor depending on the connector
situation.
12V DC
(2) Remove the cover at the left side of driver’s seat,
then connect the ends of cable to data link
connector and 12V DC.
Data Link Connector and 12V DC
Connecting 12V DC to Cable
14-5
4. Service Program Start-up
Using the integrated adjustment software (floppy disk)

for the three engine models, start the service program.
4.1 Normal Start-up Procedures

(1) Set the adjustment software in the FD drive of
the PC.
NOTE
If a different version of the adjustment software
(floppy disc) is used, the display shows an error
message: “ERROR: Service tool does not match
control software.” When this message appears,
(Screen Indications)
check the software version, and insert the
software of proper version.
(2) Turn on the power of the PC. C:¥>_

(3) Make sure the PC starts up.
(4) Enter “A” and “:” after the “>” prompt, then press
the Enter key. C:¥>A:↵
(5) The A drive of the PC becomes active.
A:¥>_
(6) Enter “D”, “I” and “R”, and then press the Enter
key.
A:¥>DIR↵
(7) The screen displays the basic content of the

floppy disk (F/D), and returns to the screen
described in step (5), as shown at the right.
A:¥>_
(8) Enter “C”, “D”, space, “D”, “M” and “M”, and
then press the Enter key.
A:¥>CD DMM↵
14-6
(9) The screen shows that the F/D content is

connected to “DMM”.
A:¥DMM>_
key to display the content of “DMM”.
A:¥DMM>DIR↵
(11) The screen displays the content of DMM, and

returns to the screen described in step (9), as
shown at the right. A:¥DMM>_
(12) Select an applicable engine model name.

(Example) For S16R engine model:
Enter “C”, “D”, space, “S”, “1”, “6”, “R”and A:¥DMM>CD S16R↵
“2”, and then press the Enter key. (Connects to
the content of “S16R”.)
(13) The screen shows that the content of the F/D

has been changed to the content of “S16R”.
A:¥DMM¥S16R>_
key to display the content of “S16R”.
A:¥DMM¥S16R>DIR↵
(15) The screen displays the content of “S16R”, and

returns to the screen described in step (13), as
shown at the right. A:¥DMM¥S16R>_
(16) Select an applicable No.

(Example) For “10100”:
A:¥DMM¥S16R>CD 10100↵
Enter “C”, “D”, space, “1”, “0”, “1”, “0”, and
“0”, then press the Enter key. (Connects to the
content of “10100”.)
14-7
(17) The screen shows that the content of the F/D

has been changed to the content of “10100”.
A:¥DMM¥S16R¥10100>_
(18) Enter “D”, “I” and “R”, and then press the
Enter key to display the content of “10100”.
A:¥DMM¥S16R¥10100>DIR↵
(19) The screen displays the content of “10100”,

and returns to the screen described in step (17), A:¥DMM¥S16R¥10100>_
as shown at the right.
(20) The screen shows “PCSVC”. Enter “P”, “C”,

“S”, “V” and “C” after the “>” prompt, and
then press the Enter key to start the adjustment A:¥DMM¥S16R¥10100>PCSVC↵
program.
14-8
4.2 Starting from DOS Mode
(1) Set the adjustment software in the FD drive of

the PC.
(2) Turn on the power of the PC.
(3) The PC screen displays a prompt.
A:\>_
(4) Enter “D”, “M”, “M”, “\”, “S”, “1”, “6”, “R”,
“\”, “1”, “0”, “1”, “0”, “0”, “\”, “P”, “C”, “S”,
“V” and “C” after the “>” prompt, then press the A:\>DMM\S16R\10100\PCSVC↵
Enter key to start the adjustment software.
NOTE
In some PCs, pressing the “\” key may not enter A:\>DMM¥S16R¥10100¥PCSVC↵
“\” on the screen. In that case, press the “¥” key.
14-9
– CAUTION
Press “U”, “S” and Enter keys to change mode
to “English”. If controller and J38351 adaptor
are not powered up, PCSVC service will report
an error and will not start-up.
When PCSVC service program starts, six windows

will be displayed at the top and basic key functions
at the bottom. (Refer to the illustration below)
PC Service Tool Display
14-10
The six windows shown on the screen enable

monitoring and adjustment of governor operation.
They are called service windows. To select a service
window, press the <PgUp> or <PgDn> key.
4.3 Instructions for Tunable Operation

of Governor
(Example) For SPEED SET-Auto Idle Speed:

Service Window Selection
(1) The selected service window is indicated by a
thick yellow line. Press the <Enter> key to display
service headers and enter the service mode.
Service Header Display

(2) To select a service header, press the <↑> or <↓>
key.
Service Header Selection

(3) When a service header is selected and the <Enter>
key is pressed, the block under the service header
becomes active, and it enables the adjustment of
the parameter or the monitoring and confirmation
of the input or output signal.
If an asterisk (*) is indicated after the displayed

value, the numeric value can be changed. Items
that are changeable are called “tunable
parameters”. To change a tunable parameter, enter
a numeric value as described in the lower section
of the diagram. To increase the value, press the
<7>, <8> or <9> key. To decrease the value, press Block Display
the <4>, <5> or <6> key. The incrementing rate
becomes higher in an order of <7> to <9>.
14-11
(4) To move from block to block, use the <↑> or

<↓> key.
Block Selection
NOTE
Press the <Esc> key to return from the lowest
block to a blank service window.
A maximum of six blocks can be flexibly
displayed on the service windows.
Return to Service Window
(5) To save settings even after the governor power

turns off, exit from the block by pressing the
<Esc> key. Then, after a service header is
displayed, press the <Esc> key again to save the
settings in the ROM. In this step, the service
window displays “SAVING CHANGES” to
indicate that the new settings are stored.
Set tunable parameters by following the
procedures described above.
–CAUTION
Changed tunable parameters are valid while the
governor is on. If the governor is turned off,
Save Governor Controller Setting
changed values are not stored in the ROM of the
governor controller. Be sure to save the settings
before turning off the power.
(6) To exit from the PC service program, keep the

<Ctrl> key pressed and push the <Break> key.
The display returns to the DOS prompt screen.
14-12
PC Service Tool Software Flowchart
14-13
– CAUTION
If a key is pressed too long or pressed before the display refreshes, the screen may show “WORKING...”
and the PCSVC program may freeze and stop responding to any key input. (Even in this condition, the
governor controller continues to operate normally with set tunable parameters.)
When this happens, exit from the PCSVC program by pressing the <Ctrl> and <Break> keys at the same
time, then restart PCSVC and repeat the setting procedures. To prevent the above-mentioned problem, do
not press the keys for too long.
The PCSVC program has a configure mode which allows the change of the number of teeth and a debug
mode which enables detailed setting and monitoring. However, most adjustments are made in the service
mode.
If an incorrect mode is activated, exit by using the <Esc> key.
(Pressing the <Shift> key and <C> or <D> key activates the configure or debug mode.) If no input is made
for a while after the PSCVC program starts, the screen shuts down. When this happens, press the <Space>
key to display the screen.
14-14
5. Setting Items List
Groups indicated with “Password” cannot be

