Mitsubishi S3Q2 Service Manual Download

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Summary of Contents for S3Q2

Page 1: ...Printed in Japan Pub No Pub No SERVICE MANUAL SERVICE MANUAL Pub No November 2007 November 2007 99619 30110 99619 30110 99619 30110 ...

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Page 3: ...ntenance and also to take necessary measures which involves the disassembly inspection repair and reassembly of the engine and engine parts Read this manual carefully and understand the work procedures fully before disassembling inspecting repairing or reassembling the engine The contents of the manual are based on the engine models that are being produced at the time of publication Due to improve...

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Page 5: ...isassembly 2 Inspections to be conducted during disassembly process are indicated in boxes in the relevant exploded views 3 Maintenance standards required for inspection and repair works are indicated in the appropriate positions in the text They are also collectively indicated in Group 2 the General Contents group 4 Fasteners to be tightened in wet condition or with engine oil applied are identif...

Page 6: ... ABDC After Bottom Dead Center TIR Total Indicated Runout API American Petroleum Institute ASTM American Society for Testing and Materials JIS Japanese Industrial Standards LLC Long Life Coolant MIL Military Specifications and Standards U S A MSDS Material Safety Data Sheet SAE Society of Automotive Engineers U S A Units of measurement Measurements are based on the International System of Units SI...

Page 7: ...i ately take corrective measures to stop it Such leakages if left uncorrected can cause fuel or engine oil to reach hot engine surfaces or hot exhaust gas to contact flammable materials possibly leading to personal injury and or damage to equipment Use explosion proof lighting apparatus When inspecting fuel engine oil coolant battery elec trolyte etc use a flameproof light An ordinary light if acc...

Page 8: ... rotating part se rious bodily injuries could result Lockout and Tagout Be sure to lockout and tagout before starting inspection and maintenance Lockout and tagout are effective methods of cutting off machines and equipment from energy sources To accomplish the lockout tagout remove the starter switch key set the battery switch to OFF and attach a Do Not Run or similar caution tag to the starter s...

Page 9: ...without fail The coolant is very hot and under pressure during en gine running or just after the engine stops If the radia tor cap is not closed tightly steam and hot coolant may gush out and can cause scalds Add coolant only after the coolant tempera ture dropped Do not add coolant immediately after the engine stops Wait until the coolant temperature lowers sufficiently to avoid a risk of burns N...

Page 10: ...s and malfunctions Obtain the Material Safety Data Sheets MSDS issued by the fuel oil and LLC suppliers and follow the direc tions in the MSDSs for proper handling Handle LLC long life coolant carefully When handling LLC always wear rubber gloves and protective face mask If LLC or cooling water containing LLC comes into contact with your skin or eyes or if it is swallowed you would suffer from inf...

Page 11: ...t away with plenty of clean fresh water and seek immediate medical attention If the battery fluid is accidentally swallowed gargle with plenty of water then drink lots of water and seek immediate medical attention When abnormality occurs Stop overheated engine after cooling run Even if the engine comes to overheat do not stop the engine immediately Abrupt stopping of an overheated engine can cause...

Page 12: ...ling speeds for 5 to 10 minutes for warming up Start the work after this operation is completed Warm up operation circulates the lubricant through the engine Therefore individual engine parts are well lu bricated before they are subjected to heavy loads This is very important for longer service life high perfor mance and economical operation Do not conduct warm up operation for a longer time than ...

Page 13: ... of tools optimum for each work Always keep in mind to select most appropriate tools for the work to be performed and use them correctly If tools are damaged replace with new tools Avoidance of prolonged time of starter oper ation Do not operate the starter for more than 10 seconds at a time even if the engine does not start Wait for at least 30 seconds before next engine cranking Continuous opera...

Page 14: ...o read For cleaning the warning caution labels use a cloth water and soap Do not use cleaning solvents gasoline or other chemicals to prevent the letters from getting blurred or the adhesion from being weakened Replace damaged or fractured labels with new ones If any engine part on which a warning label is attached is replaced with a new one attach a new identical warning label to the new part War...

Page 15: ...g rod crankshaft and crankcase 6 Reassembly of basic engine Reassembling piston connecting rod crankshaft and crankcase Reassembling timing gear camshaft and oil pan Reassembling flywheel Reassembling cylinder head and valve mechanism 7 Fuel system Removing fuel system Disassembling inspecting and reassembling fuel system Installing fuel system 8 Lubrication system Removing lubrication system Disa...

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Page 17: ... Fuel system flow diagram 1 4 2 2 Lubrication system flow diagram 1 4 2 3 Cooling system flow diagram 1 5 2 4 Inlet and exhaust system flow diagram 1 5 3 Engine serial number location 1 6 4 Main specifications 1 7 5 Tips on disassembling and reassembling 1 10 5 1 Disassembling 1 10 5 2 Reassembling 1 10 ...

Page 18: ...e Inlet manifold Glow plug Water pump Fuel feed pump Oil pan Water drain plug Flywheel Fuel injection pump Rear Front Oil filler Stop solenoid Exhaust manifold Hanger Hanger Thermostat Thermo unit Alternator Oil pressure switch Starter Crankshaft pulley Oil drain plug Oil level gauge Oil cooler Rear Front ...

Page 19: ... plug Water pump Fuel feed pump Oil pan Oil filler Water drain plug Flywheel Fuel injection pump Rear Front Stop solenoid Exhaust manifold Oil separator Hanger Turbocharger Hanger Thermostat Thermo unit Alternator Oil pressure switch Crankshaft pulley Oil drain plug Oil level gauge Oil cooler Front Rear Starter ...

Page 20: ...stem flow diagram Fuel leak off pipe Fuel injection nozzle Fuel return pipe To fuel tank From fuel tank Fuel injection pump Fuel feed pump Oil filter With built in bypass valve Oil drain plug Oil pump Relief valve Crankshaft Oil strainer Timing gear Piston Valve mechanism Tappet Camshaft Oil main gallery Push rod Valve Turbocharger S3Q2 T ...

Page 21: ...iagram Cooling system flow diagram 2 4 Inlet and exhaust system flow diagram Inlet and exhaust system flow diagram Radiator Thermostat Bypass pipe Fan Water pump Oil cooler Turbocharger S3Q2 T Exhaust Inlet Exhaust manifold Inlet manifold ...

Page 22: ...GENERAL 1 6 3 Engine serial number location The engine serial number is stamped on the side of the crankcase Stamp location of engine serial number ...

Page 23: ...94 in 608mm 23 94 in Overall width 492 mm 19 37 in 540mm 21 26 in Overall height 633 mm 24 92 in 696 mm 27 40 in Dry weight Approx 160 kg 352 7 lb Approx 165 kg 363 8 lb Basic engine Cylinder Type Dry integral with cylinder block Piston ring Number of rings Compression rings 2 Oil ring w expander 1 Valve timing when warm Inlet valve Open BTDC 30 Close ABDC 50 Exhaust valve Open BBDC 74 Close ATDC ...

Page 24: ...o 4 kgf cm 42 67 to 56 89 psi Oil cooler Type Water cooled type Heating surface area 0 063 m 97 65 in Cooling system Cooling method Water cooled forced circulation Coolant capacity engine 3 L 0 79 U S gal approx Water pump Type Volute type centrifugal pump Discharge capacity 70 L min Pump rotating speed 3000 min 1 total pump head 2 5 10 2 MPa Fan belt Type Raw edge plain silver belt type A Fan Typ...

Page 25: ...in or more Load characteristic Voltage 7 7 V Current 400 A Torque 10 59 N m 1 08 kgf m 7 8 lbf ft Speed 1280 r min or more Load characteristics Voltage 3 V Current 1000 A or below Torque 29 42 N m 3 0 kgf m 21 7 lbf ft or more Alternator Manufacturer Mitsubishi Electronic Corporation Model number A007T02077C Output 12 V 50 A Regulated voltage 14 7 0 3 V Glow plug Type Sheathe glow plug Rated volta...

Page 26: ...t losing them 4 Pay attention to assembling marks Put your marks on the parts if necessary to ensure correct reassembling 5 Carefully check each part for defects during disassembling or cleaning Do not miss symptoms which can not be detected after disassembling or cleaning 6 When lifting or carrying heavy parts exercise utmost caution to ensure safety Pay attention to balance of heavy parts when h...

