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DIESEL ENGINE FOR MARINE USE | WORKSHOP MANUAL W04D,W04C-T,WO04C-TI Hino Motors,Ltd. FOREWORD procedures on Hino Marine Engine, This workshop manual has boen prepared to provide information covering rep Applicable models: WO4D, WO4C-T, and WOSC-T1 a When marking eny repair of your engine, be careful not to be injured through improper procedures. ‘As for maintenance itams, refer to tho Operation Hand Book. All information and specifications in this manual are bated upon tho latest product information available at the ti of printing. Hino Motors reserves the right to make changes at any time without prior notice. HINO MOTORS, LTD. * INDEX: ENGINE GROUP GENERAL a Ying INTRODUCTION ENGINE Y RKSHOP FOU a TURBOCHARGER a INJECTION PUMP INJECTION PUMP. GOVERNOR GENERATOR | STARTER | INJECTION PUMP CALIBRATION TORS, LTD. [reserved. This manual may not be J or copied in whole or in part, with- {ritten consent of Hino Motors, Ltd. GENERAL INTRODUCTION Gi G1-156E-01 CHAPTER Gi GENERAL INTRODUCTION GENERAL PRECAUTIONS «22.2... eee eeeeee eee GhZ HOW TO USE THIS WORKSHOP MANUAL .............. G13 IDENTIFICATION INFORMATION ...........00.0002006.Gh4 SPECIFICATIONS ..........., TIGHTENING TORQUE OF STANDARD BOLT . RECOMMENDED LUBRICANTS.............00000e00e G16 Giz GENERAL INTRODUCTION GENERAL PRECAUTIONS ‘Some recommended and standard maintenance services for your engine are mentioned in this section. |When performing maintenance on your engine be careful not to get injured by improper work, Improper or incomplete work can cause 2 malfunction of the engine which may result in personal injury and/or property amage. WARNING ‘When working on your engine, observe the following general precautions to prevent personal injury and/or property damage in addition to the particular NOTES or WARNINGS. Most threaded fasteners are metric. | Be careful not to mix with threaded fasteners using the inch system. Always wear safety glasses or goggles to protect your eyes. Remove rings, watches, ties, loote hanging jewelry and loose clothing before starting work on the engine, Bind long hair securely behind the head. 0000 ‘To avoid serious burns, keep yourself away from hot metal parts such as the engine, exhaust manifold, radiator, muftler, exhaust pipe and tail Keep yourself, your clothing and your tools away from moving parts such as the cooling fan and V-belts when the engine is running. Always stop the engine by pulling out the engine stop knob. Leave the knob pulled out as long os the engine is stopped. And turn off the starter switch, unless the operation requires the engine running, Removing the key from the switch Is recommended, Run the engine only in a well-ventilated area to avoid inhaling of carbon monoxide. Do not smoke while working on the engine since fuel and gases from the battery are flammable, ‘on the battery. It contains corrosive sulfuric acid. Take utmost care when wor 0000 curtent flows through the battery cable and starter cable, Be careful not to cause a short which Large elect ccan result in personal injury and/or property damage. Be careful not to leave any tool in the engine compartment. The tool may be hit by moving parts and can ‘cause personal DESCRIPTION EXAMPLE: T= 190-260 (14-18) ere Ae 6 S T= 1100-1300 (0-98 Ys. xt) £20 1, Thrust bearing 5. Bushing 2. Camshaft gear 6 3, Oil pump. 1 4, Idler gear T=1,100-1,300 =e a 8 Ieler goar thrust plate Straight pin 8, Idler gear shaft GENERAL INTRODUCTION Gia HOW TO USE THIS WORKSHOP MANUAL. This workshop manual is designed as 2 guide for servicing engine An INDEX is provided on the fiest page of each chapter. ‘TROUBLESHOOTING is dealt with each chapter. When beginning operations, eter to the sections on for guide t0 appropriate diagnoses, SPECIAL TOOLS are dealt with in each chapter When ordering a special tool, make sure that the parts number PART NUMBER. REPAIR PROCEDURES. Repair procedures which are self-explanatory such as simple installation and removal of parts have been omitted. Illustra tions such as the one below have been provided to make such simple procedures clear. Only essential procedures requiring directions have been dealt with explicitly TIMING GEAR AND CAMSHAFT 1 ¢ |. 2 ‘T= Tightening torque kg:cm (lb-ft) 13, Front end plete gatket 14, Front end plate 8, Crankshaft gear 10. Injection pump drive gear 11, Alor goar thrust plats 12, Camshaft G4 GENERAL INTRODUCTION In tome cases, illustrations may be of parte which differ in some nonessential way from the parts found on your par ticular engine, In such cases, however, the principale or procedure being illustrated applies regardless of euch "on: essential differences, IDENTIFICATION INFORMATION ENGINE SERIAL NUMBERS Please quote these numbers when ordering spare parts or reporting technical matter as they will give you prompt service attention The engine serial number it engraved on the engine cylinder block GENERAL INTRODUCTION Gis SPECIFICATIONS DIESEL ENGINE FOR MARINE USE HINO = WO4D wees: © ENGINE DESCRIPTION 1. Max. output, pleasure craft 82 kW ( 110HP)/3,000 rpm 2, Max, ourput, work boat 69 kW (92 HP)/3,000 rpm (light duty) 3. Type Diesel, 4-cycle, 4-cyl,, in-line, over-head valve, water-cooled 4. Aspiration Natural aspirate 5. Combustion system Direct injection 6. Cylinder Bore x Stroke 104 x 118 mm (4.09 x 4.66 in.) 7. Piston displacement 4,009 liter {244.6 cu.in.) 8. Compression ratio 179 9. Direction of rotation Counter-clockwise viewed from flywheel 10. Dimensions without marine gear (Lx Wx H) Approx, 1,026 x 691 x 780 mm (40.4 x 27.2x 31.1 in.) 11. Dry weight without marine gear Approx. 385 kg (850 Ib) @ FEATURES 1. Cylinder block Mono block cast iron with replaceable dry liner 2. Cylinder head Single piece cast iron 3. Crankshaft Induction hardened die forged special steel with counter weights 4, Piston and rings Heat resistance aluminum alloy Two compression rings, chrome plated One oil ring, chrome plated with coll expander 5. Camshaft Induction hardened carbon stee! 6. Valves Heat resistance steel Gis GENERAL INTRODUCTION @ EQUIPMENT + ENGINE 1, Flywheel housing SAE No.3 2, Flywheel SAE 11% 3, Fuel injection pump BOSCH ” A” type with all speed governor 4. Fuel filter Paper element type 5, Water separator Equipped 6. Lube oil pump Full forced pressure feed by gear pump 7. Lube oil filter Paper element type (Full flow) 8. Lube oil cooler Multi plate type, Fresh water cooled 9. Fresh water pump Forced-circulation by volute pump 10, Raw water pump Self priming, Rubber impeller type 11, Intake manifold Inlet position at rear, with air cleaner 12, Exhaust manifold Fresh water-cooled exhaust manifold, integrated heat exchanger with expansion tank 13. Starter 12V, 2.5 KW 14, Alternator 12V, SOA, with built-in voltage regulator 15. Engine stop solenoid Equipped 16. Emergency stop relay Equipped 17, Starter block relay Equipped 18. Glow plug Equipped 19, Rigid mount bracket Equipped 20, Exhaust riser Cooled by raw water ‘* INSTRUMENT PANEL, Px~PNseNa 9. 10. " 12. Battery switch Starter switch with key Instrument panel lamp switch Tachometer (with hourmeter and trip meter} Coolant temperature geuge Oil pressure gauge Fuel gauge Volt meter Pre-heater indicator lamp Coolant temperature warning lamp Charge warning lamp Oil pressure warning lamp Memo Memo GENERAL INTRODUCTION Gig SPECIFICATIONS DIESEL ENGINE FOR MARINE USE 3.899 liters, d-cycie, HINO Tice turbocharged © ENGINE DESCRIPTION 1. Max, output, pleasure craft 112 kW (160 HP)/3,000 rpm 2. Max. output, work boat 93 kW (125 HP)/3,000 rpm (light duty) 3. Type Diesel, 4-cycle, 4-cyl,, in-line, over-head valve, water-cooled 4. Aspiration Turbocharged 5, Combustion system Direct injection 6. Cylinder Bore x Stroke 104 x 113 mm (4.09 x 4.45 in.) 7. Piston displacement 3.839 liter (234.2 cu.in.) 8. Compression ratio 179 8. Direction of rotation Counter-clockwise viewed from flywheel 10. Dimensions with marine gear (Lx Wx H) Approx. 1,134 x 661 x 780 mm (44.6 x 26.0 x 31.1 in.) 11. Dry weight with marine gear Approx, 465 kg (1,025 tb) * FEATURES 1. Cylinder block Mono block cast iron with replaceable dry liner 2. Cylinder head Single piece cast iron 3. Crankshaft Induction hardened die forged special steel with counter weights 4, Piston and rings Heat resistance aluminum alloy Two compression rings, chrome plated One oil ring, chrome plated with coil expander Camshaft Induction hardened carbon steel Valves Heat resistance steel 2 gia GENERAL INTRODUCTION @ EQUIPMENT ¢ ENGINE 1. Flywheel housing SAE No. 3 2. Flywheel SAE 11% 3, Fuel injection pump BOSCH "A" type with all speed governor 4. Fuel filter Paper element type 5, Water separator Equipped 6. Lube oil pump Full forced pressure feed by gear pump 7. Lube oil filter Paper element type (Full flow) 8. Lube oil cooler Multi plate type, Fresh water cooled 9. Fresh water pump Forced-circulation by volute pump 10, Raw water pump Self priming, Rubber impeller type 11, Intake manifold Inlet position at rear 12. Exhaust manifold Fresh water-cooled exhaust manifold, integrated heat exchanger with expansion tank 13. Turbocharger Cooled by fresh water, with air cleaner 14. Starter 12V, 25 KW 15, Alternator 12V,, BOA, with built-in voltage regulator 16. Engine stop solenoid Equipped 17. Emergency stop relay Equipped 18. Starter. block relay Equipped 19. Grow plug Equipped 20. Rigid mount bracket Equipped 21, Exhaust riser Cooled by raw water 22, Marine gear Equipped * INSTRUMENT PANEL Battery switch Starter switch with key Instrument panel lamp switch Tachometer (with hourmeter and trip meter) Coolant temperature gauge Oil pressure gauge Fuel gauge Volt meter Precheater indicator lamp Coolant temperature warning lamp Charge warning lamp Oil pressure warning lamp GENERAL INTRODUCTION Gilt F225 Fear LEFT SIDE VIEW NOTE: These specifications are subject to change without notice. Jéing, HINO MOTORS,LTD. """™ MEMO GENERAL INTRODUCTION Gi13 SPECIFICATIONS DIESEL ENGINE FOR MARINE USE 4.839 liters, d-cycle, HINO : soy wou turbocharged and intercooled © ENGINE DESCRIPTION 1. Max. output, pleasure craft 157 kW (210 HP)/3,000 rpm 2. Max, output, work boat 138 KW [185 HP)/3,000 rom (light duty) 3. Type Diesel, 4-cycle, 4-cyl., incline, over-head vatve, water-cooled 4. Aspiration Turbocharged and intercooled 5. Combustion system Direct injection 6. Cylinder Bore x Stroke 104 x 113 mm (4,09 x 4.48 in.) 7. Piston displacement 3.839 liter (224.2 cu.in.) 8. Compression ratio 16.5 9. Direction of rotation Counter-clockwise viewed from flywheel 10. Dimensions with marine gear (L x Wx H) Approx. 1,152 x 694 x 790 mm (45.4 x 27.3 x 31.1 in.) 11. Dry weight with marine gear Approx, 540 kg (1,191 tb) © FEATURES 1. Cylinder block ‘Mono block cast iron with replaceable dry liner . Cylinder head Single piece cast iron 3. Crankshaft Induction hardened die forged special steel with counter, weights 4. Piston and rings Het resistance aluminum alloy ‘Two compression rings, chrome plated ‘One oil ring, chrome plated with coil expander 5. Camshaft Induction hardened carbon steel 6. Valves Heat resistance steel Gia GENERAL INTRODUCTION @ EQUIPMENT * ENGINE 1, Flywheel housing SAE No. 3 2. Flywheel SAE 11% 3. Fuel injection pump BOSCH “AD” type with all speed governor 4, Fuel fitter Paper element type 5. Water separator Equipped 6. Lube oil pump Full forced pressure teed by gear pump 7. Lube oil filter Paper element type (Full flow} 8. Lube oil cooler Multi plate type, Fresh water cooled 9. Fresh water pump Forced-circulation by volute pump 10. Raw water pump Self priming, Rubber impeller type 11, Intake manifold Inlet position at rear 12. Exhaust manifold Fresh water-cooled exhaust manifold, integrated heat exchanger with expansion tank 13. Turbocharger Cooled by fresh water, with air cleaner 14, Intercooler Cooled by raw water 15, Starter 12V, 2.5 KW 16. Alternator 12V, 50A, with built-in voltage regulator 17. Engine stop solenoid Equipped 18. Emergency stop relay Equipped 19. Starter block relay Equipped 20. Glow plug Equipped 21, Rigid mount bracket Equipped 22, Exhaust riser Cooled by raw water 23. Marine gear Equipped © INSTRUMENT PANEL, Somnomewne W 12, Battery switch Starter switch with key Instrument panel lamp switch Tachometer (with hourmeter and trip meter) Coolant temperature gauge Oil pressure gouge Fuel gauge Volt meter Pre-heater indicator lamp Coolant temperature warning lamp Charge warning lamp Oil pressure warning lamp GENERAL INTRODUCTION G48 F229 LEFT SIDE VIEW NOTE: These specifications are subject to change without notice J#iza HINO MOTORS, LTD. = *°"" GENERAL INTRODUCTION G46 ;Payronds you st anbs01 or susuna paydde aq piNou 21GE HAD U Uan6 Soren onbs04 Su, :3L0N ~ init ements} Som oma, corm gee, faeces | ste | sce | gece ate se oe Guruerybis wnuyuinye 40 WOH 35e3 @) - 6 tcap~ ven | tow—seer | isc oer | weer ~earh 1001-900 r-su ee-su eee |" a oveccea| Ge ES | eee, | pte a a a 4 = oy Sas esate | ere | soe | soe | eon Sera see a pea oe aii | aoe | ace | aca | ace | ce “ ee] | \ est eine ere ct 7 v ve ce oz BL OL we eb OL 8 9g v (Fay aed) am L108 GHVGNVIs 40 ANOYOL ONINALHOLL G7 GENERAL INTRODUCTION Kd sassy an OI agvau one wants 1 won ssve0 was ann ing no) ossa rouse xan ve |.58%5) atti | swoutsos sinvomant ANISNA ONIH Tv ¥O4 SLNVOINENT GSGNSWWOo0sye ou MEMO ENGINE EN-1 EN-1356-02 CHAPTER EN ENGINE Models WO4D, WO4C-T and W04C-TI DATA AND SPECIFICATIONS... veeteeeees EN-DS7A +1 TROUBLESHOOTING ... EN-TSIC . 1 ENGINE OVERHAUL CRITERIA . : EN-OC3C - 1 ENGINE MOVING PARTS ... . EN-MP7A - 1 CYLINDER HEAD .... cevteeseeess ENMPTA - 5 TIMING GEAR, CAMSHAFT AND OIL PAN... EN.MP7A 16 PISTON, CRANKSHAFT, CYLINDER BLOCK AND FLYWHEEL HOUSING ........ ses. ENMP7A -23 LIQUID GASKET AND APPLICATION PARTS ... EN-MP7A -28 LUBRICATING SYSTEM EN-LS7A . 1 OIL PUMP....... : . EN-LS7A - 3 OIL COOLER AND OIL FILTER. EN-LS7A - 5 FUEL SYSTEM.......... a 7 s+. EN-FS6B - 1 INJECTION NOZZLE sessess EN-FSOB - 2 FUEL FILTER .. . EN-FS6B - 4 COOLING SYSTEM ......... EN-CS7A - 1 COOLANT PUMP be EN-CS7A - 3 HEAT EXCHANGER cess EN-CSTA - 6 THERMOSTAT <1. EN-CS7A - 8 AIR INTAKE AND EXHAUST SYSTEM . ENIEZA - 1 ENGINE COMPONENT PARTS DISMOUNTING AND MOUNTING... acral vevteeeseees EN-CPSB - 1 FUEL INJECTION PUMP ..,.......... EN-CP5B . 1 GENERATOR dant EN-CP5B - 3 STARTER oo. .scceveeeesee es EN-CPSB . 4 ENGINE TUNE.UP : EN-TUSA . 1 PROCEDURE FOR INSTALLING AND GASKETS OF ENGINE PARTS . . EN-PRIB- 1 MARINE TRANSMISSION MOUNTING AND DISMOUNTING .......0.cs0cescee tence J ENMTIA. 1 ENGINE EN-DS7A-1 DATA AND SPECIFICATIONS Model woap woact wo4e-TI TYPO eee eee eeee ++ | Diesel, 4-cyele, vertical, 7 « 4 cylinder, inline, overhead valve, water cooled Aspiration Natural aspirate Turbo charged Turbocharged and intercooled Combustion system +++ | Direct injection + < Bore and stroke... + | 104. 118 mm 104 x 113. mm - (4,09 x 4.65 in) (4.09 x 4.48 in} Piston displacement see e+ | 4,099 liters (244,6 cu.in) | 3.839 liters (234.2 cu.in) + Compression ratio... . 17.9 < 165, Firing order... 5.6 1-3-4-2 + - (A number of a cylinder is to be counted in order | from the timing gear side) | Direction of rotation . . . Counter-clockwise viewed 7 + | ‘from flywheel | ‘Maximum revolution (at full lozd) . | 3,000 rpm « « Idling revolution . . . 775-825 rpm - 750-800 rpm Dry weight with marine transmission.| Approx. 430 kg (948 Ib) | Approx. 465 kg (1,025 Ib} | Approx. 520 kg/1,146 1b Valve timing (flywheel travel), Intake opens . - 16° before T.0.C. + + Intake closes ...... 44. .++ | 40° after B.0.C, - - Exhaust opens... 55 before B.D.C. « + Exhaust closed - va [19° after T.0.C. + - Valve clearance (when cold), Intake... 0.30 mm {0.0178 in} « 0,35 mm (0.0738 in) Exhaust .. 0.40 men {0.0157 in} 0.45 mm (0.0177 in} 0.50 mm (0.0197 in} Injection nozzle opening pressure. | 220 kg/em? (3,129 tb/sq.in} - | ‘ Injection timing . . 14° before T.D.C. for No.1 | 17° before T.D.C. for No.1 < ‘eylinder on compression | cylinder on compression stroke stroke EN-DS7A-2 ENGINE a Model Wo4aD PERFORMANCE CURVE PLEASURE CRAFT RATING LIGHT DUTY RATING SAE yo0 8038 SAE saw seaoen Foe eRome 100 (eoHENT 1) po g. aioe 5 3 “te g > i : _ baz z ege fe “eH EA warren wae] is — ei 8 RCO RS 3 ENGINE SPEED vom ean ENGINE SPEED om rae Note: Engine performance at SAE standard 1349 conditions of 90m {300ft) altitude (100 kPa (29.61 inHg] baro- metric pressure), 25°C (77°F) air intake tamperature, and 1 kPa (0.30 in.Hg) water vapor pressure with No.2 diesel fuel wil be within 6% of that shown at the time of engine shipmont. Actual performance may vary with different ambient conditions ENGINE EN-DS7A.3 Model WO4C-T PERFORMANCE CURVE PLEASURE CRAFT RATING LIGHT DUTY RATING £] Sioeeret a PRESae SER rome Ee secrmenia 3" nn 8 LZ. | 7 [fesse : “ Lodesemeromnice | Bf pari" § » Figs mopei.ea oo, a | 8 * AE he |: 3 els 3 aed ENGINE SPEED rem rans ENGINE SPEED tm eae nore: Engine performance at SAE standard J1349 conditions of 90m (300ft) altitude (100 kPa [29,61 in.Hg] baro- ‘metric pressure), 25°C (77°F) air intake temperatura, and 1 kPa (0.30 in.Hg) water vapor pressure with No.2 set fuel wll be within 8% of that shown at the time of engine shipment. Actual performance may vary with differnt ambient conditions. DESCRIPTION bod 2 =A aro 4. (Gye re S Ring 5 I | J onF-206 onF.227 EN-DS7A4 Model WO4C-T1 PERFORMANCE CURVE PLEASURE CRAFT RATING SAE soa orate) LIGHT DUTY RATING SAE ir rosa diesel fuel wil be different ambient conditions, DESCRIPTION © EERE omrvaria Eee eee keer sya I l= om : 5 wel Z 5 fie {ot F £fol ve Ev Z el dee rc cs: ls Geant § “|s=5 i | i T 5S z al \S POWER PROPFLLEA Las z oe rn f I we af meme Tote ofa g : fale 3 afte i aise perros ean eeeeanese rare NoTE: Engine performance at SAE standard J1349 conditions of 90m (300ft) altitude (100 kPa [29.61 in.Hg] baro- metric pressure), 25°C (77°F) air intake temperature, and 1 kPa (0.30 in.Hg] water vapor presture with No.2 ithin 5% of that stiown at the time of engine shipment. Actual performance may vary with HF.220 ‘Symptom ENGINE TROUBLESHOOTING Engine overheating Coolant Insufficient coolant Defective thermostat Overflow of coolant due to leakage of exhaust into cooling system Coolant leakage from cylinder head gasket Defective coolant pump . —— | [Heat Exehanger Clogged with rust and scale Clogged with iron oxide due to. . leakage of exhaust into cooling system Clogged or corroded heat exchanger due to mud or other debris, Defective heat exchanger cap pressure valve ‘Abnormal combustion, Incorsect injection timing . Reduced injection pressure Poor fuel... Poor nozzle spray eee (Other problems Defective or deteriorated angine oll ..... Unsatisfactory operation of oil pump Insufficient oil Broke drag Cooling system Defective sea water pump Loose or slipping V-bett ‘Closed sea water intake valve (Seacack) Clogged sea water strainer Unsatisfactory automatic timer advance angle. EN-TSICA sdy/Prevention Add coolant. Replace the thermostat, Repair « Replace gasket. « Repair or replace, = Clean hest exchanger. Clean coolant passage and correct exhaust leakage, Clean or repiace heat exchanger. Replace heat exchanger cap. «Adjust injection timing, - Adjust injection pressure Use good quality fuel. Adjust or replace nozzle Repair or replace timer, Change engine oil, Replace or repair. «Add oil. Repair or adjust, Repair or replace. Adjust V-belt tension or replace. Open intake valve. Glean strainer. ENTS1C.2 ENGINE Symptom Possible cause Remedy/Pravention Excessive oil consumption Pistons, cylinder liners, and piston rings ‘© Wear of piston ring and eylinder liner... ‘© Worn, sticking or broken piston rings Insufficient tension on piston rings 4 Unsatisfactory break-in of piston rings ‘© Unsuitable ol (vtcosity too low). Incorrectly fitted piston rings , upside down) © Gaps of piston rings in line with each other ‘Valve and valve guides Worn vaive stem Worn valve guide Incorrectly fitted valve stem seal Excess oll feed © Defective oil level gauge © Oil level too high aoe Cooling systern © Overcooled engine .. {low temperature wear) Other problems © Oil leakage from miscellaneous parts Piston seizure Operation ‘Abrupt stoppage of engine after cunning . . . at highspeed Excessive lubricant on rocker arm... ss «Replace piston rings and cylinder liner, «Replace piston rings and cylinder finer, Replace piston rings and cvlinger liner, Replace piston rings and cylinder liner, Change oil as equired and replace piston rings and cylinder liners, Replace piston rings Reassemble piston rings, Replace valve and valve guide. Replace valve guide. Replace