displayed without entering their passwords.
ESC ENTER password password
↑, ↓ key ↑, ↓ key ↑, ↓ key (Note) ↑, ↓ key
MONITOR ANALOG SPEED SET DYNAMICS LIMIT SET A
ESC ENTER ESC ENTER ESC ENTER ESC ENTER
Engine Speed Idle Speed Tune Prop_Gain Start Fuel Limit (%)
↑, ↓ key ↑, ↓ key ↑, ↓ key ↑, ↓ key
Speed Ref. Auto Idle Speed Int_Gain Cold Start Limit 1 (%)
↑, ↓ key ↑, ↓ key ↑, ↓ key ↑, ↓ key
Actuator Out (%) Rated Speed S_D_R Cold Start Limit 2 (%)
↑, ↓ key ↑, ↓ key ↑, ↓ key
Actuator Position (V) Max Speed Tune Window width
↑, ↓ key ↑, ↓ key ↑, ↓ key
Fuel Limit LSS (%) Spd Ref Fail/Spd Sst Gain Ratio
↑, ↓ key ↑, ↓ key ↑, ↓ key
Turbo Boost (kgf/cm2) Ref Change Rate (rpm/sec) Gain Break Point
↑, ↓ key ↑, ↓ key ↑, ↓ key
Throttle Position (%) Auto Idle Delay (sec) Gain Slope
↑, ↓ key ↑, ↓ key
Speed in Ctrl Droop (%)
↑, ↓ key
Torq Lmt Ctrl
↑, ↓ key
T/Boost Lmt Ctrl
NOTE
These items usually does not require adjustment.
14-15
password password password

↑, ↓ key (Note) ↑, ↓ key (Note) ↑, ↓ key ↑, ↓ key
A TURBO BOOST LIMIT TORQUE LIMIT FAULT LIST MISCELLANEOUS
ESC ENTER ESC ENTER ESC ENTER ESC ENTER
T/Boost Limit Out (%) Torque Limit Out (%) Actuator Driver Fail Max Limit (%)
↑, ↓ key ↑, ↓ key ↑, ↓ key ↑, ↓ key
T/B P1 Limit (%) TQ P1 Limit (%) Actuator Position Fail Act_Pos Out, (V)
↑, ↓ key ↑, ↓ key ↑, ↓ key ↑, ↓ key
T/B P2 (press) TQ P2 (rpm) Sensor Supply Fail Pos.P1 set
↑, ↓ key ↑, ↓ key ↑, ↓ key ↑, ↓ key
T/B P2 Limit (%) TQ P2 Limit (%) Throttle Signal Fail Pos.P2 set
↑, ↓ key ↑, ↓ key ↑, ↓ key ↑, ↓ key
T/B P3 (press) TQ P3 (rpm) Discrete Out Fail Max Act (%)
↑, ↓ key ↑, ↓ key ↑, ↓ key ↑, ↓ key
T/B P3 Limit (%) TQ P3 Limit (%) Speed Sensor Fail Min Act (%)
↑, ↓ key ↑, ↓ key ↑, ↓ key
T/B P4 (press) TQ P4 (rpm) Boost Signal Fail
↑, ↓ key ↑, ↓ key
T/B P4 Limit (%) TQ P4 Limit (%)
↑, ↓ key ↑, ↓ key
T/B P5 (press) TQ P5 (rpm)
↑, ↓ key ↑, ↓ key
↑, ↓ key ↑, ↓ key
↑, ↓ key ↑, ↓ key
↑, ↓ key ↑, ↓ key
↑, ↓ key ↑, ↓ key
↑, ↓ key ↑, ↓ key
↑, ↓ key ↑, ↓ key
14-16
6. Checks before Parts and/or

Controller Setting Change
Be sure to record data before and after changing when

adjusting the data inside of controller.
6.1 Procedure for Checking before Part

and/or Controller Setting Change
(1) Confirm the values in Controller. (Refer to

TUNABLE LIST). Record and confirm the set
values, before and after changing.
(2) Confirm the lever angle of Actuator when

running at no-load maximum speed (high idle)
and the conditions of engine operation by
following procedure prior to replacement of fuel
injection pumps. However, it can be omitted
when confirmation is impossible beforehand.
(a) Start-up the control software.
(b) Display the Actuator Out (%) under

MONITOR ANALOG on the PC screen.
(c) Start the engine and record the value during

high-idle engine speed.
(d) Confirm the fan speed of oil cooler. (Confirm

oil temperature.)
(d) Confirm the fan speed of air cooler. (Confirm

charge air temperature.)
(e) Stop the engine.
(3) Confirm the length of each link prior to
1
replacement of fuel injection pumps. Especially,
make sure to record the length of link , which 1
attached to the output lever of actuator.
Control Linkage
14-17
7. Parts and/or Controller Setting

