S-42
03-M-DI Series, WSM
DIESEL ENGINE
2. ENGINE BODY
[1] CHECKING AND ADJUSTING
Compression Pressure
1. Run the engine until it is warmed up.
2. Stop the engine and disconnect the
2P
connector from the stop
solenoid in order not to inject fuel.
3. Remove the air cleaner, the muffler and all glow plugs.
4. Set a compression tester with the adaptor
K
to the glow plug
hole.
5. While cranking the engine with the starter, measure the
compression pressure.
6. Repeat steps 4 through 6 for each cylinder.
7. If the measurement is below the allowable limit, apply a small
amount of oil to the cylinder wall through the glow plug hole and
measure the compression pressure again.
8. If the compression pressure is still less than the allowable limit,
check the top clearance, valve and cylinder head.
9. If the compression pressure increases after applying oil, check
the cylinder wall and piston rings.
NOTE
Q
• Check the compression pressure with the specified valve
clearance.
• Always use a fully charged battery for performing this test.
• Variances in cylinder compression values should be under
10 %.
W1018639
Top Clearance
1. Remove the cylinder head.
2. Move the piston up and stick a strip of fuse (2) on the piston head
at three position with grease.
3. Lower the piston and install the cylinder head. (Use a new
cylinder head gasket and tighten with a specified tightening
torque.)
4. Turn the flywheel until the piston (1) passes through the top dead
center.
5. Remove the cylinder head and measure the thickness of the
fuses.
6. If the measurement is not within the factory specifications, check
the oil clearances between the crankpin and bearing and
between the piston pin and bushing.
W1020190
Compression pressure
Factory spec.
2.94 to 3.24 MPa
30 to 33 kgf/cm
2
427 to 469 psi
Allowable limit
2.35 MPa
24 kgf/cm
2
341 psi
Top clearance
Factory spec.
0.60 to 0.70 mm
0.0236 to 0.0276 in.
Tightening torque
Cylinder head screws
93.1 to 98.0 N·m
9.5 to 10.0 kgf·m
68.7 to 72.3 ft-lbs
(1) Piston
(2) Fuse
KiSC issued 10, 2009 A