the stem seal Check clearance of rocker arm and shaft, = Replace oil level gauge Drain excess cil Warm up engine before moving boat. Check cooling system, Repair, + Operate engine properly. Symptom Piston seizure foi} Lack of power ENGINE Possible cau: # Dintyoil . Ieee # Poor quality oil High oil temperature © Low oil pressure © Defective oil pump Reduced performance due to worn oil pump ‘© Suction strainer sucking air. ‘Abnormal combustion} . Injection pump) Tneake © Clogged air cleaner ‘Overheating Fuel and nozzle # Poor nozzle spray ‘© Clogged nozale with carbon (© Wear or seizure of nozzle © Air in Fuel system © Clogged fuel filter © Use of poor fuel = o (Abnormal combustion Pst eylinder liners, and piston rings Other probiems © Breakage of turbine or blower EN-TSIC-3 «Add oil = Change oil ._ Replace with proper engine oil = Repair Repai = Repair oll pup. Replace oil pump. + Add oil andor cepsir strainer. «See Symptom: “Engine over- heating.” ‘See Symptom: “Engine over- heating.” Refer to CHAPTER IP, FUEL INJECTION PUMP, Clean element or reptace element, ‘See Symptom: “Engine overheating.” «Adjust or replace injection nozzle Clean nozzle Replace nozzle. «Repair and bleed air from fuel syste, Replace element Use good quatity fue. See Symptom Engine overheating.” See Symptom “Engine over heating.” Replace the turbine or blower or turbocharger ENTSIC4 ENGINE Symptom Possible cause Remady/Pravention Difficulty starting engine Difficulty starting engine Electrical system © Discharged battery © Detective wiring in starter eirouit © Loose or open-circuit battery cable Breakdown of starter © Break of glow plug or intake air heater (If so equipped) Injection pump, (Air cleaner| © Clogged element 7 Fuel system| © No fuel in tank... © Clogged fue! tine Air sucked into fuel system through fuel line connections © Clogged fuel filter... ‘© Loose connection in high-pressure line © Water in fuel. Nozes| © Seized nozzle © Broken or fatigued nozzle spring (Oiteyseem © Oil viscosity too high [Other problems © Seized piston © Seized bearing . © Reduced compression pressure © Ring gear damaged or worn Improperiy adjusted or broken... accelerator cable Charge battery Repair wiring of starter Tighten battery terminal connec tions or replace battery cable. Replace starter Replace Refer to CHAPTER IP, FUEL INJECTION PUMP, Clean the element or replace the element. ‘Supply fuel and bleed air from fuel system, Clean fuel line, Tighten fue! line connections. Roplece element, Tighten sleeve nut of high pres: sure line, Drain and clean fuel system « Replace nozzle, Replace spring, Use proper viscosity oil, or install an oil immersion heater and warm up oil Replace piston, piston rings, and liner. Replace bearing and/or crankshaft, Overhaul engine, Replace the ring gear andlor starter pinion, Adjust or replace the accelerator cable ENGINE ‘Symptom Possible cause Rough idting ——-————f Injection pump Nozeles Uneven injection pressure Poor nozale spray Carbon deposit on nozzle tip Seized needle valve Engine proper| Improper valve clearance Improper contact of valve seat Idling speed too low . . Coolant temperature too tow Compression pressure of cylinders markedly different from one another Leakage of exhaust Gylinder Read gasket Fatigued gasket (aging) Damage Improper installation Cylinder head bolts Loose bolts tightening sequence [Cylinder block Cracking ‘Surface distortion . Fretting of cylinder liner insertion portion {insufficient projection of ‘eylinder liner) Cylinder head Cracking Surtace distortion = Overhaul engine Etongated bolts... wees Improper tightening torque or... EN-TSIC5 Remedy Prevention «Rafer to CHAPTER IP, FUEL INJECTION PUMP. Adjust. «Adjust or replace nozzle, Remove carbon, Replace nozzle, Adjust valve clearance Replace or repair valve and valve seat. Adjust idling speed, Warm up engine. Replace gasket. Replace gasket. Replace gasket. Tighten bolt, Replace bolt, Tighten property. «Replace cylinder block. Repair or replace. Replace cylinder liner or cylinder block. Replace cylinder heat. + Repair or roplace. EN-TS1C-6 ENGINE Symptom Possible cause Remedy/Prevention Leakage of exhaust {Cylinder liners [—[Dther problems © Cracking © Corrosion Insufficient projection of cylinder liner © Incorrect injection timing... 6. eye ev Seawater discharge is not —— sufficient Abnormal noise or vibration Seawater pump] © Sucking air. ¢ Damaged impeller © Clogging of suction pipe and/or seawater strainer —{Seawater pump © Wern bearing '® Foreign material in the pump © Incomplete mounting Bearing wears frequently Seawater pump] © Too tight V-belt tension... eee Damage of impeller ‘Seawater pump] ‘© When it has been operated for a long period... . (© When it has been operated without seawater (© When it has been operated at higher RPM © Too high or low water temperature ‘© Whan it has not baen operated for an extended period © Foreign material in the pump Replace cylinder liner «Replace cylinder liner. = Replace eylinder liner «Adjust injection timing ‘Supply seawater and blaed air from cooling system. Replace impeller. Clean suction pipe and strainer. «Replace bearing, Repair or replace. Mount completely. Adjust V-belt tension, Replace impeller, Replace impeller Replace impeller and operate at normal RPM. = Replace impeller and operate at normal temperature, Replace impeller. Repair or replace, ENGINE EN-0S3C. SPECIAL TOOL ENGINE OVERHAUL CRITERIA Prior to starting an engine overhaul, itis necessary to have these special tools. COMPRESSION GAUGE COMPRESSION GAUGE ADAPTOR (NOZZLE HOLDER) ADAPTOR (GLOW PLUG) ADAPTOR, COMPRESSION GAUGE 09652-1081 (09552.1070 FACTORS WHICH DETERMINE WHEN AN ENGINE OVER. HAUL IS NEEDED. 1. Lowered compression pressure a. Before the measurement a) Correct the vaive clearance. bb} Warm up engine {Bring the coolant temperature to about 80°C (76°F) ©) Charge the battery fully d} Remove the air cleaner, b. Measurement 1) Meature at nozzle holder hole. SAWPLE 3} Remove the nozzle holders. bb) Install the gauge adapter in the nozzle holder hole Special Tool: Compression Gauge Adapter (09408-1041) (09862-1070) 2), Measure at glow plug hole, a] Remove the glow plug. bb) Install the gauge adeptar in the glow plug hote, Special Tool: Compression Gauge Adapter (09552-1061) (09552-1070) Sws.3e8 ‘¢) Connect a compression gauge to the gauge adapter. d) Drive the engine with the starter and read the compression pressure. NOTE: Do not continuously operate the starter for more than 15, seconds at atime ©} Measure the compression pressure for each cylinder. If the compression pressure is low, be sure to repeat the measuring. NOTE: Be sure not to leak through seating face. Unit: kg/em? Ubisa.in) Compression pressure ] Difference between Engine speed Engine model : fa gine sper a Standard Lime each eylinder (cpm) woad) 33-36 (469-5: 5 (38 woac.t Hee ao Less than 3 (43) 350 woacTl 30-33 (427469) 22. (313) ‘WwosD a a [33-36 465-811) 25 (356) a WosD.TI 30-33 (427-468) 22 (513) EN-0830-2 ENGINE SaunE 2. Decreased ol pressur Check the oil pressure warring lamp when the oil and coolant, temperature is hot [about 89°C (176° FI}. 2. If the warning lamp is lighted, check the ol level b. Check oil deterioration {f oil quality is poor, replace with a suitable grade ol © Remove the ol! pressure switch and install the oil pressure gauge. 4. Measure the oil pressure at coolant temperature 80°C (176°F) or more. sws.sée| Standard oil presture: 0.5-5.0 kg/cm? (7.11—71.10 t/q Service limit: Loss than 0.6 kg/em? (7.11 Tb/sqin} ATMOSPHERIC TEMPERATURE sas ~ 3. Other factors Grape | po 5) 70s F & —Theblowby gas increases. “2-180 10 2 S230 [°c b. The engine does not start easily 7 & Engine output decreases. d. Fue! consumption increases. 30 e. Engine makes greater noise 2owi20 {Excessive ol consumption. 150/40 ENGINE EN-MP7A-1 ENGINE MOVING PARTS DESCRIPTION Representative engine model WO4C-TI 1 ). Heat exchanger cap Heat exchanger Generator Engine coolant pump Crankshaft pulley ‘Seawater pipe ”. Seawater pump Oil pan . Water separator ). Fual filter i 11. Engine stop solenoid iS 7 12, Oil level gauge et 13. Intercooler & de Ae 14, Fual feed pump i 15, Fuel injection pump 16. Starter 2 an i x cc au] ENMP7A2 SPECIAL TOOL ENGINE Prior to starting an engine overhaul, itis necessary to have the following. SLIDING HAMMER ADAPTOR (USED WITH 09420-1442) ADAPTOR (USED WITH 09420-1442), D x ig GE 09420-1442 CYLINDER HEAD BOLT WRENCH 09462-1370 for model Wo4D EYE BOLT (USED WITH 09470-1022) (09462-1120 for models WO4C-T ‘and WO4G-TI wire ee 09411-1260 VALVE SPRING PRESS 09433:1070 VALVE LAPPING TOOL 09491-1010, VALVE STEM SEAL PRESS a 09470-1022 CRANKSHAFT PULLEY PULLER, 09431-1010 TIMER SETTING TOOL 09472-1660 IDLER GEAR SHAFT PULLER 8 V) 09420-1500 09512-2090 for model WO4D (09512-2100 for models WO4C-T ‘and WO4C-TI 09420-1100 TIMING GEAR COVER OIL ENGINE EN-MP7A-3 SEAL PRESS PISTON RING EXPANDER CYLINDER LINER PULLER 09482-1530 09442-1180 (09420-1460 CYLINDER LINER GUIDE GUIDE PRESS SUB ASSEMBLY 09480-1120 09481-1130 (09402-1460 WING NUT ‘SPINDLE SPINDLE i sj 9233-10360, 09402-1470 tor models WO4C-T (08402-1460 for model WO4D and WO4C-T! GUIDE GUIDE BOLT (09481-1120 for model WO4D. 9191-06252 (09481-1140 for models WO4C-T and WOAC-TI EN-MPTA4 FLY WHEEL HOUSING OIL SEAL ey a oe ENGINE EN-MP7A-5 CYLINDER HEAD OVERHAUL ME 11~040.-0002 (1310) T= 190-260 (14-18) 190-260 (14-18) 2 [ | 7 7 8. 16 T= Tightening torque kg.cm (Ib.ft) 1. Cylinder head 7. Push rod 13, Vaive stem oil seal 2. Rocker arm shaft 8. Tappot 14. Vaive spring lower seat 3. Bushing 9. Cotter key 15, Exhaust valve 4, Rocker arm 10. Valve spring upper seat 16. Intake valve 5. Rocker arm support 11. Inner valve spring (For WO4D) 6. Valve clearance adjusting screw 12. Outer valve spring ENMPTA-6 ENGINE OVERHAUL ‘T= 450~500 (33-36) 130-190 (10-13) T= 1,300—1,400 (94-101) T= 130-190 (10-13) T+ Tightening torque: kg-om (tb.ft) Cylinder head Oil filer cap Cylinder head cover |. Cylindar head cover gasket Cylinder head gasket . Valve guide - Valve seat . Expansion plug 1. Nozzle holder gaskat 10, Packing ring 11. Shim 12. Nozzle holder 13. Nozzle 14, Nozzle holder adapter INTAKE S108 sm3.201| ENGINE ENMP7A7 IMPORTANT POINTS — DISASSEMBLY CLEAN OFF SURROUNDING AREA OF THE NOZZLES AND ‘THE FUEL LINE CONNECTORS. NOTE: If foregin matter is allowed to enter the combustion chamber, engine trouble may result. REMOVE THE INJECTION PIPES, NOTE: Cover open ends of the pipes to prevent entry of dirt. REMOVE THE NOZZLE ASSEMBLY. Using 2 special tool, if the nozzle is difficult to remove by hand. Spocial Tool: Sliding Hammer (09420-1442) Adapter (09462-1370) for WO4D (09462-1130) for Wo4C-T, Wo4c-TI NOTE: © After removal of the nozzle holder, cover the nozzle holder with cloth. Also cover the cylinder head with » ‘cloth to prevent dust trom gatting in, REMOVE THE CYLINDER HEAD ADDITIONAL BOLTS AND ROCKER ARM SUPPORT BOLTS. Loosen the cylinder head additional bolts and rocker arm support bolts in the numerical order as shown. LOOSEN THE CYLINDER HEAD BOLTS AND REMOVE THEM. Loosen the cylinder head bolts little by little in three stages and in the numerical order as shown, ‘Special Tool: Wrench (09411-1260) * Mark position (Cylinder head additional bolts) EN-MP7A8 ofA, PLACE CHISEL [AT THIS JCORNER ONLY PLY UP AND DOWN Poo ren 6.0 0 fit CYLINDER BLOCK smase a lands “\polealestan 1 2 8M3-893, svoa2s ENGINE LIFT THE CYLINDER HEAD FROM THE DOWELS ON THE CYLINDER BLOCK AND PLACE IT ON WOODEN BLOCKS 1. If the cylinder head is difficult to lift off, pry with @ chisel between the cylinder head and block. NOTE: Do not damage the machined surtece of the head or block when removing the eylinder heed, Special Tool: Eye Bott (08433-1070) Wire (09491-1010) REMOVE THE VALVE SPRINGS, 1. Remove the valve stom cotters, upper valve seats, and inner {for WO4D) and outer vaive springs from cylinder head. Special Tool: Valve Spring Press (09470-1022) 2. Remove the intake and exhaust valves 3. Tag valves to identify their eylinder numbers and to eliminate valve lapping. IMPORTANT POINTS — ASSEMBLY CLEAN THE CYLINDER HEAD THOROUGHLY WITH A SUIT- ABLE SOLVENT, NOTE: Be careful not to damage the cylinder head surface, IF NECESSARY, HAND-LAP THE VALVE AND VALVE SEAT. Lightly apply lapping compound to the valve face. Install the valve with a special tool, tap and rotete the valve against the seat, Special Tool: Valve Lapping Too! (09431-1010) ENGINE EN-MPTA-9 _NALVE SEAT. } ane weLoinc POSITIONS $3.96 / ExHausT, ‘53.386 su 524 IF NECESSARY, GRIND THE VALVES AND VALVE SEATS, NOTE: © Grinding of valves and valve seats should only be per- formed when hand-lapping does not result in proper seating. (© After grinding, always recheck the valve sink. Standard: Valve Seat (Intake) : 30° — 30°30" Valve Face (Intake) : 29°46’ — 30°15" Valve Seat (Exhaust): 45° — 45°30" Valve Face (Exhaust): 44°45" ~ 45°15" IF NECESSARY, REPLACE THE VALVE SEAT. 1, Gut the circumference of a valve head at three places with ‘a grinder and install it into the seat as shown and weld the valve to the seat, Then drive the valve and the seat out with ‘a hammer and a brass block 2. Valve seat section machining specifications. Unit: wm tn) lotake | _—~Exhaust Fe], | 46500-48516 | 41,000-41.016 i ? (1.8308-1.8313)_|_(1,6142-1.6148) a8]. 88-90 72-74 & (0.3465-0.3643) | (0.2835.0.2913) ee | c¢. | s585-48.600 | 41,130-41.145 ag (1.8341~-1.8346) | (1,6193-1,6198) ira 75-77 60-62 ee (0.2953-0.3031) | (0.2363-0.2440) 3, Valve seat installation Heat the cylinder heed to 80°~100°C (176~212°F) with hot water, On the other hand, cool the valve seat with dry ice oF liquid freon for approx. 30 minutes. Hold the seat with pincers and place it into the heated cylinder head. EN-MP7A-10 ENGINE wale IF NECESSARY, REPLACE THE VALVE GUIDE, GUIDE | pYUNDER HEAD 1. Remove the valve stem seal eee 2. Using a brass rod and hammer, drive out the valve guide. B53 3, Install the valve quide as shown. see NOTE: Apply engine ail lightly to the valve guide outer circum- EEE EEE ference before installing. ‘5M3-389 IF NECESSARY, REPLACE THE VALVE STEM SEAL, 1. Remove the valve stem seal 2. Install the vaive stem seal, First, Install the lower spring seat (for stopper of spécial tool) and valve. Then apply engine oil to the lip of the stem seal and drive the special too! until it hits the lower spring seat. Spocial Tool: Valve Stem Seal Press (09472-1650) 39.827 NOTE: © After installing stom soal, make sure that check the RUBBER GOAT OWL. rubber position for cracks or any other damage, Ft © Do not use the special too! if its tip (surface contacting f ower spring seat) is worn of deformed. M3708 ASSEMBLE THE CYLINDER HEAD. NOTE: © Apply engine oil to contact surfaces of all parts © Make sure that the valves are installed in the correct, cylinders. (© Install the valve springs with their painted side down, since they have variable pitches, PAINTED SIDE sias-907 Press upper spring seats and install the valve stem keys securely. in the upper spring seats Special Took Valve Spring Press (09470-1022) NOTE: © When pressing with the valve spring press, be careful not to damage the stem seale by contacting the upper seats, © Drive the valve stem lightly with 2 hammer to assure proper fit the valve stem key. No, 5. SUPPORT ARROW MARK TIMING GEAR SIDE Intake exhaust OILHOLE ROCKER AAM SHAFT fi No. 5 SUPPORT 9M3.204 53.28 5M32014\ ENGINE EN-MP7A-11 ASSEMBLE THE ROCKER ARM, Lubricate the rocker arm shaft and bushing, NOTE: Confirm that oil hole of rocker atm assembly No. 5 support aligns with shaft oil hole. Improper installation will result in burning of the entire vaive assembly. INSTALL THE TAPPETS IN THE CYLINDER BLOCK IN COR- RECT ORDER. NOTE: Apply engine oil to the tappet faces and tappet guide when ij them in the cylinder block, INSTALL THE CYLINDER HEAD AND ROCKER ARM ASSEM- BLY. 1. Install the eylinder head gasket. NOTE: Always use new cylinder hes surfaces of the cylinder hed, cyl gasket free of all ditt, water and grease. gasket after cleaning the block and head Install the cylinder head over the dowels on the cylinder block. 3. Insert the push rods in correct order, after applying engine oil ‘to both ends. 4, Mount the rocker arm assembly on the cylinder head, make sure that the push rods interlock with the adjusting serews. NOTE: Always loosen the lock nut and raise the adjusting screws fully to the top. 5, Tighten the cylinder head bolts litte by little in three stages and in the numerical order as shown, NOTE: Apply engine oil to the bolt threads and under the bolt head. + Mark bolts (cylindar head additional bolt): $10 mm (0.39 in} No. 1 — No. 18 Bolts (Cylinder head bolt): ¢ 12 mm (0.47 in} Special Tool: Wrench (09411-1260) EN-MP7A-12 ENGINE 6 Tighten the cylinder head additional bolts and rocker arm support bolts little by litle in three stages and in the nu= merical order as shown, Tighten the bolts to the specified torque, 7. Retighten the oylinder head bolts NOTE: Refer to SECTION ENGINE TUNE-UP. ENGINE INSPECTION AND REPAIR EN-MP7A-13 Unit: men fal Inspection Item Standard Limit Remedy Inspection Procedure Cylinder Head Flatness Less than 0.05, 0.1 | Regrind or (0.0019) (0.0039) | replace Cylinder Head Height 37.0 86.8 | Replace (3.425) (3.417 Cylinder Head Cracks and Replace, i Damage recesary * Using a Dye Penetrant 4 SM3832 Valve Seating Condition | There shauld be good | Hana-top with —~ * Using Red Lead Marking | contact around entire tapping com: : Compound sireumtrence of valve pound head. : aa 2 Oe 7 Oo Pee A swoe0 Valve Seat Angle | Intake 20-3030 Resring or replace valve ' ! exhaust | 45°—49°30 andor valve N\A ~ | sex VI Valve Ange Inake | 29°46'—30°15" PS Exhaust | 44° €5'—45"95" Nozzle Protrution from 2.75-3.25, Replace nozzle Cylinder Head Surface (0,1083-0,1279) gasket (eae He = ant 3-301 Intake Valve Sink Replace valve 7 -o- is CYLINDER, and/or MEADSURFACE valve seat Wose-TI | _(0,0019-0.0737) | (-0.0079) Exhaust Valve Sink 0.47 ~ -0.77 -087 (-0.0185 ~ ~0.0303) | (-0.0342) sm2-209| EN-MPTAA4 ENGINE Unit: mom fn) Inspection Item Limit Remedy Inspection Procedure Intake Valve Stem Diameter § 8.90 | Replace valve (0.3524-0.3531) | (0.3903) | guide and/or Exhaust Velve Stem Diameter 8.93-8.95 ao | ave (03516-03524) | (0.3484) Intake and ExhaustValve Guide | 9.000-0.015 AaB Diametor (0.3544-0,3549) 9.05 (0.3562) ce 810.197) gus.gga 9.10 25 (0.984) _ (0.3882) 45(1.771) ‘Clearance between Valve Stern 0035-0068 | A&B: ‘and Valve Guide (Intake) (0.0004-0.0026) | 9-10 (0.0040) 0.18 (0.0071) ‘Clearance betwean Valve Stem 0.050-0.083 ‘a and Valve Guide (Exhaust) (0.0020-0.0032) | 912 : (0.0047) ¢: 02 (0.0078) ‘Rocker Arm Shaft Diameter 18,97-18.98 18.95 | Replace rocker (0.7489-0.7472) | (0.7461) | arm bushing and/or shaft Clearance between Rocker Arm 0.036-0.079 01 Shaft and Rocker Arm Bushing | (0.0016-0.0031) | (0.0039) Inner Valve Spring Setting Load | 8.8kg (19.416) at | 80g | Replace (For WO4D only} 43.0 mm (1.69 in) | (17.6 1b) Outer Valve Spring Setting Lood | 27.4 kg (54.5 Ib) at | 25.5 kg 485mm /(1.79in) | (56.2 1b) ‘Valve Spring Straightness 2 Replace (oner and Outer! (0.0787) Valve Spring Seat for Weer A: 25 Repalee (0.0984) 8: 5.0 (0.1969) = c: 10 (0.0384) $M3.908 ENGINE EN-MP7A-15 Unit: om tin Inspection Item ‘Standard Limit Remedy Inspection Procedure \Vaive Stem Tip Surtaca for Rewurface or ‘Visual Check Wear replace of Racker Arm for Push Rod Bend 0.3 | Replace (0.0118) 26.95--26.97 Replace tappet {1,06 11~1,0618) ‘Tappet Guide Inside Diameter 27.00-27.02 (1,0630-1.0637) Clearance between Tappet and 0.025-0,071 ot Tappet Gi (0.0010-0.0029) | (0.0039) M3420 sM9-293, ‘Tappet for Wear Should not be worn Replace, if unevenly. necessary - Visual Check EN-MP7A-16 ENGINE TIMING GEAR, CAMSHAFT AND OIL PAN OVERHAUL Poin T= 190-260 (14-18) T= 190-260 (14-18) 800-5,700 (348-412) T= Tightening torque: kgicm (lb-ft 1. Cylinder block 9. Ball bearing 17. Oi drain plug 2. Gasket 10. Bearing holder case 18. Oil drain hose 3. Timing gear plate |. Oil seal 19. Connector bolt 4. Connector Crankshaft pulley 20. Soft washer 5. Expansion plug 13. Plain washer 21. Oil level gauge 6 Timing gear cover 14, Oil pan 22. Oil level gauge guide 7. Ovring 15. Tachometer drive assembly 8. Retainer ring 16. Connector ENGINE EN-MP7A.7 OVERHAUL T= 1,100-1,300 (80-94) T= 190-260 (14-18) T= 190-260 (14~18) 8 & T= 1,100~1,300 (80-94) ‘T= 300-350 (22-25) T= Tightening torque: kg-em (lb-ft) 1. Camshaft 7. Idler gear theust plate 13. Injection pump drive gear 2. Key 8. Straight pin 14, Coupling flange 3. Thrust bearing 9. Adler gear shatt 16. O-ring 4. Camshaft gear 10. Be 16. Timer cover 5. Thrust wash 11, Idler ge 17. Soft washer 6. Oil pump drive gear 12, Crankshaft goar 18, Plug ENMP7A18 M3838 Times cov ENGINE IMPORTANT POINTS — DISASSEMBLY REMOVE THE CRANKSHAFT PULLY. 