Page 27: ... 1 5 Cooling system 2 7 1 6 Electrical system 2 8 2 Tightening torque table 2 9 2 1 Major bolt tightening torque 2 9 2 1 1 Basic engine 2 9 2 1 2 Fuel system 2 9 2 1 3 Lubrication system 2 10 2 1 4 Cooling system 2 10 2 1 5 Electrical system 2 10 2 1 6 Inlet and exhaust systems 2 10 2 2 Standard bolt and nut tightening torque 2 11 ...

Page 28: ...e ATDC 30 Valve clearance when cold 0 25 0 0098 Both inlet and exhaust Fuel injection timing Varies depending on the specifications Fan belt deflection crankshaft pulley to alternator pulley Applox 13 0 51 Amount of deflection when pressed with the thumb firmly 98 N 10 kgf 72 lbf Table 2 2 Maintenance service data table Basic engine 1 5 Unit mm in Inspection point Nominal Standard Limit Remark Roc...

Page 29: ...4640 87 770 3 4555 14 0 55 upper from the bottom right angle to the piston pin 0 25 0 0098 OS 88 220 3 4732 88 205 to 88 235 3 4726 to 3 4738 88 020 3 4653 0 50 0 0197 OS 88 470 3 4831 88 455 to 88 485 3 4825 to 3 4837 88 270 3 4752 Protrusion from crankcase 0 13 to 0 60 0 0051 to 0 0236 Bearing clearance check Weight difference in one engine 5 g 0 20 oz or less Piston ring Clearance between pisto...

Page 30: ...l reaching the limit when exceeding the limit re gring the crankpin and replace the bearing with under size Bend and twist 0 05 100 0 0020 3 94 or less 0 15 100 0 0059 3 94 End play 0 15 to 0 35 0 0059 to 0 0138 0 50 0 0197 Replace connecting rod Connecting rod bearing inside diameter ø 58 2 28 58 000 to 58 045 2 2835 to 2 2852 Exhaust manifold Distortion of manifold 0 15 0 0059 or less Idler gear...

Page 31: ...icity of journal 0 02 0 0008 or less Clearance between camshaft journal outside diameter and crankcase hole inside diameter 0 07 to 0 11 0 0028 to 0 0043 0 15 0 0059 Camshaft hole inside diame ter No 1 No 2 ø 54 2 13 54 03 to 54 05 2 1272 to 2 1279 No 3 ø 53 2 09 53 03 to 53 05 2 0878 to 2 0886 Circularity of camshaft hole 0 02 0 0008 or less Camshaft hole coaxiality 0 05 0 0020 or less End play 5...

Page 32: ... bearing Crankcase hole main bearing lower hole Inside diameter ø 69 2 72 69 000 to 69 019 2 7165 to 2 7173 When main bearing cap is tightened Circularity 0 02 0 0008 or less Coaxiality 0 05 0 0020 or less Clearance between main bearing and crankshaft journal oil clearance 0 035 to 0 085 0 0014 to 0 0033 0 200 0 0079 Thrust bearing width cap width 23 0 91 22 979 to 23 000 0 9047 to 0 9055 Crankcas...

Page 33: ...ta table Lubrication system Unit mm in Inspection point Nominal Standard Limit Remark Oil pump Rotor case and end play 0 04 to 0 09 0 0016 to 0 0035 0 15 0 0059 Clearance between outer rotor and inner rotor 0 13 to 0 15 0 0051 to 0 0059 0 20 0 0079 Clearance between outer rotor and case 0 20 to 0 28 0 0079 to 0 0110 0 50 0 0197 Shaft outside diameter ø 13 0 51 12 985 to 13 000 0 5112 to 0 5118 Cle...

Page 34: ...20 to 27 lbf 14 7 N 1 5 kgf 11 lbf Pinion shaft thrust gap 0 5 0 020 or lower 0 0 00 lower limit Pinion gap 0 5 to 2 0 0 020 to 0 079 No load charac teristics Voltage V 11 When the tip of the pin ion is fixed at 2mm 0 08in away from stop position voltage is 8V or less Armature current A 130 or less Rotational speed min 1 3600 or more Alternator Brush spring tension 4 8 to 6 0 N 0 5 to 0 6 kgf 3 6 ...

Page 35: ...0 1 9 0 7 Crankshaft pulley 24 1 5 392 10 40 1 289 7 2 Flywheel housing 10 1 25 60 6 6 1 0 6 44 4 3 Rear plate stud 10 1 25 24 2 2 4 0 2 17 1 4 Table 2 8 Tightening torque table Fuel system Description Threads Dia Pitch mm Torque Remark N m kgf m lbf ft Fuel injection nozzle 20 1 5 59 6 6 0 6 43 4 3 Fuel injection nozzle retaining nut 16 0 75 36 8 2 45 3 75 0 25 27 1 8 Fuel leak off pipe mounting ...

Page 36: ...able Cooling system Description Threads Dia Pitch mm Torque Remark N m kgf m lbf ft Water drain plug 1 4 18 NPTF 39 4 4 0 4 29 2 9 Table 2 11 Tightening torque table Electrical system Description Threads Dia Pitch mm Torque Remark N m kgf m lbf ft Glow plug Engine body 10 1 25 18 2 1 8 0 2 13 1 4 Glow plug terminal 4 0 7 1 3 0 2 0 13 0 02 0 9 0 1 Starter terminal B 8 1 25 11 1 1 1 0 1 8 0 7 Starte...

Page 37: ... 47 17 1 7 13 30 3 1 22 M10 1 25 14 0 55 33 3 4 24 60 6 1 44 M12 1 25 17 0 67 60 6 1 44 108 11 0 80 M14 1 5 22 0 87 97 9 9 72 176 17 9 130 M16 1 5 24 0 94 145 14 8 107 262 26 7 193 M18 1 5 27 1 06 210 21 4 155 378 38 5 279 M20 1 5 30 1 18 291 29 7 215 524 53 4 386 M22 1 5 32 1 26 385 39 3 284 694 70 8 512 M24 1 5 36 1 42 487 49 7 359 878 89 5 648 M27 1 5 41 1 61 738 75 3 544 1328 135 5 979 Metric ...

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Page 39: ...3 1 SERVICE TOOLS 1 General tools 3 2 2 Special tool 3 3 ...

Page 40: ...012 Width across flats 10 12 mm 0 39 0 47 in 3 Spanner F9600 14017 Width across flats 14 17 mm 0 55 0 67 in 4 Spanner F9600 22024 Width across flats 22 24 mm 0 87 0 94 in 5 Wrench F9612 12014 Width across flats 12 14 mm 0 47 0 55 in 6 Screw driver 91267 00201 7 Socket F9614 17000 Width across flats 17 mm 0 67 in 8 Socket F9614 19000 Width across flats 19 mm 0 75 in 9 Handle F9618 25000 10 Extensio...

Page 41: ...0 to 1015 54 psi Gauge adapter 30691 21100 Engine compression pressure measuring Turnine handle 30691 21800 Engine turning Valve spring pusher 30691 04500 Valve spring removal installa tion Valve guide remover 32A91 00300 Valve guide removal Valve sheet insert caulking tool Inlet 30691 02700 Exhaust 30691 02800 Valve seat installation Stem seal installer 32C91 10400 Stem seal installation ...

Page 42: ...ler 30691 51900 Idler bushing removal installa tion Idler bushing puller MH061077 Idler shaft removal Piston ring pliers 31391 12900 Piston ring removal installation Oil seal sleeve installer guide set 30691 13010 Oil seal sleeve installation of crankshaft rear side Piston guide 30691 58100 Piston installation Table 3 2 Special tool list 2 3 Tool name Part No Shape Use ...

Page 43: ...SERVICE TOOLS 3 5 Front oil seal installer 32C91 00500 Front oil seal installation Table 3 2 Special tool list 3 3 Tool name Part No Shape Use ...

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Page 45: ...4 1 DETERMINATION OF OVERHAUL 1 Determining overhaul timing 4 2 2 Testing compression pressure 4 3 ...

