Toyota 12H-T Repair Manual Download

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CO-2

COOLING

SYSTEM

T r o u bleshOoting

TRO U B LESH OOTI NG

Problem

Possible cause

Remedy

Page

Engine

overheats

Fan bell

ose or missing

Adju s t or replace belt

CH·6

Dirt.

leaves

insects on

radiator or

Clean

radiator or

condenser

CO - 1 2

ndenser

Hoses. water pump.

thermostat housing .

necessary

radiator.

er.

cora

plugs

or head

gasket leak<lge

Thermostal f a u lty

Check thermostat

C O - 1 1

njec tion

timing retarded

Adjust liming

EM-23

Fluid

coupling

laulty

Replace

fluid

coupling

CO-5

Radiator

hose

plugged

or rotted

Replace hose

W a t e r pump taully

Replace

waler

pump

CO-5

Radialor plugged

cap faulty

C heck

radiator

CO- 1 2

Cylinder head or block cracked or

Repair

a s

necessary

plug ged

NOTE:

he engine lends to overheat,

removal o f

the

thermos tal will

erse

y effect.

cooling

e f f i ciency

Summary of Contents for 12H-T

Page 1: ...TOYOTA 2 H 1 2 H T ENGINE REPAIR MANUAL Nov 1985 ...

Page 2: ...for the 2H and 12H T engines mounted on the TOYQT A LAND CRUISER Heavy Dulyl Applicable models HJ60 61 75 series All information contained in this manual is the most up la dale al the lime of publication However specifications and pro cedures are subject to change without notice TOYOTA MOTOR CORPORATION ...

Page 3: ...e reproduced or copied in whole or in parI without the wriHen permission of Toyota Molor Corporation I NTRODUCTION m ENGINE MECHANICAL 1 9 FUEL SYSTEM 1m COOLING SYSTEM II LUBRICATION SYSTEM I STARTING SYSTEM ED CHARGING SYSTEM IB3 SERVICE SPECIFICATIO NS STANDARD BOLT TORQU E SPECIFICATIONS SST AN D SSM ...

Page 4: ...INTRODUCTION HOW TO USE THIS MAN UAL IDE NTI FICATION IN FORMATION GENERAL REPAIR INSTRUCTIONS ABBREVIATIO NS USED IN THIS MANUAL IN 1 Page IN 2 IN 4 I N 4 IN 7 ...

Page 5: ...At the beginning of each section PRECAUTIONS afe given thai pertain to all repair operations contained In that section Read these precautions before starting any rep8 r task TROUBLESHOOTING tables are included for each system 10 help you diagnose the system problem and find the cause The repair for each possible cause is referenced in the remedy col umn to quickly lead you to the solution REPAIR P...

Page 6: ... be read at a glance and only when necessary the test below it provides de1ailed information Important specifications and warnings always stand out in bold type REFERENCES Aeferences have been kept to a minimum However when they are required you are given the page to go to SPECIFICATIONS Specifications are presented in bold type throughout the lext in the applicable step You never have to leave th...

Page 7: ... negative I terminal which is grounded to the vehi cle body c To prevent damage to the battery terminal post i loosen the terminal nut and raise the cable straight up without twisting it or prying 1 d Clean the battery terminal posts and cable terminal with a shop rag Do not scrape them with a lile or other abrasive object e Install the cable terminal to the battery post with the nut loose and tig...

Page 8: ... to use SST and SSM where specified and follow the proper work procedure A list of SST and SSM can be found at the back of this manual O When replacing fuses be sure the new fuse is the correct amperage raling DO NOT e ceed the fuse amp rating or use one of a lower rating 11 Care must be taken when jacking up and supporting the vehicle Be sure to lifl and support the vehicle at the ploper location...

Page 9: ...ert the tester probe carefully to prevent terminals from bending g When using a vacuum gauge never force the hose onlo a connector thai is 100 large Use a slep down adapter instead Once the hose has been stretched it may leak 13 Afler removing and reinstalling the injection pump and fuel hoses clean olf the fuel on engine components I n par licular be sure to check the radiator hose and by pass ho...

Page 10: ...ore Top Dead Center EDIC Electrical Diesel Injection Control EX Exhaust HAC High Altitude Compensator IN Intake LH Left hand MIT Manual Transmission MP Multipurpose 0 5 Oversize PCV Positi e Crankcase Ventilation PS Power Steering RH Right hand SSM Special Service Materials SST Special Service Tools STD Standard TDC Top Dead Cenler U S Undersize VSV Vacuum Switching Val e wi With w o Without ...

Page 11: ...SIS 1 2 H n TU RBOCHARGER DIAGNOSIS 12H TI TURBOCHARGER ELECTRICAL SYSTEM DIAGNOSIS 1 2 H T ENGINE TUNE UP COMPRESSION CHECK 12HI COMPRESSION CHECK 1 2H T1 TURBOCHARGER 11 2H TI CYLINDER HEAD TIMING GEARS AND CAMSHAFT CYLINDER BLOCK EM l Page EM 2 E M 1 1 1m EM 13 E M 1 7 E M 19 EM 20 EM 36 EM 36 EM 37 EM 47 EM 77 EM 94 ...

Page 12: ...efore performing fuel system checks insure that the engine is in good running condition If necessary first check the compression timing and m jor components or systems b Check the air fil ter and clean or replace as necessary c Check for sufficient fuel in the lank d Check if the fuel is contaminated with gasoline or other foreign elements Only high quality diesel fuel should be used e Bleed air f...

Page 13: ...tarter and make L ____ __ __ __ ____ 2 DI S CHAR G ED BATTERY 3 I NO PERATIVE STARTER Check the alt ernator output and the drive belt Repair as nec essary See page CH 6 Ch eck for battery voltage at start er terminals 30 and 50 U Okay see STARTING SYSTEM page 1ST 1 1 for repair procedure E N GINE CRANKS SLOWLY Will NOT START Possible Causel 11 R R C O B DED I NOTE Minimum cranking speed fOOrpm Col...

Page 14: ...If the engine stdl does nol start check the fuel filter or line between feed pump and injection pump If normal the feed pump or injection pump is faul ty and should be repaired NOTE When feeding fue l d irectly into pump keep conta iner at same level as vehicle fuel tank With the starter swi tch turned ON and the glow plug indicator light illuminated check lhat there is voltage applied to the glow...

Page 15: ...RM E N G I N E Possible Cause IMPROPER ADJUSTMENT OF ACCELERATOR CABLE 1 Check Procedure and Correction Method With the accelerator pedal released check that the adjusting lever is n contact with the idle adjusting screw Also check if the accelera tor cable is catch ing on something If necessary adjust so lever is in cOn lact with the screw or make other requ ired repairs 2 ID L E S P E E D T O O ...

Page 16: ... kg cm2 1 493 1 778 psi 110 296 12 258 kPai 12H T 180 210 kg em2 2 560 2 987 psi 117 652 20 594 kPai If not within specification Ihe nozzle is faulty and injection pressure should be readjusted Faulty Delivery Valve II injection pressure is within specification the delivery valve is defective and should be replaced ENGINE S U D D ENLY STOPS Possible Cause Check Procedure and Correction Method 1 E ...

Page 17: ...e accelerator pedal to the f loor and check that maximum speed is as specified below See page EM 26 or 28 Maximum speed wI Fluid coupling 4 170 rpm w o Fluid coupling 4 100 rpm If not adjust with the maximum speed adjusting Refer to item 3 of ROUGH IDLE WITH WARM ENGINE Disconnect the injection pump inlet hose and outlet pipe of the feed pump and connect directly with a suitable pipe Then pour cle...

Page 18: ...xhaust smoke Is often caused by nozzle pressure being too low EXCESSIVE FUEL CONSUM PTION NOTE Check whether the clutch slips brakes grab whether the tires arethe wrong size or the air filter is clogged Possible Cause Check Procedure and Correction Method I FUEL LEAKAGE Refer to ilem 3 of ROUGH IDLE WITH WARM ENGINE L I _ 2_ _ ID _ L _ E _ S _P_E _ E_ _ T _ _ H_G _ _ lr After sufficiently warming ...

Page 19: ...and Correction Method Check coolant temperature with coolant 1emperature gauge 1f not sufficiently warm thermostat is faulty and should be r e P_ _ _ d _ __ _ _ _ _ __ _J Refer to ilem 8 of ENGINE CRANKS NORMALLY BUT WILL NOT START ENGINE WILL NOT RETURN TO IDLE Possible Causel t_ _ B_ _ N _D _ C _ 1 Check Procedure and Correction Methodl Operate adjusting lever on side of injection pump and check...

Page 20: ...ver adjusting leved on side of injection pump and check if engine stops If so stop cable is binding or maladjusted and should be repaired accordingly If engine does not SlOp injection pump is faulty and should be replaced See page FU 29 Operate SlOP lever adjusting leved on side of injection pump and check if engine stops If so EOIC system is faulty and should be repaired See page ST 21l If engine...

Page 21: ...e Othersl jFus OK Fuse Blown Check indicator light bulb Bulb No Good lBUlb OK Check for shan ci rcuit and repair if necessary Replace bulb Check for battery voltage to terminal 3 of pre heating timer connector on wire harness side If okay pre heating timer is faulty and should be replaced 1 of pre heating timer with ignition I j Check that is 1 V between terminals 9 and 12 If faully repair glow pl...

Page 22: ...ce ignition switch al ON Check for ballery voltage at plus side of glow plug and check for voltage 10 glow N O V o C ge A fI i current sensor Resister side plug a few seconds laler It okay replace sensof o e e e g e Should If no VOltage No 1 glow plug relay is faulty and should be replaced OK No 112 Vollage Thereafter Measure glow plug resistance Infinity Approx O It Glow plug okay Check lOr b lIt...

Page 23: ...ting System 1 INSPECT POWER S U PPlV SECTION s there continuity in the intake heater No Replace the intake heater I See page ST 91 Yes Disconnect the water temperature lReplace the fusible link J sensor connector Fusible Link Blown When the ignition switch is turned ON does pre heat side of the intake No 1 Check he fusible link for in ake I heater have battery voltage for 20 I heater seconds 1 2V ...

Page 24: ...ith the intake heater connector fu lly connected Disconnect the water temperature sensor connector When the ignition switch is ulned ON does the indicator lighl lighl Measure t h e time l i g h ted Yes Pre heating Timer 11 1 0 9 7 Yes Yes Replace the timer CONTINUED ON PAGE EM 15 between termi nal lOaf the timer and body g round ...

Page 25: ...terminal 1 of the intake heater timer have battery voltage Replace the timer I for 20 seconds 12V type or 14 seconds 24V typel Ves Open Cifcuit in wire harness between terminal 1 of the timer and terminal 9 of the No 1 intake heater relay Open circuit or ground faulty in wire harness between terminal E of the No 1 intake heater relay and body ground etween termmals 8 and G of the NO 2 No relay che...

Page 26: ...he I _ timer grounded L r ON does the charge warning light light Ves I Replace the timer I Open circuit in wire harness between terminal 5 of the timer and terminal 9 of the No 2 intake healer relay Open circuit or ground faulty in wire harness between terminal E of the No 2 intake heater and body ground No Replace the timer Open circuit in wire harness between terminal 9 of the timer and charge w...

Page 27: ...TEM 4 RESTRICTED EXHAUST SYSTEM 6 LEAK INEXHAUST SYSTEM I 6 ERRATIC TURBOCHARGER OPERATIO N f 5 5 7 3 psi 38 52 kPa If nat within specification begin diagnosis from Item 2 Check intake air system and repair or replace parts as necessary ISee page EM 401 Check intake air system and repair or replace parts 85 necessary See page EM 401 Check exhaust system and repair or replace paris as necessary Ise...

Page 28: ... R OR EXCESSIVE FUEL C ONSUMPTION EXCESS IVE O I L CONS U M PTION OR WH ITE EXHAUST Possible Cause Check Procedure and Correction Method FAULTV TURBOCHARGER SEAL C heck for oil leakage in exhaust system L _ _ _ Remove the turbine elbow from t h e turbocharger and check lor excessive carbon deposits on the turbine wheel Excessive carbon deposits would indicate a faulty turbocharger C heck lor oil l...

Page 29: ...ch and tachometer and check for ground connection o f switch YES I Does green indicator light come on when I 0 1 4 kg cm2 2 0 psi 1 3 7 kPal pressure is applied to both pressure switches Blown NO I OK O K N O I C h 7 k I CC or C h o t c c c u n w ire c h rn e ss be w c n o c w O K pressure switch and lachometer Amber light comes on and reparr as 1 Check lor hort I I necessary Faulty charging I sys...

Page 30: ...Fl 1 2V type 1 25 1 2 7 2 4 V type 1 27 1 29 N X series 1 25 1 2 7 Others CLEAN ING OF AI R F I LTER Paper Fi lter Type CLEAN A I R FILTER Clean the element with compressed air First blow f rom the inside thoroughly Then blow off the outside of the element O il Bath Type CLEAN AIR FILTER a Wash the oil case and air filter in kerosine by agitat ing and rubbing bl Wipe the oil case and air filter wi...

Page 31: ...NSPECTION O F GLOW PLUG 2Hl See page ST 51 INSPECTION O F INTAKE HEATER 1 2H Tl ISee page ST 9 INS PECTION O F INJECTION NOZZLES See steps 4 to 6 on pages FU 4 and 5 2H See steps 6 to 8 on pages F U l 0 and 1 1 1 2H T Opening pressure 2H I Reused nozzle 1 0 5 1 25 kg cml 11 493 1 778 psi 11 0 296 1 2 258 kPa New nozzle 1 1 5 125 kg cm 11 636 1 778 psi 11 1 278 1 2 258 kPa Opening pressure 1 2H T R...

Page 32: ...volution 360D and align Ihe mark as above 5 ADJUST VALVE CLEARA I jCES First fal Measure only those valves indicated by aHOWS Second 6 7 Valve c leara nce Holl Intake 0 20 mm 0 008 in E x haust 0 36 mm 0 0 1 4 in Using a feeler gauge measure Ihe valve clearance between the valve stem and rocker arm Loosen thelock nut and turn the adjusting screw to set the proper clearance Hold the adjusting screw...

Page 33: ... pulley with the liming pointer by turning the crankshaft clockwise with a wrench bl C heck thai the rocker arms on the NO 1 cylinder are loose and rocker arms on the NO 6 cylinder are tig ht If not turn the crankshaft one revolution 1360 and align the mark as above 5 ADJUST INJECTION TIMING a Remove the No 1 injection pipe and install the inspection pipe on the NO 1 deliV8781ve holder bl Turn the...

Page 34: ...jection tim ing 2H 18 BTDC 12H T 11 BTDC NOTE This operation should be repeated at least two or three limes 9 loosen the other injection pipe union nuts f uel pipe and oil pipe union boll at the injection pump side h Loosen the boll holding the injection pump slay to the slay i Loosen the four nuts holding the injection pump to the retainer jl Adjust the injection timing by slightly tilting the in...

Page 35: ...m m Recheck the injection timing n Remove the inspection pipe and install the No 1 injection pipe 0 Tighten the injection pipe union nuts oil pipe union bolt and fuel pipe union boll Torque Injection pipe Oil pipe Fuel pipe 300 kg em 122 ft Ib 29 N m 1 85 kg em 1 3 ft Ib 18 N m 280 kg em 20 ft Ib 27 N m 6 I N STALL CVLlNDER HEAD COVER 7 1 1 2H T IN STALL INTAKE PIPE AND INTAKE AIR CONN ECTOR See s...

Page 36: ...ra tor pedal I S released I f not adjust the accelerator linkage bl Start the engine Ie Check the id le speed Idle speed 660 rpm dl Adjust the idle speed Disconnect the accelera lor linkage Loosen the lock nut of the idle speed throttle valvel adjusting screw Adjust the idle speed by turning the IDLE SPEED ADJ U S T I N G SCREW Securely tig hten t he lock nut and recheck the idle speed Connect t h...

Page 37: ...onnect the accelerator linkage EM 27 Cui out the maximum speed adjusting speed con trail screw seal wire loosen t he lock nul of the maximum speed adjust ing screw Adjust the maximum speed by turning the MAX IMUM SPEED ADJUSTING SCREW NOTE Adjust at idle speed Then raise engine speed and recheck the maximum speed Securely tighten Ihe lock nul and recheck Ihe max imum speed Seal the maximum speed a...

Page 38: ...alor pedal is released If not adjus t the accelerator linkage bl Start the engine Ie Check the idle speed Idle speed MIT AIT 12HI AfT 1 1 2 H T 650 rpm 750 rpm 770 rpm d Adjust the idle speed Disconnect the accelerator linkage Loosen the lock nul of the idle speed adjusting bolt Adjust the idle speed by lurning the IDLE SPEED ADJUSTING SOLT Securely tig hten he lock nul and recheck the idle speed ...

Page 39: ...tor linkage EM 29 Cut out Ihe seal wire of the maximum speed adjusting bolt loosen the lock nul Of the maximum speed adjust ing bolt Adjust the maximum speed by turning the MAX IMUM SPEED ADJUSTING BOLT NOTE Adjust at idle speed Then raise engine speed and recheck the maximum speed Securely tighten the lock nut and recheck the max imum speed Seal the maximum speed adjusting bolt with a new seal wi...