Change
Refer to the service manual for the procedure of the

injection pump / actuator / control link.
8. Input for Releasing Protection
Several items in setting require passwords. For the

setting for required items, release protections by
following the procedure below;
Input order for resetting the protection
Key Input: Display Indication:

<SHIFT> + <C> For configure press *Enter*
<Enter> To shutdown I/O press *Enter*
<Enter> ENGINE DATA
<Enter> No. of Gear Teeth (S12A2:182)
↓ Enable Tune Mode 0*
=password <Enter>
<ESC> ENGINE DATA
<ESC> SAVING CHANGES After this message, PC re-start automatically
<Enter>
Here in before the protection is released.
14-18
9. Control Link/Controller Setting

2
9.1 Setting Procedures 68 to 72 mm 1
[2.68 to
(1) Confirm that the engine is not running after 2.83 in.]
replacement of fuel injection pumps and then
1 2
proceed to remove the bolt at the opposite side
of the actuator link , (Lever side).
Control Link/Controller Setting

(2) Disconnect the boost sensor attached to the rear
side of the left inlet manifold.
–CAUTION
If the boost sensor is not disconnected, it will
cause the injection to increase and could be
dangerous when the actuator control is set from
0 to 60%.
Boost sensor
Boost Sensor Location
(3) Switch off the controller and make a short-circuit

Direct control
of the wire for DIRECT CONTROL SWITCH switch
at the connecting line of the machine body side.
(Make a short circuit between J2-20 terminal and
J1-23 terminal: The line is running near the driver
seat). With a short-circuit of wiring for DIRECT
CONTROL, it allows the actuator to move by
shifting the speed lever at the driver seat.
Switch the controller on and confirm that the
actuator moves by shifting the speed lever.
(If the actuator does not move, check the
connecting wire) Direct Control Switch Location
(4) Shift the speed lever to the maximum engine

speed, then the actuator should points the
maximum lever angle (100%). In this position,
pull the control rack of fuel injection pump with
1
a hand so as to have the full control rack and
2
adjust the length of link and then connect it to
the lever .
14-19
(5) Shift the speed lever to the minimum engine

speed to make the lever angle of actuator
minimum (0%). In this position, confirm that the
distance is 68 to 72 mm [2.68 to 2.83 in.] from
the edge of pump case to the end of control rack.
When the value does not come under the above
range, adjust the lever angle of actuator by
following procedures below:
(a) Confirm that the engine has stopped, then start
up the control software.
(b) Display Min Act (%) under the
MISCELLANEOUS on the PC screen.
(c) Change the value of Min Act (%) a little and
adjust the distance (Protrusion of control rack)
to 68 to 72 mm [2.68 to 2.83 in.] from the
edge of pump case to the end of control rack.
– CAUTION
If protrusion of control rack exceeds 72 mm
[2.83 in.], it may end up overrun.
(6) Remove the short circuit wiring for DIRECT

CONTROL to make the governor control back
to the normal condition.
In order to ensure that the DIRECT CONTROL
mode is not on, shift the speed lever and confirm
that the lever angle of actuator does not move.
Shift the speed lever to the minimum engine
speed position after the confirmation.
(7) Install cable to boost sensor.

Turn off the key switch of the vehicle, and wait
until the controller shuts off.
NOTE
Due to the built-in timer, it takes about one minute
for the controller to shut off.
Then, turn on the key switch of the vehicle again.
(8) Confirm the lever angle of actuator (Actuator Out