Page 46: ...ressure 1 Decreased output power 2 Increased fuel consumption 3 Increased engine oil consumption 4 Increased blow by gas through the breather due to worn cylinder liners and piston rings Visually check the blow by amount 5 Increased gas leakage due to poor seating of inlet and exhaust valves 6 Difficulty in starting 7 Increased noise from engine parts 8 Abnormal exhaust color after warm up operati...

Page 47: ...condition of the piston rings and the valve seats But it drops later due to the wear of these parts 1 Remove the glow plugs from all cylinders 2 Attach the compression gauge adapter to the cylinder and connect compression gauge 3 Crank the engine with the starter then read the compression gauge indication while the engine is running at the specified speed 4 If the compression pressure is lower tha...

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Page 49: ...moving timing gear case 5 9 3 3 Measuring timing gear backlash 5 9 3 4 Measuring idler gear end play 5 10 3 5 Removing idler gear 5 10 3 6 Measuring camshaft end play 5 10 3 7 Inverting crankcase 5 10 3 8 Removing oil pan and oil pan gasket 5 11 3 9 Removing oil pump 5 11 3 10 Removing camshaft 5 11 3 11 Removing front plate 5 11 4 Disassembling and inspecting piston connecting rod crankshaft and ...

Page 50: ...nlet valve 4 Bolt long 11 Push rod 18 Exhaust valve 5 Valve cap 12 Cylinder head bolt 19 Valve stem seal 6 Snap ring 13 Cylinder head 20 Cylinder head gasket 7 Rocker arm 14 Valve cotter 20 18 7 8 4 2 5 9 3 14 15 19 1 10 11 6 16 13 12 17 Replace Replace Fatigue damage Damaged threads worn rod contact surface Wear Worn valve cap contact surface clogged oil holes worn bushings Uneven wear on stems a...

Page 51: ...make sure to install them in their original positions to restore the same clearance between the rocker shaft and arms Do not remove the rocker bushing unless it is defective or its inside diameter exceeds the limit Disassembling rocker shaft assembly 1 3 Removing cylinder head assembly 87 21 When removing the cylinder head gasket be careful not to damage the cylinder head or crankcase surface by t...

Page 52: ...pring 1 5 Removing valve stem seal Grab the stem seal with pliers and remove Note Be sure to replace the stem seal with the new one when reassembling the valve and valve spring Removing valve stem seal 1 6 Cleaning cylinder head bottom surface Taking care not to damage the cylinder head bottom surface remove residue of old gasket Note First roughly scrape off residue of old gasket using a scraper ...

Page 53: ...Search the top dead center of the piston by using dial guage 2 Apply the dial gauge plunger to the top surface of the crankcase and zero the dial gauge 3 Measure the protrusion at three points on the piston head and calculate the mean value Subtract the mean value from the thickness of the gasket compressed by tightening the cylinder head and the clearance between the piston top and cylinder head ...

Page 54: ...g flywheel Disassembling and inspecting flywheel Disassembling sequence 1 Flywheel 3 Oil seal 5 Gasket 2 Oil seal case 4 Rear plate 1 2 3 4 5 Replace Replace Crack abnormality of knock hole Steaks on wear surface stepped wear cracks ring gear damage abnormal wear ...

Page 55: ...bolt into the threaded hole of the bolt that has been removed 4 Remove remaining bolts from the flywheel 5 Hold the flywheel firmly with both hands and by moving it back and forth pull it out straight Note The ring gear is shrink fitted to the flywheel Do not remove the ring gear unless it is defective Removing flywheel 2 2 Removing oil seal case 87 21 Be very careful not to damage the oil seal 1 ...

Page 56: ...sassembling sequence 1 Crankshaft pulley 4 Baffle plate 7 Oil pump 2 Cover 5 Idler gear 8 Camshaft 3 Timing gear case 6 Oil pan 9 Front plate 1 2 3 4 5 6 7 8 9 Replace Replace Crack abnormality of knock hole Clogged oil holes Wear Wear Damage wear Flaking uneven contact damage abnormal key groove condition Worn belt groove worn oil seal contact surface Replace ...

Page 57: ...lts have different lengths Pay attention to the positions of bolts to ensure correct reassembling Removing timing gear case 3 3 Measuring timing gear backlash Measure the backlash of the timing gears by using one of the following two methods measure the gear play with the dial gauge plunger applied to a tooth flank on the pitch circle at a right angle to the tooth axis or measure the clearance bet...

Page 58: ...end play with the camshaft gear attached If the limit is exceeded replace the thrust plate with a new one Measuring camshaft end play 3 7 Inverting crankcase 87 21 Do not place the engine directly on the ground It causes cracking the oil pan 1 Attach the wire rope to the crankcase Using a crane hoist the crankcase and lay it with its side faced downwards 2 After that hoist the crankcase again and ...

Page 59: ...moving camshaft 87 21 Be careful not to damage the cams of camshaft and the bushings 1 Rotate the camshaft to see the thrust plate bolt through the camshaft gear hole 2 By using the socket remove the thrust plate bolt 3 Remove the camshaft from the crankcase 4 Remove the tappet Removing camshaft 3 11 Removing front plate 1 Remove the front plate bolts 2 Remove the front plate from the crankcase No...

Page 60: ...ower 8 Connecting rod bearing upper 14 Oil ring 3 Main bearing cap 9 Snap ring 15 Tappet 4 Main bearing cap lower 10 Piston pin 16 Crankcase 5 Crankshaft 11 Piston 17 Check valve 6 Main bearing upper 12 No 1 compression ring 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Damaged threads Cracks Flaking uneven contact Scratches cracks dint clogged oil holes wear Wear Wear Wear damage Fatigue Damaged thre...

Page 61: ...imit replace the connecting rod with new one Measuring connecting rod end play 4 3 Removing connecting rod cap 1 Mark the cylinder number on the connecting rod and connecting rod cap 2 Remove the connecting rod cap 3 Be sure to make the disassembled lower connecting rod bearing easy to recognize its cylinder number and upper or lower Note Be careful not to damage the bearings Be sure to arrange th...

Page 62: ...5 Pulling out piston 1 Turn the crankshaft to bring the piston to the top dead center 2 Using a piece of wood such a hammer handle push the mating surface of the connecting rod cap and pull the piston and connecting rod upward from the cylinder Pulling out piston 4 6 Removing piston ring Remove the piston rings using piston ring pliers Removing piston ring 4 7 Removing piston pin 1 Using snap ring...

Page 63: ... with new one Measuring crankshaft end play 4 10 Removing main bearing cap 87 21 When removing the main bearing cap be careful to not damage the lower main bearing lower that are attached to the cap Also be careful not to drop those parts which may damage the crankshaft 1 Unscrew the main bearing cap bolts 2 Unscrew the main bearing cap Note Mark the bearings for their cylinder numbers Removing ma...

Page 64: ...aight up 2 Arrange the bearings in the order of disassembly so that their original positions are restored when reassembling Note a When raising the crankshaft do not allow wire chain to come into contact with the crankshaft To avoid damage to the crankshaft when raising use a cloth belt or pad b Mark the bearings for their cylinder numbers Removing crankshaft ...

Page 65: ... 3 6 Measuring cam lift 6 11 3 7 Measuring camshaft journal diameter and journal bore diameter 6 11 3 8 Measuring camshaft runout 6 12 3 9 Removing camshaft gear 6 12 3 10 Installing camshaft gear and thrust plate6 12 4 Inspecting and repairing piston connecting rod crankshaft and crankcase 6 13 4 1 Measuring piston outside diameter 6 13 4 2 Measuring piston ring groove 6 13 4 3 Measuring piston r...

Page 66: ...er and rocker shaft outside diameter 1 3 Measuring perpendicularity and free length of valve spring Measure the perpendicularity and free length of the valve spring If the limit is exceeded replace the valve spring with a new one Squareness and free length of spring Item Standard Limit Bottom surface distortion 0 05 mm 0 0020 in or less 0 20 mm 0 0079 in Item Nominal Standard Limit Rocker arm insi...