Page 40: ...NECT TACHOMETE R 3 ADJUST POWER STEERING PSI IDLE UP SETTI NG SPEED a Start the engine bl Disconnect the vacuum hose trom the idle up actua tor and plug the hOse end e Apply vacuum to the idle up actuator d Race the engine to 2 500 rpm a few seconds release the throttle and check the PS idle up setting speed PS idle up setting speed 820 rpm e Adjust the PS idle up selling speed by turning the PS I...

Page 41: ...31 3 ADJUST AIR CONDITIONER lAIC IDLE UP SETTING SPEED a Slart the engine b Disconnect the vacuum hose from the idle up actua tor and plug the hose end c Apply vacuum to the idle up actuator d Race the engine to 2 500 rpm a few seconds release throttle and check the A C idle up selling speed AIC idle up setting speed 950 rpm e Adjust the Ale idle up setting speed by turning the AIC IDLE UP ADJUSTI...

Page 42: ...AIR CONDITIONER IAICI IDLE UP SETTING SPE E D a Start the engine fbi Disconnect the vacuum hose s from the idle up actuator and plug the hose endIs Ie Apply vacuum to the idle up actuator Id Race the engine to 2 500 rpm a few seconds release the IhrOllle and check the Ale idle up setting speed Ale idle up setting speed MIT 950 rpm Transmission in neutral AIT 800 rpm Tra nsmission in D range lel Ad...

Page 43: ...check thai it retum smoothly bl Apply vacuum to the actuator c Check that the vacuum does not drop immediately INSPECT VACU UM SWITC H I N G VALVE VSV a Remove the VSV b Check that air flow from pipe E to pipe F c Connect the VSV terminals to the baNery terminals d Check that air flows from pipe E to pipe G If operation is not as specified replace the VSV ...

Page 44: ...d check Ihat it return smoothly bl Apply vacuum to the actuator e Check that the vacuum does not drop immediately INSPECT VAC U U M SWITCH VALVE VSV a Remove the VSV bl Check thaI air flow from pipe E to pipe F el Connect the VSV term i nals to the baltery terminals d Check that air flows from pipe E 10 pipe G If operation is not as specified replace the VSV ...

Page 45: ...e NOTE Always use a fully charged battery to obtain engine revolutions of more than 250 rpm e Repeal sleps a through d for each cylinder Compression pressure 28 0 kg cm 398 psi 2 746 kPa or more M inimum pressure 20 0 kg cm2 284 psi 1 961 kPa Difference between each cylinder 2 0 kg cm1 2 8 psi 1 96 kPa or less f If the cylinder compression i n one or more cylinders is low pour a small amount of en...

Page 46: ...ed battery to obtain engine revolutions of more than 2 5 0 rpm Ie Repeal steps Is through dl for each cylinder Compression pressure 30 0 kg cm1 427 psi 2 942 k Pa or more Minimum pressure 20 0 kg cm2 284 psi 1 961 kPal Difference between each cylinder 2 0 kg cm 28 psi 1 96 k Pal or less fl If the cylinder compression i n one or more cylinders is low pour a small amoun t of engine oil inlo the cyli...

Page 47: ...p i t by easily deformed parts such as the actuator or rod when moving Before removing the turbocharger plug the intake and exhaust pots and oil inlet to prevent entry of dirt or other foreign material I f replacing the turboc harger check for accumula tion of sludge particles in the oil pipes and i f necessary replace t h e oil pipes Completely remove the gaskets adhered to the lubrication oil pi...

Page 48: ...Disconnect the actuator hose b Using SST turbocharger pressure gaugel apply Z1boul 0 68 kg cm2 9 7 psi 6 7 kPa of pressure to the actuator and check that the rod moves SST 09992 00240 CAUT I O N Never apply more than 0 8 kg cm2 1 1 4 psi 78 kPa of pressure to the actuator If the rod does not move replace the turbocharger assem bly 4 INSPECT TU RBDCHARGING PRESSURE a Warm up the engine bl Connect a...

Page 49: ..._ i _ _ _ _ _ _ _ _ _ _ _ _ Intake Air Connecfor with Air Hose PCV Pipe with Hosel _ _ _ _ _ _ _ Intake Pipe Stay HeatInsulator l No l WaterBy PassPipe _ o t Drain Cock GaSkel No 2 Water By Pass Pipe Gasket Gasket e au e Outlet Elbow it lb N m Specified torque Non reusable pan Turbocharger 1 61 1 3 1 8 Oil Pipe ...

Page 50: ...onnect the PCV hose and remove the P CV pipe and gasket together with the PCV hOse 4 REMOVE INTAKE AIR CONNECTOR la Remove the three bolts bl Disconnect the air hose and remove the intake air connector together with the air hose 5 REMOVE INTAKE PIPE al Remove the two bolls and intake pipe stay bl Remove the four bolls and nul lei Disconnect the air hose and remove the intake pipe and gasket togeth...

Page 51: ...2 WATER BY PASS PIPE 8 REMOVE TU RBOCHARGER STAY Remove the three bolts and stay 9 REMOVE NO 1 WATER BY PASS PIPE a Loosen the union nut b Remove the two nuts two bolts by pass pipes and two gaskets 1 0 REMOVE TURBOCHARGER la Remove the union bolt and two gaskets of the oir pipe b Remove the two nuts holding the oil pipe to the cylinder block ...

Page 52: ...e turbocharger and gasket together with the oil pipe fe Remove the gasket of the oil pipe from the cylinder block 1 REMOVE OIL PIPE Remove the IWO nuts oil pipe and gasket 1 2 REMOVE NO 2 WATER BY PASS PIPE Remove the two nuts by pass pipe and gasket 1 3 REMOVE TURBINE OUTLET ELBOW Remove the four nuts turbine outlet elbow and gasket ...

Page 53: ...harger assembly I NSTA LLATION O F TURBOCHARGER See p a g e EM 39l CAUTION After replacing a turbocharger assembly pour about 20 cc 1 2 cu in l of new oil into the oil inlet and then turn the impeller w heel by hand to splash oil on the bearing 1 INSTAll TURBINE OUTLET ELBOW InSlall a new gasket and the turbine outlet elbow with the four nuts Torque 530 kg cm 38 ft Ib 52 N m 2 INSTALL NO 2 WATER B...

Page 54: ...the turboc harger to the exhaust manifold Torque 630 kg em t38 ft Ib 52 N m d Install new IWO nuts holding the oil pipe to the cylinder block Torque the four oil pipe nuts Torque 1 86 kg em 1 3 H lb 18 N m leI Install new two gaskets and the union bolt of the oil pipe Torque the union boll Torque 250 kg em 1 8 It lb 2 5 N m 5 INSTALL NO 1 WATER BY PASS PIPE a InSlall a new gasket and the by pass p...

Page 55: ...WATER BY PASS PIPE 8 INSTALL H EAT INSU LATORS Install t he two heat i nsulators with the five bolts Torque 185 kg em 11 3 fl lb 18 N m 9 INSTALL INTAKE PIPE a Connect the air hose and install a new gasket and the intake pipe with the four bolts and nut Torque 185 I g em 11 3 It Ib 1 B N m bl Install the intake pipe stay with the two bolts Torque 185 kg em 1 3 fl lb 18 N m ...

Page 56: ... ree bolts Torque 1 86 kg em 1 3 ft Ib 18 N m 1 INSTALL PCV PIPE Connect the PCV hose and install a new gasket and PCV pipe with three boilS Torque 1 85 kg em 1 3 ft lb 18 N m 1 2 I NSTA LL VAC U U M HOSES VSV AND GAS FILTER 1 3 FILL WITH ENGINE COOLANT See page CO l 1 4 START ENGINE A N D CHECK FOR LEAKS 1 5 CHECK ENGINE O i l lEVEL See page LU 3J ...

Page 57: ... I j 0 ____ Seal Washer DIC Mow e C lind Head Cove tl E 1 Gas 1 Valve Roc e Shaft l Assembly Connecting Rod rEspring Retainer Push Rod e Outer Valve Sp ing I Inner Valve Sprmg EM 47 I Oil Seal 0 Valve Guide Bushing o t Ikg c j Specified torque Non reusable pari t I _ He Insutalof GaSkel h st Manlfold Rearl ...

Page 58: ...CHANICAL EM 48 COMPONENTS 4 _ _ _ _ _ _ E N G I N E M ICont d 1 2H T Seal Washer c ___ Cylinder Head Cover crnJft lb _ m rl b s p e f e d t O Qu e _ _ _ _ _ _ _ _ _ _ Non reusable p Gasket Valve Rocker Shaft Assembly ...

Page 59: ...rew g rommets bl Pre heating System Super Glow Type Remove the current sensor plate c Remove the six nuts and glow plug connector d Remove the six glow plugs REMOVE FUEL FilTER ASS EMBLY fa Remove the two union bolts and four gaskets and disconnect the fuel pipes from the injection pump b Remove the two bolts and the fuel filter together with the fuel pipes 6 MIT wi EDIC SYSTEM REMOVE EDIC MOTOR a...

Page 60: ...YSTEM REMOVE OV ERINJ ECTION MAGNET 8 REMOVE INTAKE MANIFOLD lal M TI Remove the two vacuum hoses b Remove the twelve nuts in take manifold and six gaskets 9 REMOVE EXHAUST MANIFOLDS a Remove the seven bolts and two heat insulators b Remove the twelve nuts plale washers exhaust manifolds and six gaskets ...

Page 61: ...g the water outlet housing to the cylinder head b Disconnect the water by pass hose from the water pump and remove the water outlet assembly and gasket together with the by pass hose 1 2 REMOVE CYLINDER HEAD COVER Remove the four cap nuts seal washers cylinder head cover and gasket 1 3 REMOVE VALVE ROC KER SHAFT ASSEMBLY a Uniformly loosen and remove the fourteen bolts in several passes in the seq...

Page 62: ...ad bolts in several passes In the sequence shown CAUTI O N Head warpage or cracking could result from removing bolts i n incorrect order bl lifl the cylinder head from Ihe dowels on the cylinder block and place the head on wooden blocks on a bench NOTE It Ihe cylinder head is difficult 10 lift ofl pry with a screwdriver between Ihe cylinder head and block saliences CAUTION Be careful not to damage...

Page 63: ... two union bolts and four gaskets and disconnect the fuel hose and pipe from the injection pump bl Remove the two bolts and the fuel filter together with the hose and pipe 4 REMOVE INTAKE MANIFOlD Remove lhe f ive bolts eleven nuts inlake ma nifold and gasket 5 REMOVE WATER BY PASS PIPE OF TURBOCHARG E R Remove t h e bolt n u l water by pass pipe a n d t w o hose 6 REMOVE EXHAUST MAN IFOLDS al Rem...

Page 64: ...ani foldS bJ Using snap ring pliers remove the two manifold rings REMOVE WATER OUTLET ASSE MBLV a Remove the three bolts holding the waler outlet housing to the cylinder head Ib Disconnect the water by pass hose from the waler pump and remove the waler outlet and gasket together with the by pass hose REMOVE CVlINDER HEAD COV ER Remove the four cap nuts seal washerS cylinder head cover and gasket ...

Page 65: ...orrect order 1 2 REMOVE CYLINDER HEAD fa Uniformly loosen and remt ve the twenty six head bolts in several passes in the sequence shown CAUTION H ead warpage or cracking could result from removing bolts In incorrect order fb lift the cylinder head from the dowels on the cylinder block and place the head on wooden blocks on a bench NOTE If the cylinder head is difficult 10 lift off pry wilh a screw...

Page 66: ...e valve spring and remove the two keepers SST 09202 430 1 3 fbI Remove the spring retainer valve springs valve and oil seal NOTE Arrange the valves valve springs and spring retainers in the correct order 2 12Hl REMOVE COMBUSTION CHA MBERS Using SST remove the six combustion chambers SST 0 9 208 4801 0 NOTE Arrange the combustion chambers in correct order ...

Page 67: ...es W A R N I N G Protect your eyes when using high pressure air 2 REMOVE GASKET MATERIAL 3 Using a gasket scraper remove all the gasket material from the manilold and head surface CAUTION Be careful not to scratch the surfaces CLEAN COMBUSTION CHAMBERS Using a wire brush remove aU the carbon from the com bustion chambers CAUTION Be careful not to scratch the head gasket contact surface 4 CLEAN VAL...

Page 68: ...er gauge measure the surfaces contacting the cylinder block and manifolds for warpage Maximum warpage Cvlinder block side 0 20 mm 0 0079 in l Man ifold side 0 20 mm 0 0079 in If warpage is greater than maximum replace the head 7 INSPECT CYLINDER HEAD FOR CRACKS Using a dye penetrant check the combustion chamber intake and exhaust porls head surface and the top of the head fOf cracks If cracked rep...

Page 69: ... valve stem Valve stem diameter Intake 8 973 8 989 mm 10 3533 0 3539 i n l Exhaust 8 954 8 970 mm 10 3525 0 3531 in l lei Subtract the valve stem diameter measurement from the bushing inside diameter measurement Standard stem oil clearance Intake 0 021 0 057 mm 10 0008 0 0022 in E haust 0 040 0 076 mm 10 00 1 6 0 0030 In 1 Maximum slem oil clearance I ntake 0 1 0 mm 0 0039 in Exhaust 0 1 2 mm 0 00...

Page 70: ... 1 tdl Using a sharp 9 0 mm reamer ream the valve guide bushing 10 obtain the standard specified clearance See page EM 59 between the valve guide bushing and new valve stem 1 1 INSPECT AND GRIND VALVES II Grind the valve only enough to remove pits and car bon tbl Check thai the valve is ground to the correct valve face angle Valve face angle 44 5 c C heck the valve head margin thickness Standard m...

Page 71: ...n the seats bl Check the valve seating position Apply a thin coat of prussian blue or white lead to the valve face Install the valve While applying light pressure to th e valve rotate the valve against the seat c Check Ihe valve face and seat tor the fol lowing If blu e appears 360 around the face the valve is conc entric I f not replace the valve If blue appears 360 around the valve seat the guid...

Page 72: ...ck the sQuareness of the valve spring Maximum squareness 2 0 mm 10 079 in I f squareness is greater than maximum replace the valve spring Ib Using cal ipers measure the free length of the valve spring Free length Inner spring 44 3 mm 1 744 in Outer spring 48 1 mm 1 894 in If the free length is not as specified replace the valve spring tel Using a spring tester measure the tension of the valve spri...

Page 73: ...t disassemble and inspect e Disassemble the valve rocker shaft assembly NOTE Arrange the rocker arms and rocker suppons in correct order If the contacting surface of the rocker arm is worn resur face it with a valve relaeer and oil stone or replace the rocker arm d Check the oil clearance betw een the rocker arm and shaft Using a caliper gauge measure the inside diameter of the rocker arm Rocker a...

Page 74: ...er 1 8 472 1 8 493 mm 0 7272 0 7281 i n Subtract the rocker shaft diameter measurement f rom the inside d iameter measurement of the rocker arm Standard oil clearance 0 007 0 049 m m 0 0003 0 00 1 9 in Maximum oil clearance 0 1 0 mm 0 0039 in l If the clearance is g reater than maximum replace the rocker arm and shaft e Assemble the valve rocker shall assembly as shown ...

Page 75: ...imum circle runou t 0 50 mm 10 0 1 97 in I f the circle runout is g reater than maximum replace the push rod 1 6 INS PECT INTAKE AND EXHAUST MANIFOLDS USing a precision straight edge and feeler gauge measure the surface contacting the cylinder head for warpage Maximum warpage tnlake E x haust 2H IFront and read 1 2H T Front 1 2H T Read 0 60 mm 10 0 1 9 7 in 0 30 mm 10 01 1 8 in 1 0 30 mm 0 0 1 1 8...

Page 76: ...BUSTION CHAMBERS a Align the combustion chamber knock pin with the cylinder head notch bl Using a plastic faced hammer tap in the combustion chamber with the shim e Using a dial ind icator check the combustion cham ber protrusion Combustion chamber protrusion o 0 1 0 m m fO 0 0039 in 2 INSTALL VALVES al Inslall the following parts 1 New oil seal 2 Valve 3 Inner spring 4 Outer spring 5 S pring reta...

Page 77: ...ENGINE MECHANICAL ___ Cylinder Head Using a plastic faced h EM 67 stem to assure proper f mer lightly tap the valve U ...

Page 78: ...dl Install and uniformly tighten the twenty six cylinder head bolts in several passes i n the sequence shown Torque 1 1 50 kg em 83 ft Ib 1 1 3 N m 2 INSTAll PUSH RODS Install the twelve push rods 3 IN STALL VALVE ROCKER SHAFT ASSEMBLY la Place t he rocker shaft assembly on the cylinder head fbl Inslall and uniformly tighten the fourleen bolts in several passes in the sequence shown Torque 1 85 kg...

Page 79: ...TALL WATER OUTLET ASSEMBLY Connect the water by pass hose to the water pump and install a new gasket and the water outlet assembly with the three bolts Torque 375 kg em 27 ft lb 37 N m 7 ASSEMBLE EXHA UST MANI FOLDS a Remove all the O ring material from the manifold grooves b InslaLi new Iwo O rings lei Usi ng snap ring pliers install the Iwo manifold rings d Position the manifold rings so Ihat Ih...