1. Remove the nut and spacer. 2. Using a special tool, remove the pulley. Special Tool: Crankshaft pulley Puller (09420-1500) DISMOUNT THE FUEL INJECTION PUMP, 1, Remove the plug from the part on the timer cover. 2. Turn the crankshaft counterclockwise viewed from flywheel side to align the injection timing mark. 3. Lock the coupling flange with a special tool Special Tool: Timer Setting Toot (09512-2090) for WO4D (09512-2100) for WO4C-T, WO4C-TI NOTE: Do not loosen the injection pump dri 4, Loosen the timer cover fittting bolts and then remove the injec: tion pump with timer cover. NOTE: Do nat loosen the injection pump body fitting nuts. REMOVE THE CAMSHAFT WITH GEAR. NOTE: Pull out the camshaft, slowly turning it so as not damage the bearings. REMOVE THE IDLER GEAR SHAFT. Using 2 special tool, remove the idler gear shaft. ‘Special Tool: Sliding Hammer (08420-1100) sMa.g41 ENGINE EN-MP7AA9 If NECESSARY, REMOVE THE CAMSHAFT GEAR, 1. Hold the camshaft with a vice through wooden piates. 2, Remove the bolt and plain washer, then using a gear puller, remove the gear. IMPORTANT POINTS — ASSEMBLY IF NECESSARY, REPLACE THE TIMING GEAR CASE COVER OIL SEAL, 1. Using a screwdriver, ramave the ol sel. 2. Using s special tool, install the new oil seal. Special Tool: Press (08482-1830) ASSEMBLE THE CAMSHAFT GEAR AND SHAFT, Install the camshaft gear with thrust bearing NOTE: When installing the gear to the camshaft: © Heat the gear in hot water (Approx, 100°C (212°F)], ‘them install tha goa to the camshaft by using» press, © When tightening the bott, apply engine oll to the threads and plate surface of the bolt. INSTALL THE CAMSHAFT. Lubricate all journals of the camshaft and insert the camshaft assembly into the cylinder block. NOTE: © Insert the camshatt, slowly turning while inserting so that the bearing will not be damaged. © When installing the camshaft, be sure that the match marks of the oil pump drive gear and camshaft gear aro aligned correctly. EN-MP7A-20 ENGINE INSTALL THE IDLER GEAR SHAFT. Install the idler gear shaft with thrust plate using @ plastic hammer, NOTE: Be suro thet the oll hole is downward, if installed the wrong way, damage to the idler gear shaft end bearing ‘can rosult INSTALL THE IDLER GEAR. NOTE: When installing the idler goar, be sure that the matching marks of the crankshaft gear, oil pump drive gear and idler ‘gear are aligned correctly. INSTALL THE INJECTION PUMP TEMPORARILY. NOTE: When installing the injoction pump, be sure that the match marks of the idler gear and injection pump drive gear are aligned correctly. MEASURE THE GEAR BACKLASH. Meacure the backlash of each gear using @ dial indicator. Replace the goar if necossary. Rotor to INSPECTION AND REPAIR, INSTALL THE TIMING GEAR CASE, 1. Clean the faces 2. Apply the liquid gasket as shown and install the timing gear cover within 20 minutes. NOTE: If leaving it more than 20 minutes, clean the liquid gasket completely and reapply the liquid gasket. Coating Width (AJ: 1.5 — 2.5 mm (0.06 ~ 0,10 in) TIMING GEAR PLATE CYLINDER. SLock sm3.268 ENGINE EN-MP7A-21 INSTALL THE OIL STRAINER. Rofer to “OIL PUMP AND OIL STRAINER” in SECTION LUBRICATING SYSTEM. INSTALL THE OIL PAN. 1, Cut the protrusion of the timing gear plate gasket from the oil ‘pan mounting surface. 2. Clean the faces, 3. Apply the liquid gasket as shown and install the oil pan within 20 minutes. NOTE: If leaving it more than 20 minutes, clean the liquid gasket completely and reapply the liquid gasket. Coating Width (A); 3 ~ 4mm (0.12 ~ 0.15 in) INSTALL THE CRANKSHAFT PULLEY. 3.2168) NOTE: Apply engine oil to the nut threads. INSPECTION AND REPAIR elastaatte Inspection Item Standard Limit Remedy Inspection Procedure Replace, if Visual check necessary am a Er —————s~ su 845| Idler Gear Shaft Diameter 49,95-49,97 49.94 | Replace bushing (0.9311-1.9318) (1.9307) | and/or shaft 50.00-50.03, ‘\ (1,9685~1.9696) | (1.9705) ete ! NS Glearance between Idler Gear 0.03-0.08 on BY Shaft and Bushing (0.0012~0.0031) _| (0.0039) 33.847] Idler Gear End Play 040.10 | 0.15 | Replace thrust (0.0016~0.0039) (0.0059) | plate sw3.a71 EN-MP7A-22 ENGINE Unit: mm {in} Inspection ttem ‘Standard Limi Remedy Inspection Procedure Camshaft Bend 0.05 | Replace (0.0020) | ‘Camshaft Com Height 49.44 48.44 | Replace {Untake) (1.9865) (1.9071) Camshaft Cam Height 49.50 48.50 (exhaust) (19488) (1.9095) sa. Sa Camshaft end Play 0.10-0.18 03 | Replace thrust (0.0040-0.0070) | (0.0118) | plete Camshaft Journal Diameter | No.1: 67.0 $6.85 | Replace shaft Journal No, (2.2481) (2.2382) | and/or bearing Woz 868 36.55 (2.2362) (2.2303) Nad 568 35.45 (2.2283) (2.2224) Camshaft Journat Beating Not: 87.0 87.18 sunose Inside Diameter (2.2441) (2.2500) Journal No,: [Wo ® 86. 56.35 (2.2362) (2.2421) No.3 568 36.78 (2.2283) (2.2342) Clearnace between Camshatt 0.03-0.12 0.15 Journal and Bearing (0.0012~0,0047) | (0.0059) Crankshaft Gear ~ Idler Gear | 0.088-0.194 03 | Replace geer, (0.0027-0.0076) | (0.0118) | it necessary § | Idior Gear — O11 Pump Gear 3 0.085-0.182 a (0.0026-0.0071) % | Oil Pump Gear — Camshaft & | Gear EI dlr Geur~tnjecton Pump | 0.005-0232 E | Gear (0.0026-0.0091) sw3.344 ENGINE EN-MPTA.23 PISTON, CRANKSHAFT, CYLINDER BLOCK AND FLYWHEEL HOUSING OVERHAUL T= Tightening torque kg-em (tb-ft) M3264 1, Piston ring 7. Crankshaft gear 13, Crankshaft bearing 2. Piston & Key 4 3. Piston pin 9. Crankshaft 18. 4. Retainer ring 10. Connecting rod cap 16 0 5. Connecting rod 11, Collar 12, Cylinder block 8. Connecting rod bearing 12, Crankshaft thrust washer 18, Bearing cap EN-MP7A-24 ENGINE OVERHAUL T= 450-500 (33-36) a ” 2) T= 1,800-2,000 (131-144) @ Ke : 2). ENGINE ENMPTA-25 ll IMPORTANT POINTS — DISASSEMBLY = oC 9, 2 0 REMOVE THE PISTONS WITH CONNECTING RODS. ° 1. Remove te chon fo he vp a he pr er ~ mi super ov owery paper fecsrmande N15 3 ) ° ¢ a See ——— Bi 290 Extract the piston and connecting rod assembly out through the top of the cylinder. NOTE: © Arrange the piston and connecting rod caps in order. GMARE 2 MATCH MARK 3 REMOVE THE CRANKSHAFT, ; 3 ae Ar ll Ll bead oo eer ire : DoCRELS | t 2 39.052 REMOVE THE CONNECTING AOD. 1. Remove the retainer ring installed on both ends of the piston ‘pin, by means of retainer ring pliers. 2. Apply # metal pad to the pin and strike out the pin with a hammer. NOTE: Warm up the piston first in hot water 80-90°C (176— 194°F) for approx. 5 minutes before removing the pin. 33.204 REMOVE THE PISTON RINGS Special Tool: Piston Ring Expander (09442-1180) NOTE: © Handle the piston rings carefully because they are made of a special casting which is easily broken, © Keep the rings for each cylinder separate. EN-MP7A-26 sMa.a51 WX, ANOZ MARK 3-387 Dy) SMa.) ENGINE REMOVE THE CYLINDER LINER. 1. Place the metch marks with a pen on the cylinder block and liner flange, before removing the cylinder fir NOTE: Do not put the match marks with a punch. 2. Using a special tool, remove the cylinder liners, Special Tool: Cylinder Liner Puller (09420-1460) NOTE: After removing the cylinder liners, put numbers on their periphery or arrange them in sequence, IMPORTANT POINTS — ASSEMBLY INSERT THE CYLINDER LINER INTO THE CYLINDER BLOCK. 1. When @ new cylinder liner is used, make sure thet the liner has the same mark as the mark on the cylinder block. NOTE: © There are 4 different liner and eylinder block matches. The flange section of each liner has a marking any, W, X, Y, Z, or indicating the size of the outer diameter of the finer on which it Is stamped. The markings W, X, ¥ and 2, indicating the inner diameter of the cylinder bore supporting the liner on the sides and top of the oylinder block (the boss section for attaching the cool- ant gallery cover), are inscribed on each cylinder. 2. When reusing a liner, insert the liner its original position aligning the marking marked before disassembly. ers 33.953 Unit: mm fn ‘Guteie diameter Ganka oumel o2s | 8189-6171 7269-7271 (247e—2.425) | (2.8619~2.86251 oso |, 81.44-61.46 7246-72-46 i (zatea—2.4196) | (29620-28527) 1.19-61.21 078 | i2a001-2.4008) 0.94-60,96 300 | (23992"2.4000) conneer L_—__— wrona——] sMa-sat ENGINE EN-MP7A.27 Apply a small amount of fresh engine oil on the outer periphery of the liner, and apply pressure on the entire flange section of the liner. If insertion by hand is difficult, use a ceylinder guide, and the cylinder liner will easily be pushed in, Special Tool: Cylinder Liner Guide (09480-1120) NOTE: © Do notuse a liner that has been dropped. (© Take extra care when handling the liner sinco the liner is easily deformed. MEASURE THE PROJECTION OF THE CYLINDER LINER. Tighten 2 special tool with a tightening torque of 100 kg:cm (7.23 lb-ft} and measure the amount of projection of the top tend of the finer from the cylinder block with a dial gauge or straight edge and a thickness gauge. Special Tool: Cylinder Liner Puller (09420-1460) Tightening Torque: 100 kg-cm (7.23 Ib.ft) Assembly Standard: 0,010.08 mm (0.0004—0.0031 in) IF NECESSARY, GRIND THE CRANKSHAFT AND USE UNDER SIZE BEARINGS, Dimension of Fillet R: Crank pin: 3.60 ~ 4.00 mm (0.1378 ~ 0.1574 in) Journal: 3.05 ~ 3.50 mm (0.1201 ~ 0.1377 in} EN-MP7A-28 sma-78| TIMING GEAR ARROW SIDE No. 1.2.3, 52.855 ENGINE INSTALL THE CRANKSHAFT, 1. Install the crankshaft bearings on the cylinder block and bearing cap. NOTE: Apply fresh engine oit to each bearing surface, 2, Install the crankshaft on the cylinder block 3. Insert the crankshaft thrust bearings along the groove of the cylinder block. 4. Install the thrust bearings on the No, 4 bearing cap sides. NOTE: Apply fresh engine oil to each thrust bearing surface, 5. Install the crankshaft bearing caps. Install the bearing caps in numbered order from timing gear side with the arrow point toward the timing gear side, 6. Tighten the cap bolts in three stages following the tightening order. NOTE: Apply engine oil to the bolt threads and under the bolt head. Tightening order: 3—2-4—1-5 NOTE: © Make sure that the erankshstt rotates smoothly. © Inspect the crankshaft end play. - @ Tae PRESS SUB ASSEMBLY 3.-1565| GONNECTING ROD Ris =e PRESS SUB ASSEMBLY swo-1869 ‘Model woaD Groove. “ASSEMBLY sw3-15678| ‘Models Woac-T and wOaG-TT ‘genous Gnooven ay BUSHING /CONNECTING Roo Ol HoLEs-7 PRESS sua ‘ASSEMBLY sma.15678| ENGINE ENMP7A-29 IF NECESSARY, REPLACE THE PISTON PIN BUSHING, 1. Prepre the special tools. ‘Assemble the guide and press sub assembly inserting its pin into the guide, then secure ther with the wing aut. Special tools: Guide (09481-1130) Press sub assembly (09402-1450) Wing nut (9233-10360) NOTE: © Bring leter “W" punched on the guide above the pin, © Make sure to align both supporting surface of the guide and press sub assembly flush on a flat plane, 2. Using a special tool, remove the piston pin bushing. a. Set the connecting rod assembled without crank pin bore bearing on the guide and press sub assembly. b. Set the spindle on the bushing Special Tool: Spindle (09402-1460) for WOAD (09402-1470) for WO4C-T and Wo4C-TI Nov! Align the grooving of the spindle with the oil hole of the bushing, EN-MP7A:30, CONNECTING ROD, 10. 05-6.1.0 mm CONNECTING Roo sm3-1569] ‘Model WORD | _-sroove Oil Howe: ay ‘OIL HOLE Guide 7 CeUsHING a 3013-16708 ‘Models W04G-T and WO4CTT = SPINDLE GROOVE it HOLE: a sue a, ou, HOLE BUSHING sour swa.is70| J press OIL HOLE tans | O1L PATH: Sw3.1871C] ENGINE ©. Using a hydraulic press, remove the bushing. NOTE: Always operate the press slowly and smoothly, ‘Assemble the piston pin bushing, Chamfer one edge of the bushing hole at the small end of the connecting rod uniformly by C 0.51.0 mm (0.0196~0.0393, in), NOTE: © Irregular chamfaring can cause out-of-roundness of the pressed bushing, which may result in jamming during insertion. (© Remove dust from the inner surface of the small-end hole, 4. Mount the bushing on the spindle. a. Set the bushing and guide on the spindle aligning oil hole (AP in the bushing the grooves on the both the spindle and guide, b. Secure the bushing and guide with the bolt Special Tool: Spindle {09402-1460} for WOAD (09402-1470) for WOAC-T and WO4C-T1 Guide (09481-1120) for Wo4D (09481-1140) for WOSC-T and WO4C-T1 Bolt (9191.08252) NOTE: © Be sure to stip the bu: proper direction so that ail hole (A) wil with the oil path in the connecting rod, (© Apply fresh engine oil to the bushing and guide, over the spindle in the later align 5. Install the bushing in the connecting rad, Position the bushing-special tool assembly 0 that oil hole (A) align with the oil path through the connecting rod, NOTE: © Fully coat the bore in the connecting rod with fresh engine oil. (© Always operate the press slowly and smoothly. BUSHING f CONNECTING ROD 113-1872] sus.azal OMARK MATCH MARKS ‘sm3.407) ENGINE ENMP7A-31 6, Inspect the bushing position after installation, NOTE: © Make sure that tho oil holes of the bushing and connect: ing rod are aligned. © Insert a pin of 3 mm (0.1781 in) dia. into an hole at the end of the connecting rod, and make sure that the pin fully penetrates. If there is any deviation in the alignment of the oil holes correct it with a drill of 3 mm (0.1181 in) © Misalignment of the oil holes can lead to insufficient lubrication, which may resutt in seizure. © Insert a new piston pin and rotate it slowly to make sure that there is no rattling, ASSEMBLE THE PISTON AND CONNECTING ROD. Make sure that the O-mark at the top of the piston and the connecting rod match marks in opposite directions. NOTE: © Use the new retainer rings. (© Heat the piston to 80-90°C (176--194°F} in hot wat approx. 5 minutes. EN-MP7A-32 SISCRIMINATION MARK ga Ot TOP RING (woeop JOINT SECOND RING OIL AING 33.295 S¥3.s08 sM-4a3 OIL RING, SECOND RING OMARIC TOP RING sMa.270| GH TAPPET CHAMBER, 53.387 Massa MARK MATCH MARKS 8M3.407 ENGINE INSTALL THE PISTON RING. 1. Install the piston rings in the sequence oil rng, second ring and top ring with the identification mark at the top of the ring facing up. NOTE: © Identification mark of second ring and oil ring is applied! with gold paint. (© Apply oil to the piston rings. Special Tool: Piston Ring Expander (09442-1180) 2. Connect the ends of the coil expander and then fit the coit inside the piston ring after encuring that the gap of the piston, 1g is 180° away from the joint of the coil 3. Arrange the piston rings so that their gaps are equally spaced INSTALL THE PISTON IN THE CYLINDER LINER, 1. Apply engine oil to the piston, eylinder liner and connecting rod bearing surface, 2. Using a special tool, hold the piston rings and push the piston with connecting rod assembly with a wooden rod. Nor! Check the piston that the O:mark on the top ie on the tappet chamber side, Special Tool: Piston Ring Holder (09441-1260) INSTALL THE CONNECTING ROD CAP. 1. Apply engine oil to the eap bearing surface 2. Align the match marks on the connecting cod and cap, 3. Apply engine oil to the bolt thraads end under the bolt hesd. 4, Tighten the cap bolt in three stages. 33.213) sMa.271 oss wun GQ) BOLT © @ @ 6 g en ENGINE EN-MP7A-33 INSTALL THE OIL SEAL IN THE FLYWHEEL HOUSING, Using a special-tool, press in the oil seal in the flywheel hous- ing Special Tool: Press (09482-1540) INSTALL THE FLYWHEEL HOUSING. 1. Clean the faves. 2. Apply the liquid gasket as shown and install the flywheet ‘housing within 20 minutes, NOTE: If leaving it more than 20 minutes, clean the liquid gasket ‘completely and reapply the liquid gesket. Coating Width: 1.5--2.5 mm (0.08-0.10 in) INSTALL THE FLYWHEEL. Install the flywheel and tighten the bolts through several repetitions of the tightening order so as to reach specified torque evenly and gradually, then slacken and tighten them ‘one by one to the specified torque. NOTE: 0 Al fon the flywheel and crankshaft coll (© When tightening the bolt, apply engine oil to the threads and flywheel surface of the bolts. EN-MPT7A-34 ENGINE INSPECTION AND REPAIR Unit: mm tind ‘Small End Bushing Inspection Item Standard Limit Remedy Inspection Procedure Piston Diameter 103,860-103.884 = [Replace piston (4.0890—4.0899) land/or liner ($2 Orlinder Liner Inside 304.008-104,040 | 104.15 50 ee Diameter (4.0949~4.0960) | (4.1003) suoi0 ‘Clearance between Piston 0.140-0.172 = feEeosse and Cylinder Liner (0.0056-0.0067) swo4oa | swdara Piston Pin Diameter |WO4D | 34.989-35.000 | 34,980 | Replace piston (.3776~1.3779) _| (1.371)_| andor piston pin woact | 36.087-37.003 | 36.98 woac-71| (1.4562-1.4568) | (1.4559) Piston Pin Hole insidel WoaD | $4.967—36.003 | 35.02 Diameter (1.3775—1,3780)_| (1.3787) ~san.ss| woae |” 36.987~37.003 37.02 woasTi | (1.4561—1.4563) | (1.4574) ‘Clearance between Piston oorsr—o014. | 008 Pin and Piston Pin Hole (0.00052T-0.000581) } (0.0075) Ti Tight L: Clearance Crankshaft end Play 0.05-0.22 0.4 [Replace thrust (0.0020--0.0086) | (0.0187) |bearing Connecting Rod | WOAD | —_35.015-35.025 | 35.080 | Replace bushing Smail End | @.gzes—1.3789) | (1.3811) _| andor piston pin Bushing Inside woac-t | 37.015~37.028 | 37.080 = Diameter wose-ti| (1.4573-1.4575) | (1.5172) Piston Pin Diameter |WO4D | 34.989—25,000 34.980 [_01.3776-1379)_ | «1.37711 woac-r | 36.987-37.003 | 36.98 swage wose-ri| (7,4562—1.4568) | (7.4559) Clearance between Piston 0.015~0.036 oa Pin and Connecting Rod (0.00016~-0,0014) | (0.0039) 39-297] ENGINE EN-MP7A-35, Unit: mm fin) lnspection Item Standard Limit Remedy Inspection Procedure Connecting Rod Big end 65.985--66.000 Replace Inside Diameter (2.5979-2,5984) = connecting rod (Without bearings) assembly ‘sé-300] Crank Pin Diameter 61.94-61.96 -0.20 | Regrind and use (2,4386~2,4393) | (-0,0078) | undersize bearing 60.76 | Replace crankshaft (2.3921) ‘Clearance between Connecting 0.12 | Replace bearing Rod and Crank Pin (0.0047) ‘Connecting Rod End Play 0.20-052 0.6 [Replace connect- (0.0079-0.0204) | (0.0236) ing rod | sus.asa Connecting Rood St 01 — Replace | (0.0039) = Per 200 (7.8740) sua.sai| Connecting Rod Twist 0.1 | Replace (0.0039) = Per 200 (7.8740) s1a.saa] EN-MPTA-36, ENGINE Unit: mon tind Inspection ttem_ Standard, Limit Remedy | Inspection Procedure Connecting Rod Bearing 67.05-67.56 Replace ‘Spread Dimension (2.6398-2.6594) i ‘Crankshaft bearing 79.00-79.60 ' spread dimonsion (3.1102-3.1339) F sa:29] Crankshaft Bend 0.04 | Repair or (0.0018) |repiace Crankshaft Main Bearing 77,985-78.000 = | Replace Cap Inside (3.0703-3.0709} Diameter (Without Bearing) (Crankshaft Journal Diameter 72.94-72.96 -0.20 | Regrind and use (2.8717-2.8724) | {-0.0078) | undersize bearing { 71.76 | Replace (2.8521) | crankshaft Clearance between Crankshaft 0.039-0.090 0.13 |Reptace bearing Journal and Main Bearing (0.0016-0.0035) | (0.0051) ‘Crankshaft Main Bearing 79.00-79.08 Replace ‘Spread Dimension (3.1103-3.1128) — J ‘sM3-298] ENGINE EN-MP7A.37 Unit: mm tin) Inspection Item Standerd Limit Remedy Inspection Procedure Piston Ring |Top | WOaD 247-249 232 [Replace Breadth (0.0972-0,0900) _| (0.0914 WHET a a wose-71 I Bad | woaD 197-188 ie (0.0776~0.0783)__| (0.0716) WoT | 247-249 2.32 [wose-T1 | (0.0972-0.0980)__} (0.0914) oir 497-499 495 PECEEEEEEE (0.1957-0.1964) | (0.1948) | swa.ar Piston Ring | Top |WOaD 257-259 2.74 | Replace piston Groove (o.1012-0.1019) | (0.10781_| ring and/or Breadth ‘wo4c-T piston j WO4C-TI 7 im Bad | WOAD 35-208 230 j {0,0800—-0.0807) (0.0866) woIeT | 253-255 270 WO4C-TL {0.0996—0.1004) (0.1063) on 301-809 3.08 {0.1973-0.1980) (0.2000) Clearance between Piston | Top: 0,080.12 03 Ring and Piston Ring Breadth (0,0032—0,0047) | (0.0118) Ring Ne {Model W04D only) 2nd: 0.04-0.08 oF us.0y {0.0016—0.0031) | (0.0118) Gil: 0.02-0.08 0.08 {0.0008-0,0023) | (0,0031) Piston Ring Gap All Rings: 03-045 12 | Replace * Insert the Piston Rings {0.0119-0.0177) (0.0472) ‘here the Waar ofthe Liner isa CO sao Cylinder Block Flatness Les than 0.05 0.1 | Regrind and/or (0.0019) {0.0039} place Flywheel Faso Alignment ~ 0.15 | Regrind andjor (0.0059) | replace EN-MP7A-38 ENGINE LIQUID GASKET AND APPLICATION POINTS The WO4D, WO4C-T and WO4C-T! type engine use liquid gasket (Three Bond T81207C 04132 1207) instead of con- ventional sheet gaskets. Apply liquid gasker, therefore, taking the following items into account. 