Page 67: ...er the valve or the valve guide with a new one Measuring valve stem outside diameter Measuring valve guide inside diameter Item Standard Remark Push rod runout 0 3 mm 0 012 in or less Total indicated reading TIR 1 2L 1 2L L Pushrod Item Nominal Standard Limit Valve stem outside diameter Inlet ø 8 mm 0 31 in 7 940 to 7 955 mm 0 3126 to 0 3132 in 7 900mm 0 3110 in Exhaust ø 8 mm 0 31 in 7 920 to 7 9...

Page 68: ...e installer 1 To remove valve guides use a valve guide remover 2 To press fit valve guides use a valve guide installer 3 Check contacts between valves and valve seats after replacing valve guides Pulling out valve guide Press fitting valve guide Valve guide remover P N 32A91 00300 Valve guide 15 5 mm 0 610 in Valve guide Valve guide installer P N 32C91 00300 Press ...

Page 69: ...the valve when pressing the valve face coated with Shinmyoutan or equivalent lead free dye against the valve seat c Always lap the valve and valve seat after the valve has been refaced or replaced Checking valve face Valve to valve seat contact Valve to valve seat contact position Item Nominal Standard Limit Valve seat Valve seat angle 30 Valve sinkage 0 8 mm 0 031 in 0 7 to 0 9 mm 0 028 to 0 035 ...

Page 70: ...t the cylinder head to 80 to 100 C 176 to 212 F and cool the valve seat sufficiently in ether or alcohol mixed with dry ice before fitting it into the hot cylinder head 4 Fit the cold valve seat into the cylinder head using a insert caulking tool Driving in valve seat 1 9 Refacing valve face If the valve face is significantly worn out reface the valve face using a valve refacer Note a Grind the va...

Page 71: ...e seat 1 11 Lapping valve and valve seat Always lap the valve against the valve seat after refacing the valve seat or after replacing the valve 1 Apply a thin coat of lapping compound evenly to the valve face Note a Do not allow the compound to adhere on the valve stem b Compound spreads more evenly if it is mixed with a small amount of engine oil c Use medium grain compound 120 to 150 mesh for in...

Page 72: ...e and tap the combustion jet inner face perimeter lightly to pull out the combustion jet 2 When installing the combustion jet align the positioning hole and jet nozzle with the center of cylinder press fit with tapping by plastic hammer Removing combustion jet Press fitting combustion jet Round rod ø6 mm 0 24 in Combustion jet 15 Combustion jet Jet nozzle Center of cylinder Positioning hole ...

Page 73: ...evenly using an acetylene torch or other appropriate heat source 2 With a rod placed on the periphery of ring gear tap the rod with a hammer evenly around the ring gear and remove the ring gear 2 2 2 Installing ring gear 1 Heat the ring gear evenly up to approx 150 C 176 F with an appropriate heater 2 Install the ring gear onto the flywheel with the no gear chamfering side faced to the flywheel No...

Page 74: ...r 3 2 Inspecting oil seal contact surface Inspect the oil seal contact surface of the pulley If the pulley waers due to oil seal replace the pulley with new one 3 3 Measuring clearance between idler bush ing and idler shaft Measure the inside diameter of the idler bushing and outside diameter of the idler shaft Replace the bushing if the clearance exceeds the limit Measuring idler bushing inside d...

Page 75: ... N MH061077 Item Nominal Standard Limit Cam lift Inlet Major axis 46 916 0 3 0 1 mm 1 8471 0 012 0 004 in Major axis Minor axis 6 684 mm 0 2631 in Major axis Minor axis 6 184 mm 0 2435 in Exhaust Major axis 45 944 0 3 0 1 mm 1 8088 0 012 0 004 in Major axis Minor axis 7 344 mm 0 2891 in Major axis Minor axis 6 844 mm 0 2694 in D1 D2 Measuring locations Measuring directions Item Nominal Standard Li...

Page 76: ...haft gear by using a press Note Remove the camshaft and thrust plate only when the camshaft gear has defect Removing camshaft gear 3 10 Installing camshaft gear and thrust plate 1 Install the key and the thrust plate to the camshaft 2 Heat the camshaft to approximately 250 C 482 F by using gear heater 3 Press fit the camshaft gear by tapping Note Do not forget to insert the thrust plate before ins...

Page 77: ...ng and ring groove If the limit is exceeded replace the piston ring with a new one Measuring piston ring groove Item Nominal Standard Limit Piston outside diameter STD 87 970 mm 3 4634 in 87 955 to 87 985 mm 3 4628 to 3 4640 in 87 770 mm 3 4555 in 0 25 OS 88 220 mm 3 4732 in 88 205 to 88 235 mm 3 4726 to 3 4738 in 88 020 mm 3 4653 in 0 50 OS 88 470 mm 3 4831 in 88 455 to 88 485 mm 3 4825 to 3 4837...

Page 78: ...necting rod bushing and the outside diameter of the piston pin Replace if the limit is exceeded Measuring connecting rod bushing inside diameter Item Standard Limit Piston ring end gap No 1 2 compression ring 0 25 to 0 40 mm 0 0098 to 0 0157 in 1 50 mm 0 0591 in Oil ring 0 30 to 0 50 mm 0 0118 to 0 0197 in Sickness gauge Item Nominal Standard Limit Piston pin inside diameter ø 28 mm 1 10 in 28 000...

Page 79: ...standard If the standard is exceeded after correction replace the connecting rod with a new one 2 In general a connecting rod aligner is used to check bend and twist Note Before checking bend tighten the connecting rod cap to the specified torque 3 To inspect the connecting rod with the piston installed turn the piston upside down and place it on a surface plate Insert a round bar having the same ...

Page 80: ... specified undersize refer to the following chart 87 21 a When grinding the crankshaft pin be sure to grind the all pin to same size b Finish the fillet R to R3 0 2 mm R0 1181 0 0079 in or less Width of crankshaft thrust bearing surface Item Nominal Standard Limit connecting rod bearing inside diameter ø 58 mm 2 28 in 58 000 to 58 045 mm 2 2835 to 2 2852 in Measuring directions Measuring points Ti...

Page 81: ...U S If an undersize bearing is used grind the crankpin to the specified undersize refer to the following chart 87 21 a When grinding the crankshaft journal be sure to grind the all journals to same size b Finish the fillet R to R3 0 2 mm R0 1181 0 0079 in or less Width of crankshaft thrust bearing surface Tightening torque 83 5 N m 8 5 0 5 kgf m 61 3 6 lbf ft Item Nominal Standard Limit Journal ou...

Page 82: ...il seal and oil seal sleeve with the new spare parts Installing oil seal sleeve Installing front oil seal 2 4 10 2 Removing oil seal sleeve 87 21 When making a cut in the sleeve be very careful not to damage the crankshaft with the chisel Make a cut at three locations on the periphery of the oil seal sleeve to reduce its tension To do so hold a chisel against the sleeve periphery in the radial dir...

Page 83: ...d replace the crankshaft If the crankshaft has been repaired by grinding or pressing inspect the crankshaft for cracks and other harmful damage using a magnetic particle method Measuring crankshaft runout 4 12 Removing crankshaft gear Using a gear puller remove the gear from the crankshaft Note Do not strike the gear with a hammer Removing crankshaft gear 4 13 Installing crankshaft gear 1 Install ...

Page 84: ...asuring position in the outside diameter is shown in the illustration 3 Calculate the boring dimensions based on the piston outside diameter that has been measured A Piston outside diameter mm oversize piston that has been selected B Clearance between piston and cylinder standard 0 03 mm 0 0012 in C Horning allowance 0 04 mm 0 0016 in or below Boring dimension A B C 4 Bore each cylinder to dimensi...

Page 85: ...kcase top surface Measuring crankcase top surface distortion 4 16 Inspecting tappet Inspect the cam contact surface of the tappets Fit new tappets if the surface is excessively worn or damaged Contact surface of tappet and cam 4 17 Measuring clearance between tappet and tappet guide hole Measure clearance between the tappet and tappet hole Replace the tappet with a new one if the limit is exceeded...

Page 86: ... Insert the round bar ø4 mm 0 1575 in or less to the top of the piston cooling nozzle installed on the crankcase Inspect that the steal ball operates smoothly If it does not operated smoothly replace the piston cooling nozzle with new one Inspecting piston cooling nozzle Round rod ...