Page 80: ... manifOlds with the twelve plate washers and new nuls Torque 210 kg em 1 6 ft Ib 21 Noml b Inslall the two heat insulators with the seven bolts Torque 1 86 kg em 1 3 ft lb 18 N m l 9 I NSTA l l INTAKE M A N I FOLD lal Install new six gaskets and the intake manifold with the twelve nuts Torque 1 85 kg em 1 3 It lb 18 N m Ib MIT I nstall the two vacuum hoses ...

Page 81: ...e fuel fil ter assembly with the two bolts Torque 376 kg cm 27 ft Ib 37 N m b Connect the two fuel pipes to the injection pump with new four gaskets and the two union bolts To q ue the union bolts Torque 280 kg em 20 It Ib 2B N m 1 3 INSTALL GLOW PLUGS a Install the six glow plugs Torque 1 2 5 kg em 9 ft Ib 12 N m Ib I nstall the glow plug connector with the six nuts Ic Pre heating System Supper G...

Page 82: ...J ECTION NOZZLES See sleps 1 to 3 on page EM B 1 6 INSTALL PCV HOSE 1 6 FILL WITH ENGINE COOLANT See page CO 3 1 7 START ENGINE A N D CHECK FOR LEAKS 1 8 CHECK ENGINE Oil LEVEL See page lU 3 1 9 READJ UST VALVE CLEARANCES See steps 1 3 to 6 on page E M 221 ...

Page 83: ...d bolls d Install and uniformly tighten the twenty six cylinder head bolts in several passes 10 the sequence shown TorQue 1 1 60 kg em 183 ft Ib 1 1 3 N m 2 INSTALL PUSH RODS Install the twelve push rods 3 INSTALL VALVE ROCKER SHAFT ASSEMBLY a Place the rocker shaft assembly on the cylinder head fbi Instal and uniformly tig hten the fourteen bolls in several passes in the sequence shown Torque 185...

Page 84: ...Ib seal 6 9 N m INSTAll WATER OU onnect the w TLET ASSEMBLY Install a new aler by pass hos he hoee bOIt aske and he w o he wale pump Torqu 375 eo ou le aSSembIY g cm 27 ft lb 37 Nom ASSEMBLE EXHAUST al Remove all the AN IFOlDS grooves O nng malerial from th Ibl Insta new e mandold wo O rings e Using snap ring pliers install the Iw o manifold rings d Position the m as shown snllold rings so Ih CAUT...

Page 85: ...elve plate washers and new nuts Torque 210 kg em 1 6 fHb 2 1 N m h I nstall the two heat insulators with the five bolts Torque 1 86 kg em 1 3 It Ib 18 N m 9 INSTALL WATER BY PASS HOSE OF TU RBOCHARGER 1 0 INSTALL INTAKE MANIFOLD a Install a new gasket 10 the intake manifold b Install the intake manifold with Ihe five bolts and eleven nuts Torque 1 85 kg em 1 3 ft Ib 1 B N m ...

Page 86: ... w f o u r gasket s and t h e t w o union bolls Tor Que the union boils Torque 280 kg em 20 it lb 28 N m 1 2 INSTAll INJ ECTION NOZZLES See steps 1 to 4 on pages F U 1 4 and 1 5 1 3 INSTALL TU RBOCHARG E R See steps 3 to 1 2 on pages E M 44 a n d 46 1 4 FILL WITH ENGINE COOLANT See page CO l 1 5 START ENGINE AND CHECK FOR LEAKS 1 6 CHECK E N G I N E OIL LEVE L See page LU 3 1 7 READJUST VALVE CLEA...

Page 87: ...Gears and Camshaft EM 77 2 H wio PS AiC Timing Gear Cover T I M I N G GEARS C O M P O N ENTS Crankshaf P J ullev 600 26 I 1 i 2H wi P i T O and 12H or AlC 0 Sea G Co 0 1 P P m fji Non reusable part S pecified lorque AND CAMSHAFT ...

Page 88: ...TURBOCHARGER See steps 1 to 10 on page EM 40 to 42 4 REMOVE VALVE ROCKER SHAFT ASSEMBLY See steps 12 to 14 on page E M 5 1 and 52 2H See steps 9 to 1 1 on page EM 54 and 551 1 2 H T 5 REMOVE PUSH ROD COVERS Remove the eight bolls push rod cover and gasket Remove the two push rod covers 6 REMOVE VALVE LIFTERS Remove the twelve valve lifters i n order begining from the NO 1 valve lifter NOTE Arrange...

Page 89: ...nul 8 SST 0 9 2 1 3 5 8 0 1 1 and 09330 000 2 1 b Using SST remove t h e pulley SST 092 1 3 600 1 7 Iwlo PS 0 AICI SST 0921 3 600 1 7 and 09950 200 1 7 Iwl P S 0 AIel 1 2H T REMOVE OIL PIPE al Remove three union bolts and six gaskets b Remove the two bolts and oil pipe 9 REMOVE TIMING GEAR COVER Remove the sixteen bolts gear cover and gasket ...

Page 90: ...ard backlash Automatic timer drive gear 0 050 0 1 1 1 mm 0 00 1 9 0 0043 in Camshaft timing gear 0 050 0 1 1 3 rnm 0 00 1 9 0 0044 in 1 Max imum backlash 0 30 mm 0 0 1 1 8 in If the backlash is greater than maximum replace the gears as set 1 1 REMOVE AUTOMATIC TIMER al Remove the round n u t a n d washer 1 2H n b Using SST remove the timer SST 09260 4 70 1 0 109 2 6 7 7 60201 ...

Page 91: ... idle gear 0 050 0 1 1 6 mm 10 00 1 9 0 0046 in l No 2 idle gear 0 050 0 1 1 3 mm 0 00 1 9 0 0044 in Maximum backlash 0 30 mm 0 01 1 8 in If the backlash is greater than maximum replace the gears as a set 1 4 CHECK THRUST CLEARANCE OF NO 1 AND NO 2 IDLE GEARS Using a dial indicator measure the thrust clearance Standard thrust clearanc e 0 050 0 1 50 mm 0 00 1 9 0 0069 in Ms imum thrust clearance 0...

Page 92: ...E MECHANICAL Timing Gears and Camsha ft 1 6 REMOVE NO 1 IDLE GEAR ve the t w o bolts thrust plate i d l e gear a n d idle gear 1 7 REMOVe CRANKSHAFT TIMING GEAR Using SST remove the liming gear SST 0921 3 600 1 7 ...

Page 93: ... Ex haust 2H 41 S mm 1 2H T 42 3 mm the lobe height is less than minimum replace the camshaft k Using a micrometer measure the journal diameter Journal diameter from front side STD size No 1 5 1 1 6 1 6 1 1 70 mm 12 01 38 2 0146 in No 2 50 951 50 970 mm 12 0059 2 0067 in No 3 50 761 60 770 mm 1 9981 1 9988 in No 4 60 651 60 670 mm 11 9902 1 9909 in U S 0 1 25 No 1 5 1 025 5 1 035 mm 12 0089 2 0092...

Page 94: ... 1 771 7 1 7726 in bl Using a micrometer measure the dia meter o f the idle gear shu ft Idle gear shaft diameter 44 950 44 975 mm 11 7697 1 7707 in leI Subtract t h e idle g e a r sha fl diameter measurement from the idle gear inside diame ter mea5uremenl Sta ndard oil clearance 0 025 0 0 75 mm 0 00 1 0 0 0030 i n Ma imum oil clearance 0 20 mm 0 0079 in I I the clearance i5 g reater than maximum r...

Page 95: ...iming gear set key to the camshaft b Assembly the camshaft thrust plate and timing gear as shown c Using a 29 mm socket wrench and press align the timing gear set key with the key g roove of the timing gear and press i n the camshaft timing gear dl Using SST i nSlall Ihe plale washer and bolt Torque the bolt SST 09278 540 1 2 Torque 450 kg em 33 ft Ib 4 4 N ml 3 CHECK CAM SHAFT THRUST CLEARANCE Se...

Page 96: ...R 1 2H T 1 REMOVE DRIVE GEAR a Mount the t imer hub in a soft jaw vise bl Remove the four boils spring washers and drive gears 2 INSTALL N EW DRIVE GEAR a Install the drive gear onto the limer as shown b I nSlall the four spring washers aod boll Torq ue the bolts Torque 230 kg em 1 7 It lb 23 N m ...

Page 97: ...wdriver and hammer tap oul the oil seal b Using SST and a hammer tap in a new oil seal until its surface is flush wilh the liming gear COver edge SST 092 1 4 760 1 1 lei Apply MP grease 10 Ihe oil seal lip B If timing gear cover is installed to cylinder block a Using SST remove the oil seal SST 09309 1 00 1 0 fb Apply M P grease t o a n e oil seal lip cl Using SST and a hammer lap in the oil seal ...

Page 98: ...upward by turning the crankshaft clockwise b Assemble the idle gear gear and gear shaft Ie Align the 0 timing marks of the crankshaft timing and idle gears and mesh the gears dl Apply a light coal of the engine oil on the threads and under the bolt heads el Inslali lhe thrust plate with the two bolls Torque the bolts Torq u e 475 kg cm 34 ft Ib 4 7 N m 3 CHECK BACKLASH O F NO 1 IDLE GEAR See page ...

Page 99: ...CHECK BACKLASH OF NO 2 IDLE GEAR See page E M 8 1 1 Standard backlash 0 050 0 1 1 3 mm 0 00 1 9 0 0044 in Maximum backlash 0 30 mm 0 01 1 8 in l 7 CHECK THRUST CLEARANCE OF NO 2 IDLE GEAR See page EM Bl 1 Standard thrust clearance 0 060 0 1 60 mm 0 00 1 9 0 0059 in 1 Maximum thrust clearance 0 30 mm 0 0 1 1 8 in 8 INSTALL CAMSHAFT TIMING GEAR AND CAMSHAFT ASSEMBLV al Insert the camshaft inlo the c...

Page 100: ...lign the automatic timer set key with the key groove of the automatic timer hl Align the 2 timing marks of the No 1 idle and automa tic timer drive gear and mesh the gears e Apply a lig h t coal of engine oil on the threads and under the round nut d Install the washer 1 2H Tl and round nul Torque the round nut Torq u e 760 kg em 54 ft Jb 74 N m 1 1 CHECK BACKLASH OF AUTOMATIC TIMER DRIVE GEAR See ...

Page 101: ...8 and C Install a new gasket and the gear cover with the sixteen bolts Torque 250 kg em 18 ft Ib 25 N m wI PS or A C NOTE Use the bolts indicated A S C and 0 Install a new gasket and the gear cover with the sixteen bolts Torque 260 kg em 1 8 ft Ib 26 N m 1 3 i1 2H TJ INSTALL OIL PIPE Torque the union bolls Torque 1 85 kg em 113 It Ib 18 N m ...

Page 102: ...nt boll SST 0921 3 580 1 1 and 09330 000 2 1 Torque 4 500 k g e m 3 2 5 ft Ib 4 4 1 N m 1 5 INSTALL VALVE LIFTER Carefully insert the twelve li fters into t h e lifter bores 1 6 I N STALL PUSH ROD COVER Install a new gasket and the push rod cover with the eight bolls Install the two push rod covers Torque 1 30 kg em 9 ft lb 13 N m 1 7 INSTALL VALVE ROCKER SHAFT ASSEMBLY See steps 2 to 6 on pages E...

Page 103: ...ANICAL Timing Gears and Camshaft 20 I NSTALL AND ADJ UST DRIVE B E LT See page CH 6 21 START ENGINE A N D CHECK FOR LEAKS 22 CHECK ENGINE OIL LEVEL 23 READJUST VALVE CLEARANCES See steps 1 to 7 on page EM 22 EM 93 ...

Page 104: ...s So 0 on n9 0 1 A on n91 C p 9 P Slon P n 9 end Co 1I Conneehn 9 onnectlng Rod Beann t PISlon Rod c p ConnectUlg Rod 88 1 I 0 C E xpansion P IU 9 1 Seal amsh Inlecllon Pomp r I t i It 80 1 I J I J 1 Crankshah Main Bearing Main Bearing Cap Gasket Specified torque 4 J Rear End Plate Thrust Washer Gasket 186 1 Oil Strainer Oil Pan Gasket ...

Page 105: ...to 52 2H See pages EM 53 to 55 1 2H T 8 REMOVE TIMING GEARS AND CAMSHAFT See pages EM 78 to 82 9 REMOVE I N J ECTION PUMP See pages fU 30 and 3 1 1 0 REMOVE OIL PAN AND OIL PUMP See page lU 6 and 7 1 1 REMOVE REAR OIL SEAL RETA I N E R Remove the six bolts retainer and gasket 12 CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator measure the thrust clearance while moving the rod back and ...

Page 106: ...ing a plastic faced hammer lightly lap the con necting rod bolls and lift o f f the connecting rod cap NOTE Keep Ihe lower bearing inserted with t he con necting rod cap d Cover the connecting rod bolts with a short piece o f hose t o protect t h e crankshaft from damage e l Clean the crank pin and bearing f Check Ihe crank pin and bearing for pilli n g and scratches If the crank pin o r bearing a...

Page 107: ...the bearing If necessary grind or replace the crankshaft NOTE If using a standard bearing replace with o n e hav ing the same number marked on the connecting rod cap There are two sizes of standard bearings marked 1 and 2 accordingly Standard bearing thickness at center walll STD size 1 1 480 1 485 mm 10 0583 0 0585 in 1 STD size 2 1 485 1 490 mm 10 0585 0 0587 In 1 k Completely remove the P lasti...

Page 108: ...3 mm 10 1 1 78 0 1 1 98 n 1 DIS 0 250 3 055 3 1 0 5 mm 10 1 203 0 1222 n 1 1 6 REMOVE MAIN BEARING CAPS A N D CHECK OIL CLEARANCE a Remove the main bearing cap bOlts b USing the removed main bearing cap bollS pry the cap back and forth and remove the main bearing caps lower bearings and lower thrust washers No 4 main bearing cap onlyl NOTE Keep the lower bearing and main bearing cap together Arran...

Page 109: ...er than maxi mum replace the main bearing If necessary grind or replace the crankshaft NOTE If using a standard bearing replace with one hav ing the same number marked on the cylinder block There are three sizes of standard bearings marked 1 2 and 3 accordingly Standard bearing thickness at center wall STD s ize 1 1 981 1 986 mm 10 0780 0 0781 InJ STO size 2 1 985 1 989 mm 10 0781 0 0783 inJ STD s...

Page 110: ... head gasket lor war page Maximum warpage 0 20 mm 0 00 79 in If warpage is greater than maximum replace the cylinder block 4 INSPECT CYLINDER FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scra tc hes 5 If deep scratches are presen t rebore all six cylinders I N SPECT CVLlNDER BORE DIAMETER Using a cylinder gauge measure Ihe cylinder bore diameter at positions A B and C in the thr...

Page 111: ...G ROD A S S E M B L I E S See page EM 94l 1 CHECK FIT BETWEEN PISTON AND PIN 2 3 Try to move the piston back and forth on the piston pin If any movement is felt replace the piston and pin as a set REMOVE PISTON RINGS a Using a piston ring expander remove the piston rings b Remove the oil ring and coil by hand NOTE Arrange the rings In correct order only DISCONNECT CONNECTING ROD FROM PISTON la Usi...

Page 112: ...l ap oul t h e piston pin and remove the connecting rod NOTE The piston and pin are a matched s e t Arrang ethe pi stons p i n s r i n g s connecting rods and bearings in COrrect order INSPECTION O F PISTON A N D CONNECTING ROD ASSEM B L I E S 1 CLEAN PISTON la Using a gasketscraper remove the carbon from t h e p i s t o n lOp b Using a groove c leaning 1001 or broken ring clean the ring grooves ...

Page 113: ...eter measurement from the cylinder bore diameter Oil clearance 2H 0 060 0 080 mm 10 0024 0 0032 in 1 1 2 H T 0 060 0 070 mm 10 0020 0 0028 in 1 If the clearance is not within specification replace all six pistons If necessary rebore all six cylinders o r replace the cylinder block 3 INSPECT CLEARANCE BETWEEN WALL OF PISTON RING GROOVE AND NEW PISTON RIN G No 1 Ring Install a new NO 1 piston ring t...

Page 114: ...3 nJ Maximum end gap No 1 2H 1 24 mm 0 0488 in 1 2 H T 1 2 7 mm 0 0500 in No 2 1 24 mm 0 0488 in Oil 1 29 mm 0 0508 in I f the gap is g realer than maximum replace t he piston ring If t he gap is greater than maximum even with a new piston ring rebore the cylinder and use an oversized piston ring 5 CHECK PISTON PIN FIT At eocc 1 40 F you should be able to push the pin into the piston with your thu...

Page 115: ...the diameter of the piston pin Piston pin diameter 2H 29 000 29 0 1 2 mm 1 1 1 4 1 7 1 1 422 in 1 2H T 32 000 32 0 1 2 mm 1 1 2598 1 2603 in d Subtract the piston pin diameter measurement from the bushing inside diameter measurement Standard oil deara nce 0 004 0 0 1 2 mm 10 0002 0_0005 i n 1 Maximum oil clearance 0 03 mm 0 00 1 2 in If the clearance is grea ter than maxi mum replace the con necti...