1. LIQUID GASKET APPLICATION POINTS AND COATING WIDTH Urs ren at Parts name Coating width (@ Ollpan Flange face which mates with eylinder block 3-4 and timing gear cover (0.12—0.16) sw3-2140 (0) Timing gear cover Faces which mates with timing gear plate | 18-25 (flange face, boss face} {0.06 — 0.10) | | swa.247 (6). Flywheel housing Faces which mates with cylinder block | 18-25 (fange face, boss face} j (0.06 — 0.10) | | { | ENGINE EN-MP7A.39 Unit: mm (in) Parts name Application point Coating width {a) Oil cooler Flange face which mates with cylinder 18-28 block (0.06 — 0.10) 33.269 (e) Coolant pump Flange face which mates with gear cover 18-28 (0.08 ~ 0.10) (1) Thermostat case Flange face which mates with cylinder head 15-25 (0.06 0.10) (g)_ Seal plate Flange face which mates with gear cover 15-28 (0.06 — 0.10} th) Intake pipe Flange face which mates with inteke man- 15-25 fold (0.06 — 0.10) 2, COATING LIQUID GASKET AND PARTS ASSEMBLY PROCEDURE (1) Completely remove old liquid gasket from each part and the respective mating part, and remove oil, water, and dire using a cloth (2) Be careful not to apply excessive or insufficient liquid gasket, Also, be sure to overlap the stert and end of each coating (3) When assembling coated parts, be careful that there is no misalignment between mating parts. If there is any misalignment, coat the parts again. (4) Assemble the various parts within 20 minutes after applying liquid gasket, If more than 20 minutes have elapsed, remove the liquid gesket and apply it again, (5) After assembling the various parts, wait for at least 16 minutes before starting the engine. EN-MP7A40 ENGINE 3, REMOVING PARTS When removing each part, do not sttempt to pry one portion of the flange alone but use the flange collar or clearance to pry the flange at several points alternately, Pry _— Collar ) Timing gear cover Coolant pump 9 8M3.1933 4, TIMING GEAR PLATE GASKET When replacing the gear plate gasket, cut it so that no steps are formed in it, then liberally apply liquid gasket to the ‘cut face and assemble the oil pan, Cylinder block Cylinder block Liquid gatker 6 (Cut using 3 cutter or the like, taking oreet cara that no steps are formed, ‘Timing gear plate gasket sus.i992 NOTE: The flange of the oil pan may sometimes become deformed preventing it from being reused, To prevent this, therefore, first insert plates with a thin edge at several points around the periphery of the oll pan, it pan using a screwdriver. then remove the ENGINE EN-LS7A-1 LUBRICATING SYSTEM DATA AND SPECIFICATIONS il pump Type - Full forced pressure feed by gear pump Drive ide By gear Oil cooler Type eee eee ee e ses ++ Multi plates type, water-cooled 1 2 3. Oil pump 4, Oil cooler 5. Oil filter 6. 7. 8. 3. Main oil hole . Camshaft Rocker atm shaft 9. Rocker arm 10. Crankshaft journal 11. Crankshaft pin LUBRICATING SYSTEM DIAGRAM 46 12. Connecting rod 13. Piston hot Rater, 18. Fu injection pump dive (SSS ao a Pos on 16, Fue inetion pump 17. Turbocharger | e A. Oil cooler safety valve 8 B, Oil filter safety valve ©. Regulator valve D, Chock valve 10 L's | swa-1820 EN-LS7A2 ENGINE OVERHAUL HE 11—040—00X07 (1400) x 0 0 T= 190-260 (14—18) \ ; T= 200-260 (15-18) T = Tightening torque: kg-cm (Ib.ft) 1, Oil filter 6. Plug. 11. Oil pump driven gear 2. O-ring 7. Connector bolt 12, O-ring guide 3, Oil cooker 8. Oi pump cover subassembly 13. Oil strainer 4. Soft washer 9. Gasket 14, Oil strainer screen 5. Connector pipe 10. Bushing 15. Snap ring ENGINE EN-LS7A-3 OIL PUMP DESCRIPTION . Driven gear Gasket 1. Drive gear (Outside) Drive shaft . Driven shaft YD owensaae © suction PORT PORT [oPERATION} INSTALL THE OIL PUMP, 1. Apply oil liberally to cylinder block pump case and bearing before installing oil pump. 2, Confirm smeoth rotation of of pump after tightening bolts. 2 sw364] EN-LSTAS ENGINE INSPECTION AND REPAIR Unit: mm tnd Inspection Item Standard Limit Remedy Inspection Procedure (Gear Backtash 0.09-0.21 0.30 | Replace gear {0.0036-0.0082) | (0.0118) Drive Gear Shaft Diameter 18.088-18.106 | 18.060 | Replace (o7122-0.7128) | (0.7110) suse70 Drive Shaft Bearing inside 1.148-18.173 | 1020 | Replace ameter (07145~0.7154) | (0.7168) Cterancebaween DrveStaht | aav0-0.086 | a1 | alos bar \ys oh and Bearing {0.0080-0.0033) | (0.0039) | and/or shatt ey yi = 5 y Driven Gear Shaft Diameter 17.979-17.997 | 17.970 | Replace (07079-07085) | (07078) Driven Gear inside Diameter | 18.037-18.054 | 18.070 | Replace (o.7102-0.7107) | 10.7114) Clearance between Oriven Gear | 0.040-0.075 0.1 | Replace bearing and Shatt (0.0080-0.0023) | (0.0039) | and/or shaft {BSS Ee sua.cs| Gear Teeth itting or Wear Replace, if Visual check necessary sma.eas ENGINE EN-LSTAS OIL COOLER AND OIL FILTER SPECIAL TOOL Prior to starting an engine overhaul, itis necessary to have these special tools. WRENCH (09853-1010 For spin-on type oil filter OVERHAUL s4t9m vaasc Feno2t 1-N0.20 T= 250-350 (19-25) T= 100-150 (8-10) T= Tightening torque: kg-cm (Ib.Ft) 4, Oil fitter 7. Oil eooler ease ‘A. Oil filter safety valve 2. Oil filter cover 8, Gasket 1.3 kg/em? (18,5 Ib/sa.in) 3, Valve 9. Oil cooler element B. Oil cooler safety valve 4, Spring 4.0 ke/em? (66.9 Ib/sq.in} 5, O-ing Regulator valve 6, Plug 4,0 kefem® (56.9 tb/sq.in} EN-LS7AS ENGINE IMPORTANT POINT — DISMOUNTING REMOVE THE SPIN-ON TYPE OIL. FILTER, Using a special too}, unscrew the oil filter. Special Tool: Wrench (09553-1010), IMPORTANT POINTS — MOUNTING INSTALL THE OIL COOLER. 1. Clean the faces. 2. Apply the liquid gasket as shown and install the oil cooler ‘within 20 minutes. NOTE: If leaving it more than 20 minutes, clean the fiquid gasket ‘completely and reapply th gasket, Costing Width (A): 1.5-2.5 mm (0,06-0.10 in) INSTALL THE SPIN-ON TYPE OIL, 1. Apply a slight amount of engi fitter. FILTER, ine oil to the gasket of the new 2, Tighten the new filter by hand until the gasket touches the cover and the tighten another tool, Special Tool: Wrench (09653-1010) INSPECTION AND REPAIR 3/4 to 1 full turn with a special Inspection item Standard Limit | Remedy Inspection Procedure Valve and Springs of Replace, if Visual check it Fitter. - - necessary, War or Damage, ENGINE EN-FS6B-1 FUEL SYSTEM DATA AND SPECIFICATIONS Injection nozzle Type presure « « Multshole nozzle type + 220 kg/em? (3,129 tb/sq.in) FUEL SYSTEM DIAGRAM 203 NOTE: Figure illustrates 4-cylindor engine i 1, Water separator {Alf 0 equipped) 7 2, Fuel injection pump 3, Fuel foed pump 4, Injection nozzle 5, Fuel filter A. To fuel tank B, From fuel tenk aA —s sv3.2276 M3501 AIR BLEEDING FROM FUEL SYSTEM. 1, Loosen the blesder plug on the fuel filter. 2. Loosen the priming pump knob. 3. Operate the priming pump knob until the air will not come out from the bleeder plug. 4, Tighten the bleeder plug. Tightening Torque: 40-60 kgem (34 Ibft) NOTE: The bleeder plug should be tightened while the priming pump knob is operated. 8. Once again, operate the priming pump knob several times. 6 Push back the priming pump knob and tighten it. NOTE: Wipe off any splashed fuel. EN-FSBB-2 ENGINE INJECTION NOZZLE OVERHAUL 1s20v, 1ENo. 20) For WO4C-T, WO4C-TI, Wosp, Woso-T1, WosE For Wo4D 5M3-1258A 1. Connector 6. Retainer ring 11, Distance piece 2. Packing ring 7. Shim 12, Nozzle 3. Gasket 8. Spring 13. Nozzle retaining nut 4 Joint bott 9. Nozzle holder pressure pin 1 5. Nozzle holder 10. Pin i IMPORTANT POINTS — DISMOUNTING REMOVE THE NOZZLE HOLDER ASSEMBLY. Refer to Section ENGINE MOVING PARTS, smgers| & & San yp we 00D COARSE «COARSE COARSE 3M3450) ‘6000 FAULTY sM3.861 ENGINE EN-FS6B-3 IMPORTANT POINTS — ASSEMBLY TEST THE NOZZLE SKINKING. Wash the nozzle proper with diesal fuel oil, then immerse it in diesel fuel oil Next slide the needle inside the nozzle proper and encure that it move smoothly. The needle valve should fall under its own weight when withdrawn vertically about 1/3 and released, If Its motion is sluggish, caplace the nozzle with a new one. ADJUST THE INJECTION PRESSURE, 1. Connect the nozale holder with 2 nozzle tester and move the lever at the rate of about 0 to 60 timas per minut. Injection Pressure: 220 kg/em? (3,129 tb/sq.in) WARNING iasel fuet is flammable, This nozzle adjusting should be done a well ventilated room and away from any open flames or electric spark. © The spray must always be covered. Keep your face and body away from the spray. This is because of the risk of fuel oif getting in your eyes or passing into your body. 2, If the injection pressure is not within specification, change the shim. ‘TEST THE SPRAY PROFILE. In the case of the new nozzle, operate the lever at the rate of 30 to 80 strokes per minute, and for a used nozzle, operate the lever at the rate of 15 to 60 strokes per minute. TEST THE FUEL LEAKAGE, When checking for fuel leekage from the nozzle, apoly 4 pressure of about 10 t0 20 kg/cm? (142-284 tb/sq.in} lower than the correct injection pressure to the nozzle by means of the nozzle tester, If there is no fuel leakage, the nozzle is normal EN-FS6B-4 ENGINE FUEL FILTER SPECIAL TOOL Prior to starting an engine overhaul, it is nacessory to have these special tools. WRENCH (09503-1040 For spin-on type fuel IMPORTANT POINT — DISMOUNTING REMOVE THE SPIN ON TYPE FUEL FILTER, Using a special tool, unscrew the fuel filter. NOTE: O Be careful not to spill diesel fuel. © When removing the fuel filter for WO4C-TI and WO6D- Tl, use. suitable wrench, ‘Special Tool: Wrench (09503-1040) for WO4D, Wo4c-T, WOGE IMPORTANT POINT — MOUNTING INSTALL THE SPIN-ON TYPE FUEL FILTER, 1. Apply @ small amount of diesel fuel to the gasket of 2 new fuel filter. 2. Manually tighten the new fuel filter until its gasket touches the cover and then tighten ancther 2/3 turn with 2 special tool. NOTE: When installing the fuel filter for WO4C-TI and WO6D-TI, use a suitable wrench, ‘Special Tool: Wrench (09503-1040) for WO4D, WO4C-T, WOSE ENGINE COOLING SYSTEM EN-CS7A.1 DATA AND SPECIFICATIONS Coolant pump Type + +++ Forced circulation by volute pump Drive sees By Vebolt Seawater pump ++ Solf priming type (Flexible impeller pump) ++ By gear Wax type, bottom bypass system 765°C (170°F) COOLING SYSTEM DIAGRAM =-=-SEA WATER ENGINE COOLANT WATER 3.1854 1 F cooled exhaust manifold 13. Engine oll cooler 2 fitter 8. Exhaust pipe 14, Water cooled turbocharger 3 pump 9. Coolant pump 15, Coolant filler cap 4, Intercooler 10. Cylinder block 16, Air bleeder plug 5. Transmission fluid cooler 17. Coolant drain plug 6. Heat exchanger 12. Thermostat EN-CSTAZ ENGINE OVERHAUL HE11~038-00x0 30° Te 7-110(5.5-7.9)P T= 190-260 (14-18) T= Tightoning torque: kgom (lb-ft) 1. Coolant pump 6. Coolant manifold 11. O-ring 2. Coolant pump pulley 7. Connector bolt 12, Hoe 3. Thermostat 8. Soft washer 13. Clamp 4, Thermostat gasket 9. Pipe 14. Engine hanger 5. Thermostat case 10. Connector ENGINE EN-CS7AI COOLANT PUMP OVERHAUL tes9N, FENe. 21 1, Pulley center 2. Pump case 3. Shaft subassembly 4, Slinger 5. Coolant seal 6. Vane IMPORTANT POINT - DISMOUNTING REMOVE BY PRYING LOOSE WITH SCREWDRIVER AT THE 2 POINTS ON THE FLANGE. 315.873 IMPORTANT POINTS — DISASSEMBLY REMOVE VANE FROM SHAFT BY SCREWING IN A BOLT. Bolt Size; Diameter: 10 mm (0.284 in} Pitch: 1.5 mm (0.059 in) smas74 ENACS7A-4 A ei WZZM sma.224| ENGINE USING A PULLER, REMOVE THE PULLY CENTER FROM THE SHAFT. USING A STEEL PIPE AND PRESS, REMOVE THE SHAFT FROM BODY. Steel Pipe Dimention: A: More than 57 mm (2.244 in} B: 18-21 mm (0.7087 — 0.8267 in) Less than 29.5 mm (1.161 in) IMPORTANT POINTS — ASSEMBLY USING A STEEL PIPE AND PRESS, INSTALL THE SHAFT TO THE CASE. NOTE: Bearing face must be aligned with edge of body. USING A PRESS, INSTALL THE PULLEY CENTER. DIMENSION (A): 61.5 mm (2.421 in} for WoaD, Woac-T 90 mm (3.543 in} for WO4C-TI INSTALL THE NEW COOLANT SEAL. 1. Apply a little liquid sealer to the coolant seal outer circumference and coolant pump body, 2. Install the slinger and coolant seal. sm377 ENGINE EN-CS7A.S USING A PRESS, INSTALL THE VANE TO THE SHAFT. NOTE: Apply alittle il to the coolant seal face. AFTER THE COOLANT PUMP HAS BEEN ASSEMBLED, CHECK THAT THE SHAFT ROTATES SMOOTHLY. IMPORTANT POINT — MOUNTING INSTALL THE COOLANT PUMP TO THE TIMING GEAR COVER. 1. Clean the contacting surface of the coolant pump and timing ‘9ea° cover free of old sealer, water and oi Apply the fiquid gasket as shown and install the coolant pump within 20 minutes. NOTE: If leaving it more than 20 minutes, clean the liquid garket ‘completely and reapply the liquid gasket. Coating Width: 1.5-2.5 mm (0.06-0.10 in} EN-CS7A6 ENGINE HEAT EXCHANGER DESCRIPTION 5 sus.1819 — SB OVERHAUL Housing Filler pipe seat Engine coolant inlet 1 6 A 2. Cap 7. Gask B. Engine coolant outlet 3. Eloment 8 Water gallery cover ©. Seawater inlet 4, O-Ring 9. Coolant pipe D. Seawater outlet 5. Engine coolant drain cock 10. Plate ENGINE EN-CS7A.7 7 IMPORTANT POINTS — ASSEMBLY a ASSEMBLE THE HEAT EXCHANGER. : NOTE: © Replace the O-rings and gasket with new ones. © Before installing the plates “A” and “8”, apply sealing compound (Three bond No. TB-1207¢ or equivalent). © When installing the plate “A’ on the heat exchanger, the “0” mark should face outside, INSPECTION AND REPAIR Unit mn tin) Inspection Item ‘Standard Limit Remedy Inspection Procedure Heat exchanger Less than 0.1 05 | Returiace or (Exhaust Manifold). (0.0039) (0.019) | replace. Flarness Eiomont. Clean with Clogged. 7 = [sameresadir | etek | sodium hydroxide cD) sms-1800| Coolant filler eap valve 0.4-06kg/em? | _ | Replace opening pressure. (57-85 th/sq.in) EN-CS7A-8 ENGINE THERMOSTAT A: To HEAT EXCHANGER B: From HEAT EXCHANGER C: Te COOLANT PUMP. sM3-1a60 IMPORTANT POINT — ASSEMBLY INSTALL THE THERMOSTAT, 1. Remove water and dirt adhering to the thermostat case, 2. Replace the gasket without fail if it is corroded, damaged or flattened, 3. Before installing the thermostat, apply sealing compound to ‘the hose installation portion of the coolant manifold. 4. Assemble the thermostat, gasket, case and coolant manifold as shown, IMPORTANT POINT ~ MOUNTING INSTALL THE THERMOSTAT CASE, 1. Clean the faces. 2. Apply the liquid gasket as shown and install the thermostat ‘case on the cylinder head within 20 minutes, NOTE: If leaving it more than 20 minutes, clean the liquid gasket completely and reapply the liquid gasket. Coating Width: 1.5~2.5 mm (0.06-0,10 in) Thermostat Clasing Condition Fully opened valve should close com- plately within 5 minutes when ther- mostat is immersed in water of normal temperature. sma267 INSPECTION AND REPAIR Unit: me (ind Inspection Item Standard Liew Remedy Inspection Procedure Thermostat Valve Opening 745-785°C = Temperature (166-173"F) stinnwa nog | rHemnoweren Thermostat Valve Lift ‘At least 10 (0.4) = Tea at 90°C (194°F) aioe Slovonten thermostat smg83 | ENGINE EN-IEZA-1 AIR INTAKE AND EXHAUST SYSTEM OVERHAUL ME11~040--00x07 (13201 Model Wo4D T= 190-260 (14—18) T = 450-600 (33-36) ‘sMa897 ‘T= Tightening torque: kg-om (lb-ft) 1. Heat exchanger (Exhaust manifild) 8, Heat exchanger bracket 2, Exhaust manifold gasket 9. Water pipe 3, Water hose 10. O-ring 4, Intake manifold gaskot 11. Exhaust pipe | 8. Intake manifold 12. Gasket 6. Intake pipe 13, Exhaust pine bracket 7. Air eleaner 14, Drain cock ENAEZA2 ENGINE OVERHAUL |. Heat exchanger He11-038-00x08 (Exhaust manifold) esenane 2. Exhaust manifold gasket . Water hose 1. Clamp 5. Oring . Water pipe . Engine coolant drain ‘cock 3. Intake manifold gasket . Intake manifold . Intake air pipe |. Oil pipe . Soft washer . Air blader plug |. Engine coolant drain plug 5. Gasket 5. Turbocharger Bir hose Air cleaner 9. Exhaust pine ). Exhaust pine bracket |. Heat exchanger bracket T= Tightening torque: kg-em (Ib.ft) sMa.1838 ENGINE EN-IEZA-3 OVERHAUL E11-039—00x08, 06 Model WO4C-TI 1, Heat exchanger (Exhaust manifold) Exhaust manifold gasket Water hose Clamp O-ring Water pipe Engine coolant drain cock 8. Intake manifold gasket 9, Intake manifold 10. Intake air pipe 11, Oil pipe 12, Soft washer 13, Air Bleeder plug 14, Engine coolant drain plug 15, Gasket 16. Turbocharger 17. Airhose s. Air cleaner . Intercooler ). intercooler bracket |. Exhaust pipe .. Exhaust pipe bracket 3. Heat exchanger bracket [= 190-260 (14-18) T= Tightening torques ke-em {Hb} si#9-1690 EN-IE2A4 sais-1837] woe sus.1834] ENGINE IMPORTANT POINTS — MOUNTING INSTALL THE EXHAUST PIPES. 1, Install the connector and turbocharger on the heat exchanger (Fer WO4C-T and WO4C-T1) 450-500 kg-em (33-36 lb-ft) Tightening Torqui 2. Temporarily install the mounting brackets and exheust pipes, 3. Tighten the bolts to the specified torque in the tightening order as shown, Tightening Torque: For Wa4D 1: 500-600 kg-em (37—43 Ib.ft) 2: 500-600 kg.em (3743 Ib.ft) 3: 600-600 kg-em (37-43 Ib.ft) 4: 450-500 kg-em (3336 Ib.ft) 5: 450-500 kg-em (33-36 Ib.ft) 6: 1,001,300 kg-om (73-94 tb.ft) For Wo4c-T 190-270 kg-cm (14-19 Ib.ft) 400-600 kg-cm (3743 tb.ft) ‘500600 kg-om (37~43 Ib.ft) 450-500 kg-om (33-36 Ib.ft) ‘350-400 kg-em (26-28 tb.tt) 350-400 kg-cm (26~-28 Ib.ft) ‘950-400 kg-em (26-28 Ib.ft) 450-500 kg-em (33-36 Ib.ft} 1,000~1,300 kg-om {73-94 Ib.ft} 800-600 kg-om (37—43 Ib.ft) Seosaasuns ENGINE, ENAEZAS For WOaC-TI 190-270 kg-em (14-19 Ib.ft) '500--600 kg-em (3743 Ib.ft) 500-600 kg-em (37-43 Ib.ft) 450-500 kg-cm (33-36 Ib.ft) 350400 kg-cm (26-26 tft) 30-400 kg.cm (26-28 ib. ft) 350-400 kg-em (26-28 lb-ft) 1,000—1,300 kg-om (73-94 Ib. ft) 350-400 kg-cm (26-28 tft) 450-500 kg-em (23-36 Ib.ft) ENGINE EN-CPSB. ENGINE COMPONENT PARTS DISMOUNTING AND MOUNTING SPECIAL TOOL, Prior to starting an engine overhaul, it is necessary to have these special tools, TIMER SETTING TOOL \V-BELT TENSION GAUGE smo.266| (09512-2090 for WOaD 09444-1210 (09512-2100 for WO4C-T, WO4C-TI ‘WosD, WOSD-TI, WOGE [~ Ftywneet wousine | FUEL INJECTION PUMP IMPORTANT POINTS — DISMOUNTING TUBING REMOVE THE FUEL INJECTION PUMP. 1, Disconnect the fuel lines, oil lines and engine contro! lines. Et 2. Tum the crankshaft counterclockwise viewed from the f- ‘wheal side to align the injection timing mark on the flywheel at A® before top dead center for No.1 cylinder on compression stroke with the pointer on the flywheel housing, POINTER 83-8858 Injection Timing (A°}: Refer to SECTION DATA AND SPECIFI- CATIONS. NOTE: In case of marine engine equipped with seawater pump, never rotate crankshaft viewed from the flywheet side). Reverse rotation may damage impeller in seawater pump. FLYWHEEL CRANKSHAFT 3, Remove the timing inspection hole plug Cheek that the injection timing mark on the automatic timer is aligned with timer cover pointer. TIMER coven maak\ \ poinTER, Maes EN-CP5B-2 eae 4 suze Cree CF f a ronres SMa.2858| \ TIMER COVER mann\ \poiTeR 5Ma.904} ENGINE 4. If not, remove the timing gear cover and then loosen the drive eer fitting bolts NOTE: Do not remove the drive gear fitting bolts. 5. Rotate the drive gear clockwise to align the injection timing ‘and then tighten the drive gear fitting botts, Tightening Torque: 300-250 kg-om (22-25 Ib.ft) 6. Lock the coupling flange with a special tool, ‘Special Tool: Timer Setting Tool (09512-2090) for Wo4D (09512-2100) for Wo4c-T, wo4e-T1, Wo6D, WosD-T1, wose 7. Loosen the timer cover fitting bolts (B) and then remove the Injection pump with timer cover. NOTE: Do not loosen the injection pump body fitting nuts (C). IMPORTANT POINTS — MOUNTING INSTALL THE INJECTION PUMP, 1. Check that the injection timing mark on the fivwheel is aligned with flywheel housing pointer. Injection Timing (A°): Refer to SECTION DATA AND SPECIFI- CATIONS, 2. Cheek that the injection timing mark on the eutomatic timer is aligned with timer cover pointer. {If not, adjust the injection timing ENGINE EN-CP5B-3 3, Lock the coupling flange with a special tool, Special Tool: ‘Timer Setting Too! {09512-2090} for Wo4D {09512-2100} for WOdC-T, WO4C-T1, WOSD, WOBD-TI, wosE SETTING TOOL \\ il 4, Install the injection pump with timer cover Fitting Bolts Tightening Torque: 190-260 kg-cm (14-18 Ib.) 5, Remove a special tool and Install the timing inspection hole plug. 6. Connect the fuel lines, ol lines and engine control lines. GENERATOR IMPORTANT POINT — MOUNTING INSTALL THE GENERATOR ON THE ENGINE. 41. Install the V-belts, and adjust the belt tension. NOTE: © Do not under any circumstances apply the lever directly against the generator body owing to the risk of damag- ing the generator. © When installing @ new V-belt or adjusting the tension, bbe sure to repeat the adjustment two or three times, after cunning the engine for several minutes each time, 2. Vibalt deflection ‘Apply 2 load of about 10 kg (22 Ib} by pressing with your finger or a special too! Assembly Standard {A}: 10-18 mm (0.40-0.59 in} Special Tool: V-belt tension gouge (09444-1210) NOTE: If the belt is excessively tensioned, there is 2 risk of damag- ing the bearings of the generator or coolant pump and also shorting the life of the V-belt. Conversely, if there is insufficient tension on the V-belt, cag} the bel, will slip, unusual noise will be amitted, the battery ‘may run down and the engine may overheat. SAMPLE ‘Through Bolt Tightening Torque: 450—500 kg-em (3326 tb-ft) EN-CP5B-4 ENGINE STARTER IMPORTANT POINT — DISMOUNTING REMOVE THE STARTER FROM THE ENGINE, 1. Turn off the battery switch (If s0 equipped). 