Page 87: ...8 2 1 Installing front plate 7 8 2 2 Installing camshaft 7 8 2 3 Installing oil pump 7 8 2 4 Installing oil pan 7 9 2 5 Inverting crankcase 7 9 2 6 Installing front idler gear 7 10 2 7 Inspecting and adjusting timing gear after installation 7 10 2 8 Installing oil seal 7 10 2 9 Installing timing gear case 7 11 2 10 Installing crankshaft pulley 7 11 3 Reassembling flywheel 7 12 3 1 Installing rear ...

Page 88: ... without groove to the main bearing cap 2 Install the flange main bearing to the rearmost crankcase mating surface 3 Apply a small amount of engine oil to each bearing Installing main bearing 1 3 Installing crankshaft 1 Wash the crankshaft thoroughly with cleaning oil and dry it completely by compressed air Note When washing the crankshaft clean the inside of the oil holes completely and make sure...

Page 89: ...s are in numerical order from the front of the engine Installing main bearing cap 1 5 Installing main bearing cap bolt 1 Tighten the main bearing cap bolts alternately and progressively to the specified torque 2 Make sure that the crankshaft rotates smoothly Installing main bearing cap bolt Inspecting crankshaft for rotation 1 2 3 5 Engine front side Front mark Cap No Surfaces must flush Surfaces ...

Page 90: ...ecting rod shown in the illustration Note The pistons and piston pins are assembled to each other in clearance fit However the piston pins are more easily inserted into the pistons if the pistons are warmed up with a heater or in hot water 2 Using ring pliers install the snap ring Check the snap ring for its tension and make sure the ring fits snugly in the groove Note Install all the snap rings s...

Page 91: ...expander Piston and piston ring arrangement 2 Install the oil ring with its end gap 180 away from the joint of the coil spring as shown in the illustration Installing oil ring and coil spring 1 9 Preparation for installing pistons 1 Lay the engine along its side 2 Clean the cylinder sleeve inner surface and the crank pin with a cloth and apply engine oil Lay the crankcase on its side Preparation f...

Page 92: ...o the piston rings and crank pin 1 Apply engine oil to the circumference of the piston and piston rings 2 Orient the ring end gaps diagonally opposite each other avoiding the piston pin direction and its right angle direction 3 Turn the crankshaft to bring the crank pin of the cylinder to the top dead center 4 Using a piston guide insert the piston from the top face of crankcase into the cylinder ...

Page 93: ...connecting rod cap nuts by using hand 4 Tighten the connecting rod cap nuts evenly and progressively to the specified torque 5 Inspect end play of the connecting rod If end play is small loosen and retighten the cap nuts Installing connecting rod cap 1 Installing connecting rod cap 2 1 13 Uprearing crankcase Uprear the crankcase softly with its upper faced downward Inverting crankcase 1 14 Inspect...

Page 94: ...ne oil to the camshaft journals and cams 2 Slowly insert the camshaft assembly 3 Tighten the thrust plate bolt to the specified torque 4 Make sure that the camshaft rotates lightly Move the camshaft gear back and forth and make sure there is end play Applying engine oil to camshaft Installing camshaft 2 3 Installing oil pump 1 Insert the oil pump to the oil pump hole on the crankcase then make sur...

Page 95: ... the crankcase under face with pushing the gasket circular part into the No 1 and 4 main bearing cap grooves and pushing the gasket protrusion into the mating surface clearance where sealnt is filled 3 Install the oil pan and tighten the bolts to the specified torque Installing oil pan 2 5 Inverting crankcase 87 21 Do not place the engine directly on the ground It causes cracking the oil pan 1 Att...

Page 96: ...er installation Be sure to inspect and adjust the timing gear when the timing gear has been reassembled Measuring timing gear backlash 2 8 Installing oil seal Install oil seal to the timing gear case using installer and make sure that oil seal is flush with timing gear case Installing oil seal Inspection pump gear Camshaft gear Crankshaft gear Idler gear 2 22 3 3 3 1 1 1 Apply engine oil Thrust pl...

Page 97: ...nkshaft pulley 87 21 The bar could come off Be very careful 1 Apply the engine oil to the oil seal contact surface of the crankshaft pulley 2 Drive into the crankshaft pulley aligning with the crankshaft key 3 Prevent the crankshaft turning using the threaded hole at the rear end of the crankshaft 4 Install the nut with the washer tighten the nut to the specified torque Installing crankshaft pulle...

Page 98: ...tall the O ring into the oil seal case and install the assembly onto the near plate Installing oil seal 3 3 Installing flywheel 87 21 The person who holds the pulley must be very careful to assure safety by communicating with the person who is installing the flywheel 1 One person must firmly hold the pulley with a wrench to prevent the crankshaft from turning 2 Screw the guide bolt into the rear e...

Page 99: ...n the valve guide Install the valve cotter using a valve spring pusher 2 Tap the top of valve stem lightly several times with a soft hammer to make sure that the valve spring and valve cotter are properly installed and seated firmly Installing valve and valve spring Inspecting valve cotter 4 3 Installing cylinder head gasket 87 21 Do not use liquid gasket 1 Wipe off oil grease and other stains fro...

Page 100: ...mbly 1 Apply engine oil to the rocker shaft 2 When reassembling install the rocker shaft assembly in the same position as it was Note If the rocker shaft assembly is not installed as it was the clearance becomes different and it may result in a defect such as wear increase 3 After reassembling make sure the rocker arm and oil pipe move freely Reassembling rocker shaft assembly 4 7 Inserting push r...

Page 101: ...orque 3 Tighten the short bolts of the rocker bracket Installing rocker shaft assembly 4 9 Adjusting valve clearance Adjust the valve clearance For adjusting procedures refer to Adjustment and Operation Adjusting valve clearance Tightening torque long 15 2 N m 1 5 0 2 kgf m 11 1 4 lbf ft short 11 3 1 5 N m 1 15 0 15 kgf m 8 1 1 lbf ft Adjustment screw Lock nut 0 25 mm 0 0098 in ...

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Page 103: ... system 8 4 2 1 Disassembling and inspecting fuel injection nozzle 8 4 2 1 1 Inspecting and adjusting fuel injection valve opening pressure 8 5 2 1 2 Inspecting fuel spray pattern of fuel injection nozzle 8 6 2 1 3 Cleaning and replacing faulty nozzle 8 6 2 1 4 Reassembling fuel injection nozzle 8 7 3 Installing fuel system 8 8 ...

Page 104: ...h as injection pump openings nozzle openings injection pipes 1 Fuel return pipe 7 Oil pipe 2 No 1 fuel injection pipe 8 Pump bracket 3 No 2 fuel injection pipe 9 Injection pump gear 4 No 3 fuel injection pipe 10 Injection pump flange 5 fuel leak off pipe 11 Fuel injection pump 6 Fuel injection nozzle 6 5 1 4 3 2 9 10 7 8 11 Replace Replace Replace Replace ...

Page 105: ... gear and the idler gear 4 Remove the fuel injection pump flange bolt and remove the fuel injection pump from the front plate together with the flange Note a Do not operate the engine without the fuel injection pump b When removing the fuel injection pump gear loosen the fuel injection pump gear nut with the pump is installed on the engine Removing fuel injection pump 1 Removing fuel injection pum...

Page 106: ...g and inspecting fuel injection nozzle Disassembling and inspecting fuel injection nozzle Disassembling sequence 1 Nozzle retaining nut 5 Spring 2 Nozzle tip assembly 6 Water 3 Piece 7 Nozzle holder 4 Pin 7 1 2 3 4 5 6 Settling breakage Wear damage Carbon deposit nozzle hole clogging Wear ...

Page 107: ... more it increases the pressure 4 After adjusting the pressure tighten the retaining nut to the specified torque 5 Check the injection valve opening pressure once again to make sure the pressure is within the standard range Note a Standard is a value of new parts b A chauge in thickness of the shim by 0 1 mm 0 004 in results in a chauge in the fuel injection pressure by 1 0 Mpa 10kgf cm 142 psi Th...