(%)) at the high idle engine speed and during high
idle speed by following procedures below:
14-20
(a) Place a person who can stop the engine for (9) Confirm the low idle engine speed and the auto
emergencies. idle engine speed. When the values do not meet
Start the engine and warm it up with no-load the specification, adjust it by following
minimum speed (low idle), and then raise the procedures:
engine speed to high idle (at this point, the
fan speeds of oil cooler and air cooler shall (a) Display Engine Speed under MONITOR
be adjust to the conditions as those were at ANALOG and Idle Speed Tune and Auto Idle
the speed before replacement of fuel injection Speed under SPEED SET.
pumps.)
(b) Make fine tuning of the value for Idle Speed
(b) Display Engine Speed and Actuator Out (%) Tune and adjust Engine Speed (idle engine
under the MONITOR ANALOG and Min Act speed) within the specified values.
(%) under the MISCELLANEOUS on the PC
screen. (c) Make fine tuning of the value for Auto Idle
Speed and adjust Engine Speed (auto idle
(c) Confirm the high idle engine speed and make engine speed) within the specified values.
sure that the value of Actuator Out (%) during (d) Stop the engine.
high-idle is the same as the value before the Reconfirm that the distance (protrusion of
replacement of fuel injection pump. control rack) is 68 to 72 mm [2.68 to 2.83 in.]
High Idle Revolution (Reference) from the edge of pump case to the end of
control rack when the engine is stopped.
Engine min–1
Without operating oil pump.
1752
Adjustment of engine on test bench.
With operating oil pump.
1729
Adjustment of engine installed in vehicle.
(d) When high idle engine speed does not meet

the specification or the value of Actuator Out
(%) is not the same as the value before the
replacement of fuel injection pump, make fine
tuning of Min Act (%) so as to make both
values point the right values. (By increasing
the value of Min Act (%), engine speed
becomes high and Actuator Out (%) becomes
low)
In addition, in case the confirmation before
the replacement of fuel injection pump has
not been made, adjust the value of the Min
Act (%) as follows:
S16R: 53 to 54%
NOTE
(a) Do use the controller for the adjustment of
Idle Speed Tune, Auto Idle Speed, Rated
Speed or Max. Speed Tune.
(b) Do not use the controller for high-idle
adjustment. If the controller is used for this
adjustment, a shift in the engine operating
speed can result, causing deviations in the
rotation speed and low-idle speed.
14-21
10. Resetting of Protection
Reset the protection immediately after changes are

completed.
Input order for resetting the protection
Key Input: Display Indication:

<SHIFT> + <C> For configure press *Enter*
<Enter> To shutdown I/O Press *Enter*
<Enter> ENGINE DATA
<Enter> No. of Gear Teeth (S16R:193)
<Enter> Enable Tune Mode 0*
=0 <Enter>
<ESC> ENGINE DATA
<ESC> SAVING CHANGES After this message, PC re-start automatically
<Enter>
Here in before the protection is released.
11. Disconnection of PC and Actuator Controller
Disconnect the PC and actuator controller after adjusting controller and actuator linkage.
14-22
12. PC Set-up (Confirmation of Faulty

PC Start-up)
12.1 Confirmation of Serial Port Setting in

IBM PC (WINDOWS98)
(1) BIOS Setting

(a) Turn-on the PC
(b) Start up BIOS (Press F1 key)
(c) Display the menu of IBM BIOS Setup
Utility
(d) Select <Config> from the menu.
(e) Select <Advanced Setup> from the menu.
(f) Select <Serial port> from the menu.
(g) Confirm <Serial port [ ]>
Confirm that the indicated sign in [ ] is
“Enabled”:
Enable: The port is enabled.
Disabled: The port is disabled.
(h) OS controlled: OS is controlled.
NOTE
Refer to the proper attached manual when using
a PC other than IBM.
14-23
13. Malfunction Display

Criterion for malfunction Malfunction Pulse indication Backup and other processing
Malfunction determination indicating lamp (note (a)) in the event of malfunction
Accelerator signal is lower

Accelerator signal than 0.25 V or higher than WARNING LAMP 2-5 Fix the speed setting at 1000
error 4.75 V. min-1.
Turbo boost signal Boost signal is lower than Cancel the boost-dependent
error 0.25 V or higher than 4.75 V. WARNING LAMP 2-3 fuel restriction function.
Speed detection
(MPU) Engine speed of 100 min-1
signal error is detected, or signal STOP LAMP 2-1 Stop the engine.
(note (b)) operating is less than 1.5 V.
Actuator driver Short-circuit in actuator STOP LAMP 4-1 Stop the engine.
signal error
Position signal is lower