Page 116: ...bushing SST 09222 660 1 0 3 HONE CONNECTING ROD BUSHING AND CHECK PISTON PIN FIT IN CONN ECTING ROD a Using a pin hole grinder hone Ihe bushing to obtai n the standard specified clearance See page EM l OS between the bushing and piston pin bl Check the piston pm f i t at nOlmal room temperature Coal the piston pin with engine oil and push it into t h e rod with your thumb ...

Page 117: ...ORE CYLINDER la Using a micrometer measure the piston d iameter a t a right angle 0 the piston pin hole center line 25 mm 0 94 1 in l or 9 mm 0 35 in from the skirt bottom edge bl Calculate the amOunt each cylinder is to be rebored as follows Size to be rebored P C H P Piston diameter C Piston clearance 2H 0 060 0 080 mm 10 0024 0 0032 in l 1 2H T 0 060 0 070 mm 10 0020 0 0028 in l H Allowance for...

Page 118: ...U S 1 00 68 980 69 990 mm 2 7 1 57 2 7 1 6 1 in Crank pin dia meter STD size 64 980 65 000 mm 2 1 646 2 1 654 in J U S 0 26 64 730 54 740 mm 2 1 547 2 1 5 5 1 n 1 U S 0 50 54 480 54 490 mm f2 1 449 2 1 453 in U S 0 75 54 230 54 240 mm 2 1 3 50 2 1 354 in 1 U S 1 00 53 980 53 990 mm f2 1 252 2 1 269 in l If the diameter i s not within specification check lhe oil clearance If necessary grind or repl...

Page 119: ... 739 mm 1 1 9950 1 9976 in No 4 60 474 60 639 mm 11 9872 1 9897 in U S 0 25 No 1 50 950 5 1 01 5 mm 12 0069 2 0085 in 1 No 2 50 750 50 81 5 mm 1 1 9980 2 0006 in 1 No 50 550 60 6 1 5 mm 11 9902 1 9927 in 1 No 4 60 350 60 4 1 6 mm 11 9823 1 9848 in bl Subtract the journal diameter measurement See page EM 83 from the bearing inside diameter measurement Standard oil clearance 0 030 0 1 1 5 mm 10 001 ...

Page 120: ... 1 50 092 1 5 00 2 1 0 B Remove camshaft bearings Using SST remove the bearings SST 092 1 5 001 00 1092 1 5 001 20 09 2 1 5 00 1 30 092 1 5 00 1 40 092 1 5 00 1 5 0 0 9 2 1 5 001 60 092 1 5 00280 C Inslall new camshaft bearings a Install new bearings in their proper location b Align the oil holes of the bearing and cylinder block cJ Using SST install the bea rings SST 092 1 5 00 1 00 109 2 1 5 0 0...

Page 121: ... SST 092 1 5 00 1 00 092 1 5 002801 INS PECTION OF VALVE L I FTER BORES INSPECT VALVE LIFTER OIL CLEARANCE a Using calipers measure the valve lifter bore d iameter Bore diameter 22 200 22 221 mm 10 8740 0 8748 in 1 bl Subtract the valve lifter diameter measurement See page EM 841 from the vale lifter bore diameter measurement Standard oil clearance 0 01 0 0 061 mm 0 0004 0 0020 in 1 Maximum oil c ...

Page 122: ...er lap in the oil seal unlil its surface is flush with Ihe rear oil seal relainer edge SST 09223 560 1 0 I c Apply MP grease to the oil seal lip SST B If rear oil seal re tainer is installed to cylinder block al Using a knife cui off the oil s e a l l i p Ibl Using a screwdriver Pry o ut the oil sea CAUTIO N Be careful not to damage the crankshaft Tape the screwdriver Ie Apply MP grease to a new o...

Page 123: ...ng on one side of the piston pin hole bl Gradually heat the pis ton to approx 60 C 1 40 Fl Ie Position the piston sized mark 01 the piston with the front mark of connecting rod and push in the piston pin with your thrumb d Install a new snap ring on the other side i f the piston pin hole 2 INSTALL PISTON RINGS fal Install the coil and oil ring by hand NOTE Fa ce the end gap of the oil ring in t h ...

Page 124: ...der install the twO com pressl on rings with the code mark facing upward c Posilion the piston rings so that the ring end gaps are as shown CAUTJON Do not 81ign the end gaps 3 INSTA LL BEARINGS al Alig n the bearing claw with the claw groove of the connecling rod or connecting rod cap b Install the bearings in the connecting rod Dnd con necting rod cap ...

Page 125: ...al Align the bearing claw with 1he claw groove 0 1 the main bearing cap or cylinder block bl Install the bearing in the cylinder block and main bearing caps in the proper location 2 INSTALL U PPER THRUST WASHERS Inslall the thrusi washers under the No 4 main bearing cap posilion 01 the block wilh Ihe oil grooves lacing oul ward 3 PLACE CRANKSHAFT ON CYLINDER BLOCK 4 INSTALL MAIN BEARING CAPS AND L...

Page 126: ...ft turns smoothly f Check the crankshaft thrust clearance See page EM 981 5 INSTALL PISTON AND CONNECTING ROD ASSE M BLIES lal Cover the connecting rod baits with a short piece of hose to protect the crankshaft and cylinder bore from damage bl Position the piston sized mark of the piston Ie Using a piston ring COmpressor push the correctly numbered piston and connecting rod assembly into the cylin...

Page 127: ...iner with the six bolts Torque 1 86kg cm 1 3 rt Ib 1 8 N m 8 INSTALL OIL PUMP A N D Oil PAN See pages lU l 1 to 1 3 9 INSTALL INJ ECTION PUMP See pages FU 98 and 991 1 0 INSTALL TIMING GEARS A N D CAMSHAFT See pages EM S8 to 92 1 1 INSTALL CYLINDER HEAD See pages EM 68 to 7 1 2H See pages EM 73 to 76 1 2H 1 2 INSTALL INJ ECTION PIPES ISee p ge FU BI 2H See page F U 1 4 and 1 5 1 2H T 1 3 1 1 2H TI...

Page 128: ... oil o n the threads and under the bolt heads 1b I nstall the f lywheel on the crankshaft e Install and uniformly tigh ten the six bolls in several passes in lhe sequence shown Torque 1 200 kg em 87 ft Ib 1 1 8 N m 1 7 A T INSTALL DRIVE PLATE See procedure step 1 61 Torque 1 000 kg em 72 h Ib 98 N m ...

Page 129: ...bleshooting procedures refer to DIESEL ENGINE DIAGNOSIS E M Section REPLACEMENT OF FUEL FILTER INJ ECTION NOZZLES 2HI INJECTION NOZZLES 1 2H T1 FUEL FEEO PUMP AUTOMATIC TIMER I N J ECTION PUMP _ Page FU 2 FU 3 FU 9 FU 1 6 FU 21 F U 29 ...

Page 130: ...ghten the filtet 2 BLEED FUEL F I LTER 3 la Connect a vinyl lube to the fuel filter bleeder plug bl Insert other end of the tube i n a container 01 fuel Ie Loosen the fuel filler bleeder plug d Turn the priming pump handle counterclockwise to free it e Operate the priming pump handle until there are no air bubbles emi1ted from the fuel filler bleeder plug Il Turn the priming pumP handle clockwise ...

Page 131: ...2H R E M O V A L A N D T E S T OF I N J ECTION NOZZLES 1 6 00 36 491 I Fuel Hose 1 REMOVE INJECTION PIPES 1 fa Loosen the union nuts of the six injection pipes b Remove the five nuts six injection pipes and clamps 2 REMOVE NOZZLE LEAKAGE PIPE fa Disconnect the f uel hose from lhe leakage pipe b Remove the six nuts leakage pipe and six gask ets ...

Page 132: ...G Do not place your finger over the nozzle injection hole b Pump the lester handle a few li mes a s lasl as poss i ble by hand to discharge the carbon from the Injec tion hOle e Pump the leSler handle slowly and observe the press ure gauge Idl Read the pres sure gauge when the i njection pressure just beg ins to drop Opening pressure Reused nozzle 1 05 1 25 kg cm 1 493 1 778 psi 1 0 296 1 2 268 kP...

Page 133: ...ng the adjusting shim t hickness by 0 05 mm 0 0020 in l changes Ihe injection pressure by about 6 4 kg cm t 91 psi 628 kPa Only one adjusting shim should be used e There should be no dripping afler injection LEAKAGE TEST While maintaining pressure a t aboul 10 0 20 0 kg cml 142 284 psi 98 1 961 kPa below opening pressure adjust by tester handle check that there i s no dripping for 1 0 seconds from...

Page 134: ...er retaining nul SST 09268 6401 0 CAUTIO N When d isassembling t h e nozzle be care ful not to drop the inner parts b Remove the adiusting shim pressure spring pressure pin distance piece and the nozzle assembly 2 NOZZLE CLEANING 031 To wash the nozzles use a wooden slick and brass brush Wash in clean diesel fuel NOTE Do nOt touch the nozzle mating surfaces with yOur fingers ...

Page 135: ...ese conditions are presented replace the nozzle assem bly r 3 SIN KING TEST a Wash the n O z z le in clean d iesel fuel NOTE Do nOt touch t h e nozzle mating surfaces with your fingers fbi Tilt t h e nozzle body about 60 degrees and pull the needle out aboul one third o f i t s leng t h e When released the needle should s i n k d o w n i n t o t h e b o d y v e n t smoothly b y ils o w n weight d ...

Page 136: ...CTION NOZZLES See page FU 3 _ INSTAll INJECTlDN NOZZLES lal Place new six gaskets and the sixnozzle seals in the cylinder head bl Using SST install and torque the six nozzles SST 09268 640 1 0 Torque 700 kg em S 1 ft Ib 6 9 N m 2 INSTAll NOZZLE lEAKAGE PIPE r a Install new six gaskets and the leakage pipe with the six nuts Torque the nuls Torque 500 kg em 36 ft Ib 49 N m b Connect the fuel hose to...

Page 137: ...N NOZZLES 1 REMOVE INTAKE A I R CONNECTOR A N D INTAKE PIPE See steps 1 to 5 on page EM 401 2 REMOVE HEATER PIPES a Remove the bolt b Disconnect the three hoses and remove the heater pipes together with the three hoses 3 REMOVE NOZZLE LEAKAGE PIPE lal Remove the fuel hose fb Remove the six hollow bolts leakage pipe and twelve gaskets together with the fuel hose ...

Page 138: ...zle hand lester and bleed the air from the union nul WA R N I N G Do not place your f i nger over the nozzle injection hole fbi Pump the tester handle a few times as fast 3S possi ble by hand 10 discharge the carbon f r o m the i njec tion hole c Pump the tester handle slowly and observe the pressure gauge idl Read the presSure gauge when the i njection pressure just beg ins to drop Opening pressu...

Page 139: ...0 04 531 1 650 0 06 50 1 1 7 5 0 0463 1 700 10 06691 1 200 10 04 72 1 750 0 0689 1 2 2 5 10 04 82 1 800 10 07091 NOTE Varying the adjusting shim t h ickness by 0 025 mm 10 00 1 0 in l c h anges t h e injection pressure by about 3 8 kgicm2 154 psi 3 7 3 kPa Only one adjusting shim should be used I e There should be no dripping aller injection LEAKAGE TEST While maintaining pressure at about 1 0 0 2...

Page 140: ...2 la Using a 14 m m deep socket wrench unscrew the nozzle holder retaining nul CAUTION When disassembling the nozzle be care ful not to drop the inner parts b Remove the nozzle assembly d i s t a nce piece pressure pin pressure spring and adjusling shim NOZZLE CLEANING tal To wash the nozzles use a wooden stick and brass brush Wash in clean diesel fuel NOTE Do nol louch the noz zle mating surfaces...

Page 141: ...rrosion I f any of these conditions are presenl replace the nozzle assembly SINKING TEST a Wash the noz zle in clean diesel fuel NOTE 00 not touch the nozzle mating surfaces with your fingers b Tilt the nozzle body about 60 degrees and pull the needle out about one third o f its length e When released the needle should sink down into the body vent smoothly by its own weight d Repeat this test rota...

Page 142: ...ERN TEST See steps 6 to 8 on pages F U l 0 and 1 1 I NSTALLATION OF I N J ECTI ON NOZZLES See page FU 9J _ INSTAll INJ ECTION NOZZLES Install the nozzle seat ring packing a nd injection nozzle with the two nuts Install the six injection nozzles Torque the nuts Torque 1 85 kg em 1 3 ft Ib 1 8 N m INSTAL L INJ ECTION PIPES al Place the three lower clamps in posi tion on the intake manIfold b Install...

Page 143: ...ALL HEATER PIPES FU 1 5 Connect the three hoses and install the hea ter pipes with the bolt Torque 1 86 kg em 1 3 ft Ib 18 N m 5 INSTALL INTAKE PIPE AND INTAKE AIR CONNECTOR See steps 9 to t 3 on pages E M 46 and 46 6 START ENGINE AN CHECK FOR LEAKS ...

Page 144: ... torque Non reusable part I DISCONN ECT INLET AND OUTLET PIPES FROM FEED PUMP 2HJ Remove the two union boll and four gasket a nd discon nect the fuel pipes 1 1 2H TJ a Remove the union boll two gaskets and inlel fuel pipe b Remove the union bolt and two gasket and discon nect the outlet fuel pipe 2 REMOVE FEED PUMP FROM I N J ECTION PUMP Remove the three nuts spring was hers a n d feed pump ...

Page 145: ...rged Fuel must discharge within 25 strokes d Drain any fuel from the feed pump e Operate the feed pump at 1 50 rpm and check the amount o f time until fuel is discharged Fuel must discharge within 40 seconds 4 DISCHARGE TEST al Install the pressure gauge to the feed pump dis charge side bl Operate the feed pump at 600 rpm and check the discharge pressure Discharge pressure 1 8 2 2 kg cmt 26 31 psi...

Page 146: ... ing Push Rod Non reusable part DISASSEM BLY OF F U E L FEED P U M P 1 REMOVE PRIMING PUMP A N CHECK VALVES la Remove the chamber plug gasket spring and check valve b Remove the priming pump gasket spring and check valve 2 REMOVE FEED PUMP PISTON Remove t h e chamber plug gasket spring and piston ...

Page 147: ...NSPECT FEED P U M P PISTON Check that the piston smoothly falls into the piston hole by ilS own weight II abnormal replace the piston If necessary replace the feed pum p assembly 2 INSPECT PRIMING PUMP firmly block the priming pump inlet pOri with your finger and check that pressure and vacuum are created when the pump is operated If abnormal replace the priming pump ASSEM BLY OF FUEL FEED P U M P...

Page 148: ...1 INSTA L L FEED PUMP tal Place a new O ring in position on the injection pump housing b Install the feed pump with the three spring washers and nuts Torque 9 5 kg em 82 in Ib 9 3 N m 2 INSTALL I N LET AND OUTLET FUEL PIPES 12Hl Connect the fuel pipe with new two gaskets and the union bolt Connect t h e two fuel pIpes Torque the union bolts Torque 280 kg em 20 ft Ib 27 N m 1 1 2H Tl Install the in...

Page 149: ...FUEL SYSTEM Automalic Timer 2H 1 2H T cm Specified torque AUTOMATIC TIMER REMOVAL O F AUTOMATIC TI M E R Automatic Timer r 1 I J Set Key FU 21 ...

Page 150: ...ge CO 6 3 REMOVE CRAN K S H A FT PU LLEY AND TIMING GEAR COVER See staps 7 to 9 o n pages EM 79 to 80 4_ REMOVE AUTOMATIC TIMER al Place the malchmark s on each gear to ensure correct assembly b Remove the round nut and washer 1 2 H T e Using SST remove the limer SST 09260 470 1 0 1092 6 7 7 60201 ...

Page 151: ...2H 1 2H T Timer Hub I FUEL SYSTEM Automatic Timer FU 23 COMPON ENTS Timer We ghl Orive Gear Tlmer Spnng Inner Sp ing Seat Drive Gear with Frange ...

Page 152: ...s greater than maximum replace the thrust washer Thrust washer thickness 2H 0 1 mm 0 004 in 0 2 mm 0 008 in l 1 2 H T 0 1 mm 0 004 in 0 36 m m fO 0 1 4 in l 0 5 mm 0 020 in 2 DISASSEM BLE AUTOMATIC TIMER fal Using snap ring pliers remove the snap ring plale washer ancl thrust washer Ibl Cover the timer with a shop towel 10 prevent the spring seats 12H springs and adjusting shims from flying Out Ie...

Page 153: ...2H T 68 8 mm 2 3 1 6 in If the free length is not as specified replace the spring ASSEMBLY O F AUTOMATIC TIMER See page FU 23J 1 ASSEMBLE AUTOMATIC TIMER a Mount the limer hub in a soh jaw vise bl Install the timer weights to the timer hub c Assemble the limer hub and drive gear as shown Idl 12HI Install the spring seats ti mer springs and adjusting shims Ie 1 1 2H TI Inslall the timer springs and...

Page 154: ...sealS 2Hl springs and adjusting shims hi Slide the thrust washer and plale washer onto the shaft of the timer hub i Using snap ring pliers Install the snap ring 2 CH E CK T H R UST CLEARANCE OF DRIVE G E A R See page F U 241 Standard thrust c learance 0 0 1 0 0 200 mm 10 0004 0 0079 in M aximum thrust c learance 0 30 mm fO 0 1 18 inJ ...