Page 108: ...to dam age the tip 1 Loosen the retaining nut then remove the nozzle tip and clean the needle valve and body 2 Clean the nozzle tip in clean wash oil After cleaning assemble the needle valve and body in clean diesel fuel Note The needle valve and body are precision parts Handle them carefully and do not change the combination of the valve and body 3 Tighten the nozzle tip retaining nut to the spec...

Page 109: ...EL SYSTEM 8 7 2 1 4 Reassembling fuel injection nozzle Reassembling fuel injection nozzle Tightening torque 59 6 N m 6 0 6 kgf m 43 4 3 lbf ft Tightening torque 36 8 2 45 N m 3 75 0 25 kgf m 27 1 8 lbf ft ...

Page 110: ...Installing fuel system 64 5 N m 6 5 0 5 kgf m 47 3 6 lbf ft 59 6 N m 6 0 6 kgf m 43 4 3 lbf ft 23 2 N m 2 3 0 2 kgf m 16 6 1 4 lbf ft 29 3 N m 3 0 3 kgf m 22 2 2 lbf ft 20 2 N m 2 0 2 kgf m 14 1 4 lbf ft Replace Replace Replace Replace Replace ...

Page 111: ...brication system 9 5 2 1 Disassembling and inspecting oil pump 9 5 2 2 Measuring clearance between outer rotor and inner rotor 9 5 2 3 Measuring end play of rotor and pump case 9 6 2 4 Measuring clearance between outor rotor and pump case 9 6 2 5 Reassembling oil pump 9 6 2 6 Inspecting relief valve 9 6 3 Installing lubrication system 9 7 3 1 Installing oil pan oil pump and oil pressure switch 9 7...

Page 112: ...er and relief valve Removing sequence 1 Plug 5 Rebber hose 9 Connector 2 Connector 6 Oil cooler pipe 10 Oil cooler 3 Sealing washer 7 Rebber hose 11 Relief valve 4 Oil pump cover 8 Rebber hose 12 Gasket 11 12 5 6 7 10 9 4 1 3 2 8 Clogging deformation damage Spring for fatigue and damage Replace Replace Replace Replace Replace Replace Replace ...

Page 113: ...emoving and inspecting oil pan oil pump oil pressure switch Removing and inspecting oil pan oil pump oil pressure switch Removing sequence 1 Oil pan 3 Oil pump 2 Oil pan gasket 4 Oil pressure switch 4 3 1 2 Replace Replace Replace ...

Page 114: ...l pipe 6 Breather hose 11 Spacer 2 Oil hose 7 Breather hose 12 Oil separator 3 Oil return pipe 8 Breather hose 13 Separator bracket 4 Oil return pipe 9 Breather pipe 14 Oil level gauge 5 Breather hose 10 Breather pipe 15 Level gauge guid S Q H E Replace Replace Replace Replace Replace Replace Replace Replace Replace 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ...

Page 115: ...ween outer rotor and inner rotor Measure the clearance between the outer rotor and the inner rotor If measured value exceeds the limit replace the oil pump with new one Measuring clearance between outer rotor and inner rotor 1 Oil strainer 2 Oil pump cover 3 Oil pump 3 2 1 Gear defect wear Replace Item Standard Limit Clearance between outer rotor and inner rotor 0 13 to 0 15 mm 0 0051 to 0 0059 in...

Page 116: ... valve and its valve seat for contact condition Check the spring for fatigue and damage If it is faulty replace the relief valve with new one 2 Measure the valve opening pressure oil pressure when the engine is running at rated speed of the relief valve If the measured value is out of the standard remove the plug and make an adjustment by increasing and decreasing the shim thickness Engine oil pre...

Page 117: ... oil pressure switch Installing oil pan oil pump and oil pressure switch 39 5 N m 4 0 5 kgf m 29 3 6 lbf ft 8 1 N m 0 8 0 1 kgf m 6 0 7 lbf ft 29 4 N m 3 0 kgf m 22 lbf ft Replace Replace Replace 34 4 N m 3 5 0 4 kgf m 25 2 9 lbf ft Oil pan side Drain plug side Gasket installation direction ...

Page 118: ...STEM 9 8 3 2 Installing oil cooler and relief valve Installing oil cooler and relief valve Replace Replace Replace Replace Replace Replace Replace 69 10 N m 7 1 kgf m 51 7 2 lbf ft 49 5 N m 5 0 5 kgf m 36 3 6 lbf ft ...

Page 119: ...LUBRICATION SYSTEM 9 9 3 3 Installing oil pipe and oil separator Installing oil pipe and oil separator S Q H E Replace Replace Replace Replace Replace Replace Replace Replace Replace ...

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Page 121: ... and reassembling cooling system 10 3 2 1 Disassembling inspecting and reassembling water pump 10 3 2 1 1 Inspecting water pump for smooth rotation10 3 2 2 Disassembling inspecting and reassembling thermostat 10 4 2 2 1 Inspecting thermostat 10 4 3 Installing cooling system 10 5 ...

Page 122: ...em Removing sequence 1 Cooling fan 4 Water pump pulley 2 Fan spacer 5 Water pump assembly 3 V belt 6 Thermostat 6 1 2 5 4 3 Replace Crack water leakage damage Crack damage Cracked elongation wear damage aging Cracked distortion damage Cracked distortion damage Replace ...

Page 123: ...pecting water pump for smooth rotation Check to make sure that the impeller and shaft of water pump rotate smoothly without noise and irregularities If faulty replace the water pump assembly Inspecting water pump rotation condition 1 Water pump cover 2 Gasket 3 Water pump 3 2 1 10 1 0 N m 1 0 0 1 kgf m 7 2 0 7 lbf ft Crack water leakage distortion Crack water leakage damage impeller and shaft of r...

Page 124: ...hown in the table below If the temperatures are not within the standard range replace the thermostat Note a Stir the water in the container with a stick to ensure uniform temperature distribution b Before installing the thermostat be sure to check the valve opening temperature stamped on the thermostat valve side face Inspecting thermostat 1 Thermostat cover 3 Thermostat 2 Gasket 4 Thermostat case...

Page 125: ...COOLING SYSTEM 10 5 3 Installing cooling system Installing cooling system Replace Replace Replace ...

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Page 127: ...1 1 INLET AND EXHAUST SYSTEMS 1 Removing inlet and exhaust sysytem 11 2 2 Inspecting inlet and exhaust system 11 3 2 1 Measuring exhaust manifold distortion 11 3 3 Installing inlet and exhaust system11 4 ...

Page 128: ...nd exhaust sysytem Removing inlet and exhaust sysytem Removing sequence 5 1 3 2 6 4 The illustration is an example of S3Q2 T Replace Replace Replace Replace Replace 1 Air hose 4 Air inlet elbow 2 Air hose 5 Inlet manifold 3 Air pipe 6 Exhaust manifold ...

Page 129: ...Measuring exhaust manifold distortion 1 Check the flange for crack 2 Check the flange suface for distortion If the distortion exceeds the standard retouch the surface Measuring exhaust manifold distortion Item Standard Exhaust manifold distortion Less than 0 15 mm 0 0059 in ...

Page 130: ...system R 5 m m 0 2 0 in Replace Replace Replace Replace Replace The illustration is an example of S3Q2 T Exhaust gasket installing direction Exhaust manifold side Cylinder head side 1 mm 0 04 in 6 1 N m 0 6 0 1 kgf m 4 0 7 lbf ft 7 1 N m 0 7 0 1 kgf m 5 0 7 lbf ft 7 1 N m 0 7 0 1 kgf m 5 0 7 lbf ft ...

Page 131: ... diameter12 10 2 3 7 Inspecting brush holder for insulation 12 10 2 3 8 Measuring undercut depth 12 10 2 3 9 Inspecting overrunning clutch 12 11 2 3 10 Inspecting continuity of magnetic switch between M terminal and case 12 11 2 3 11 Inspecting insulation of magnetic switch between M terminal and B terminal 12 11 2 3 12 Inspecting continuity of yoke assembly 12 11 2 3 13 Inspecting insulation betw...

Page 132: ...ternator 1 Connect battery cables correctly B terminal is positive and E terminal is negative 2 Do not use any high voltage tester such as megger 3 Do not disconnect lead wire from B terminal of the alternator while the engine is running 4 Battery voltage is constantly applied to B terminal of the alternator Do not ground at this terminal 5 Do not short circuit or ground at L terminal For a built ...