2, Put the match marks on the harness and starter terminals With a pen and then disconnect the harness. 3. Remove the starter from the er IMPORTANT POINT — MOUNTING INSTALL THE STARTER ON THE ENGINE. 1. Install the starter on the engine, Fitting Bolt and Nut Tightening Torque: 42 mm (0.47 in) dia, : 650-900 kg-em (47-66 Ib.ft) 14 mm (0.56 in} dia, ; 1,100—1,500 kg-om (80~108 Ib.ft! 2. Connect the starter harness to match the marks. ENGINE EN-TUGA-4 ENGINE TUNE-UP NOTE: In case of marine engine equipped with seawater pump, never rotate the crankshaft in reverse direction (Clock- viewed from flywheel). Reverse rotation may damage ipeller in seawater pump. TA VALVE CLEARANCE INSPECTION AND ADJUSTMENT OF THE VALVE CLEARANCE 1. Set the No. 1 piston to top dead center on compression stroke. 2. With the No. 1 piston positioned at top dead center and of the compression stroke, adjust the No. 1 valve clearance using 2 thickness gauge. ‘The thickness gauge should move with a very slight pull Valve Clearance: Rafer to SECTION DATA AND SPECIFICA- TIONS. 3. Adjust the other valves. Turn the crankshaft counterclockwise 180° viewed from fly- wheel side, Adjust the valve clearance for each cylinder in the firing order. Firing Order: 1-3-4—2 VALVE CLEARANCE 3-716) METHOD FOR DETERMINING IF THE NO. 1 OR NO. 4 PISTON I$ AT THE TOP DEAD CENTER ON COMPRESSION STROKE, Turning the crankshaft, align the mark “1-4” on the flywheel with the pointer on the flywheel housing. In this position either the No. 1 or No. 4 piston is at the top dead center on compression stroke, 1. If both the No. 1 intake and exhaust rocker arms can be \ movad easily by hand, the No. 1 piston is at top dead centor on compression stroke, 13-1773) EN-TUSA-2 ‘TimeR COVER mans\ \ pomnres su3.sq PUSH RODS: STANDING {Overlapping stroke) PUSH RODS: MOVE Compression stroke) 53-7132] FLYWHEEL HOUSING \ pees T POINTER sug-eess| TIMER cover = suse ENGINE 2. If the injection timing mark is nearly aligned with the pointer, the No. 1 piston is at top dead center on the compression stroke. NOTE: If not, turn the crankshaft one complete revolution and align marks at above. 3, While locking at the push rod of No. 1 and No. 4 pistons, Turn the flywheel counterclockwise and clockwise about 30° to 40° (see left fleure). If the piston whose exhaust and intake push rods do not mave during the interval, itis at the top dead center on the compres: sion stroke, I the piston whose push rods have moved, its at the comple: tion of the exhaust and begun of the intake stroke (overlapp- ing stroke). NOTE: Always loosen the lock nut and raise the adjusting screws fully to the top. If the adjusting screws are too low, the piston and valves may strike each other during valve clearance adjustment, INJECTION TIMING INSPECT THE INJECTION TIMING. 1. Turn the crankshaft counterclockwise viewed from the fly- ‘wheel side to align the injection timing marks on the flywheel at A before top dead center for No. 1 cylinder on compres- sion stroke with pointer on flywheel housing, Injection Timing (A°|: Refer to section DATA AND SPECIFICA. TIONS. BTDC: Refer Top Dead Center 2, Check that the injection timing mark on the automatic timer is aligned with timer cover pointer If not, adjust the injection timing. NOTE: When adjusting the injection timing, refer to “FUEL INJECTION PUMP" in section ENGINE COMPONENT. PARTS DISMOUNTING AND MOUNTING for details, swore caus STIRRING RoD {| THERMOSTAT, crosoneren wearer saa 7, : Valve apening temperature 1) Vale opened tmperture oma t i eI 1 3 i H Oc pC | Tem. mc rc SM3-1133] ENGINE EN-TUSAS INJECTION NOZZLE INSPECT AND ADJUST THE INJECTION PRESSURE. Refer to “INJECTION NOZZLE” in SECTION FUEL, SYSTEM. ‘TEST THE SPRAY PROFILE. Refer to “INJECTION NOZZLE" in SECTION FUEL. SYSTEM, ‘TEST THE FUEL LEAKAGE. Refer to "INJECTION NOZZLE" in SECTION FUEL SYSTEM THERMOSTAT INSPECT THE THERMOSTAT FUNCTION. 1. Place the thermostat in hot water and check the opening temperature and the lift 2. Using a thermometer, check to see the thermostat opens at the specified temperature: Refer to “THERMOSTAT” in SEC TION COOLING SYSTEM. 3. Immerse the thermostat in hot water and measure the lift of the pellet after a period of 5 minutes using vernier calipers. Measure the position of the bottom of the pellet before and after heating the thermostat, Refer to “THERMOSTAT” in SECTION COOLING SYSTEM, 4, Immerse a heated thermostat in water of normal temperature. If it completely closes within 5 minutes itis satisfactory. If it remains even slightly open, it is defective and must be re- placed. Valve Li COOLANT FILLER CAP INSPECT THE FILLER CAP FUNCTION. (Check the filler cap pressure using a cap tester 0.8 : 0.40.6 kg/em? (5.7~8.5 Ib/sq.in} 0.9: 0.75~1.05 kg/em? (10.7--14.9 Ib/sq.in) NOTE: © The filler cap pressure is shown on the filler cap, and it should be confirmed, © If the cap pressure is incorrect, there is a risk of ab- normally high pressure being generated in the cooling system, which may cause the hose to drop off or burst and, in turn, damage the engine. WARNING Do not remove the cap while the engine and cooling system are still hot. If the cap is removed whife the engine and cooling system are still hot, scalding water and steam under pressure can be blown out. This can result personal injury. EN-TUSAS ENGINE ENGINE CONTROL ADJUST THE SOLENOID (ENGINE STOP) LINK ROD. ma HEN 1. Adjust the fink cod length ¢o that the clearance between the Nuticy Link 209. ENGINE STOP tever sua.1906] ‘CONTROL LEVER IDLING seen STOPPER BOLT SEAL CAP ENGINE STOP. Lever £183) MAXIMUM SPEEO” STOPPER BOLT stopper of the governor case and the engine stop lever becomes A" when the solenoid plunger is fully pushed in, Assembly Standard “A"*: 2-3 mm (0,08-0.11 in) NOTE: O Install the link rod with the nut(c} at the top. Of the clearance adjustment is unsatisfactory or the action of the solenoid is sluggish, solenoid seizure, insufficient output or engine stoppage may result. 2. After the above adjustment is over, move the link rod by hand and make sure that it moves lightly 3. When the engine is running, the clearance between the engine Stop lever and the stopper becomes “8. Assombly Standard “B's 0 mm (0 in) ADJUST THE ENGINE IDLING SPEED. When straight drive navigation is not smoothly made at the time of a sea trial in engine at idle, adjust it according to the following procedures. 1, Disconnect the throttle control cable from engine port (left) side and the starboard (right) side, Loosen the idling speed stopper bolt lock nut. 3. Adjust through verying the engine speed using the idling Speed stopper bolt on the injection pump so that straight drive navigation is made. NOTE: Increase in engine spi Turn the idling speed stopper bolt clockwise, Decrease in engine speed: Turn the idling speed stopper bolt counter-clockwise, Idling Speed: Refer to section DATA AND SPECIFI- CATIONS. 4, Upon completion of adjustment of ongine idling speed, lock the stopper bolt with nut and apply paint on the stopper bolt and nut NOTE: When adjusting the all adjusting devices on the fuel injec- tion pump governor, except the idling speed stopper bolt, refer to CHAPTER GV, INJECTION PUMP GOVERNOR, Engi ENGINE EN-TUSA-5 ENGINE TUNE-UP ON TEST BENCH NOTE: In case of marine engine equipped with seawater pump (© Never rotate the crankshaft in reverse direction (Clock- 8 [AN wise viewed from flywheel), els Reverse rotation may damage impeller in seawater pump. GENERATOR © Do not run engine without water in the seawater cool ing system. The seawater pump damage can result, ‘Starting the engine when the generator it not connected to the battery may damage tho generator. Always connect to the battery. TYPICAL, sarreay = DIAGRAM sm3.907 SET THE ENGINE ASSEMBLY ON A TEST BENCH. ‘Add the proper amount of the specified engine oll through the cil filler cap on the cylinder head cover, 2. Add coolant. © The connectors exist at male and female connectors. [ aa (Ss © — Male and female connectors are classified according to the i {! sape of the terminals in the connector {eter tothe fguce on the ef FEMALE ate © Male and female connectors are provided with a lock, s0 thet they can not be separated easily _, woe © For connector separation, hold the connector, uniock the S lock ang separate the connector. NOTE: When the connector is pullad by pulling the wires, the connection between the terminals and the wires will be SZ damaged. SN\ 1. Remove the terminal from the connector, mat a, Insert @ minature screwdriver or 3 terminal puller between terminal and connector and” unlock the lock between ter minal and connector. When the lock hat been released, pull the wire to remove the terminal : arr 2, nstall the terminal in the connector. y ‘2. Insert the terminal into the connector until the clicking sound — of lock engagement can be hesrd. - b. Pull the wire to confirm correct lock engagement, sm20-947 FUSE The power supply must be switched off for fuse replacement. ae |) © Use a fuse with a suitable amperage. — NOTE: Wire burning may be caused when 2 fuse with an exces: sively large curtent capacity is used. © If the fuse shoule blow frequently, invessigate the cause and si20-343 ramove It EES ENSURE THAT THE BATTERY IS ALWAYS FULLY CHARGED sng0.c@ac ELECTRICAL EQUIPMENT BATTERY CONVERSION FORMULA FOR SPECIFIC GRAVITY. © The specific gravity of electrolyte changes according to the temperature of the electrolyte itselt, hence it is based on a temperature of 20°C (68°F) Consequently, if the temperature is not 20°C when the specific cravity Is measured, It is necessary to convert the ‘measured value to the equivalent value at 20°C. Temperature conversion formule: $20 St + 0,0007 (¢ ~ 20) where, ‘© S20 is the specific gravity at 20°C (reference temperature) © Stis the specific gravity at the measuring temperature ‘© Cis the tomparature during measurement ‘© 0.0007 is the temperature coetticient of the electrolyte NOTE: As a rough guide, If the temperature of the electrolyte rises or falls by 15°C (59°F), the specific gravity of the electrolyte will vary by about 0.01. BATTERY CHARGING © Becareful of the following points. 1) While the battery is being charged, ensure that the temperature of the electrolyte dos not rise above 45°C (113°F) 2)_ While the battery is being charged, be particularly careful to keep it away from sources of fire. 3) The amount of electrolyte must be within the specified level ‘Specific gravity when battery is fully charged: 1.250 ~ 1.270 at 20°C (68°F) CLEANING THE BATTERY (© If the terminals at the top of the battery are dirty, clean them with cols water or lukewarm water. © Apply a light coating of grease to the terminals to prevent them from rusting so as to prevent faulty contact. CONNECTING THE BATTERY CABLES © Clamp the cables securely to prevent improper contact be- ‘ween the cables and the battery terminals Be very careful not to connect the (+) and {—-) leads in reverse. (because this may cause equipment -un damaged.) ELECTRICAL EQUIPMENT EET ENGINE STARTING CIRCUIT (CHECK THE CONTINUITY OF THE STARTER SWITCH. Check the continuity between terminals. If continuity is not correct, replace the starter switch. “Terminal ‘Switch position PRE-HEAT OFF ow START sp ir, |r, | m jer CHECK THE OPERATION OF BATTERY RELAY. 1. Check that ther continuity between terminals 1 and 2. 2. Check that there is no continuity between terminals 9 and 4, 3. Connect the positive (+) lead from the battery to terminal 1 Gonnect the negative (-) lead to terminal 2, Check that there is continuity between terminals 3 and 4, 4 If operation is not correct, replace the battery refey. CHECK THE OPERATION OF THE STARTER BLOCK RELAY. ‘Check that there is no continuity between tarminals C and B. 2, Connect the positive (+) lead from the battery to terminat | S. Connect the negative (~) lesd to terminal E, Check that thore is continuity between terminals C and B. 3. Connect the positive (+) lead from the battery to terminal P. Connect the negative (~) lead to terminal €. Check that ‘there is no continuity between terminals C and B. 4. If operation is not correct, replace the relay, zee ELECTRICAL EQUIPMENT PRE-HEAT CIRCUIT CHECK THE OPERATION OF THE INTAKE AIR HEATER RELAY. 1, Check thar there is continuity between terminals SW and L. Check that there is no continuity between terminals $ and F. Connect the positive (+) lead from the battery to terminel SW. Connect the negative (—] lead to terminal L. Check that there is continuity between terminals S and F. 4, H operation is not correct, replace the relay. is sw 20-1306 CHECK THE CONTINUITY OF THE HEATER PLUG. CChack the continuity between terminal and body. ground. If shere is no continuity, replace the glow plug, su20-s94| ENGINE STOP AND WARNING LAMP CIRCUIT CHECK THE OPERATION OF THE SOLENOID AND ADJUST THE LINK ROD. 1. Connect the battery to the solenoid terminals and confirm that the solenoid is drawn in. 2. Push in the plunger by hand and confirm that there is a clearance between the stopper and the stop lever. LINK AOD Standard clearance: 2 — 3 mm (0.01188 — 0.1181 in} If thare is no clearance, perform adjustment with the link rod. NOTE: © If the clearance adjustment is unsatisfactory or the action of the solenoid is sluggish, solenoid burnout, sufficient output or insufficient engine stoppage may sult (© Install the link rod with the nut at the top. -> FANDARD CLEARANCE Sunk roe tT - STOP LEVER — in STANDARD CLEARANCE ELECTRICAL EQUIPMENT EEg CHECK THE OPERATION OF THE WATER TEMPERATURE ‘SWITCH. Check the continuity between terminals. Li continuity is not correct, replace the temperature switch. Termi Water temperature: °C CF) Not iess than 98 = 2 (208-212) Between 95 (203) and 98 + 2 (205-212) 520-1181 CHECK THE OPERATION OF THE PRESSURE SWITCH. =O } 1. Chesk the continuity between terminal and body ground. a. Check that there is continuity when engine is stopped, bb, Cheek that there is no continuity when engine is running, 2. Mf continuity is not correct, replace the oil pressure switch NOTE: Engine oil pressure should be more than 0.5 ke/em? (7.2/ sq.in) sMtz0-1290 CHECK THE OPERATION OF THE RELAY. (WATER TEMPERA. ‘TURE WARNING LAMP RELAY) 1, Check that there is continuity between terminals 1 and 2. 2. Check that there is no continuity between terminals 3 and 4 3. Connect the positive (+) lead from the battery to terminat 1, Connect the negative () lead to terminal 2. Check that there is continuity between terminals 3 and 4 4. Hoperation is not correct, replace the rela suao-ia12 7 c a METER AND GAUGE CIRCUIT CHECK THE OPERATION OF THE TACHOMETER, 1, Connect a turnsup test tachometer, and start the engine. 2. Check the tester and tachometer indications. If the indicated value of tachometer is not correct, replace the tachometer. ‘Standard revolution (rpm) ‘Allowable value (rpm) 1800 | 3,000 i007) = 100 EEO ELECTRICAL EQUIPMENT CHECK THE OPERATION OF THE FUEL RECEIVER GAUGE. 1. Wire the receiver gauge, variable resistor and battery, as shown | in the figure at left. Check the indicated value on the receiver gauge at the reference resistance value, 2. If tho indicated value is not correct, replace the receiver gauge. | Resistance: 2 33.5 103, 240 Gauge reading F 12 E +e 0 | Allowable value: % 7 +4 oe sw20-1308 | CHECK THE OPERATION OF THE FUEL SENDER GAUGE. Measure the resistance between terminals, If the indicated value Is not correct, replace the sender gauge, Float position F V2 E { Standard resistance: £2 30.1 103 250 Allowable value: 2. 234 £103 £24 'SM20-1314 CHECK THE OPERATION OF THE WATER TEMPERATURE RECEIVER GAUGE. 1. Wire the receiver gauge, variable resistor and battery, as shawn in the figure at left. Check the indicated value on the receiver ‘gauge at the reference resistance value. ea | & ‘Sy 2. If the indicated value is not correct, replace the receiver gauge. Resistance: @ 43.2 23.7 i ‘Gauge reading: °¢ (PF) 80 (176) 100 (212) 20-1310, ‘Allowable value: °C CF) 3.5 (38) £55 (41) CHECK THE OPERATION OF THE WATER TEMPERATURE SENDER GAUGE. 1. Wire the sender gauge and ohmmeter as shown in the figure ‘at left. Chock the resistance value of the sender gauge at the reference water temperature 2. If the indlested value is not correct, replace the sender gauge. Water temperature: °C (°F) | 50 (122) | 80 (176) [100 (212) ‘Standard resistance: 130 485 | 267 20-043} ‘Allowable value: 92 | 242 | 226 CHECK THE OPERATION OF THE OIL PRESSURE RECEIVER GAUGE, 1. Wire the receiver gauge, variable resistor and battery as shown in the figure at left, Check the indicated value on the receiver gauge at the reference current value. 2. If the indicated value is not correct, replace the receiver gague. Resistance: 2. 19 12 ~ Gauige reading: bar (px) 0 6 (ea) su20-13tt Allowable value: bar (psi) |+0.3 (4.1) ELECTRICAL EQUIPMENT EEA 820-1315 Lig? 20-1316 CHECK THE OPERATION OF THE OIL PRESSURE SENDER GAUGE. 1. Wire the ssender gauge and ohmmeter 35 shown in the figure at left. Check the resistance between the sender gauge and the body ground. 2. If the indicated value is not correct, replace the sender gauge. Oil pressure kg/em? (ib/sq.inl| 0 4is7) | 6 (85) Stanclard rsistan 13 80 110 Allowable value: & [2 zs | =e CEHCK THE OPERATION OF THE VAOLTMETER. 