Page 155: ...ADVANCE ANGLE a Using a timing lig ht measure the advance angle Ilem Pump rpm Advance angle 640 0 5 or less 800 0 2 1 20 2H 1 1 00 1 5 2 50 1 400 2 7 3 70 1 680 4 0 5 00 1 2H T 1 450 0 50 or less 1 700 5 5 6 50 b Disassemble the automatic timer and adjusting by changing the adjusting shim Adjusting shim thickness 2H 0 mm 0 004 in 0 2 mm 0 008 in J 0 3 mm 0 0 1 2 in J 0 6 mm 0 020 in 1 0 mm 0 039 i...

Page 156: ...ars c Apply a light coat 01 engine oil on the threads and under the ro und nul d Install the washer 1 2H Tl and round nut Torque the round nut Torque 750 kg em 64 It lb 7 4 N m 2 INSTALL TIMING GEAR COVER AND CRANKSHAFT PULLEY See steps 1 2 t o 14 o n pages EM 91 and 92 3 INSTA L L WATER PUMP PULLEY AND FAN See page COo 0 4 INSTALL AND ADJUST DRIVE BELT See page CH 61 5 START ENGINE AND CHECK FOR ...

Page 157: ...EM Injection Pump FUEL SYST N J ECl ION PUM P I NJECT ECTI O N PU M P 2H 1 2H T OVAL O F I N J REM Injection P u m p A T Injection Pump Re ainer FU 29 Gask et ...

Page 158: ...ATIC TIMER See steps 1 to 4 on page F U 221 4 12H MIT wi EDIC SYSTEM REMOVE CONN ECTING ROD OF EDIC MOTOR 5 2H MIT Iw o EDIC SYSTEM REMOVE CONNECTING WIRE OF OVERINJ ECTION MAGNET 6 2H MIT REMOVE VAC U U M HOSES Remove the two vacuum hoses connecting the venturi 0 t h e governor of t h e i njection pump 7 2H REMOVE OIL PIPES 8 DISCONN ECT FUEL PIPE 12H OR HOSE 1 1 2H T Remove the union bolt and tw...

Page 159: ...EMOVE IN JECTION PUMP RETAINER a Before removing the injection pump check i f the m a l c h m a r k s a r e a l i g n e d If no I place new matchmarks for rei nstallation b Remove the four nuts plate washer and retainer e Remove Ihe O ring 1 1 REM OVE PARTS 1 1 12HI Remove the two bolts and injec tion pump stay b Remove lhe boll and oil pipe stay lei i 1 2H TI Remove the union boll with relief val...

Page 160: ...__ __ __ __ __ __ __ __ __ __ F UE EL L SYSTEM __ __ ln II e c l ion Pump C O M PO N ENTS I d l e Spring Capsule r _ Connecting BoH Governor Diaphragm Gasket Governor Cover Adjusting Lever Gasket Go ernQ Housing ...

Page 161: ...UEL SVSTE M Injection Pump COMPO N ENTS Cont d l _ Thrusl washer ContrOl Leve r Jt F loating Arm Return SPriflg 1 II t R Sp 9 I j o Floa ting Lever I Sliding Weight Shaft I SI d I _ _ _ I J 6 S Poo g Lev 6 gJ Non reusable part FU 33 Supporting lever Sh dt ...

Page 162: ...09 5p og 5p og Full load Stopper Housing O Rmg h 0 Je________B h 09 O e Adi 09 W e j No 2 Ad Plo 5mw No I AdaplO looe Idle 5P 09 W h U it T 5 WaSI1 r looe Ad 09 I _______________ Speed Coo 1Ool 5p og F SlOp looe 5p 09 Seal Cooo og P o 9 C a m Moeh 5p 09 ftfj JO O OgBoll _ O Ci t Not 0 s i oppe G de Boack B hoo9 l YWe 9ht Lock Plale Non reusable part Governor Housing ...

Page 163: ...ul 0 0 Collar Spring Guide i t Sliding Plat Outer Idle Sp ing I Spring Outer AdJusling Wa sher 0 Spring 1 1 Bushing Innel Idl Spnn g No 2 Adaptol SolOW NO 1 Adaptor Inn Ad ng Washe y SCIew Speed Canllol Sp 9 __ Inoel Spliog Se I het Rauod Nul Meeh n S plOOg FuJI Stop Cam 12 1 I t Z caaae tiog Pia tD Wash A T q q 1i r P 41 I e I FI we ghl O mp Round Nut I M Tl I Guide Bushing Camshaft Bushlllg MIT ...

Page 164: ... T Thrust Washer L IRear Bearing Outer Race li R cm Ht Ib Nom J S pecified torque Non reusable part Camshaft LO Ck_ p a eI r 27 _ _ 37 _ _ 1 _ _ _ _ Delivery Valve Holder V i i ry Valve 9_ Gasket Delivery Valve r Pump Cylinder _ COOlrol Pinion U pper Spring Seal I j Plunger Spr ing r PIUnger Spring Seal AdJ u s t ing Shim fl TaPPOl o Plale Plug ___ Gasket Pump Cover i J Gasket Outer Aace w tL Plat...

Page 165: ...PHRAGM Remove the follow HOUSING A N D 3 4 5 II I Four screl pans 121 Iw o EDICI 3 Wi e bracket ue i t housing Governor main spring REMOVE GOVERN Remove the fall OR DIAPHRAGM 1 Nul oWing parts 12 S 3 pnng washer 4 Connecting bracket Governor diaphragm Iwl HAC REMOVE HIGH e the three bolls and HAC PENSATOR HAC Remov ALTITUDE COM REMOVE G SPRING OVERNOR COV ER A ND SPEED Remove the folio CONTROL 0 S...

Page 166: ...e following paris 1 Plate washer 121 Slider 3 Si steel balls REMOVE STEEL BALL G U I D E al Using SST remove the round n u l a n d spring washer SST 09260 4 70 1 0 109260 780 1 01 CAUTIO N Be careful not to damage the camshaft Tape the screwdriver lip b Using S ST remove the ball g u ide SST 09 260 4 70 1 0 109 2 6 7 7 6 0 1 1 1 REMOVE A D J U STING AND STOP LEVERS Remove the following parts 1 Bol...

Page 167: ...E UP ACTUATOR 3 2H A TI REMOVE FU LL LOAD STOPPER HOUSING ASSEM BLY Remove the four bolls the stopper housing assembly and D ring 4 1 1 2H T REMOVE fULL LOAD STOPPER HOUSING ASSEMBLY ANO BOOST COMPENSATOR Remove t h e four bolts the stopper housing assembly and G ri ng together w i t h the boost compensator 6 1 1 2H TI SEPARATE F U LL LOAD STO PPER HOUSING ASSEMBLY AND BOOST COMPE NSATOR a Remove ...

Page 168: ...r screw Thrust clearance 0 03 0 08 mm 0_00 2 0_0032 n 1 If the clearance is not within specification replace the thrust washer Thrust washer thickness 0 05 m m 0 0020 in 0 1 0 m m 0 0039 in 0 20 m m 0 0079 in 7 DISASSEMBLE FU LL LOAD STOPPER HOUSING ASSEMBLY 2H Am Disassemble the following pariS 1 Two bolts 2 Cover plate 3 D nng 4 Cap n u l and gasket 5 Lock nul and gasket 6 Stopper screw 7 Screw ...

Page 169: ...hing and spring 1 5 Slid ing plate 1 2 H T Disassemble the following parts 1 Cap nut and gasket 2 Lock nut and gasket 3 Stopper screw 4 Screw plug S Slidi ng plate shaft 6 Full load stopper housing and spring 7 E ring thrust washer and connecting pin S Two lock nuts collar No 2 adaptor screw a nd spring 9 Full stop cam 1 0 Lock nut 11 1 1 No 1 adaptor screw spring and bushing 1 2 Sliding plate REM...

Page 170: ...he t w o return springs lei 1 2 H T Remove the t h ree boils pump stay and spring arm I Remove the six bolts 9 Turn the SlOp lever and d isconnect the sliding block of the steering lever from the floating lever hole Remove the governor cover assembly and gasket CAUTION Be careful not drop the supporting levers and slider ...

Page 171: ...0266 in 0 70 mm 0 0276 inJ 0 76 mm 0 0295 in 0 80 mm 0 0 3 1 5 in 1 0 CHECK THRUST CLEARANCE O F CAM PLATE Using a feeler gauge measure the thrust clearance bet ween the cam plate and governor cover Thrust clearance 0 08 0 1 2 mm 10 0031 0 0047 in 1 If the clearance is not within specification replace the thrust washer Thrust washer thickness 0 2 mm 0 008 in l 0 3 mm 0 0 1 2 in 0 4 mm 0 0 1 6 in l...

Page 172: ...IDER 1 3_ REMOVE FLOATING LEVER ASSEM BLY Remove the E rmg and t he floating lever assembly 14 CHECK THR UST CLEARANCE OF FLOATING ARM Using a leer gauge measure the t hrust clearance between the floating arm and floating lever Thrust clearance 0 05 0 2 mm iO 0020 0 0047 in If the clearance is not within specification replace the thrust washer Thrust washer thickness 0 05 mm 10 0020 in 0 10 mm 10 ...

Page 173: ...PPER ARM Remove the E ring and separate the shackle and stopper 1 B CHECK THRUST CLEARANCE OF JOINTING BOLT See page FU B l l Thrust clearance 1 5 2 0 mm 10 059 0 079 in 19 C H ECK FITTING DIMENSIONS O F SLIDING WEIGHT SHAFT While pulling on the sliding weight shaft measure the fit ling di mensions with calipers as shown Fitting dimensions 49 7 50 1 mm 1 957 1 972 in l If the dimensions are nOI wi...

Page 174: ...REMOVE FLYW EIG HT ASSEMBLY al Using SST remove the round nut SST 092 60 470 1 0 109260 7801 01 Ibl 12H An and 1 2H T A TI Remove the spring washer lei 11 2H MITI Remove the thrust washer and the flyweight assem bly Idl 12HI Using SST remove the flyweigh t assembly SST 09260 470 1 0 10926 7 760 1 1 1 2 3 1 1 2H T MIT CHECK THRUST C L EARA NCE OF FLYWEIGHT al Install the flyweig h t without the dam...

Page 175: ...709 in 1 85 mm 0 0728 in 1 90 mm 0 0748 in 1 95 mm 0 0768 in 2 00 mm 10 0787 in 2 10 mm 10 0827 in 2 20 mm 0 0866 in 2 30 mm 0 0906 in Id Remove the flvweight assembly 24 1 1 2H T MiTI REMOVE CAM SHAFT BUSHING Using SST remove the camshaft bushing SST 09260 580 1 0 109267 760301 2 5 DISASSEMBLE FLYWEIGHT ASSEMBLY Remove the following part s 1 1 Adjusting nut 2 Spring guide 131 Outer idle spring 14...

Page 176: ...m and governor housing Thrust clearance 0 05 0 20 mm 0 0020 0 0079 in If the clearance is not within specification re place the thrust washer Thrust washer thickness 0 1 mm 0 004 in l 0 2 mm 10 008 in O S mm 0 020 in 27 REMOVE STOP LEVER A N D STOPPER ARM Remove the following paris 1 Boll 21 Stop lever 31 Return spring 4 Thrust washer s 5 a ring 6 Stopper arm ...

Page 177: ...ng a dial indicator measure the thrust clearance while prying the camShaft back and forth with a screwdriver Standard clearanc e 0 03 0 06 mm 0 00 1 2 0 0020 in Maximum clearance 0 1 mm 10 004 in CAUTIO N Be careful not to damage the camshaft Tape the screwdriver tip If the clearance is greater than maxim um Ieplace the thrust washer Thrust washer thickness 2 H Front and rearl and 1 2H T Rear 0 1 ...

Page 178: ...plate plugs 5 REMOVE CAMSHAFT AND GOVERNOR HOUSING lal 11 2H TJ Turn the camshaft and position the k ey g roove of i t as shown b Remove the four bolls of the bearing cover e Using SST remove the bearing cover SST 09260 4 7 0 1 0 109287 580 1 0 Id 1 2 H I Remove the camshaft ...

Page 179: ...nor housing and gasket If 12H AIT and 1 2H T Remove the seven bolts stopper bracket g overnor housing and gaske t 1 9 1 1 1 2H T I Remove t h e two screws a n d gaskets of t h e camshaft cenler bearing Ihl 11 2H TI Remove the camshaft together with the camshaft center bearing ...

Page 180: ...sh the tappet to remove SST Al SST 09260 4 7 0 1 0 109 2 7 2 7 6 0 1 1 0 9 2 7 4 4 60 1 1 1 b Using SST IB hold the tappet in the camshaft chamber and lake out the lappet through the camshaft bearing hole wi th SST Ie SST 092 60 4 70 1 0 109 2 7 2 7 60 1 1 09273 7601 1 1 Ie Remove lhe adjusting shim sl dl Using SST hold the lower spring seat and take it oul together with the plunger SST 09260 470 ...

Page 181: ... your hand Arrange all palts in correct order 8 REMOVE CONTROL RACK Remove the gUide screw and pull out the control rack 9 REMOVE DELIVERY VALVES A N D PUMP CYLIN DERS a Remove the three lock plates bl Using SST remove the delivery valve holder C ring 1 2H Tl stopper 1 1 2H n spring and gasket 1 1 2H Tl SST 09260 4 70 1 0 1092 70 760 1 01 ...

Page 182: ...move the delivery valve and gasket 12HI SST 09260 470 1 0 109 2 7 1 760 1 1 1 NOTE Do not touch the sliding surfaces o f the delivery valve with yOur hand d Raise the pump cylinder with yOur forefinger and remove it NOTE Arrange aU paris in correct order ...

Page 183: ...e valve seat and press down with your finger When your finger is released the valve should rise back to its original position Replace il defeclive c Remove your thumb from the valve seat hole The valve should close completely by its own weig ht Replace If defective NOTE Belore using a new valve set wash off the rust prevention com pound with light oil or gasoline Then Ie wash wilh diesel fuel and ...

Page 184: ...ernor control idling odling spring spring spnng spring spnng 4 3 5 1 1 7 1 3 38 0 1 1 4 9 6 1 0 2 OA02 24 0 0 945 25 7 1 1 0 1 2 23 8 0 9371 1 0 2 0 402 24 0 a 9451 2 5 7 1 0 1 21 23 8 10 9371 If t h e free length is not as specified replace the spring 5 INSPECT TAPPETS Measure t h e combined looseness with the tappet roller in the assembled slate Maximum combined loosen e s s 0 3 mm 0 01 2 in l I...

Page 185: ...be 0 1 0 3 mm 0 004 0 012 in plus the amount of push rod shift as shown in the figure 1 1 2H TJ INSPECT BOOST COMPENSATOR la Apply 1 36 kg cm 1 9 3 psi 1 3 3 kPal of pressure to the boost com pensator fb Measure the push rod stroke Push rod stroke 4 0 5_0 mm 0 1 58 0 1 97 in If the stroke is nol within specification replace the boost compensator Ic ApplV 1 36 kg cm 2 119 3 psi 133 kPa of pressure ...

Page 186: ...4 70 1 0 109 287 580 1 01 b Using SST and a press press in a new bearing together with the plate washer and thrust washer sl SST 09260 4 70 1 0 109 2 8 5 760201 Outer Race of Front Bearingl a Using SST and a press press out the outer race SST 092 60 4 70 1 0 09 286 760 1 1 1 2H 09286 780 1 0 1 2H T bl Using SST and a press press in a new outer race SST 09608 1 20 1 0 109608 000401 2H 09260 4701 0 ...

Page 187: ...ess oul Ihe outer race SST 09260 4 70 1 0 109286 7601 1 1 bl UsinG SST and a press press i n a new outer race SST 09608 1 20 1 0 109 608 000401 2 2H M Tl REPLACE BEARING OF SPEED CONTROL SCREW Inslall new gaskets 3 REPLACE O I L SEAL OF LEVE R SHAFT Apply MP grease to a new oil seal lip ...

Page 188: ...4 1 76022 and 09245 7801 0 2 INSTA L L PUMP CYLIND ERS AND DELIVERY VALVES fa Align the notch of the pump cylinder with the knock pin of the pump housing bl InSlall the pump cylinder c Install the delivery valve Idl 1 2 HI Using SST and a plastic faced hammer lightly tap in new gasket SST 09260 470 1 0 109262 7601 01 lei 1 1 2H T I Install a new gasket IfI 12HI InSlali Ihe delivery valve spring an...

Page 189: ...oth and effortless movement 4 INSTALL PLUNGERS AND TAPPETS tal Install the upper spring seal and plunger spring bl Assemble the plunger and lower spring seal e Using SST i nsert the plunger and lower seal assem bly with the designation mark of the plunger d riving face facing pump cover side SST 09260 47 0 1 0 092 75 4601 01 Designation mark Example 6 799 NOTE After inserting the plunger turn the ...

Page 190: ... 0 109272 7601 1 09274 460 1 1 1 hi When installing each plunger and tappet check the control rack for smooth and effortless movement 5 TORQUE DELIVERY VALVE HOLDERS lal Torque the six delivery valve holders Torque 37 5 kg em 27 ft Ib 37 N m NOTE When one delivery valve holder is lightened move the conlrol rack to the righ t and left and check the lightness o f the rack Ibl Install the three lock ...