Page 133: ...r to the ammeter then connect the voltmeter between B terminal and ground 3 Connect the battery ground cable 4 Start the engine 5 Immediately apply all loads such as lamps 6 Increase the engine speed and measure the maximum output current at the specified alternator rotation speed with the voltmeter indicated the specified value 7 If the measured value meets the standard the output is normal Inspe...

Page 134: ...RICAL SYSTEM 12 4 1 3 Removing alternator Removing alternator Removal sequence 1 Harness 3 Adjusting plate 5 Alternator bracket 2 V belt 4 Alternator 2 4 3 1 5 Elongation of belt degradation cracked Rotaion ...

Page 135: ...ELECTRICAL SYSTEM 12 5 1 4 Removing glow plug Removing glow plug Removing sequence 2 1 3 1 Nut 2 Connection plate 3 Glow plug ...

Page 136: ...ration The magnetic switch is normal if the pinion springs out when the switch is turned ON Pull in test 3 Holding test Connect the starter to the circuit as shown in the illustration Pull out the pinion fully by hand The magnetic switch is normal if the pinion does not return when it is released Holding test 4 Return test Connect the starter to the circuit as shown in the illustration Pull out th...

Page 137: ...in the illustration 2 In normal condition the pinion pops out when the switch is turned ON and the starter rotates at or more the specified rotation speed If the terminal voltage current or rotation speed does not meet the standard disassemble inspect and repair the starter Test at no load Item Standard No load characteristics Terminal voltage 11 V Current 130 A or less Rotation speed 3600 min 1 o...

Page 138: ... gear 5 Armature 11 Ball 17 Gear shaft 6 Bearing 12 Planetary gear Magnet switch open circuit short Bend deflection open circuit and short of armature Looseness abnormal noise and rotation condition of bearing 1 14 10 2 17 12 11 8 3 4 16 15 9 13 5 6 7 Pinion gear wear Replace Pinion gear wear Wear Replace Wear and damage of gear Wear and insulation condition Replace Yoke open circuit short Loosene...

Page 139: ...ring with a new one Measuring brush spring load 2 3 3 Inspecting armature coil 1 Inspect the armature coil using a growler Hold a piece of iron plate against the armature core If the iron plate vibrates replace the armature with a new one Inspecting armature coil 2 Check that there is no continuity between the commutator and the shaft core If any continuity is observed replace the armature with a ...

Page 140: ...lue is less than the limit replace the armature with a new one Measuring commutator outside diameter 2 3 7 Inspecting brush holder for insulation Check that there is no continuity between each brush holder and the brush holder base If continuity is observed replace the whole brush holder assembly Check the brush holders for looseness Inspecting brush holder insulation 2 3 8 Measuring undercut dept...

Page 141: ...c switch between M terminal and B terminal Check that there is no continuity between M terminal and B terminal If continuity is observed replace the magnetic switch with a new one Inspecting magnetic switch 2 3 12 Inspecting continuity of yoke assembly Check that there is continuity between M terminal of field coil and the lead wire for the brush If no continuity is observed replace the yoke assem...

Page 142: ...urrent conducting compo nents are free from grease When overhauling the starter apply grease to the following sliding surfaces gears and bearings Reassembling starter 10 8 1 0 N m 1 1 0 1 kgf m 8 0 7 lbf ft 3 32 0 77 N m 0 34 0 08 kgf m 2 0 6 lbf ft MOLYKOTE AG 650 Dow Corning Toray CO Ltd or equivaleat Multemp 6129 KYODO YUSHI CO LTD or equivalent Multemp OA 171 KYODO YUSHI CO LTD or equivalent M...

Page 143: ... packings is increased the pinion gap decreases If proper adjustment cannot be achieved by varying the number of packings replace the lever Ajusting pinion gap 1 Ajusting pinion gap 2 2 5 2 No load test 87 21 Use as thick a wire as possible and firmly tighten each terminal When detecting the rotation at the tip of the pinion be careful as the pinion pops out during operation 1 Connect the starter ...

Page 144: ...otor bearing 9 Rectifier 2 Pulley spacer 6 Stator 10 Nut set 3 Through bolt 7 Rear bracket 4 Front bracket bearing 8 Regulator 1 2 3 4 6 9 7 8 10 5 Crack damage Rotation Deformation and damage Broken wire and ground of coil Rotation Crack damage Sliding state and wear of brushes Dirt damage and seizure of slip ring and coil resistance Short cincuit and open circuit ...

Page 145: ...ing the rotor in a vise be sure to hold the base of the rotor claw Do not hold the rotor claw as it causes damage to the claw 1 Apply a cloth to the rotor and set it in a vise 2 Remove the pulley nut and then pull out the pulley and spacer 3 Remove the rotor from the front bracket Removing pulley 2 6 3 Removing stator 87 21 Unsoldering must be finished as quickly as possible Extended heating will ...

Page 146: ...uch as possible The current flow during test is significantly lower than the current that normally flows in the rectifier by which the accurate resistance may not be measured using a tester and this tendency is noticeable if the measuring range is small Inspecting rectifier 2 6 5 Inspecting rotor 1 Check that there is continuity between slip rings If no continuity is observed replace the rotor wit...

Page 147: ...here is no continuity between each lead wire and the stator core If continuity is observed replace the stator Note The core cannot be replaced as a single item Checking for continuity between leads Checking for grounding between the leads and the core 2 6 7 Inspecting brushes for wear Measure the length of the brushes If the measured value is less than the limit replace both the brush holder assem...

Page 148: ...r bearing Insert the rotation retaining snap ring so that the highest protruded section of the ring is positioned at the deepest section of the groove 2 When replacing the rear bearing press fit the rear bearing so that the groove on the periphery of the bearing faces the snap ring side 3 When press fitting the rear bearing into the rear bracket heat the rear bracket to 50 to 60 C 122 to 140 F fir...

Page 149: ...glow plug Check continuity between the terminal and the body as shown in the illustration If no continuity is indicated or the resistance is large replace the glow plug with a new one Inspecting glow plug Item Standard Resistance value 1 0 Ω ...

Page 150: ...TRICAL SYSTEM 12 20 3 Installing electrical system Installing electrical system 18 2 N m 1 8 0 2 kgf m 13 1 4 lbf ft 1 3 0 2 N m 0 13 0 02 kgf m 0 9 0 1 lbf ft Terminal B 11 1 N m 1 1 0 1 kgf m 8 0 7 lbf ft ...

Page 151: ...rack setting maximum output 13 6 1 5 4 Setting governor setting maximum speed 13 7 1 5 5 Measuring speed variation rate 13 7 1 5 6 Adjusting speed variation rate changing governor notch setting 13 8 1 5 7 Sealing 13 8 2 Break in operation 13 9 2 1 Starting up 13 9 2 2 Inspecting engine condition after starting up 13 9 2 3 Break in operation time 13 9 2 4 Inspection and adjustment after break in op...

Page 152: ...pointer on the timing gear case and neither the inlet valve nor the exhaust valve is not lifted off its seat by the push rod 3 Insert a thickness gauge between the rocker arm and valve cap to inspect the clearance Turning engine Inspecting and top dead center of No 1 cylinder on compression stroke 1 1 2 Adjusting valve clearances 1 Insert the feeler gauge of the specified thickness between the roc...

Page 153: ...priming pump With flowing the fuel out from the injection pipe rotate the crankshaft gradually in the normal direction 5 When the fuel flow is getting fewer rotate the crankshaft more slowly When the fuel flow stop completely stop rotating the crankshaft 6 Make sure the pointer indicates the fuel injection timing of the graduation mark on the crankshaft pulley Inspecting fuel injection timing 1 In...

Page 154: ...ug of fuel injection pump Bleeding fuel injection pump 1 4 Inspecting V belt 1 Inspect the belt visually for separation or damage If any defect is found replace the belt with a new one 2 Inspect belt tension deflection When it is strongly pressed down on with the thumb at the center of its span it is normal that the amount of deflection is 13 mm If the amount of deflection is not within the standa...