1. Wire the voltmeter and transformer as shown in the figure at left. Check the indicated value on the voltmeter at the reference voltage value 2. If the indicated value is not correct, replace the voltmeter. Gauge reading: V 2 14 Aliowabie valuo: V 08 205 CHECK THE OPERATION OF THE GENERALLY USE SWITCH (ILLUMINATION LAMP SWITCH), (Check the continuity between terminals. I operation is not correct, replace the switch. Terminal 7 Switch position OW OFF Memo (ky) TURBOCHARGER TUT ‘TU-19E-02 CHAPTER TU TURBOCHARGER DATA AND SPECIFICATIONS DESCRIPTION TROUBLESHOOTING ... +. TUS OVERHAUL CRITERIA . +. TUS SPECIAL TOOL TURBOCHARGER 0.0 -...c eee cceeeee ee eeee eee eee eens TURBOCHARGER Tue DATA AND SPECIFICATIONS Type --. RHCE Turbine type = Radial flow type Blower type Centrifugal type Lubricating method Besring type Direction of rotating termperature xternal lubrication type ull floating type ‘ounterclockwise as seen from the turbine side DESCRIPTION 1, Turbine case 2. Turbine rotor 3. Bearing case ce ssm1-100 4, Blower impeller 5. Blower case m1-101 TURBOCHARGER TU.3 TROUBLESHOOTING Symptom Possibie cause Ramedy/Prevention Dense black smoke Insufficient ai intake © Air cleaner is choked with dust,..........,+ Disassemble and clean or repiace causing greater intake air resistance. the air cleaner element, © Airinlet is choked ceceee es Repair © Airis leaking from intake menifold .... Repair, “Turbocharger does nat rotate smoothly. © Engine oil impurities deposited on... Overhaul and clean turbocharger rotor, resulting in heavy rotation and/or change engine oil, Bearing sticking © Insufficient lubrication or blockalue Check tubricating oil system, of lubricating oft lines, and/or repair. © Abnormal wear or damage of seal Repair ring caused by wear of journal beering, due to insufficient lubeication, ‘© Temperature of lubricating oil too high = Cheek cooling system. © Unbalanced rotating parts s+ Change rotating parts, © Incomplete warming-ue, failure «+ Operate vehicte properly to idle before stopping engine, or jack rabbit starts, BEE Eh ose e eee ee eee eee |_{ Loose or damaged turbine rotor or blower impeller. © Overrosation.. + Check and adjust the engine. ‘© Temperature of exnaust gas too high ++ Check and adjust the engine. © Foreign matter present Remove foraign material Inspect the air cleaner and air intake manifold. Repair if necessary. © Worn thrust bearing veteee eee ec eee Qverhaul and reg Incomplete assembly eee Reassembly. High volume exhaust Exhaust gas leaking before turbocharger, (Check and repair connections. like noise. therefore insufficient revolution {deformed or blocked exhaust gas ‘ines co Repair. therefore insufficient revolution. White smoke———7— Choking defects, or deformation of ss «Repair and replace the tines. oil return lines so that oil Jeaks around blower or turbine sides. L_— seal ring may be broken or worn due Replace the thrust washer. to abnormal wear of thrust washer Tus Symptom Loss of power Poor response of ————— turbochargor TURBOCHARGER Possible cause Gas leakage from exhaust system | Air leakage from air manifold |— ciagged air cleaner element L__rurbocharger dirty or damaged +—Carbon accumulation on the turbine side seal ring and heavy rotation L_poor combustion Naive High pitched noise ang vibration # Socalled “surging” Surging sometimes occurs when the gas passage at the nozzie of the turbine housing is choked or when comoressed air does not flow in proper responses to acceleration © Loosen rotating parts Vibration © Joints loose between turbocharger and intake, exhaust manifold or cil lines. Damage imbalanced rozating parts, etc. Dearing, loose rotating parts, -. Romedy/Provention « Repair. Repair Ciean or replace. Repair or replace Change engine oil, clean turdocharcer. Check fuel system and improve combustion, Overhaul and elsan turbocharger. ++ Replace. Check the mounting and repair. Repair. OVERHAUL CRITERIA CONDITIONS WHICH DETERMINE WHEN A TURBOCHARGER OVERHAUL MAY BE NEEDED. THE ENGINE LACKS POWER OR ENGINE EXHAUST EMITS BLACK SMOKE. BOOST PRESSURE IS BELOW THE NORMAL VALUE. Inspect the turbocharger boost aressure according to the following procedures. NOTE: Before measurement © Coolant temperature should approximately 80°C. © Alrelaaner element should be clean. WARNING ‘when making a pressure test, be sure that personnel are adequate- ly protected against any stream of pressurized air that might be released by a leak or the rupture of a hose, 351015 ‘sus 1.014) TURBOCHARGER TUS 1, Remove the blind plug on the intske pipe and install the hose and pressure gauge Ispecial soos Special Tools: Pressure Gauge (09444-1250) Hose (17108-1040), 3. Reed boost pressure It the boost pressure is below the specified value, turbocharger } overhaul is needed. | Boost Pressure: Less than 0.13 kg/em? (1.85 lb/sq.in) at no load with maximum ravolution, OTHER FACTORS: Noisy of excessive vibration of the turbocharger. Excessive engine oil consumption, Gas leakage at the turbine end or blower end. Oil leakage from the turbocharger. SPECIAL TOOL Prige to starting an turbocharger overhaul, it ism ATTACHMENT FOR MEASURING TURBINE SHAFT RADIAL PLAY BOOST PRESSURE GAUGE essary to have these special tools, BOOST PRESSURE GAUGE HOSE | 2 | o 9444-1230 09444-1250 17308-1040 Tus TURBOCHARGER TURBOCHARGER veeim 480.23 3 T= 52-60(38-63) | Ts 78-85 (5.6-6.1) \ 7 12 4 & @ ai Nitra ee tg TE 14 (09-2.89 oN 14 oss T= Tightening torque: ka-cm (Ib.ft) 1. Turbin casing 7. Retainer ring 13. Blower casing 2. Turbin totor 8. Oil thrower 14. Bearing 3. Seal ring 9. Seal ring 15, Thurst spacer 4, Heat protector 10. Seal ring 16. Thurst bearing 5, Bearing casing 11. Seal plate 17. Blower impeller 6. Holding plate 12. Holding plate 18. Lock nut IMPORTANT POINT [S) ~ BEFORE DISASSEMBLY 1. Rotate the blower impeller by hand to see ifit turns smoothly. If it does not tura smoothly, clean and inspec: the bearing and turbine rotor ‘smsi-0028 2. Cheek the turbine rotor for axial play (A). If the axiai play is greater than she service limit, replace the ‘thrust bearing and/or thrust spacer. Axial Play: 0.06 ~ 0.09 mm {0.0024 — 0,0035 in) Service Limit: 0.11 mm (0.0043 in} 151.002} TURBOCHARGER TT ‘51-0024 MATCHING MARK. M5101 51951.087 iv5i.088) 3. Check the turbine rotor for radial play using a snecial tool, If the radial play is greater than the service limit, replace the bearings and/or turbine rotor, Special Tool: 09444-1330 Radial Play: 0.10 ~ 0,15 mm (0.0039 ~ 0,059 in) Service Limit: 0.19 mm (0,0074 in} IMPORTANT POINT (S) ~ DISASSEMBLY REMOVE THE BLOWER CASING, NOTE: © Make matching marks on the blower case and bearing case to aid alignment during reassembly. © If the biower cating cannot easily be removed by hand, tap it carefully all around using 2 plastic hammer and carefully remove it, (© Be careful not to damage the blower impeller, REMOVE THE TURBINE CASING. NOTE: © Make matching marks on the turbine case and bearing ‘case to aid alignment during reassembly. © Because the bolts on the turbine side are exposed to high temperature, if they have seized, do no apply an Uunreatonable force 10 remove them because they may break. Spray a lubricant onte them, then wait for about 16 minutes and loosen them, © Be careful not to damage the turbine blades, © If the turbine casing cannot easily be removed by hand, tap it carafully all round using a plastic hammer and carefully remove it. REMOVE THE BLOWER IMPELLER. 1. Remove the blower impeller fitting nut. NOTE: Turn the lock nut clockwise to loosen the nut (lefthand threads). 2. Remove the blower impeller by hand. REMOVE THE TURBINE ROTOR WITH HEATER PROTECTOR, TURBOCHARGER SMeTaEE s1451-024] TURBINE ROTOR | f susi-a25| AEMOVE THE BEARING 1, Remove the saa! plate Pull out the seal plate using the two screws. 2. Remove che oll thrower from the seal piste. 3. Remove the thrust bearing and thrust spacer. Loosen the bolt, then remove the thrust bushing using 2 10 dia. copper rod. NOTE: When removing the thrust bearing and thrust spacer, be cateful not to damage the thrust bearing hole in the bearing 4. Remove the retainer cings of each bearing. NOTE: When removing the retainer ring, be careful not to damage the front face of the hole in the bearing case. 5, _ Remove the bearings. REMOVE THE SEAL RINGS. NOTE: When removing the seal ring, be vary careful not to damage the groove of the seal ring. IMPORTANT POINT (S) ~ ASSEMBLY CLEAN ALL PARTS, 1. Before cleaning, the disassembled parts should be visually inspected to check for burning, abrasion, carbon deposits, ges and oll leakage. 2. Thoraughly clean all the parts with brush, and dry with compressed air. iasel fuel, using 2 soft NOTE: © Never use a caustic cleaning solution, as it may attack ‘aluminum, © Nover use a wire brush, TURBOCHARGER Tus TURBINE sLoweR nore on IMPELLER ire) lL INLET 8 S view FROM TS Tursine ROTOR Sig1-0268 1 SMB1-O2TA ‘SMs1-0284 OIL INLET, 51.024 SMB1-0054 sms1.030} ASSEMBLE THE JOURNAL BEARINGS, 1. Install the first retainer cing in the bearing casing. NOTE: © Bevelled adge of the rotainer ring should be towards the bearing. (© Make sure that the retsiner ring is securely fitted in the groove. © Install the retainer ring with the gap facing as shown in ‘the drawing 2. Install the bearing in the bearing case, NOTE: Apply clean engine oil. 3, Install the other retainer ring. NOTE: The only nearest turbine side of the retainer ring should bbe installed according to the figure on tha left. 4, Repeat step 1) through 4) to instal the second bearing, ASSEMBLE THE THRUST BEARING, 1. Install the thrust spacer.on the turbine shaft NOTE: Lubricate thrust spacer surface. 2. Coat the thrust bearing with clean engine cif and install the thrust bearing. NOTE: Always use new screws and lack washers, INSTALL THE SEAL PLATE. 1. Insert tivo new seal rings on the oil thrower, 2. Install the oil thrower in the seal plate, NOTE: The openings of seal rings should be positioned as shown, 3. Install the seal plate in the bearing case, NOTE: © The oll return hole should face the oil outlet side. Apply silicone R.T.V. sealer to the flanged surface of the seal plate. (© Take care that the silicone sealer does not protrude from the flange. 4, Tighten the four screws with lock washers. NOTE: Always use new screws and washers. Tu-10 SEAL RING TURBINE SHAFT O1LMLET HEAT PROTECTOR se Sy ANIMA \ ~ i \ y BEARING CASE 1451.08 SEAL RING GAP swsi.056] smsi.032| TURBOCHARGER ASSEMBLE THE TURBINE ROTOR. 1, Jastall 8 new seal ring in the seal ring groove of the turbine shaft 2 jest protector on the bearing case. 3. Coat the journals of the turbine rotor with cian engine oil and install the turbine rotor in the bearing case, NOTE: © The gap in the seal ring of the turbine shaft must face rowards the oil inlet. © Insert the seal ring concentric with the carbine shaft. If it is insarted with unreasonable force, it may be damaged. © When inserting the turbine shaft, be very careful not 10 ‘damage the journal bearing. FIT THE BLOWER IMPELLER ON THE TURBINE ROTOR AND TIGHTEN THE LOCK NUT. NOTE: Remember that this nuthas left-hand threads. INSTALL THE TURBINE CASE TO THE BEARING CASE, BEING SURE TO ALIGN THE MATCHING MARKS, NOTE: Always ute new lock plates. ASSEMBLE THE BLOWER CASE. 1, Install the blower case to the bearing case referring to the matching marks. NOTE: Coat the flange face of the blower case with silicone R.T.V. sealant 2. Tighten the six fitting bolts ASSEMBLY TEST 1. Rotate the blower impeller by hand to see if it turns smoothly. Refer to page TUS, 2. Check the turbine rotor for axial play (A). Refer t0 page TU, (Cheek the turbine rotor for radial play using a special toot, Refer to page TU-7, TURBOCHARGER Tut INSPECTION AND REPAIR Lem i Inspection Item ‘Standard Limit | Remedy Inspection Procedure Turbine Shatt Diameter 7 1039 | Replace (0.2090) Turbine Shoft Bene : aor | Replece (0.0008) | 1 Seal Ring Groove Wath 7 [134 | Repteceshatt of Turbine Shaft | (0.0527) assembly. oe gee RE Bearing Case Inside c epee Diamar Journal Bearing inside a woas | favlce Diameter (0.8114) ‘Journal Bearing Outside : 1498 | Replace Diameter (0.5897) sus.07| “Thrust Spacer Height c “00 | Replace (0.1610) | Seal Ring Groove Width 7 er Reploe of Oil Thrower 182 (0.0598) ez: 132 (0.0519) M1008 Tus2 TURBOCHARGER INSPECTION AND REPAIR nits mm fl Inspection tern Standard Limit | Remedy Inspection Procedure Thrust Bearing Thickness 3.98 (0.1566) Replace | Seating Bore of Seal Plate | Hi: 14.05 (0.5531) 2: 12.48 (0.4901) | Replace ¥5-0088| (Ky) ee ELTA IP P-1216-01 CHAPTER IP FUEL INJECTION PUMP DESCRIPTION . TROUBLESHOOTING . SPECIAL TOOLS ... LIP. 6 INJECTION PUMP P.7 TIMER ...... P15 Zi FEED PUMP . 1P.19 ADJUSTMENT P21 Pee FUEL INJECTION PUMP DESCRIPTION FUEL INJECTION PUMP 1 2. 3, 4, High pressure pipe . Delivery vaive Plunger barrel Plunger 5. Control rod 9, Com shaft 6. Control sleeve 10. Cam 7, Plunger spring 11, Fuel feed pump 8. Tappet FUEL INJECTION PUMP P3 Symptom Engine dows not start TROUBLESHOOTING Possible couse [Fuel not reaching injection pump Fuel lings clogged or damaged Fuel filter clogged Air in fuel caused by improper .. connections of fuel line between fuel tank and feed pump Filter incorporated in inlet side .. of feed pump clogged Faulty feed pump check valve Feed pump piston spring broken Feed pump push rd or tappet sticking Fuel reaching injection pump Faulty connection of accelerator . wire to pump adjusting lever. Comtrol rack faulty or sticking .. 5... Damaged camshaft bearing . Plunger worn or sticking Faulty connection of engine... stop wire to pump stop lever. Nozzle faulty Fuel leakage caused by loosened nozzle holder. Low opening pressure of nozzle Nozzle pressure spring broken Nozzle needle sticking to nozzle body Pump out of timing Improperly retarded injection timing Incorrect timing caused by improper . Installation of pumo. Woodruff key for pump camshaft cut off. Improper pre-stroke adjustment Remedy/Prevention Clean or replace fuel tines Clean or replace the filter element. Repair connections. Remove foreign mat Repair or repiace it Replace it Repair or replace it, Repair connection. Repair it Repair it. Correct or replace it. Repair it. Inspect and tighten it Adjust it. Replace it. Correct or replace it. Correct injaction timing Check engine timing and correct it Replace it Correct it to obtain specified Injection timing. Ps FUEL INJECTION PUMP Symptom Possible cause Black smoke Excessive smoke: Low idle speea ineegular Engine always runs. at hig speed Engine starts and stops: ‘© Excessive fuel delivery caused by incorrect adjustment of fuel load stopper screw, © Excessively advanced injection timing. © Large spread in fuel delivery (© Bad nozzle fuel spray characteristics rpeeral White smoke © Improperly retarded injection . . timing. © Water in fuel. -— Improper adjustment of idle button [-— Bad fuel spray characteristic of « nozzles. }— Incorrect injection timing }— Incorrect initial tension setting of {ling spring or the spring broken. [— Comtrot rack not smoothly move . L— Large spread in fuel delivery f— Plunger worn [— Governor linkage not smoothly move Defective feed pump +— Accelerator cable sticking |-— Governor linkage sticking (contrat rack sticking ‘ 1— Fuel ines clogged {Air in fuel caused by damaged fuel lines or improper connection of fuel lines, Remedy/Prevention Adjust fuel detivery on test stand. Corract it Adjust it. ‘Check and correct them, Advance injection timing (Check and clean fuel lines. Correct it. (Check and repair them, Correct it. Adjust or replace it, Disassemble pump and repair it Adjust it Replace it Correct it Disassemble and repair it Check and correct it. Disassemble and repeir the governor. Check and correct it. Clean or replace fuel lines, Ropair fuel lines or replace fuel lines and gaskets. Symptom Engine has low power. —————-—| Pump aut of timing Loud knocking FUEL INJECTION PUMP © Excessive advanced timing, resulting in loud knocking © Excessively retarded timing resulting in black smoke. © Defective injection pump overtlow valve, © Feed pressure too low ‘© Improper accelerator cable adjustment Nozzle faulty Fuel leakage from nozzle holder © Bad nozzle spray characteristic Loosened adjusting screw in nozzle holder, resulting in low opening pressure, Nozzle pressure spring broken {Pum fautty ‘© Fuel leakage from delivery valve holder © Defective seat of delivery valve assembly © Delivery valve spring broken © Plunger worn Large spread in fuel delivery © Wear of tappet collar ‘* camshatt bearing worn or broken '# Impcoper adjustment of governor fuel load stopper screw, J— Impriper injection timing }— Bad fuel nozzle spray pattern after-dribble |— High nozzle opening pressure | incorrect fuel detiveries to some nozzles, Remedy/Prevention (Check and correct it (Check and correct it. Repair or replace it Aepair the feed pump. Adjust it Check and repair nozzle holder Repair or replace it Adjust it Replace it Retighten the delivery valve holder if it i loosened or replace O-ring if the O-ring is defective, Repair or replace it. Replace the soring, Replace it Adjust it Replace the roller Replace it Adjust it Correct it, (Check and correct it. Adjust the opening pressure. Readlust the fuel deliveries. P68 FUEL INJECTION PUMP SPECIAL TOOL Prior to starting an injection pump overhaul, it is necessary to have these special tools. UNE coer rarrer cuane TaPPETinocky ella CAMSHAFT BEARING OUTER RACE PULLER, TAPPET INSERTER CAMSHAFT CLEARANCE GAUGE 08512-1160 (REAR) 096121380 09512-1150 09512-1430 (FRONT) SPRING HOLDER ‘TAPPET GAP INSTRUMENT HOLDING WRENCH 095121370 09812-1410 09512-1710 TIMER EXTRACTOR ‘SPRING HOLDER, (09512-1230 (SA-TYPE] oosi241200 (09512-1280 (SCZ-TYPE) FUEL INJECTION PUMP ip? INJECTION PUMP A-TYPE PUMP. (4-CYLINDER] T= 350-400 (25-28) —~ 9 & T= 850~1,000 (62-73) ord W \ ‘T= Tightening torque kg:em (lb-ft) 1. Injection pump housing 17, Shim 33, Tappet assembly 2. Lock plate 18, Adjusting ring 34. Shim 3. O-ring 19. Camshaft 38. Tappet 4. Delivery valve holder 20. Woodruff key 36, Retainer ring 5. Stopper 21. Control rod cover 37. Tappet roller pin 6. Delivery vaive spring 22. Bolt 38. Tappet roller 7. Gasket 23, Nut 38. Roller bushing 8, Delivery valve 24, Stop wire bracket 40. Plug 9. Plunger 25, Overflow valve sub-assembly 41. Sorow 10, Screw 26. Special washer 42. Control pinion 11. Nut 27. Bolt 43. Control sleave 12, O-ring 28. Control rod 44, Plunger spring seat, upper 13. O-ring 29, Cover gasket 45. Plunger spring 14, Bearing cov 30. Cover ‘46. Plunger spring seat, lower 15. Gasket 31. Plain washer 16. Tapar roller bearing 32. O-ring pa FUEL INJECTION PUMP TAPPET inseRTER caysart eno ae PLAY GAUGE & IMPORTANT POINT (S) — DISASSEMBLY WARNING © Breaking of the lead seals or crimp caps by anyone other than HINO or pump manufacture suthorized service stations to make these adjustment will void the warranty. If fuel pump or governor difficulties are suspected, consult only HINO or pump manufacture authorized service stations, where the problem can be corrected and the injec: tion pump lead seals and crimp caps can be reinstalled as required. Measure and record the fuel delivery characteristics of the pump before disassemblir Keep the parts for each cylinder in separate groups and in an orderly arrangement. Parts to be replaced and parts to be used again must be kept separately. REMOVE THE TIMER ASSEMBLY. Refer to “TIMER AND COUPLING". REMOVE THE GOVERNOR. Reter to “GOVERNOR”. INSERT THE TAPPET INSERTER IN THE TAPPET HOLE. Turn the camshaft and insert the tappet inzerters in each tappet hole when their tappet is at the highest position. Special Tool: Tappet Inserter (09512-1380) MEASURE THE CAMSHAFT END PLAY. 1, Mount the camshaft end play gauge on the camshaft drive end and be sure tighten “B”. ‘Special Tool: Camshaft End Play Gauge (09512-1150) 2. By turning “A”, create a clearance of about 1 mm (0.04in) betwean “A’"and the bearing cover 3, Lightly strike the end “B" 3 or 4 times with a plastic hammer. FUEL INJECTION PUMP ip — suim PLATE (RIVE ENO) saa208] si4204 4 Lightly tighten “A” until it cames into contact with the bear ing cover, 5. Lightly strike the camshaft governor and 9 or & times a plastic hammer. 6. Lightly tun “A” until it comes into contact with the bearing ‘cover, then read the clearance. ‘Assembly Standard: 0,03—0,06 mm (0,0012-0.0019 in) Service Limit: 0.10 mm (0,004 in) 7. if the specification is not met, use appropriate shim plates at the drive end of camshaft. REMOVE THE TAPPET ASSEMBLY. 1. Push the tappet with the tappet roller clamp and remove the tappet inspecter. Special Tool: Tappet Roller Clamp (09512'1130) 2. Remove the tappet through the camshaft bearing hole. ‘Special Tool: Tappet Clamp (09512-1120) 149 PLUNGER CLAMP BEARING REMOVER Oe sia.t2a BEARING cuioe REMOVER guren nace (I~ Puuen u.126 FUEL INJECTION PUMP REMOVE THE PLUNGERS, SPRINGS AND CONTROL SLEEVE. 1. Use the plunger clamp hold the spring lower seat and remove It together wich the piunger. Special Tool: Plunger Clamp (09512-1360) REMOVE THE TAPER BEARING FROM THE CAMSHAFT. 1, Remove the taper bearing from the dive end of the camshaft, Special Tool: Bearing Remover (09510-1160) 2 Use the guide to remove the bearing at the governor side. 3. Use the outer race puller, to tap out the outer race in the bearing cover. Special Tool: Outer Race Puller (09512-1430) FUEL INJECTION PUMP ett IMPORTANT POINT (S) — ASSEMBLY sa.213 WARNING (© Wash all parts with clean diesel fuel before installing them, and any defective or damaged parts must be replaced. © Do not allow dust or other foreign matter to enter the ‘pump during assembly, © Apply grease to O-rings and oil seals before installing them, (© Assemble the parts in correct order and to correct tighten: ing torques, assembled dimensions etc, © Assembly takes place in the reverse order of disassembly. INSTALL THE PLUNGER BARRELS. 1. Before install the plunger barrels should be inspect the plunger barrels and plungers for wear, scratches, or discoloration, 2 Tilt the plunger to about 60°. Pull the plunger out approxi- mately 10 10 15 mm (0,390.59 in) and release it to see if it slides down smoothly from its own weight, 3. Metch the plunger notch with the injection pump housing knock pin, INSTALL THE DELIVERY VALVES, SPRINGS AND HOLDERS. 1. Before install the delivery valves, inspect the delivery valves for scratches on the valve teat or the piston sections, P12 M216 FUEL INJECTION PUMP 2. Install the gasket, spring, shim and stopper on the delivery valve, 3, Provisionally tighten the delivery valve holder with 2 new O-ring by hand. NOTE: Tighten the delivery valve holder after installing the plung er. INSTALL THE CONTROL SLEEVES ON THE BARRELS. NOTE: Make sure that the control sleeve swings evenly right and left when the control rack is moved to the right and left, INSTALL THE PLUNGER AND TAPPET. 4. Assembly the plunger and spring lower seat, Inserting the Criving face marked with a number and the lower seat notch part upward (cover plate side). Special Tool: Plunger Clamp (09512-1360) 2, Install the tappet to the pump housing with the adjusting shim, ‘Special Tool: Tappet Roller Clamp (09612-1130), ‘Tappet Clamp (08512-1120) 3. Using the tappet roller clamp to press in the tappet and hold it in with the tappet inserter. ial Tool: Tappet inserter (09512-1380) CONTROL SLEEVE FUEL INJECTION PUMP 1P.13 NOTE: © Check that the driving face of the plunger fits to the ‘groove of the control sleeve before inzerting the tappet, © When inserting the tappet, check that the control rack slides smoothly and without catching, TIGHTEN THE DELIVERY VALVE HOLDER. When one delivery valve holder is tightened, move the contro! rack to the right and teft and inspect the tightness of the rack, itening Torque: 400-480 kg-em [29-32 Ib.ft) p14 FUEL INJECTION PUMP INSPECTION AND REPAIR Inspection Item Standard Limit Remedy Inspection Procedure Plunger springs tension. 