Page 191: ...gaskets and the two screws lei 12H MIT I Install a new gasket and the governor housing with the five screws Torque 10 mm bolt head 86 kg em 74 in Ib 8 3 N m 1 2 mm bolt head 1 90 kg em 1 4 It lb 1 9 N m Idl 12H AfT and 1 2H TI Install a new gasket the governor housing and stop per bracket with the seven screws Torque 10 mm bolt head 86 kg em 174 in Ib 8 3 N m 1 2 mm bolt head 1 90 kg em 1 4 It lb ...

Page 192: ...ur bolts of the bearing cover Torque 85 kg em 74 in Ib 8 3 N m INSTALL PLATE PLUGS a Apply liquid sealer on the threads and under the plate plug heads b Install the six plate plugs Torq ue 650 kg em 47 It lb 64 N m 9 CHECK THRUST CLE ARANCE O F CAMSHAFT See page FU 49 Standard c learanc e 0 03 0 05 mm 10 00 1 2 0 0020 in Maximum c learance 0 1 mm 0 004 in ...

Page 193: ...ection Pump 1 0 REMOVE SST FROM TAPPET SERVICE HOLES Turn the camshaft and remove SST SST 09260 470 1 0 1092 74 460 1 1 1 1 1 I N STALL PUMP COVER FU SS Install the gasket and pump cover with the two gaskets and bolts ...

Page 194: ... 1 2H T 1 70 _ 1 2 258 kPal 2 4 1 8 1 80 kg cm2 H 671 2 560 psi b Check the accurac 7 651 kPal Allowable error 4 Y O of the tachometer rpm at 2 000 rpm lei Remove the injection pump and conlrol rack cavers Idl Mount the injection pum ie Rotate the P body on Ih smoothly pump by hand and pump leste check that it t urns III Inslall Ihe aek position w here t C e a le so that its zero te 90vemO sid e n...

Page 195: ...stallation sur face and fill the pump camshaft chamber with engine oiL Ikl 12Hl Fuel feeding pressure 10 iniection pump should be 0 5 kg em 17 1 psi 49 kPal III 1 1 2H TJ Fuel feeding pressure 10 injection pump should be 2 0 kg cm2 28 psi 1 96 kPa 1m Fuel temperature for pu mp testing should be 40 45 C 1 1 04 1 1 3 Fl n Bleed the air from the pump housing NOTE Be careful thai fuel does not enter t...

Page 196: ...ylinder d isappear before measuring CHECK SLIDING RES ISTANCE OF CONTROL RACK Using a spring tension gauge measure the sliding resis 1ance Sliding resistance g ozl 1 20 4 21 or less 50 1 8 or less 3 ADJUST INJECTION TIMING A Adjust pre stroke for No 1 Plunger a Set the control rack position Control rack positio n 2H 1 1 0 mm 0 433 i n or less 1 2H T 1 0 0 mm 0 394 in l or less bl Loosen the overfl...

Page 197: ... No 1 plunger when it moves from SDC to the injection starting position the point where fuel flow ing from the overflow pipe stops Pre stroke 2H 1 90 2 00 mm 0 0748 0 0787 in I 1 2 H T 3 55 3 65 mm 0 1 398 0 1 437 in f Using SST adjust by changing the adjusting shim SST 092 60 47 0 1 0 09280 4601 0 Adjusting shim thickness 0 1 0 mm 10 0039 In l 0 1 5 mm 0 0059 in 0 20 mm 0 0079 in 0 30 mm 0 01 1 8...

Page 198: ...the i njection starling angles in the order o f injection Cylinder No Injection starting angle i f _ _ _ _ 1 59 30 60 30 1 1 ga30 1 20 30 t 7 9 3 0 8 0 3 0 239 30 240 30 299 30 300 30 bl Adjust by using the same procedure as pre stroke adjustment NOTE The injection starting angle will change about 30 with 0 1 mm 0 004 in Change is shim thickness C Adjust Tappet C learance a Using SST Al i nsert th...

Page 199: ...9 30 300 30 4 ADJ UST I N J ECTION VOLUME lal Remove the blind plug from the bleeder hole and inSlall an overflow valve bl Measure each injeclion volu me Measuring Pump rpm stroke 1 00 200 1 000 200 1 1 00 200 1 7 00 200 3 2 5 500 l Oa 200 1 000 200 1 1 00 200 1 700 200 325 500 1 00 200 1 1 00 200 390 500 Injection volume of each cylinder cc Icu in 1 2 8 1 5 0 0 7 8 0 9 2 4 1 5 3 10 25 0 321 8 2 9...

Page 200: ...1 00 1 7 5 0 340 1 00 1 1 00 1 7 5 0 390 200 200 200 500 200 200 200 500 200 200 200 500 200 200 200 500 cc eu i n J 8 6 1 0 8 0 5 2 0 66 8 8 9 8 0 5 3 0 50 9 2 1 0 8 0 56 0 6 6 2 5 5 5 0 1 5 0 3 4 1 4 0 1 8 0 0 85 1 0 1 1 3 1 2 3 O G9 0 75 1 1 3 1 2 5 0 6 9 0 7 61 3 0 6 5 10 1 8 0 401 9 0 3 0 0 5 5 0 7 9 1 1 3 1 2 3 0 69 0 7 5 1 1 3 1 2 5 10 69 0 76 3 0 6 5 0 1 8 0 40 9 0 1 3 0 0 5 5 0 79 1 1 3 1...

Page 201: ...g SST install the ball guide with the s pring washer and round nul SST 09260 4 7 0 1 0 109260 7601 01 Torque 660 kg em 40 It Ib 64 N m CAUTIO N Be careful not to damage the camshaft Tape the screwdriver tip 3 INSTALL STEE L BALLS A N D SLIDER Inslall the following parts 1 Six steel balls Apply MP grease to the steel balls 2 Slider 3 Plate washer thickl 4 INSTALL CONTROL RACK LEVERS a Install the u...

Page 202: ...ee bolts Torque 86 kg em 74 in Ib 8 3 N m 7 IN STALL GOVERNOR DIAPHRAGM B a Install the f ollowing parts 1 Governor diaphragm 2 Connecting bracket 3 Spring washer 4 N u t b Align t h e knock of the governor diaphragm w i t h t h e k n o c k groove o f the governor cover c I nsert the governor diaphragm into the governor cover IN STALL GOVERNOR M A I N SPRING AND GOVERNOR DIAPHRAGM HOUSING Install ...

Page 203: ... 2 8 0 Mechanical Governor Section 450 mmH9 Idle Spri ng Set 7 5 I Vacuum 530 mmHg i w G 1 9 2 20 Pump Speed Irpm 20 5 pee Sprin 2 1 C 1 00 1 PRE TEST CHECK AND PREPARATION See page FU 66 2 PREPATATION a Remove the sealing screw plug d Control g Set Ib Using SST loosen the idle spring capsule to keep il inoperative SST 09260 470 1 0 109282 760 1 01 c Remove the cap nut and gasket dl Fullv tighten ...

Page 204: ...ore If the pressure is less than specification retigh ten the screws of the governor diaphragm housing I f necessary replace the governor diaphragm 4 A D J U ST PNEUMATIC GOVE RNOR SECTION A Adjust I n itial Position of Control Rack a Measure the control rack position Vacuum Control rack position mmHg m Hg kPa mm linJ 600 23 62 80 0 1 0 3 1 0 9 0 406 0 429 Ibl Iwlo HAC Using SST adjust by turning ...

Page 205: ...9 In 2 0 mm 0 079 in 3 0 mm O S in NOTE The control rack position will inCrease with a decrease in shim thickness and decrease with an increase Ie Recheck the initial position of the control rack 5_ ADJ UST MECHANICAL GOVERNOR SECTION A Adjust Speed Control Spring tal Measure the con trol rack pasi lion Vacuum COntrol rack position m mHg in Hg kPaj mm lin 450 t 7 72 60 01 1 0 4 1 0 8 0 409 0 4 2 5...

Page 206: ...n volume Vacuum Measuring T clal injection of each stroke cylinder volume mmHg lin Hg kPal cc cu inJ 60 12 36 8 01 1 000 2 3 7 2 6 1 1 1 4 5 1 5 9 1 50 5 9 1 20 0 1 000 255 267 tt 5 6 1 6 31 400 1 5 7 5 53 3 1 000 2 6 7 2 9 1 1 6 3 1 7 81 6 0 12 36 8 01 1 000 2 3 7 26 1 11 4 5 1 5 9 1 50 S 9 20 01 1 000 255 267 1 1 5 6 1 6 31 400 1 1 5 7 5 5 3 3 1 1 000 258 282 1 5 7 1 7 21 lei Iw o HACi Using SST...

Page 207: ...wire and lead seal 1 w o HAC Full SlOp capsule with screw of governor diaphragm housing 12 w o HAC Cap nut of speed control screw 13 wi HAC Nipple of HAC 14 wi HAC Cap n u l of speed control screw with screw of governor diaphragm housing bl Using a plastic faced hammer carefully lap in a new sealing screw plug ...

Page 208: ...T CLEARANCE O F STOPPER ARM See page FU 48 Thrust clearance 0 05 0 20 mrn 10 0020 0 0079 n 3 ASSEMBLY FLYWEIGHT al Install the following paris 1 Spring seal 2 Mechanical spring 131 Inner spring seal 14 Speed control spring 15 Inner adjusting washer 16 Inner idle spring 17 Ouler adjusting washer 18 Ouler idle spring 191 S pring g u ide 1 0 Adjusting nut b Preset the protrusion of the adjusting nut ...

Page 209: ...ng 6 I N STALL FLYWEIGHT ASSEMBLY lal 12H AlT and I 2H T A T Inslall the sel key to the camshaft Ibl 12H AlT and 1 2 H T A T Align the set key with the flyweight key groove c Slide the flyweight assembly onto the camshaft Idl 12H AIT and 1 2H T A T Install the spring washer 1 1 1 1 2H T Mm Install the thrust washer If Using SST install the round nul SST 09260 470 I 0 109260 780 I 01 Torque 560 kg ...

Page 210: ... 4Sl F itting dimensions 49 7 60 1 m m 1 957 1 972 in d Slake the lock washer ASSEMBLE SHACKLE AND STOPPE R ARM Assemble the shackle and stopper arm with the E ring 1 0 INSTALL SHACKLE AND STOPPER ARM ASSEMBLV Install the following parts 1 Shackle and s topper arm assembly 121 Ann nul 131 Spring washer 141 Bolt 151 Return Spring 1 1 ASSEMBLE FLOATING LEVER a Assemble the following parts 1 Floating...

Page 211: ...ust c learance of the cam plale See page FU 43J Thrust cleara nce 0 08 0 1 2 mm 0 0031 0 0047 in 5 Return spring 6 Steering lever and t h rust washers 0 Sleering lever shaft Check the thrust clearance of t h e steering Jever See page FU 431 Thrust clearance 0 05 0 20 mm 10 0020 0 0079 in 8 Tapered bolt Position the key g roove of the steering lever upward and install the tappred boll Torque 65 kg ...

Page 212: ...g block with your f inger and insert it into the floating lever hole CAUTION Position the long end of the sliding block upward dl Using a small screwdnver align the shaft holes of the supporting levers and governor cover el Push in the supporting lever shaft If Install the governor cover with the six bolts Torque 85 kg em 74 in Ib 8 3 N m 191 1 1 2H TI Install the spring arm and pump stay with the...

Page 213: ...gs indicated A S and C Assemble the following parts 1 Sliding plate 21 No 1 adapter screw bushing and 8 spring 3 Lock nut 4 Full slop cam 5 No 2 adaptor screw A spring and two lock nuts 6 Connecting pin thrust washer and E ring Check the thrust clearance of the full stop cam See page FU 401 Thrus t clearance 0 03 0 08 mm 0 001 2 0 0032 in 7 C spring and full load stopper housing lSI Sliding plate ...

Page 214: ... Assemble the following paris 1 Sliding pia Ie 2 No 1 adaptor screw bushing and A spring 3 lock nul 4 Full stop cam 51 NO 2 adaptor screw B spring collar and two lock nuts 6 Connecting pin thrust washer and E ring C heck the thrust clearance of the full SlOP cam See page FU 40l Thrust clearance 0 03 0 008 mm 0 00 1 2 0 0032 In 1 7 C spring and full load stopper housing 8 Sliding plate shaft 9 Scre...

Page 215: ...nd boost compensator with the four bolts Torque 86 kg cm 74 in Ib 8 3 N m d Install a new O ring to the cover plate e Install the cover plale with the two bolts Torque 8 6 kg em 74 i n Ib 8 3 N m l B 2H AITl INSTALL FULL LOAD STOPPER HOUSING ASSEMBLY la Install a new a ring to the stopper housing fbi Install the stopper housing assembly with the four bolts Torque 86 kg cm 74 in Ib 8 3 N m 1 9 1 2H...

Page 216: ...FU SS FUEL SYSTEM Injection Pump 20 wi PS OR A C INSTALL IDLE UP ACTUATOR ...

Page 217: ... or s Lessl c o 7 9 1 1 3 1 1 3 o 1 6 e 5 5 g 4 1 u 1 2H T MIT 1 3 3 o Idle Speed Control 1 I I 3 9 5 6 1 1 1 2 Pump Speed rpm Medium Speed Control f H I 6 4H t f T t i 5 5 u 1 2H T AfT _ 1 2 7 E s 9 0 8 3 R t i 5 8 1 4 4 u Pump Speed rpm Pump Speed rpm 1 1 3 1 0 8 8 5 5 1 1 7 5 1 9 20 75 2 2 x 1 00 Maximum Speed Control 5 or Less f U l tS7 45 ...

Page 218: ...page FU 66 2 REMOVE CAP NUP AND COVER PLATE 3 INSTALL ANGLE GAUGE TO ADJUSTING LEVER 4 PRESET IDLE SPEED CONTROL tal Measure tl1e control rack position Adjusting Control rack position lever Pump rpm mm in angle Appro 3 390 7 7 8 1 0 303 0 3 1 9 Approx 3 340 8 6 9 2 0 3 3 9 0 362 ApprOK 3 390 8 7 9 3 10 343 0 366 b Adjust by turning The idle speed adiusting screw ...

Page 219: ...g nut or washers 3 4 4 8 10 1 34 0 1 B9 1 2 9 1 3 7 0 50B 0 53 9 B 6 9 2 0 339 0 3 62 Idle adjusting screw 6 9 8 3 0 2 7 2 0 3271 6 0 6 B 0 236 0 26B Adjusting nul or washers 4 3 5 7 10 1 69 0 2241 1 2 4 1 3 0 10 488 0 5 1 2 8 7 9 3 0 343 0 366 Idle adjusting screw 7 6 9 0 10 299 0 354 5 4 6 2 0 2 1 3 0 244 Adjusting nut or washers 3 7 5 1 10 1 46 0 20 1 Ib Adjust b y turning t h e idle speed adju...

Page 220: ...uide sleeve side NOTE By adding a thicker adjusting washer the governor Characteristic will change as shown in the illustration The adjusting nut will change the governor charac teristic as shown in the illustration 6 PRESET MAX I M U M SPEED CONTROL 1 1 1 1 2H TI Adjusting laver ar gle Approx 43 Approx 38 Apply 0 27 kg cm1 3 9 psi 26 kPa of pressure to the boos compensator bl Measure the control ...

Page 221: ...n Control rack position Adjusting point mm in 1 1 0 1 1 6 10 433 0 4 5 7 No 1 adapter screw 1 1 1 1 1 5 10 437 0 453 Full load topper screw 1 1 0 1 1 6 0 433 0 4 5 7 N o I and No 2 adapter screws 1 0 4 1 1 2 0 409 0 44 I 1 0 3 1 1 0 4 06 0 4371 No 1 adapter screw 1 0 1 1 0 9 0 3 98 0 429 1 0 4 1 1 0 0 409 0 4331 Full load stopper screw 1 0 3 1 1 1 0 406 0 43 7 1 No 1 and No 2 adapter screws 9 8 1 ...

Page 222: ...2 together the governor characteristic will change as shown in the illustration 8 _ ADJUST M A X I M U M SPEED CONTROL 1 1 1 1 2H TJ Pump rpm I 2 0 7 5 2 200 2 050 2 200 0 Apply 0 27 k g cm2 3 9 psi 26 kPa 01 pressure to the boost compensator b Measure the COntrol rack position Control rack position mm in l Adiusling point 8 2 8 8 0 323 0 34 6 Maximum adjusting screw 5 5 0 2 1 7 or less 1 6 0 0 63...

Page 223: ...n I Se ew Pump rpm Pump rpm 500 9 1 1 2H TI ADJUST BOOST C OMPENSATOR a Measure the control rack position Boost compensator Conltol lack posilion pressure Adjusling point k9 cm psi kPa m m fin 0 1 2 1 1 7 1 21 9 8 1 0 4 0 386 0 409 SlOP screw 1 0 3 1 1 1 10 406 0 4371 Guide bushing b Adjust the stop screw Remove the cap nut adjust by turning the stop screw c Adjust the guide bushing 1 Using SST re...