Page 155: ... warranty Be sure to seal all of the specified locations c When inspecting and adjusting the governor be prepared to operate the engine stop lever manu ally in anticipation of engine overrunning Note Prior to inspecting and adjusting the governor be sure to warm up the engine long enough to raise the coolant and oil temperatures to 70 C 158 F or higher 1 5 1 Starting engine 1 Pull the speed contro...

Page 156: ...ed stability 1 5 3 Setting rack setting maximum output 1 Hold the speed control lever at the specified engine output and speed position In this condition check if the engine output and speed are stable 2 While maintaining the engine in the stabilized condition adjust the full load stopper bolt Tighten or loosen the full load stopper bolt to find the position where the rated output is attained 3 Wh...

Page 157: ... Measuring speed variation with load applied While operating the engine in a no load condition instantaneously apply a specified load to the engine Record the momentary maximum speed Ｎ5 stabilized speed Ｎ6 and time needed for the engine to stabilize its speed from the moment the load is applied ｔ2 3 Calculating speed variation rate Calculate the speed variation rate from the results of above measu...

Page 158: ... swivel lever will turn up showing the head of the adjusting screw Use a flat head screwdriver to turn the adjusting screw 3 The speed variation rate decreases as the adjusting screw is tightened and increases as the screw is loosened A quarter of a turn of the adjusting screw equals to one governor notch and changes the engine speed by three to five revolutions per miute 4 Turning the adjusting s...

Page 159: ...d take appropriate measures 1 The oil pressure must be within the specified value 2 The coolant temperature must be within the specified value 3 The engine must be free from any leakages such as oil coolant and fuel Pay special attention to oil leakage from the fitting face of turbocharger lube oil pipe 4 Check for an abnormal noise Note Knocking noise will disappear as the coolant temperature ris...

Page 160: ...d conditions 3 2 2 Continuous load test Operate the engine continuously for 10 hours at 90 load continuous load application of nominal net brake power while the engine speed is maintained at revolutions corresponding to the nominal brake power In this test evaluate the fuel consumption rate and operating condition and confirm that the engine is capable of continuous operation 3 2 3 Low idle test C...

Page 161: ...rrection equation use ޓ 6JG TCPIG QH EQTTGEVKQP HCEVQT ǩ c KU CU HQNNQYU 0 9 ǩ c 1 1 Natural aspiration engine and engine with mechanically driven air charger Turbocharged engine without air cooler or with air to air cooler Turbocharged engine with air to liquid cooler f a 㨯 99 Pd T 298 f a 㨯 99 Pd T 298 f a 㨯 99 Pd T 298 Calculation of correction factor fa Calculation of engine factor fm fm 0 036...

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Page 163: ...on of Cylinder Head Bottom Surfaces 5 Measurement of Oil Clearance of Connecting Rod Bearing 6 Measurement of Rocker Arm Inside Diameter and Shaft Diameter 7 Measurement of Piston Pin Bore Diameter and Piston Pin Diameter 8 Measurement of Valve Clearance 9 Measurement of Injection Pressure of Fuel Injection Nozzle 10 Measutrement of Clearance between Camshaft Journal Bore Diameter and Camshaft Bus...

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Page 165: ... Unit Measurement of Cylinder Bore Diameter Date Customer Approved by Examined by Model Engine Serial No Cylinder bore diameter A Limit B mm in Nominal value C Standard 0 2 0 0079 φ88 3 46 Standard 88 000 to 88 035 3 4646 to 3 4659 Measured by Remarks X 3 No Position X Y 1 2 Y X Y A B C X Y Square with piston pin Parallel with piston pin ...

Page 166: ...Inlet Measured by Examined by Maximum Minimum Y X X Y A Measuring positions Measured values No Exhaust Inlet Exhaust Inlet Position Name Y 3 2 1 Exhaust Inlet A 7 850 0 3091 0 130 0 0051 0 150 0 0059 Nominal value Inlet φ8 0 31 φ8 0 31 Exhaust Valve guide bore diameter Clearance between valve stem and valve guide Inlet Exhaust Standard 8 000 to 8 015 0 3152 to 0 3154 φ8 0 31 φ8 0 31 0 060 to 0 095...

Page 167: ...n Valve seat 30 1 18 0 0465 0 8 0 031 Valve seat angle Seat width Valve sinkage Nominal value Standard Limit Measured by Remarks Model Engine Serial No Approved by Examined by mm in Customer Standards S3Q2 S3Q2 T Inspection Item Unit Measurement of Valve Sinkage Seat Width and Valve Margin Date Measuring positions Measured values 3 2 1 No Exhaust Inlet Inlet Exhaust Inlet Exhaust Valve margin Valv...

Page 168: ...ds mm in Standard S3Q2 S3Q2 T Inspection Item Unit Measurement of Distortion of Cylinder Head Bottom Surface Date Customer Limit 0 20 0 0079 0 05 0 0020 or less Distortion of cylinder head bottom surface Measuring positions 3 No 1 2 Measured values Name B C D Distortion of cylinder head bottom surface A G H E F ...

Page 169: ...o 58 045 2 2835 to 2 2852 Connecting rod bearing oil clearance φ58 2 28 57 950 to 57 970 2 2815 to 2 2823 Connecting rod bearing inside diameter Crankshaft pin outside diameter Nominal value Standard Limit 0 030 to 0 095 0 0012 to 0 0037 0 200 0 0079 Oil clearance φ58 2 28 X Y Z X Crankshaft pin outside diameter Y Name Connecting rod bearing inside diameter Measured values Measuring positions 3 2 ...

Page 170: ...aft S3Q2 S3Q2 T Inspection Item Unit Measurement of Rocker Arm Inside Diameter and Shaft Diameter Date mm in Customer Maximum Minimum Y X Rocker shaft outside diameter Y X 3 Position Inlet Exhaust No 1 2 Inlet Exhaust Exhaust Name 18 98 to 19 00 0 7472 to 0 7480 φ19 0 75 Clearance Measured values Rocker arm inside diameter 0 01 to 0 05 0 0004 to 0 0020 0 07 0 0028 19 01 to 19 03 0 7484 to 0 7492 φ...

Page 171: ...en piston pin bore and piston pin Piston pin bore diameter Piston pin diameter φ28 1 10 φ28 1 10 0 050 0 0020 Y S3Q2 S3Q2 T Inspection Item Unit Measurement of Piston Pin Bore Diameter and Piston Pin Diameter Date mm in Customer Measured by Remarks Model Engine Serial No Approved by Examined by Standards Limit A B B A A 3 2 1 B Measuring positions Measured values No X Name Piston pin bore diameter...

Page 172: ...er Standard Inlet 0 25 0 0098 Unit Measurement of Valve Clearance Date S3Q2 S3Q2 T mm in Valve clearance cold Exhaust 0 25 0 0098 Valve Clearance Measuring positions Measured values Before adjustment After adjustment 1 Inlet 2 After adjustment Before adjustment After adjustment Before adjustment 3 No Adjusting screew Lock nut 0 25mm 0 0098 in ...

Page 173: ...g pressure Measuring positions Standards S3Q2 S3Q2 T Inspection Item Unit Measurement of Injection Pressure of Fuel Injection Nozzle Date Customer Measured by Remarks Model Engine Serial No Approved by Examined by Injection pressure Mpa kgf cm2 psi 3 Injection pressure After adjustment 2 Service hours h Measured values 1 Before adjustment No ...

Page 174: ...g positions Measured values Camshaft bushing bore diameter X No 1 Name Clearance Maximum Minimum Nominal value Standard 0 15 0 0059 0 07 to 0 11 0 0028 to 0 0043 Limit φ54 2 13 53 94 to 53 96 2 1236 to 2 1244 Camshaft journal diameter 53 90 2 1220 φ53 2 09 52 94 to 52 96 2 0842 to 2 0850 52 90 2 0827 Clearance between camshaft journal diameter and camshaft bore diameter of crankcase 54 03 to 54 05...

Page 175: ...by During reassembly Standard Limit 0 100 to 0 204 0 0039 to 0 0080 0 300 0 0118 Model Engine Serial No Remarks Customer During disassembly Crankshaft end play Measuring positions Standards Measured values S3Q2 S3Q2 T Inspection Item Unit Measurement of Crankshaft End Play Date ...

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