24.4 kg (49.415) | 21.0 kg__| Replace, spring. at 41.4 mm (1,63 in} | (48.3 1b) Delivery valve springs tension. | 3.1 kg (8.8 Ib) 27kg | Replace, spring. at 17.0 mm (0.67 in} | (6.0 1b) Tappet wear. 0.3mm | Replace, tappet (0.012 in} | assembly, Camehaft cun-out, 0.16 mm | Replace, cam- {0.006 in} | shaft. SCZ-TYPE TIMER Drive gear ‘Adjusting shim 5. Spring seat O-ring Par epe |. Timer driving flange ). Spring seat |. Timer weight . Timer hub FUEL INJECTION PUMP Pas Timer spring IMPORTANT POINT (S) — DISMOUNTING REMOVE THE TIMER ASSEMBLY FROM INJECTION PUMP. Special Tool: Timer Extractor (09512-1230) IMPORTANT POINT (S] — DISASSEMBLY REMOVE THE DRIVE GEAR FROM TIMER, NOTE: Place matchmarks on the timer flange and timer hub. PAG FUEL INJECTION PUMP 1. Remove the snap ring. 2. Pullup the timer flange. NOTE: Be careful that the springs and shims do not fly out, TIMER DRIVING FLANGE Timer WEIGHT Timer HUB IMPORTANT POINT (S} — ASSEMBLY SET THE TIMER SPRINGS. ‘Special Tool: Spring Guide (09512-1240) INSTALL THE TIMER FLANGE WITH DRIVE GEAR. 1. Align the marks on the drive gear and timer hub, 2, Hold the drive gear so that the springs will not fall out, IMPORTANT POINT (S) — MOUNTING INSTALL THE TIMER ASSEMBLY TO INJECTION PUMP, ADJUSTMENT OF THE TIMER. INSPECT THE TIMER ADVANCE. 1. Seta stroboscope on @ pump tester. 2. Check the timer advance. Advance Angle: Refer to “CALIBRATION chart”, If angle is not within specification, adjust with proper shim, FUEL INJECTION PUMP PAT FP/KS-TYPE T= 400-450 (29-32) T= 800-900 (58-65) Feed pump serial No. Joint bott Soft washor . Connactor O-ring Chock valve spring Chock valve Priming pump Retainer ring . Tappet assembly |= Roller M14, = 130-150 (9-10) ‘Nylon gasket M14, T= 200-260 (14-18) ‘Comet packing, Copper gasket ___1 = 500-850 (36-39) ightaning torque: kg-em (lb.f2) 12, Tappot 13, Pin 14, Sliding block 15. Feed pump housing, push rod, & oil seal 16, Piston 17. Spring 18, Gasket 19, Plug 20. Soft washer 21, Filter FUEL INJECTION PUMP (P18 INSPECTION AND REPAIR Vovpeetion team suanders | Limit | Remedy Inspaction Procedure Valve Seat. - = | Replace, Visual check if nocossary Woar, Damage a4 | AR... Visual check Piston, Cylinder and Oil Seal - — | Replace, Wear, Damage if necessary. a = | clean Visual check smasie FUEL INJECTION PUMP p19 ADJUSTMENT PREPARATION 1, Mount the injection pump correctiy on the pump tester. Flamove the timer case in case of the SCZ type timer. sua.aae| 2. Attach a rack messuring device to the control rack and set to ag 2, Install calibration nozzles and lines of the following specifica- tions. a) Nozzle Nozzle type: 12SD12 (BOSCH Type) Opening pressure: 178 kg/em (2,489 Ib.ft) 6) Line Outside digmeter: 6.0 mm (0.24 in} nner diameter: 2.0 mm (0,08 in) Length: 600 mn (23.6 in} 4, Calibration oll a] Calibration oll: SAE J987C b} Oil temperature: 40—45°C (104—113°F) RACK MEASURING DEVICE 5, Install the cover on the feed pump mounting surface and fill the pump camshaft chamber with engine oil ADJUSTING THE INJECTION TIMING 1, Preperation of the pre-stroke, al Remove the plete cover b) Install a pre-stroke measuring instrument. Bring the tappet of the first cylinder to its bottom dead center, and set the pointer tip on the tappet. 1.20 OVERFLOW Pre HIGH PRESSURE | Fuet. — PLUNGER, PRESTROKE BARREL FUEL INJECTION PUMP 2. Measure the pre-stroke (No.1 plunger) al Set the controt rack at full-load position, b) Loosen the overflow screw of each nozzle holder. ©) Operate the high-pressure pump of the pump tester and tet fuel run out of the overfiow line, ) Move the angle dial to set the first cylinder of the pump to bottom dead center and adjust the pre-stroke gauge to zero, NOTE: Bottom dead center is the point at which the pointer of the dial gauge does not move even when the angle dial is rotated while fuel is flowing from the overflow line, ¢} Turn the camshaft clockwise with the angle dial and reed ‘the dial gauge when the fual stops running out of the over flow line. This reading is the pre-stroke value of the pump, Pre-stroke: Refer to “CALIBRATION chart” f) If the pre-stroke value is not within specification, adjust by ‘changing the tappet adjusting shim. Special Tool: Spring Holder (09572-13701 ADJUST THE INJECTION INTERVAL, 1. Using the No.1 cylinder injection starting point as 2 base, inspect and adjust the injection interval in the order of injec: tion, A-cylinder Injection interval: 89°45" Injection Order: 1-3-4-2 P15" FUEL INJECTION PUMP 1P2t 2. If the injection intervals are not within specification, adjust ‘SPRING by using the same procedure as for pre-stroke adjustment, srvcezens 3, Set the No.1 cylinder at the injection starting point, and check that the marks on the timer and the marks on the pump body are aligned, | the timing marks are not aligned, make 3 new mark on the timer and erase the old mark, TIMING MARK CHECK THE TAPPET TOP CLEARANCE. 1, Set the No.1 cylinder at the injection starting point, then ‘move the tappet with the handle. Tappet Top Clearance: More than 0.2 mm (0.0078 in) Special Tool: Tappet Handle (09512-1410) 2. Follow the above procedure to check the other cylinders (No.2 through No.6). 3. If the tappet clearance Is Jess than 0.2 mm (0.0079 in}, re- tascoeal check the pre-stroke. ‘TAPPET HANDLE MEASURING AND ADJUSTING THE INJECTION VOLUME. ‘Measure the injection volume for each contral rack position and pump revolution, Injeciton Volume: Refer to “CALIBRATION chart.” pyouume VARIATION To adjust the injection volume, loosen the pinion screw and ingart the adjusting pin into the hole in the control sieeve, ‘then move the sleeve slightly. (KPy MEMO v1 GV-06E-03 CHAPTER GV INJECTION PUMP GOVERNOR (MODEL: RSV) DESCRIPTION ..2.....eecseesesseeeeececeesieteeeene Gv2 GOVERNOR SPECIAL TOOL 1.20.20. ee eeece tee ees ese eseeee neces avd Gvz GOVERNOR DESCRIPTION [MODEL: RSV] [Representative model] 1, Governor spring 11. Sleeve 2. Control rod 12, Link 3. Knuckle 13, Start spring 4, Swivel lever 14, Guide lever 5, Maximum speed stopper bolt 15, Tension lever 6. Camshaft 16. Idle sub spring 7. Control lever 17. Full load stopper bolt 8, Stop lever 18. Idle spring 8. Supporting lever 19, Floating lever 10, Flyweight GOVERNOR GOVERNOR v3 - Governor housing . Stopper bolt . Woodruff key Flyweight Sleeve 5. Bearing shim Guide lever assy Link Start spring ‘Supporting lever . Tension lever 3. Full load stopper 14, Idle 15, Lock nut 16. Governor cover 17. Swivel lever 18. Governor spring 19. Gasket 20. Pin 21. Plug 22. Control lever 23, Woodrut key 24, Coller 25, Oil seal 26. Bush 27. O-ring 28. Snap ring 29. Stop lever 30. Cap 31, Idle stopper bolt 32, Idle sub spring 33, Nut 34. Cap out 36. Closing cover 36. O-ring 37. Cap aut ova GOVERNOR SPECIAL TOOL Prior to starting an injection pump governor overhaul, itis necessary to have these special tools, FLYWEIGHT EXTRACTOR ROUND NUT WRENCH 09517-1900 08517-1500 IMPORTANT POINT (S) — DISASSEMBLY WARNING © Breaking of the lead seals or crimp caps by anyother other than HINO or pump manufacture authorized service Stations to make these adjustment will void the warranty. © If fuel pump or governor difficulties are suspected, consult only HINO or pump manufacture authorized service stations, where the problem can be corrected and the injec: jon pump lead seals and crimp caps can be rainstalied as required, DISASSEMBLY THE GOVERNOR COVER FROM PUMP BODY. 1. Disconnect the shackle from the control rack, NOTE: When remove the governor cover fitting bolt, hold the governor cover. 2. Disconnect the start spring suas GOVERNOR evs REMOVE THE FLYWEIGHT ROUND NUT. NOTE: Use the holding spanner to keep the camshaft from rotate ing. Special Tools: Round Nut Wrench (09511-1500) REMOVE THE FLYWEIGHT, USING THE FLYWEIGHT EX- TRACTOR. Special Tool: Flyweight Extractor (09611-1800) IMPORTANT POINT (S) ~ Assebmly WARNING, © Wath ail parts with clean diesel fuel before installing them, and any defective or damaged parts must be replaced. © Do not allow dust or other foreign matter to enter the ump during assembly. ‘© Apply grease to O-rings and oil seals before installing them, (© Assemble the parts in correct order and to correct tighten ing torque, assembled dimensions ete. © Assembly takes piace in the reverse order of disassembly. INSTALL THE ADJUSTING LEVER 4. Install the shaft of the adjusting lever so that wide side of the shaft head surface is toward the pump body. NOTE: Installing in reverse may cause the floating lever to contact ‘the speed controt spring, resulting in operational malfunc- tion CHECK THE GOVERNOR LINKAGE FOR SMOOTH OPERA- TION. Hook under the quide lever, and pull upwards, using a spring balance. Starting force: 140-180 g (4.9~6.3 02) av6 Maximum SPEED STOPPER BoLT SWIVEL Lever ADJUST SCREW AS Q contrat) tever IDLING SCREW FULL LOAD STOPPER BOLT lone sua SETTING ScneW 514.206) stop Leven GOVERNOR INSTALL THE FLYWEIGHT TO PUMP CAMSHAFT. Using a special tools, tighten the round nut. ‘Special Tools: Round Nut Wrench (09511-1500) INSTALL THE GOVERNOR HOUSING TO PUMP BODY, 1. Connect the start spring. 2. Connect the shackle to control rack. ADJUSTMENT OF THE GOVERNOR [MODEL; RSV] 1 PREPARATION 1. Connect the rack measuring device to the control rack and set to "0", 2. Gonnect the fuel line. 3. Refill the camshaft chamber with engine oil 4, Install the angle gauge on the adjusting lever. STEPS IN GOVERNOR ADJUSTMENT. Perform governor testing and adjustment in the following sequence (For values of N. and R Refer to “CALIBRATION chart"): 1. Adjustment of maximum speed control. Adjustment of speed droop. 3, Adjustment of idling speed contro, RK RACK POSITION lnm) 2 — PUMP SPEED (rom) Ne FULL LOAD STOPPER BOLT 54.296) IDLING SCREW z Re g 3 3 et ND ume sezeD bom £ 3 me a Re g y g uve veven ay Bonet SEMEN 7 Ke PUMP SPEED (pn! suse Ipuina sup SETTING SCREW sm4.200| sa-068 ERNOR ov.7 1. Adjustment of maximum speed control NOTE: The control lever should be full load position. a) Adjust the full load stoprer bolt. Ata pum sed of Ne Tm, Sut the rk mm with the full load stopper bolt, f wer b) Adjust the maximum speed stopper bolt At a pump speed of Nb rpm, adjust the rack position to Rb mm with maximum speed stopper bolt. NOTE: The control rack should start to be pulled. 2. Adjust of speed droop. At a pump speed of Ne rpm, adjust rack position to Re mm with swivel fever adjusting serew. ‘Adjusting of idling speed control a} At s pump speed of Na rpm, adjust the rack position to Ad mm with idling serow. NOTE: The contro! lever angle, refer to CALIBURATION chart. bb} At 2 pump speed of Ne rpm, adjust the rack position to Re mm with idling sub setting screw. GOVERNOR EXTERNAL LEAD SEALS AND CRIMP CAPS, NOTE: All adjusting devices on the fuet injection pump governor, are wired and lead sealed as a protection for the customer, This is to prevent unauthorized readjustment which may cause engine malfunction and/or engine failure, Pariodical- ly check to insure that these seals are not broken as this will void the warranty. MEMO > GOVERNOR Gvt GV-23E-01 CHAPTER GV INJECTION PUMP GOVERNOR (MODEL: RSV with BOOST COMPENSATOR) Gv2 GOVERNOR GOVERNOR 1. Governor housing 2. Stopper bolt 3. Woodruff key 4, Flyweight 5. Sleove 6. Beating 7. Shim 8 Guide lover assy 9% Link 10, Start spring 11, Tension lever 12. Full load stopper 13, Idle spring 14. Lock nut 15. Governor cover 16. 2. 18, 19, a 23, 26. 26, 21, 28, 29. 30. Swivel lever Governor spring Gasket Pin . Plug Control lever 2. Woodrutf key Collor Oil seal Bush O-ring Snap ring Idle stopper bolt Ile sub spring Nut 31 34, 35, 36, 27. 38, 39, 40, an 42, 45, Cap ut Closing cover O-ring Cap nut Cap nut Lock nut Adjust sorew Cover fixing bolt Cover Diephragm Puth tod Spring Adjusting shim Gasket Union bolt Prior to starting an injection pump governor overhaul, itis necessary to ha FLYWEIGHT EXTRACTOR GOVERNOR 6v.3 SPECIAL TOOL ‘these special tools ROUND NUT WRENCH cf} Oo 08517-1900 09577-1500 IMPORTANT POINT (S$) — DISASSEMBLY WARNING (© Breaking of the lead seals or crimp caps by anyother other than HINO or pump manufacture authorized service Stations to make these adjustment will void the warranty. (© If fue! pump or governor difficulties are suspected, consult ‘only HINO or pump manufacture authorized service stations, where the problem can be corrected and the injee- tion pump lead seals and crimp caps can be rainstalled as requi DISASSEMBLY THE GOVERNOR COVER FROM PUMP BODY. 1. Disconnect the shaokle from the control rack. NOTE: When remove the governar cover fitting bolt, hold the governor cover, 2, Disconnect the start spring 6v.4 GOVERNOR REMOVE THE FLYWEIGHT ROUND NUT. NOTE: Use the holding spannar to keep the camshaft from rotat- ing. Special Tools: Round Nut Wrench (09511-15001 REMOVE THE FLYWEIGHT, USING THE FLYWEIGHT EX. TRACTOR. Special Tool: Flyweight Extractor (09511-1900) IMPORTANT POINT (S) — Assebmiy WARNING © Wash all parts with clean diesel fuel before installing them, and any defective or damaged parts must be replaced. © Do not allow dust or other foreign matter to enter the pump during assembty. © Apply grease to O-rings and oil seals before installing them, (© Assemble the parts in correct order and to correct tighten- ing torque, assembled dimensions ete. (© Assembly takes place in the reverse order of disassembly. INSTALL THE ADJUSTING LEVER 1. Install the shaft of the adjusting lever so that wide side of the shaft head surface is toward the pump body. NOTE: Installing in reverse may cause the floating lover to contact the speed control spring, resulting in operational malfunc- tion, CHECK THE GOVERNOR LINKAGE FOR SMOOTH OPERA. TION. Hook under the guide lever, and pull upwards, using a spring balance. Starting force: 140-180 g (4.9-6.3 oz) oua.gea Maxine SPEED STOPPER Bour swivel Lever ADMUST SCREW contro. \ eeuER “E17 rune | SCREW \ FULL LOAD Sto? Lever sropPen SOLT \ opin sus_\ SETTING Screw 183-386) GOVERNOR OVE INSTALL THE FLYWEIGHT TO PUMP CAMSHAFT, Using a special tools, tighten the round nut Special Tools: Round Nut Wrench (09611-1500) INSTALL THE GOVERNOR HOUSING TO.PUMP BODY. 1. Connect the start spring, 2. Connect the shackle to control rack, ADJUSTMENT OF THE GOVERNOR [MODEL; RSV] 1 2 PREPARATION 1. Connect the rack measuring device to the control cack and set to "0" 2. Connect the fuel line, 3. Refill the camshaft chamber with engine oil 4, Install the angle gauge on the adjusting lever. STEPS IN GOVERNOR ADJUSTMENT. Perform governor tasting and adjustment in the following sequence (For values of N. and R Refer to “CALIBRATION chart"): Adjustment of maximum soeed contro! 2. Adjustment of speed droop. 3. Adjustment of idling speed control ov6 RACK POSITION trv) Na PUMP SPEEO (com! FULL LOAD STOPPER BOLT 3.396 RACK POSITION (mm) Ab e Ne PUMP SPEED (rom) t = Sy, g pe SSR \ a et 5 re _ g Z \ ub fo ADJUST SCREW ee Ne. PUMP SPEED rom! | sccm] gua sus IDLING SCREW syia386 SETTING SCREW GOVERNOR 1, Adjustment of maximum speed contrat NOTE: The control lever should be full load position. a} Adjust the full 1oad stopeer bolt |At 2 pump speed of Na rpm, adjust the rack position to Ra ‘mm with the full load stopper bolt b) Adjust the maximum speed stopper bolt. ‘At @ pump speed of Nb rpm, adjust the rack position to Rb, min with maximum speed stopper bolt. NOTE: The control rack should start ta be pulled, 2. Adjust of speed droop. At @ pump speed of Ne rpm, adjust rack position to Re mm with swivel lever adjusting screw. 3. Adjusting of idling speed control a) At a pump speed of Ne rpm, adjust the rack position to Rd mm with idling serew, NOTE: The control lever angle, refer to CALIBURATION chert. bb) At a pump speed of Ne rpm, adjust the rack position to Re mm with idling sub setting screw, GOVERNOR, av-7 BOOST COMPENSATOR Cap nut Lock nut Adjust sorew Cover fixing bolt Cover . Diaphragm 7. Push rod 8. Spring 8. Adjusting shim 10. Gesket 11. Lock nut 12, Union bolt ADJUSTMENT OF BOOST COMPENSATOR TEMPORARY FIXING OF ADJUST SCREW FOR BOOST COM. PENSATOR STROKE, 1. Remove the cap nut (1) and loose the feck nut (2). 2. Fully tighten the adjusting screw (3) and fack the lock aut (2) temporarily ADJUSTMENT OF MAXIMUM SPEED CONTROL. 1. Adjustment of full load position. 2. Adjustment of maximum speed control point ADJUSTMENT OF SPEED CHANGE RATE, ADJUSTMENT OF ANGLEICH, we 3 g é 3 5 8 oe PUMP SPEEO lpm) z = 3 g — = ha 3 co £ 1 8 o—> GOVERNOR ADJUSTMENT OF BOOST COMPENSATOR STROKE, 1. Connect the air nose to union bolt (12) 2. Lock the control lever at the full load position, 3, Keep the pump revolution with in “Na” rpm, then adjust the control rack position “Ab” to “Ra” with adjust screw (3) and lock it with lock nut (2) NOTE: No need to pressurization with this adjustment. ADJUSTMENT OF BOOST COMPENSATOR SPRING 8). 1, Keep the pump revolution with in “Na” rpm then set the contre! lever to full load position. Raise the boost pressure gradually and when reaches the “P"" confirm of the control rack is start to move from “Ra” position to direction of “fuel delivery increase”. 2. In case of nonstandardized, replace with adjusting shim (9) as follow, 1) Remove the cover {6) with !oosening three bolts of installing the cover (4). CONTROL RACK POSITION BOOST PRESSURE (mms) | ‘CONTROL RACK POSITION o e ? BOOST PRESSURE iments) | GOVERNOR Gv. 2) Using 2 screw driver for hold the push rod (7) to not turn it ‘when removing the aut (11), 3) Remove the gasket {70}, disphragm (6), and spring (8). 4) Replace the adjusting shim (9) Az Replace the adjusting shim (9} with thick one, Replace the adjusting shim (9} with thin one. 4, Raise the boost pressure to “P;"", confirm the control rack Position is "Rb". In case of nonstendardized, replace the spring (8) with new one. NOTE: In case of change the boost compensator stroke, when remove the cover for this adjustment, reconfirm the boost compensator stroke. eva GOVERNOR GOVERNOR EXTERNAL LEAD SEALS AND CRIMP CAPS. NoTE: All adjusting devices on the fuel injection pump governor, are wired and lead sealed as a protection for the customer This is to pravent unauthorized readjustment which may ‘cause angine malfunction and/or angine failure. Periodical- ly check to insure that these seals aro not broken as this will void the warranty. (KPa GENERATOR GE GE-92E-01 CHAPTER GENERATOR (12V, 50A) DATA AND SPECIFICATIONS 2.0... .. ccc eeee eee ee ee GE2 DESCRIPTION ...... Sata aaa ata tcl GSD: TROUBLESHOOTING $e GE3 GENERATOR See beeee eee ee GEMM GE2 GENERATOR DATA AND SPECIFICATIONS MODEL 270401300 GENERATOR Types Alternator Rated voltage Rv Rated output : 50a Operating output and speed T3BV, SDA at 4000 rpm (at cle) Rotating direction Clockwise (Seen from pulley side} REGULATOR Type 16 Regulator DESCRIPTION 2 1 3 \ 5 6 aN : | i i = 14 HD- AE Taal ii — fet Hl = NN Vy a2 sere Still 4 2 GENERATOR 1. Rotor assembly 4, Le, Reguiator assembly 2 Ball bearing 5. Brith holder asmbly 3, Stator assembly 6. Slip ring GENERATOR GE3 sw21.225 1. Condenser 4 1.6, regulator 2. Stator coil 5. Diode 3, Field coil TROUBLESHOOTING Symptom Posible cause Ramedy/Prevention Charging warning lamp does- 7— Fuse blown + Determine cause and replace not light with starter switch ON and engine off Charge warning lamp does: not go out with engine running (Battery requires frequent recharging) -—~ Lamp burned out [— Wiring connection hose... [— Charge lamp relay faulty. — ic regutator faulty — Drive belt foose oF worn [— Battery cable loose, corroded or worn [— Fuse blown : [— Fusible link blown [= Charge lamp relay, 1C regulator or generator faulty — wiring faulty fue Replace lamp Tighten foose connections «Check relay + Replace IC regulator = Adjust or replace drive belt «Repair or replace cabies Determine cause and replace fue Replace fusible link Check charging system Repair wiring GEA GENERATOR GENERATOR yazae ENO, 22 T= 800-1,000 (S872) .. Drive and frame Collar |. Retainer ring 10, Rear bearing cover 11, Stator assembly 12, Rotor assembly 16. Bush 17, Through bolt 18, Cover 28 T= Tightening torque: kg-cm (Ib-ft) 19, Ball bearing 20. Condenser 21, Brush 22. Spring 23, Brush holder 24, 1.C. Regulator assembly 28. Cover 26. Lead wire swigg.141] SMGE.1 4] suce.11¢0) sice-139| GENERATOR GES IMPORTANT POINT(S) — DISASSEMBLY REMOVE THE REAR END COVER, Remove the rear end cover with besrings. REMOVE THE I.C. REGULATOR AND BRUSH HOLDER. 