Page 224: ...ECTION VOLU M E a Measure t h e total injection volume Measuring Total injection volume Pump rpm stroke of each cylinder cc leu in 500 1 000 2 1 0 0 264 0 1 2 82 1 6 1 1 1 1 1 00 1 000 270 0 282 0 1 6 48 1 7 2 1 1 1 7 5 0 1 000 2 8 8 0 3 1 8 0 1 7 5 7 9 4 1 1 500 1 000 1 98 0 2 3 4 0 1 2 08 1 4 28 1 1 00 1 000 3 4 5 0 363 0 21 05 2 2 1 5 1 7 5 0 1 000 3 39 0 3 7 5 0 120 69 22 881 500 1 000 1 5 6 0...

Page 225: ...2 0 0 079 or less 1 2H T Idle 7 5 0 295 or less 1 2 INSTALL CAP NUT AND COVER PLATE OF F U L L LOAD STOPPER HOUSIN G 1 3 SEAL PARTS Seal the following parts with new seal wire and lead sea l 1 Maximum adjusting screw 2 2H Bolt of cover plate with cap nut of lull load stopper screw 31 1 2H T Bolt o f cover plate 4 1 2H T Cap nut of full load stopper screw 51 1 2H T Cap nut of boost compensator stop...

Page 226: ...20 lb 27 N ml 2 INSTAll INJECTION PUMP RETAI N E R a Install a n e w O ring to the bearing cover groove 01 the injection pump b Align the matchmark of the injection pump body and retainer leI Install the relainer with the four plate washers and nutS Torque 376 kg em 27 It lb 37 N ml 3 INSTAll INJECTION P U M P I e Install a n e w O ring retainer groove 01 t h e injection pump b Install the i nject...

Page 227: ...with the bolt 6 2H MITI INSTALL VACU U M HOSES 7 2H MIT wi EDIC SYSTEMII INSTALL C O N NECTING ROD OF EDIC MOTOR 8 2H MIT w o EDIC SYSTEM I IN STALL CONNECTIONG WIRE OF OVER I N J ECTION MAGNET 9 INSTALL A UTOMATIC TIMER See steps 1 to 4 on page FU 201 1 0 INSTALL FUEL FEED PUMP See step 1 and 2 on page F U 20l 1 1 INSTALL INJ ECTION PIPES See step 3 on page FU 8 2H See steps 2 4 and 6 on pages FU...

Page 228: ...COOL I NG SYSTEM TROUBLES HOOTING CHECK AND REPLACEMENT OF ENGINE COOLANT WATER PUMP THERMOSTAT RAD IATOR CO I Page CO 2 CO J CO 4 CO I I CO 1 2 1m ...

Page 229: ...ary radiator hea ter cora plugs or head gasket leak lge Thermostal faulty Check thermostat CO 1 1 Injection timing retarded Adjust liming EM 23 Fluid coupling laulty Replace fluid coupling CO 5 Radiator hose plugged or rotted Replace hose Water pump taully Replace waler pump CO 5 Radialor plugged 01 cap faulty C heck radiator CO 1 2 Cylinder head or block cracked or Repair as necessary plugged NOT...

Page 230: ...d be free from oil If excessively dirty replace the coolant 3 REPLACE E N G I N E COOLANT lal Remove the radiator cap b Drain the coolant from the radiator and engine drain cocks Engine drain cock is at left front of engine block c Close the drain cocks d FiJI the system with coolant Use a good brand o f ethylene glycol base coolant mixed according to the manufacturer s directions Capacity wI Fron...

Page 231: ...CO 4 Drive Belt Non reusable part COO LING SYSTEM Water Pump Fan WATE R P U M P REMOVAL O F WATER P U M P r w I Ulley Fluid Coupling I I r Gasket wi 0 f w l F a n Spacer Fan ...

Page 232: ... tan fan spacer and pump pulley 4 DISCONN ECT HOSES FROM WATER P U M P a Radiator i n l e t hose b wi Heater Heater hose 6 REMOVE WATER P U M P a Remove the f o u r bolts bl Disconnect the water by pass hose and remove the water pump and gasket INSPECTION OF WATER P U M P CO M PO N E NTS 1 I N S PECT WATER PUMP Turn the pulley seat and check that the water pump bear ing moves smoothly and quietly ...

Page 233: ...t I Water Pu Water Pump Bearing mp Cover DISASSEMBLY OF 1 REMOVE w WATER PU M P Remove the TER PUMP BODY and gasket Ive nuts spring washers water pump body SS T ti 2 REMOVE PULLEY S Using SST and a EAT remove the press press th SST 0 pulley seat e shaf of he b 9236 00 1 0 1 109 ea og aod r j C OO24 l 2 3 7 000 1 0 09237 000401 ...

Page 234: ...r SST 09236 001 0 1 09 2 3 7 000 1 0 092 3 7 00040 4 R E MOVE WATER P U M P BEAR NG al Remove the retaining wire 5 b Grad ually heat the water pump body to approx 85 C 1 85 FI e Using SST and a press press the outer race of the bearing and remove the beari ng SST 09236 00 1 0 1 109237 00040 REMOVE SEAL SEAT AND PACK ING ...

Page 235: ...WATER PUMP BEARING a Gradually heat the water pump body to approx 8S C 1 1 85 F bl Using SST and a press press i n the outer race of the bearing SST 09236 00 1 0 1 109237 00020 e Install the retaining wire 2 INSTA LL SEAL 3 Using SST and a press press in a new seal SST 09236 00 1 0 1 109237 00020 INSTALL ROTOR a Place new packing and seat into the rOtor ...

Page 236: ...shaft edge of the water pump bearing SST 09236 00 1 0 1 109237 000301 Distance A wi Fluid coupling 49 5 50 9 mm 1 949 2 004 in w o Fluid coupling 84 5 85 9 mm 13 327 3 382 in 1 6 INSTALL WATER PUMP BODY I nstall a new gasket and the water pump body with the five spring washers and nuts Torque 1 85 kg cm 1 3 ft Ib 18 N ml 6 CHECK WATER PUMP BEARING ROTATES SMOOTHLY ...

Page 237: ... N ml 2 CONNECT HOSES 3 4 5 6 la Radiator inlet hose bl wI Heater Healer hose INSTALL WATER PUMP PULLEY A N D FAN wI F luid Couplingl Install the pump pulley and the fluid coupling and fan assem bly with the four nuts w o Fluid Coupling Install the pump pulley and the drive shaft and fan assem bly with the four nuts INSTALL ANO AOJUST DRIVE BELT See page CH 61 REFill W ITH COOLANT See page CO 3 ST...

Page 238: ...m bered with the valve open ing temperature al Immerse the thermostat in water and gradually heat the water bl Check the valve opening temperature Valve opening tempera ture 82 C type 80 84 C 1 76 1 83 FI 88 C Iype 86 90 C 1 87 1 94 F If the valve opening temperature is within specification replace the thermostat Ie C heck the valve lift Valve lift 82 C type 1 0 mm 0 39 in or more at 95 C 203 F 88...

Page 239: ...leaner nozzle pressure is 30 3 5 kg cm2 427 498 psi 2 942 3 432 kPa keep a distance of at least 40 SO e m 1 5 75 9 69 inJ between the radiator core and cleaner nozzle INSPECTION OF RADIATO R 1 INSPECT RADIATOR CAP Using a radiator cap tester pump the tester and measure the relief valve opening pressure Standard opening pressure 0 75 1 0 5 kg cm 1 0 7 1 4 9 psi 74 103 kPal Minimum opening pressure ...

Page 240: ... ICATION SYSTEM TROUBLESHOOTING OIL PRESSURE CHECK REPLACEMENT OF ENGINE O I L Page LU 2 LU 3 AND Oil FilTER lU 4 OIL PUMP L U 6 OIL COOLER ANO RELIEF VALVE LU 1 S OIL NOZZLES AND CHECK VALVES 1 1 2 H TI LU 20 II I ...

Page 241: ... _ f a u l Y _ _ _ _ _ _ _ _ _ _ _ Low oil pressure Oil leakage Relief vahle faulty Oil pump faulty Engine oil poor quality Crankshafl bearing fauhy Repair as necessary Repair relief valve Repair oil pump Replace engine oil Replace bearing onneCllng rod bearing faulty Oil filter clOgge _ d_ _ _ _ _ _ _ _ _ _ _ _ High oil pressure Relief vaive raullY Replace bearing Replace oil filter Repair relief...

Page 242: ...charger 2 CHECK E N G I N E OIL LEVEL The oil level should be between the L and F marks on the le el gauge If low check for leakage and add oil u p to the F mark 3 REMOVE OIL PRESSURE SWITCH OR SENDER GAUGE 4 INSTA L L OIL PRESSURE GAUGE 5 START ENGINE Start engine and w a r m it up to normal opera ting tem perature 6 CHECK OIL PRESSURE O i l pressure At idle 0 3 kg cm2 4 3 psi 29 kPal or more At ...

Page 243: ...nd to where you feel resistance e Using SST tighten i t another 1 tum S S T 09228 600 1 0 FILL WITH ENGINE OIL a Clean and inStall the oil drain plug with a new gasket Torque the drain plug Torque 400 kg em 29 rt Ib 39 N m b Fill the engine with new oil API grade CC CD or bet ter NOTE Be sure to use C D type or belter for the vehicle with turbocharger Capacity Drain and refill w o Oil filter chang...

Page 244: ...__________ ILLlUJIBRICATIDN SYSTEM Oil Pump OIL P U M P LU 5 REMOVAL OF OIL NOTE P U M P strain r s h n repairing the a u d be removed an 1cie d the oil pan and ...

Page 245: ...nkshaft cl ockwIse and set the 3 timing mark of the camshafl liming gear and the key groove of the crankshaft timing gear as shown 6 REMOVE AUTOMATIC TIMER NO 2 NO 1 IDLE GEAR AND CRANKSHAFT TIMING GEAR See steps 1 15 to 17 on pages EM SO t o B21 7 REMOVE CAMSHAFT TIMING GEAR 8 a Using SST remove the bolt and plate washer holding the camshaft to l he liming gear SST 09278 540 1 2 hi Using SST remo...

Page 246: ...TRAIN E R AND OIL PIPE a Remove the two bolts two nuts oil strainer and gasket b Remove the union boll two n uts oil pipe and gaskets 1 0 1 2H Tl REMOVE STI F F E N I N G PLATE Insert the SST blade between the stiffening plate and cylinder block cut off applied sealer and remove the stiffening plale SST 09032 00 1 00 CAUTIO N D o n o t u s e S S T for t h e t i m i n g gear case s i d e and rear o...

Page 247: ... _ i Body ear Case Non reusable part COMPONE NTS DI SASSEM B LY 1 REMOVER OF OIL P U M P R ELiEF VALVE emove the plug gasket S pnng and relief valve 2 REMOVEDRIV a Remove Ih ND DRIVEN ROTORS b Remo eig h t screws and ve t h e d rive and d all pump cover riven rotors ...

Page 248: ... gauge and precision straight edge measure the clearance belween the rotor and precision straight edge Sta ndard side clearance 0 035 0 090 mm 0 001 4 0 0036 in Maximum side clearance 0 1 5 mm 10 0069 in 1 If the clearance is g rea ler than ma imum replace the rotors If necessary replace the oil pump body C Inspect Rotor Tip Clearance Using a feeler gauge measure Ihe clearance between the drive an...

Page 249: ...rning the crankshaft CAUTIO N Do not turn the crankshaft more than 1 4 revolution c Using a chisel and hammer lap the drive spline out of the hole until SST can be hooked to spline s end d Using SST remove the drive spline SST 09950 200 1 7 2 INSTALL NEW DRIVE SPLINE a Using SST and a hammer lap in the drive spline SST 09608 3 5 0 1 4 09608 060401 b Install the two set keys ...

Page 250: ... RELIEF VALVE Instatl the relief valve a n d spring with a new gasket and the plug Torque 500 kg em 36 ft Ib 49 N m INSTALLATION OF OIL P U M P See page L U 51 1 INSTALL OIL PUMP NOTE Use the bolts indicated A and 8 la Apply a light coat o f engine oil to a n e w O ring and place the O ring i n position on the injection pump retainer b Place a new gasket in position on the cylinder block k Install...

Page 251: ...e figure Seal packing Part No 08826 00080 or equivant Install a nozzle thai has been cut to the 3 mm 0 1 2 in opening NOTE Avoid applying an excess amount to the surface Be especially careful near oil passages Parts must be assembled within 1 5 minutes of application Otherwise the material must be removed and reapplied Immediately remove nozzle from t ube and reinstall cap tel Attach the stiffenin...

Page 252: ...has been cut to t he 3 mm 0 1 2 in opening NOTE Avoid applying a n excess amount to the surface Be especially careful near oil passages Paris must be assembled within 15 minutes of application Otherwise the material must be removed and reapplied Immediately remove nozzle from tube and reinstall cap c Install t he oil pan wilh the twenty eig h t and twa nuts Torque 1 30 kg em 9 rt Ib 1 3 N m 5 I NS...

Page 253: ... engine oil on the t hreads and under the bolt heDds e Inslall the thrust plate with the two bolts Torq ue the bolts Torque 475 kg em 34 ft Ib 47 N m 8 INSTALL TIMING GEAR COVER AND CRANKSHAFT PULLEY See steps 12 to 1 4 on pages EM 91 and 92 9 I N STALL WATER P U M P PUllEY AND FAN See page CO l 0 1 0 I NSTA LL A N D ADJUST DRIVE BELT See page CH 6 1 1 FILL WITH ENGINE OIL See page LU 4 1 2 START ...

Page 254: ...LUB RICATION S Y STEM Oil Cooler and Relief Valve l U 1 6 cm h Ib Specified torque Non reusable parI OIL COOLER AN D RELIEF VALVE COMPONE NTS Gaskel I I 280 j20 2jU ...

Page 255: ...80 5 REMOVE AUTOMATIC TIMER See page FU 22 6_ 12H MIT wi EDIC SYSTE M REMOVE E D I C MOTOR 7 2H MIT w o EDIC SYSTEM REMOVE OVERINJ ECTION MAGNET 8 REMOVe INJECTION PUMP See page fU 30 and 3 1 9 REMOVE OIL FILT E R See page LU 4 1 0 REMOVE RELIEF VALVE Remove the plug gasket spring and relief valve 1 REMOVE OIL FilTER BRACKET Remove the lour boils bracket and gasket 1 2 REMOVE O I L COOLER AND Oil ...

Page 256: ...I N S PECTION OF OIL COOL E R AND RELIEF VALVE INSPECT RELIEF VALVE 2 C o a t the val le w i t h e n g i n e oil and check t h a t it falls smoothly into the val le hole by its own weigh If operation is nol a s speci fied replace the relief valve I f necessary replace t h e oit filler bracket I NSPECT OIL COOLER Check the oil cooler for damage or clogging ...

Page 257: ...rings Install the four nuts Torque 250 kg em 1 8 ft lb 2 5 N m 2 INSTALL O I L C O O L E R AND OIL C O O L E R CASE ASSEMBLY NOTE Use the bolts indicated A and B Install a new gasket the oil cooler and oil cooler case assembly with the twenty four boils Torque 185 kg em 1 3 ft lb 1 8 N m 3 INSTA L L OIL F I LTER BRACKET NOTE Use the bolts indicated A 8 and C Install a new gasket and the oil filter...

Page 258: ... 7 2H MiT wi EDIC SYSTEMI INSTALL EDIC MOTOR 8 2H MiT w o EDIC SYSTEMI INSTALL OVERI NJECTION MAGNET 9 INSTAll AUTOMATIC TIMER ISee page fU 2Sl 1 0 INSTALL TIMING GEAR COVER AND CRANKSHAFT PULLEY ISee steps 12 to 14 on pages EM 91 and 92 1 1 INSTALL WATER PUMP PULLEY AND FAN See page CO 1 0 1 2 INSTALL AND ADJUST DRIVE BELT ISee page CH Sl 1 3 FILL WITH ENGINE COOLANT See page CO 3 1 4 START ENGIN...

Page 259: ...TION SYSTEM Oil Nozzles and C heck Valves l 12H TI it Ib Specif ied torque Non reusable part OIL NOZZLES A N D CHECK VALVES 1 2H T COMPON ENTS l Slif fening Plate Gasket 6 iiiQ I i _ Oil S rainer 1 Oil Pan mr Gaskel ...

Page 260: ...N ANO STIFFENING PLATE See steps 8 to 12 on pages lU 6 and 7 3 REM OVE OIL NOZZLES AND CHECK VALVES INSPECTION OF OIL NOZZLE A N D CHECK VALVES 1 INSPECT CHECK VALVE 2 Push t h e valve w i h a wooden s l i C k to check to c h e c k if it is stuck If operating i s not as specified replace the check valve INSPECT OIL NOZZLES Check the oil nozzle for damage o r clogging ...

Page 261: ...ES a Align the pin of the oil nozzle with t h e pin hole of the cylinder block bl I nstall the oil nozzles and check valves Torque the check valve Torque 275 kg em 120 It lb 27 N m 2 INSTALL STIFFENING PLATE AND OIL PAN See steps 2 to 4 on pages L U 1 2 and 1 3 3 FilL WITH ENGINE Oil See page L U 4J 4 START ENGINE CHECK FOR LEAKS 5 RECHECK ENGINE OIL lEVEL See page lU 3J ...