Actuator position than 0.05 V or higher than STOP LAMP 4-5 Stop the engine.
signal error 4.95 V.
This malfunction alone does

Voltage of power supply to not produce any symptom,
Governor power boost sensor and accelerator but if the voltage change
error signal is lower than 4.75 V WARNING LAMP 4-3 results in an output
or higher 5.25 V. fluctuation, the above-
mentioned symptom is
generated.
NOTE
(a) When the diagnosis switch is ON, the WARNING LAMP indicates the pulse.
(b) Even when the engine is not operating, pulse signals are generated and pulse counts are displayed.
However, the number of pulse display generating operations is not counted.
(c) In the above pulse indication, “2-5” indicates that the lamp flashes twice, then after a pause, it flashes
five times.
14-24
14. Tunable List (for Reference)
(password) ✡ (Not recommendable to adjust)
14-25
14-26
14-27
Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162
SERVICE MANUAL REVISION REQUEST FORM
NAME OF COMPANY: MODEL:

PUBLECATION NO.:
YOUR NAME: (Located at the left bottom corner in the cover page)
PAGE NO.:
DATE: (Located at the bottom center in the page. If two or more
revisions are requested, use the comment column)
FAX:
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch is required.
If your need more space, please use another sheet.
REPLY:
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How should one use this manual?

Engine Manual

Vol No.: KM-925E-03

● Disassembly, inspection and repair

How to Use This Manual

Clogged oil hole

6. Pay attention to the special notes, cautions, and warnings.

Notes, Cautions, Warnings, Dangers

–DANGER ............................................................. Indicates the most serious specific potential hazard

–WARNING ............................................................. Indicates a specific potential hazard resulting in

–CAUTION ............................................................. Indicates operating procedure, practice, etc., resulting

NOTE ....................................................................... An operating procedure, condition, etc. that will help

Terms Used in This Manual

Nominal Value .................................... Indicates the standard dimension of a part.

2. Maintenance Standards Maintenance standards, tightening torque, sealants and lubricants.

3. Special Tools A list of special tools required.

9. Lubrication System Disassembly, inspection, and reassembly of lubrication system, to include

10.Cooling System Disassembly, inspection, and reassembly of cooling system, to include

12.Electrical System Disassembly, inspection, and reassembly of electrical system, to include

14.Adjusting Procedure of Adjustment of Actuator: PC set-up, adjustment of control link and

1. Outline ........................................................................................................................................ 1-2

1.1 External View

Front side Rear side

Viscous Water drain

By-pass oil filter

Rear side Front side

Timing gear case

1.2 Engine Serial Number Location

The engine serial number is stamped on the

Example: Model Serial No. 8 7 6 5 4 3 2 1

1.3 Engine Model and Application Codes

1 ................ Serial No. of approved model

Engine Type S16R-Y1TAA1

Engine Type S16R-Y1TAA1

Governor Control system (Electrical)

Type 3-Phase alternating generator, Internal IC regulator

Regulated voltage V 28.5±0.5

3. Tips on Disassembly and Reassembly

(2) Use only the correct tools and instruments.

1. Maintenance Standards Table ..................................................................................................... 2- 2

1. Maintenance Standards Table

The rated rpm is

[28 to 43] minimum at idling or less

Roundness 0.02 [0.0008]

inside ø70 [2.76]

STD 3.000 2.972 to 2.985 2.930

distance 90 [3.54] ±0.1

Cylindricity of 0.02 [0.0008]

0.04 [0.0016] 0.10 Repair or replace,

pressure 0 pressure is 6.86 kPa

shaft diameter ø25 [0.98]

Output current (24 V)

5000 min-1, load

2. Tightening Torque Table

2.1 Important Bolts and Nuts