1. Remove the bolts and disconnect the wires. 2. Remove the I.C. regulator and brush holder assembly, 3, Remove the through boits and separate the frent cover from the stator. REMOVE THE ROTOR. Using a press, remove the rotor and collar. REMOVE THE FRONT BALL BEARING, 1. Remove the retsiner plate 2. Using a press, remove the front ball bearing. 3. Remove the plate and falt, REMOVE THE STATOR AND RECTIFIER. 1, Remove the nuts, insulator and stator terminal with the rectifier, 2, Unsolder the stator lead from the rectifier. NOTE: Hold the ‘ctifier terminal with long nose pliers, GES Gooo 121.0134) “fe 2 M21. 23] GENERATOR IMPORTANT POINT (S) — TESTING RECTIFIER. Test the each positive side rectifier condition. Connect the circuit tester @) eed to the rectifier holder and the ©) lead to the rectifier terminal @® ead tothe rectifier terminal and ©) lead to the cect holder, Test the each negative rectifier condition. Connect the cirouit tester @ lead to the rectifier terminal and the © led to the rectifier holder @ toad to the rectifier holder and ©) lead to the rectifier termina GENERATOR GET IMPORTANT POINT(S) — ASSEMBLY INSTALL THE STATOR AND RECTIFIER. 1. Install the stator lead to the rect NOTE: 2. Install the nuts, terminal insulator and stator with rectifier. Hold the rectifier terminal with long nose pliers. INSTALL THE FRONT BALL BEARING, 1. Install the felt and felt cover. 2, Using a press, install the front ball bearing. 3, Install the eetainer plate. NOTE: Apply the bearing grease to bes ing and oil soa lip, SMGE-124) INSTALL THE ROTOR. Using a press, install the rotor. INSTALL THE 1.C, REGULATOR AND BRUSH HOLDER, 1. Connect the front cover to the stator and tighten the through bolts 2. Install the I.C. regulator and brush holder assembly, 3. Install the bolts and connect the wires. smige.141 INSTALL THE REAR COVER, Install the rear cover with bearings. smoe.t4i| GE VARIABLE motor VARIABLE MOTOR sMGe.0720| VARIABLE MOTOR AMMETER 2 SOT ‘iss [es] SMGE-072| GENERATOR PERFORMANCE TEST NOTE: © Note the battery polarity carefully so as not to make revarsa connectior If the connections are reversed, the diodss will short the circuit and allow large current to flow through and damage the diodes and IC regulator as well as turn up the wiring harness. Q Use care not to make wrong connections of terminals. © When charging the battery with » quick charge. ° Disconnect the battery terminals. ith Do not perform tests Insulation resistance tester, (© Whan in operation, never disconnact the battery, GENERATOR PERFORMANCE TEST. 1. Turn on switch SW, and off SW, to increase the rotation of the alternator slowly. 2. When voltage reaches 13.5V, turn on switch SW regulate load resistance, Increase the rotation of the rotor keeping voltage at 13.8. MAX Generator Speed: Loss than 4,000 rpm at 13.5V, SOA. VOLTAGE REGULATION TEST. Turn on switch SW, and off SW; to increase the rotation of rotorto pm, Stendard Voltage: 14.2-14.8V GENERATOR GES INSPECTION AND REPAIR Unit: mm {in} T Inspection Item Standard imit Remedy Inspection Procedure Brush length 20.0 (0.787) 5.5 | Replace (0.217) SMiGE-127| Function of the brush holder 2 ~ | Reptace, Visual check if necessary. & | SMGE-128) Chocking of the rotor coil. About 2.9. — | Replace. suGe-1298] Insulation between the slip = = | ifeontinuity ring and the core. | replace the rotor. F ls | / stige-1300| meter of the slip ring, 32.5 (1.280) 321 | Replace. (1.264) Checking of the stator coil = ~ [if net continuity, replace the stator coil. Insulation of the stator eail - = | Hot continuity, replace the stator 3121-038) GENERATOR Unit: mm (in) | 1 aera ‘ : = Bact SF aor Ties ae See an sucesal an LI i (KP) STARTER sT-4 ST-76E-02 CHAPTER ST STARTER (12V, 2.5 KW) DATA AND SPECIFICATIONS ........... 0.000006 0000s ST-2 DESCRIPTION TROUBLESHOOTING ............. ST-3 STARTER... eee ee eee eee nent ee eee eee eeee sees STS ST-2 STARTER DATA AND SPECIFICATIONS Model No, 28700-1661 28100-1960 Starter Type Reduction gear type Output : TV, 2.5 KW Number of teeth of pinion Ti Module 3 Rotation Clockwise, viewed from pinion side DESCRIPTION | | | 1, Loead wire 7. Cluteh gear 2. Brush 8. Overrunning clutch 3. Field coil 8. Pinion 4, Armature 10. Stoo! ball 5. Armature shaft gear 11. Spring 6. Idle gear 12. Magnetic switch STARTER Symptom TROUBLESHOOTING Possible cause Engine does not erank, {Key swith fo cranks slowly. Engine does not erank while starter is cunning in good condition, © Poor contact Bartery) © Discharges bavery ‘Short circuited benween electrodes * Poor contact at battery terminal —Enaine of} © Improper viscosity oil. | -Hagnetic switer] Poor contact caused by burnt contact plate « * Contact plate worn out... ee © Hold:in coil disconnected (Qverrunning clutch moves back and forth) ‘Pullin coil disconnected or short circuited © Detective or poor contact... {Starter © Brush worn our. . Commutator burt Commutator worn out Field winding shorted or grounded Armature winding shorted or grounded © Insufficient brush soring tension * Poor contact between magnetic switch... and field windings © Armature contacts pole core because of worn bearing bush or bent semature shaft © Overrunning clutch muifunction {Overrunning clutch] © Overrunning clutch mulfunction Pinion teeth worn out © Poor stiding of spline teeth Remedy/Prevention Polish or replace contacts Charge Replace battery Plish oF retighten Change off Polish or replace contact plate Repair Replace field coil Replace Repair or replace Replace + Correct on lathe = Correct by undercutting = Rewind or replace + Replace armature Replace brush spring Repair Replace bearing brush or armature = Replace Replace Replace Remove foreign materiale, diet, or replace sT4 STARTER Symptom Postible cause Starter does not sico. Key siren] running tet © Koy switch sticks. Contacts keep closing. © Overrunning clutch sticks to armature Sear lay) © Contacts keep closing Remedy/Pravention » Replace Replace Repair o¢ replace overrunning clutch or armature Repair of replace STARTER STARTER ST 5 Felt washer Armature assembly Yoke assembly |. Brush holder Steel plate Lead wite Rear end flame Through bolt Through bolt Drive end frame = Idle gear Retainer Roller Overrunning clutch Steal ball Return spring Steel washor Magnatic switch assembly agst47| ARMATURE 65165: 85:49] STARTER IMPORTANT POINT (S) — DISASSEMBLY REMOVE THE YOKE FROM THE MAGNETIC SWITCH. 1. Disconnect the lead wire from the magaetic switch 2. Remove the through bolts from the magnetic switch, 3. Remove the steel plate from the magnetic switch REMOVE THE ARMATURE FROM THE YOKE 1, Remove the rear end frame from the yoke. 2. Using 2 long-nose pliers, take off the brushes and remove the brush holder. 3. Loosen the two through bolts and detach the brush hotder from the armature shatt REMOVE THE BALL BEARING FROM THE ARMATURE. 1. Using a press and a suitable tool, remove the ball bearing. REMOVE THE OVERRUNNING CLUTCH. Remove the screws from the drive end frame. Remove the drive end frame from the magnetic switch. Remove the oversuning clutch. Remeve the steel ball from the overcuning clutch. REMOVE THE IDLE GEAR. 1. Remove the idle gear, retainer with rollers, and steel washer from the drive end frame, NOTE: Do not drop the retainer and the rollers. STARTER st? IMPORTANT POINT (S) — ASSEMBLY BEFORE REASSEMBLING, APPLY THE RECOMMENDED GREASE TO THE FOLLOWING: Nippondenso No. 50 grease or equivalent. Felt wosher Bearing Iie gear Retainer Roller Overruning clutch Steel bati Return spring @96e8900 (ste INSTALL THE STEEL WASHER, RETAINER WITH ROLLER, » as IDLE GEAR, RETURN SPRING, AND STEEL BALL IN THE sane ou MAGNETIC SWITCH. Or ian RETAINER ROLLER INSTALL THE OVERRUNING CLUTCH IN THE DRIVE END FRAME. NOTE: Install the steel ball and the return spring, 1. Connect the drive end frame to the magnetic switch and tighten the screws, INSTLL THE ARMATURE IN THE YOKE. “ / NOTE: Do not forget to place o fle wosher on the armature shaft - bearing wns\ ATOR f weoanive POSITIVE BRUSH HOLDER HOLE NEGATIVE aRUSH HODER HOLE ores gsi Gamat STARTER INSTALL THE BRUSH HOLDER ON THE YOKE 1. Install the negative brush (brush holder side) to the brush holder negative hole (not insulated), and the positive brush yoke side} to the brush holder positive hole (separated from pate with insulator). Make sure that the positive brush fead wires ere not grounded 2, When assembling the brush holder to the yoke, take care not to damage and get oil on it NOTE: Match the lead wire grommet with the rear end frame groove. INSTALL THE STEEL PLATE ON THE MAGNETIC SWITCH. 1. Install the steel plate on the magnotic switch, 2. Securely put the rubber boot over the terminal . > a ——oiscunecteD 4 ( se Peso in aareRT | snare J Figs tea oe GATTERY, Fig, 22.38 oiscoNNEcTED LEA WIRE, eCTED LEAD WIR! STARTER ST-o TEST MAGNETIC SWITCH TEST ‘The following test should be performed with the starter assem- bed and the field coll lead wire disconnected. NOTE: © Each test should be performed for a short time only (2 to § sec.) to prevent the magnetic switch winding from burning, © Each test should be performed with the specified vol- tage applied. 1, Pullin test Connect the test leads as shown, When switch 1 (SW1) and switch 2 (SW2) are closed, the pinion should jump out. 2. Holdin test In the same conditions as the pullin test, open switeh 1 (SW a. ‘The pinion shauld ramain in the jumoed aut position. 3. Return test Jn the same conditions as the hold-in test, open switch 2 (SW 21 ‘Tha pinion should return immediately PERFORMANCE TEST ‘The following test should be carried out after reassembling the starter, If suitable equipment is not available, at least the No-load ‘ast should be carried out 1. Nosdoad test With the starter securely clamoad in a vice, and using a battery and suitable ammeter, connect the positive laad of the battery, and the ammeter to the “50” terminal, Connect the negative lead to the starter body. The starter should show smooth and steady rotation immediately after jumping out of the pinion and shoul draw less than the specified current sT10 Eeouee| Ore, ARTE eA 8818 STARTER 2. Load test Read the ammeter and voltmeter when the specified torque is applied. The ammeter should indicate less than the specified current, and the tachometer should indicate more than the specified speed, 3. Lock torque test Read the torque meter and ammeter when the tachometer reading becomes 0 1pm after appling the load. The torque meter should indicate more than the specified torque and the ammeter should indicate less than the specified current. Standerd value of ach Gunn Voltoe | Revelation & woraue Noload test | Less than 1808 | ae 11 ‘ors tha outest | Less han 600.8 | at @V Wore han tock woreue est | Less than 7200] av |g More than STARTER INSPECTION AND REPAIR stat Inspection tem Standard Limit Remedy | Inspection Procedure ‘Armature Short Cireuit i IF the iron plate Tost is not vibrated, the rmature is goed Armature Insulation More than 1M | Less than | Replace 0.1 m2 Commutator continuity Should be continuity |_| Replees if thore atany point is no continuity at any point Commutator run-out ‘Les than 0.02 0.05 | Replace (0.0008) {.002) Commutator Outside 36 35 | Replace | Dismeter ar (ize) i saa. Mica Depth 07 02 | Replace | cowmutator unoencur (0.0276) (0.0078) f MW AE a suazass Conductance between the | Should be conducted Replace Field Coll and the Yoke ) 05165] STARTER sTz INSPECTION AND REPAIR i Inspection Item ‘Standard Limit Remedy Inspection Procedure Field Coil Insulation More than 1M | Lessthan | Replace 0.1 Mo. ot 1 \ Aasie? Wear or Damage of the 7 - Replace, if Bearing necessary | Field coil and yoke damage | 85140) Brush length 205 13 | Replace (0.807) (0.512) (| a5 66| Insulation between the [More shan tic, | bess than | Replace Springs enuresis oama nce ‘Overrunning clutch test | Replace mm | Sen | | oe \ : ___ asstzo) Tension of the Brush 3.9 kg 1,9k9 Replace i (8.6 Ib) (4.2ib) (ky) CALIBRATION CHAPTER C INJECTION PUMP CALIBRATION CALIBRATION INJECTION PUMP NUMBER: 22030-20708 and 22030-20718 €-996.03 ca INJECTION PUMP SPECIFICATION Engine model [oa Injection pump part number | 22030-20708, 22030-2077 Injection pump type | NO-PES@AS5D327 AND 168 Governor type RSV 400—1500 Timer type soz Feed pump type ND-FPIKS Test Test nozzle type (003400-0540 (ON 128012) “Test nozzle opening pressure 175 kglem? (2,489 psi) (Outer diameter 6.0 mm (0.236 in} lous SCREW stop Lever FULL Load STOPPER BOLT + Lover angle "VP" ‘means. Vertical postion, sm4-820 CONDITION Injection pipe Inner diameter 2.0 mm (0.078 in) ‘erat 600 mm (236 in) : Type SAE 876 bration ot [eee Oil wemperature | 40~45°C (104—110°F) Fuel feed pressure 2.0 kg/em? (28.4 psi) OVERFLOW (Opening presure 1.51.8 kafem? (2158225 59 pal Rotten Cochin viewed rom drive ie tnuecrion [Injection order eed TIMING Injection interval 80° 30" Prestroe 305-31 OO A Rack postion | Pump peed] Meosurina | Injection volume | Max variation ima om tem | Mercer ce teusnl ete wuecrion [A 380368 _[ 1600 | ~200 74 0-ta w.i7 mawsTy | eden Votan Su of Mass? | soo [emo | ae-soiores-aisa | sioonn 1 Aalanng Tver oan Paro peed Uy TAatenaale TIMER Bond 1300 estan 08 | 414 load 1600. 3.0° = 4.0° ADJUSTING POSITION CONTROL LEVER ANGLE wow auivel waver ume sue BUS Hbrven RINEGLENEL puns me « rou, |, soe conrnoe Governor ADJUSTMENT ve nove MENGLE: set aes | cz CALIBRATION ‘Adjusting | Adjusting | Pump speed Control rack position item | lever position (rom) mm (in) Adjusting position | Na: 1800 | Ra: 9.0-9.4 (0.354-0.370) _| Full load stopper bolt 7 | Maximum Rb: Should be stort to Se] Say" | ramet | mw tes Should be tart | saximum sea stopper bot . Fer Lest than 3.0 0.118) | "Swivel lover adjusting serow | og | <] tating tale Nd: 250 | Ré:64-6.8(0.262-0.267) | lating wo-spring set speed j “NOTE: Recommend setting of swivel adjusting screw: 10 clinks from buttom end. Governor characteristic diaphragm i GOVERNING RANGE: 400-1500 ram rao] I ra: 9.0-04| x 3 ra 64-68 carted 3 \ fb: 48-58 8 h \ \ \ Fe: Las than 3.0 ' 4 g 3 g& 2 g 22 | PUMP SPEED (rom) —e sMsez0 } i TREK) CALIBRATION INJECTION PUMP NUMBER: 22020-3462A and 22020.3463A ca -986.03 Engine model WOACT1 Injection pump part aumber 72020-3462A, 22020-24630 INJECTION a PUMP injection pump type NP-PES4AD 1008320852 eeeok ‘Governor type ‘ASV 200-1600 aoe Timer type Not equipped | Feed pump type NP-EP/KS-ADS 5 Test nozzle type 105780-8140 Test nozzle opening pressure 175 ka/em? (2,489 pai : | [Outer dfameter | 6.0 mm (0.296 in) Test Inject Toner diamet 2.0 mm (0.079 in) Sa Injection pipe [Inner diameter 0 mm (0.079 in [eeneth 00 mem (23.6 in) t Type SAE J067C tration cit =; 7 ————] Gatbration ell [oi wemperazure | 40—48°C (108 110°F) Fuel feed pressure 1.6 ko/em? (22.8 psi ir aeeas Opening pressure 1.5-1.8 kolem? (21.33-25.59 psi) Rotation Clockwise viewed from dive side | INJECTION Injection order 1-3-2 TIMING Injection invert oor 230" Prestroke 4,354.45 am (0.172-0.178 m) Rack position | Pump speed | Measuring Injection volume Max. variation limit mm fin) (com) | stroker ‘2 (eusin) % isection [AT 1.9 (0.489) 1500 500 | 68.2-68.2 (2.018-4.099) 23 | VOLUME ‘About 7.6 i 7 7 ea 0 500 59.0 (0.458-0.549) 18 ADJUSTING POSITION CONTROL LEVER ANGLE MaxiMun SWIVELLEVER IDLING SUB SPEED STOPPER — ADWUST SCREW SETTING BOLT screw AU oun SPEED. controu tever Governor ADJUSTMENT ve nore TANGLE: 1.. 2 1uING ; screw “mn Ut goson shor tever Aut Loan Sr0PPER BOLT smote cz CALIBRATION Tdjusting | Adlusting | Pump soeed Control rack pation aan item lever position (rpm) mm fin} Adjusting positio Na: 955-595 | Ra: 119 (0.469 in} Full loud stopper bot 7 ie | Meximum 1500-1610 | RO: Should be star to iat = 28) “Speed” | Fulllood [Nos 1600-1610 | TP plied contol rack | Maximum speed stopper Plt GS 23 Ne: 1600-1650 | Re: 6.0 mm (0.236 in} * Swivel lever adjusting screw oF a 2 : iaing | tae | nas ao0 Re: 7.8mm (0.298 in), ling subsprng set ing of swivel adjusting screw: ! 10 clinks from buttom end. Governor characteristic diaphragm GOVERNING RANGE: 400-1500 rom i : More than 14 GOVERNOR SPRING SET IDLING sue SPRING SET | 20ST COMPENSATOR STROKE aati — tana === == == 4 i 3 £ —* g é fe:7 fs 3 Re: 6 f = \| \ g \ \ i 1 7 Le | ¥ s ae 2 2 pa ea | Z ote | gg | PUMP SPEED (rpm! —— SM4216 CRETIKR! CALIBRATION cH C-97E.03, INJECTION PUMP NUMBER; 22020-27312 and 22020-35908 Engine model wosceT INJECTION Injection pump part number 22020-2731A, 22020.3580A Sorat Injection pump type NP-PES4A95C321R CATION Governor type RSV 200=1600 Timer type Not equipped 7 Feed pump type NP-FP/KS z Test nozzle type 105780-8140 Test nozale opening pressure 175 kglem? (2,489 pai Test Outer diamier | 6.0 men (6.236 inl CONDITION Injection pipe Inner diemeter _|_2.0 mm (0.079 in) Lenath {600 mrn (23.622 in} Type ‘SAE J967 6 Gallatin oll oilzemparature | 40-45% (104-119°F] Fuel feed pressure 1.6 kg/emn? (22,8 psi) i 2 [ta Opening pressure 1.5-1.8 kg/em?® (21.33~25.59 pai) Rotation Clockwise viewed from drive sie INJECTION Injestion order 13-42 TIMING Injeotion interval oo 215" Pro-stroke 3.17-3.23 am (0.125-0.127 in) Rack position | Pump speed | Measuring Injection volume | Max. variation limit ‘em (in) com) strokes (evn) % jinuection [A] fu 10.4 (0.409) | 1500 500 | 47.0-48.0 (2.869-2,980) z3 VOLUME ‘About 7.1 7 Nes 400 500 | 53-68 (0.240.414) 4 ADJUSTING POSITION CONTROL LEVER ANGLE Maximum SWIVEL LEVER IDLING SUB SPEED STOPPER ADIUSTSCREN SETTING 1 soLt Screw conTROL ig Lever GOVERNOR ADJUSTMENT i ve. NoTe TANGLE: 1.2 LING oe screw + Lever angie "Ve sto? Lever FULL Lomo neon. Vertical poston STOPPER BOLT iedate ce CALIBRATION Governor characteristic diaphragm GOVERNING RANGE: 400-1500 rpm : More than 14 (GOVERNOR SPRING SET i 2 Ato. i 3 * i g I x a g | q 3 z sa 3 \ i 8 | ( o ¢ 3 E 88 geo 1635115 5 PUMP SPEED (rpm) —e CaTEOT KR) CALIBRATION ct c-s394e-01 Engine model woaath TNUECTION [itiection pump parts number 22020-3841 PUMP Injection pump type ‘NP-PES4AD 1008320882 Foner Governor type RSV200-1600 Timer type ‘Not equipped Feed pump type NP-FP/KS-ADS, Test nozzle type 705780-8140 Test nozzle opening pressure 17.2 MPa {175 kol/emf, 2,485 ps Outer diameter 6.0 mm (0.236 in. rest Injection pipe [Trner diameter 2.0 mm (0.079 in.) CONDITION Length 600 mm (23.6 n)} Type SAE J9676 alirati Calibration oll | Girtemperature | 40-45" (108-113 Fuel food pressure 157 KPa (1.6 Kot/em?, 22.8 pal OKEGE OY | Opening pressure 255 kPa (2.6 kaf/em*, 37.0 psi Rotation Tlockwise viewed from drive side iyection — [iniestion order ro42 TIMING Injection interval wa Pre-stroke 4-35-4.45 tam (0.1 72-0178 in) Rack postion [Pump speed | Measuring | Injection volume [Max.Varlation imi ‘mn i) timin | strokes em (eu.in} % Terie A 12.2 (0.480) 1500 ‘600 70.5-72.5 (4.301-4.423) ry B | About 7.1 (0.280) 400 500 7.5-9.0 (0,450-0.549) HS ADJUSTING POSITION CONTROL LEVER ANGLE FULL 1 rOLING SPEED + MAXIMUM SWIVELLEVER IDLING suB Web stbecen AbWUST ScREW SETTING sor Screw’ CONTROL fee GOVERNOR ADJUSTMENT ve. LNs STOP Leven SCREW pun Loan EYGPpEA BOLT means Vertical posi CALIBRATION C2 Toedcontrol | Pump speed | Gontrolrack position | Adjusting position Adjusting Item | jover position | (r/mini men tin. Noro | Par 12.2 (0.480) Full foad stopper bolt iby should be stort to | Maximum speed Maximum speed Full load Nb: 1830 pulled control rack | stopper bolt Ne: 1845, Ro: 8.8-9.0 ‘Swivel lever adjusting (03346-0254) scrow (When boost 5 Pressures 0 mmHg) a no 10.7 10.398) Control fever lating speed 5 ni ane Nd: 255 Ra: 7.1 {0.280) Idling sub-spring set 2 Np: 700 Re: 12.2 (0.480) Adjusting screw 8 ip: 700 s = (0.366.076 i=) When boost pressure is 2 Pi: 9.3-14.7 kPa c (70-110 mmHg) 5 control rack begins to 3 move from Ri:83-98 Boost compensator | Ful load mseeaana ih ta direction of "Fuel dalvery increase”, Np:700. | When control rack | Confirm returns to position Re 122 (0.480) the available pressure corresponds to Pr 66.7 kPa 00mg) Governor characteristic diagram More than 14 Be /—IDLING suB SPRING SeT EE (GOVERNOR SPRING SET BE 2 tase {BOOST COMPENSATOR STROKE 8 s 2,820.1 mm 3 patron 12.2 Boost compensator = at10.1 EN A 2 E characteristic diagram SB Reaeto.t f sé g R71 ge G é O Rr 12.2 ai g aro 2 8 & < \ =m ; g 259 1d:255 Nb:(1630) | 1655 TV ere00) 5 0 pa 6h 400 sep ot § fe0=20) (coo) P, P. PUMP SPEED {r/min} —~ BOOST PRESSURE kPa (mmHg) —~

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