Page 262: ...G SYSTEM 1 1 2H TJ TROUBLESHOOTING ST 1 Page ST 2 ST 8 ST 1 0 STARTING SYSTEM CIRCUIT ST 1 0 STARTER ST 1 1 STARTER RELAY 5T 20 ELECTRICAL DIESEL INJECTION CONTROL EDIC SYSTEM 12H MIT wi EDIC System ST 21 OVERINJECTION MAGNET 2H MIT w o EDIC System ST 23 ...

Page 263: ...y 24V Type H J 7 5 Series Ignition SwitCh Fusible Link o 0 Battery IG ST2 PRE HEATING SYSTE M 2H Super G low Type Europe Austra lia and Ca nada SYSTEM CIRCUIT Glow Plug Indicator Light Waler Temperat ure Sensor Glow Plug Indicator Light To Regulator Terminal L Waler Temperalure Sensor ...

Page 264: ...s for inspection procedures See page EM 1 1 J TIMER CHARACTERISTIC DIAGRAM 80 I _ pre eatin Ti e I V 1 light lighting Time i I J 30 20 1 0 0 1 0 20 30 40 50 60 70 22 4J 1 4 32 SOl 68 86 1 04 2 2 1 40 1 58 Water Temperature C OF Europe and Canada f24V Type o li9 t ug ting ime V _ I f r Pre healin Time t J L J h 4 30 20 1 0 0 1 0 20 30 0 50 60 70 2 2 1 41 1 4 32 501 681 186 1 1 04 1 1 2 2 1 401 1 1 ...

Page 265: ...specif ied replace the relay 2 INSPECT RELAY OPERATION a Apply battery voltage ac ross terminals E and g bl Check that there is continuity between terminals B and G I I operation is n o t a s specified replace the relay No 2 G low Plug Relay LOCATION On the fender apron i n the engine compart ment 1 INSPECT RELAY CONTlNUtTY al Check that there is continuity between terminals E and g b C heck that ...

Page 266: ... an open circuit or shorlen the life of the plugs Avoid getting oil and gasoline on the glow plugs when cleaning During inspection use a cloth be sure to wipe any oil off the glow plug terminals and bakelite washer Be careful not to apply more than 7 volts to the glow plug as it could cause an open circuil G low Plug Current Sensor INSPECT G LOW PLUG CURRENT SENSOR Using an ohmmeter check that the...

Page 267: ...n ohmmeter check the resistance between the water temperature sensor terminals Resistance Reter to the chart I f the resistance is not as specified replace the water lem perature sensor 5 40 r 20 1 0 8 6 I 0 8 0 6 0 2 0_1 20 0 20 40 60 80 1 00 1 20 4l 32 68l 1 04 1 40 76 2 1 2 248 Temperature c OF Ignition Main Relay See page CH 25l ...

Page 268: ...he instrument panel on the HJ80 In the cowl on the passenger side HJ7 5 Under the instrument panel on the passenger side INSPECT PRE HEATING TIMER a T u r n the ignition switch to G and measure the lig ht ing time of the glow indicator light L i g h t l i g h t i n g time 16 1 9 6 seconds b Check thai there is voltage a t terminal S of the pre heating timer when the starter switch IS turned to G G...

Page 269: ... SYSTEM CIRCUIT I N S PECTION O F COMPO N E NTS Pre heating Timer LOCATION Intake Heater Indicator Light Water Temper31ure Sensor HJ60 In the cowl on the passenger side HJ7 S Under the l nSlrument panel on the passenger side Refer to Diesel Electrical System Diagnosis for Inspection procedures See page EM l 3 ...

Page 270: ...ke Heater r o 32 INSPECT INTA K E H EATER 1 0 ISO Using an ohmmeter check that t here is continuity be tween terminal s of lhe intake heater and ground I I continuity is not as specified replace the relay No 1 and No 2 I ntake H eater Relays See No 1 G low Plug Relay on page ST 41 Water Temperature Sensor ISee page ST 6 Ignition Main Relay See page CH 2S ...

Page 271: ...on SWII _ C_ h _ _ _ _ _ _ _ _ _ R _ e p_ 30 _ e _ 9 _ d_ 0 _ _ W _ _ IC _ h_ _ L_ 1 Engine cranks slowly Slaner keeps running Starler spins bul engine will nOl crank Fusible link O 5G Battery charge low Check ballery specific gravity CH 6 Battery cables loose corroded or worn Starter faulty Charge 01 repl ace bal 1 e ry Repair O replace cables Repair starter Slarter laully Repair star1er Ignition...

Page 272: ...g OISASSEM BLY OF STARTER 1 REMOVE FIELD FRAME AND ARMATURE ASSEMBLY ST 1 1 a Remove the nul a nd disconnect the leed wire from the magnetic switch terminal b Remove the two through bolts e Pull out the field frame together with the armalure d Remove the fell seal and lock plate ...

Page 273: ...tch assembly 3 Return spring 4 Idle gear 5 Bearing 6 Plate washer 3 REMOVE STEEL BAll Using a mag netic finger remove the steel ball from the clutch shaft hole 4 REMOVE BRUSH HOLDER a Remove the two screws and end cover from the field frame b Using a screwdriver hold the s pring back and dis connect the brush from the brush holder Disconnect the fOur brushes and remove the brush holder 5 REMOVE AR...

Page 274: ...b e t w e e n the commutator a n d armalUre coil core If there is continu ity replace the armature Commutator 1 INSPECT COMMUTATOR FOR DI RTY A N D BURNT S U RFACE I f the surface is dirty or burnt correct with sandpaper No 400 or a lathe 2 INSPECT COMM UTATOR CIRCLE R U N O U T M a x i mum circle runou t 0 0 5 mm 0 0020 i n If the circle r u n O u t i s greater t h a n maxim um correct with a lat...

Page 275: ... conlinuity replace Ihe field frame INSPECT FIELD COIL FOR G R o U N D Using an ohmmeter checkt h a t there is no continuity bet ween Ihe field coil end and field frame I f there is continuity repair or replace Ihe field frame Brushes I NSPECT BRUSH LENGTH Using calipers measure the brush length Standard length 20 6 mm 0 807 in Minimum length 1 3 0 mm 0 5 1 2 in II the length is less than minim um...

Page 276: ...sembly for wear or damage Replace if damaged If damaged also check the flywheel ring gear for wear or damage 2 INSPECT CLUTCH PINION GEAR Rotate the pinion gear clockwise and c heck that it turns f reely Try to rotate the pinion gear countercl ockwise and check that it locks If necessary replace the clutch assembly Bearings I INSPECT BEARINGS Turn eac h bearing by hand while applying inward force ...

Page 277: ... PERFORM PULL IN COIL OPEN CIRCUIT TEST Using a n ohm meter check thai there is continui ty be tween terminals 50 and C If t h ere is no continu ity replace the magnetic switch 2 PERFORM HOLD IN COIL OPEN C I R C U I T TEST Using an ohmmeter c heck that t here is continuity be tween terminal 50 a nd the swi tch body If there is no continu ity replace the magnetic switch ...

Page 278: ... armature b Using a screwdriver hold the brush spring back and connect the brush i nto the brush holder Connect the four brushes NOTE Check that the positive l J lead wiles are nal grounded e Inslall the end caver with the two screws 3 INSERT STEEL BALL I NTO CLUTCH S H AFT HOLE aJ Apply grease to the steel ball bl Insert the steel ball into the clutch shaf t hole 4 I N STALL C LUTCH ASSEMBLY AND ...

Page 279: ...s 5 INSTALL FIELD FRAME AND ARMATURE ASSEMBLV a Place the felt seal in position on the armature shaft bl Align the lock plate with the notch o n the field frame e Install the field frame and armature assembly with the two throug hl boils dl Connect the lead wire to the magnetic switch ter minal and install the nut ...

Page 280: ...onnecl t h e negative 1 1 lead from terminal C C heck thai the pinion gear remains out If the pinion gear returns inward replace the magnetic switch assembly 3 INS PECT PLUNGER RETURN Disconnect the negative 1 lead from the switch body Check thai the pinion gear returns inward If the pinion gear does not return replace the magnetic switch assembly 4 PERFORM NO LOAD PERFORMANCE TEST a Connect the b...

Page 281: ...UITY a Check that there i s continuity between terminals E and ST Ib Check that there is no continuity between terminal B and MG If continuity is nOI as specified replace the relay 2 INSPECT RELAY OPE RATION a Apply battery voltage across terminals E and ST bl C heck that there is continuity between terminals B and MG If operation is not as specified replace the relay ...

Page 282: ...IG Oil O N VEHICLE I N S PECTION 1 IN SPECT CONN ECTING ROD LENGTH tal Disconnect the connector from the oil pressure switch bl When the ignition switch is turned to ON the fuel control motor lever and pump adjusting lever should be positioned between the marks If necessary adjust with the connecting rod 2 INSPECT LEVER OPERATION A Starting Overinjection IOverinjection Posi1ionl When the ignition ...

Page 283: ...er should move to the stop position and the engine should stop I N S PECTION OF COMPONENTS EDIC Motor INSPECT EDIC MOTOR C heck the continuity between the terminals and body ground __________ Terminal lever Posili Overinjection position Drive position SlOP position 0 1 If continuity is not as specified replace the motor Oil Pressure Switch INSPECT OIL PRESSURE SWITCH Bod C heck t he continuity bet...

Page 284: ...ET 2H M T w o EDIC System ON VEH ICLE INS PECTION 1 INSPECT CONNECTING WIRE LENGTH When the ignition switch is turned to ON the pump adjusting lever should be positioned as shown 2 INSPECT LEVER OPERATION When the ignition switch is turned 10 START the pump adjusting lever should move to the overjection position ...

Page 285: ...INSPECTION ALTERNATOR _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ALTERNATOR REGULATOR CHARGE LIGHT RELAY wi le Regulator 1 2V Type CHARGE LIGHT RELAY wI le Regulator 24V Typell IGN ITION MAIN RELAY HJ60 6 1 Series CH l Page CH 2 CH 2 CH 3 CH 6 CH l 0 CH 21 CH 23 CH 24 CH 25 E J ...

Page 286: ...g TRO U B LESH OOTI NG Possible cause Fuse blown Light burned out V filing connection loose Alterll Jtcr regulator faultv C h a rge light relay Ie regulater faulty Drive belt loose or worn Battery cables loose corroded or worn Fuse blown Ignition main relay faulty Fusible link blown I Alternator regulator IC regula ter charge light relay or alternator faulty Wiring faulty Remedy Check CHARGE and E...

Page 287: ...t CHARG I N G SYSTE M C I RC U IT HJ60 6 1 Series w o IC Regulatorl Fusible Link Bat tery 24V Typel Alterncl or RegulaTor HJ60 61 Series wi IC Regulator 1 2V Type IG Fusible g Link N 0 Ignition Main Relay Ballery Alternator i1 L u U IG CH 3 ...

Page 288: ...t CHARG ING SYSTEM CIRCUIT Cont d HJ60 6 1 Series wI IC Regulator 24V Type Fusible link Batt ery Battery Ignit ion Main Relay HJ75 Series w o I C Regulator Ignillon Switch Fusible Link 1 0Y fuse ENGINE l 5A Charge Warning light Fuse CHARGE 7 SA ...

Page 289: ...CHARGING S Y STEM Charging System Circuit C H 5 CHARG I N G SYSTEM C I RC U IT Cont d HJ75 Series wi Ie Regulator Fusible Link Fuse ENGINE 1 5A Charge Warning Light Charge Lighl Relay ...

Page 290: ...E BELT lal Visually c heck the drive belt for cracks oiliness or wear C heck that the bell does not touch the bottom of the pulley g roove If necessary replace the drive bell b l C n d Using a bell tension gauge check lhe drive belt ten sian Belt tension gauge Nippondenso BTG 20 95506 00020 or Borroughs No 8T 3 3 73F Drive belt tension New belt 1 25 25 I b Used b e l t 1 1 5 1 5 Ib I f the belt te...

Page 291: ... been used on a running engine for 5 minutes or more After installing a new belt run the engine for about 5 minutes and recheck the deflection 4 VISU ALLY CHECK ALTERNATOR WIRING A N D LISTEN FO R ABNORMAL NOISES s Check that the wiring is in good condition bl C heck that there are no abnormal noises from the allernator while the engine is running 6 INSPECT CHARGE WARNING LIGHT CIRCUIT a Warm up t...

Page 292: ...from the positive 1 ter minal of the ammeter 0 terminal B of the alterna tor C onnect the positive 1 probe of the voltmeter O terminal B of the alternator Ground the negative probe of the voltmeter b Check the charging circuit a s follows With the engine running from idle 10 2 000 Ipm check the reading on the ammeter and voltmeter w o Ie Regulator Standard amperage 10 A or less Standard voltage 1 ...

Page 293: ...tmeter I f the voltage reading is more than standard vollage rep lace the IC regulator If the voltage reading is less than standard voltage check the alternato r 7 CHECK CHARGING CIRCUIT WITH LOAD a With the engine running at 2 000 rpm turn on the high beam headlig hts and place the heater fan con trOl switch al HL b Check the reading on the ammeter Standard amperage 2V type 30 A or more 24V type ...

Page 294: ...f RUbberWasher ReCld e H 10 ul O W he Spacer A o O S to T O l d I B u h Holdeo 1 I r a T 1 l _ r wI IC Regulator R End me V cuum Pump S Orive End Frame f l 1 f i t IC Re9ulato Terminal I b Rub n ulato Aliemalo Wi be Wa h riP J e B u h HoIO Co B U h Ho d RO lo St to Wo fzf SP R n9 til 9 q il J o I I So p R 09 Te m T mi part Rectifier Holder 0 ...

Page 295: ...C ring 2 REMOVE BRUSH HOLDER COVER w o IC Regulator Remove the two nuts terminal insulator rubber washer brush holder cover and insulator washer wi Ie Regu lator Remove the two nuts terminal insulalOr rubber washer and brush holder cover 3 Iw o IC REGU LATORI REMOVE BRUSH HOLDER a D isconnect the lead wire bl Remove the nut and brush holder ...

Page 296: ... brush holder and I e Reg ulator assembly 5 w IC REGU LATOR 6 SEPARATE BRUSH HOLDER AND Ie REGU LATOR a Remove the two screws and alternator wire b Remove the two screws and separate the brush holder and Ie regulator REMOVE DRIVE E N D FRAME AND ROTOR ASSEMBLY FROM STATOR a w o Ie Regulator Remove the three through screws b wi Ie RegulalOr Remove the four through screws ...

Page 297: ... out the rotor b Remove the spacer collar from the drive end frame Ie Remove the spacer ring and snap ring from the rotor shalt 9 REMOVE RECTIFIER END FRAME a wi Ie Regulator Remove the two rubber caps b Remove the four nuts and two terminal insulators Ie Remove l he rectifier end frame d Remove the two terminal bushings and collars from the rectifier holder studs 1 0 REMOVE RECTIFIER HOLDER Hold ...

Page 298: ... If there is continui ty replace the rOlor 3 INSPECT SLIP RINGS t1 Check that the slip rings are not rough or scored rough or scored replace the rotor b Using calipers measure the slip ring diameter Standard diameter 32 3 32 5 mm 1 1 272 1 280 in Minimum diameter 3 2 1 mm 1 264 in If the diameler is less Ihan minimum replace the rotOr Stator 1 I N S PECT STATOR FOR OPEN C I RCUIT Using an Ohmmeter...

Page 299: ... 0 787 in l e Check that the brush moves smoothly i n the bru s h holder f Cut off any excess wire Rectifiers 1 INSPECT POSITIVE RECTI FIER a Connect the ohmmeter positive probe t o the rec tifier terminal and the nagtive I probe to the rec tifier holder and check that there is no continuity b Reverse the ohmmeter probes and check that there is continuity If continu ity is not as specified replace...

Page 300: ...ghtly lap the beari n g with a plastic faced hammer 4 Retainer 51 Felt 6 Fell cover ASSE M B L Y O F ALTERNATOR S e e p a g e CH l 0 1 INSTA L L RECT I F I E R HOLDER TO STATOR Hold the rectif ier terminal with needle nose pliers while soldering the leads CAUTION Protect the recti fiers from heat 2 I N STALL RECT IFIER END FRAME TO RECTI F I E R HOLDER s Place the lwO insulator washers on the posi...

Page 301: ... the four nuts gl Check thai the wires are not touching the frame h wi Ie Regulator Install the two rubber caps to the positive studs of the rectifier holder 3 INSTALL ROTOR 4 a Install the snap ring on the rotor shaft groove b Slide the spacer ring onto the rotor shaft e Using a press press in the rotor I N STALL FAN A N D PULLEY a Mount the rotor in sa l t jaw vise bl Slide the spacer COllar ont...

Page 302: ...N m 5 ASSEMBLE DRIVE END FRAME A N D RECTI FIER E N D FRA M E a Assemble the drive e n d frame a n d rectifier end f rame fb w o Ie Regulatorl InSIall the t hree through screws Ie wi Ie Regulator Install the four through screws d Make sure the rolor rotales smoothly 6 lw o IC REGU LATOR INSTALL BRUSH HOLDER a Install the brush holder with the nul ...

Page 303: ...he two screws b Connect the two alternator wires to the terminal of the IC regulator with the two screws as shown 8 w IC REGULATOR INSTALL BRUSH HOLDER AND IC REGU LATO R ASSEMBLV la Install the brush holder and IC regulator assembly with the screw Connect the alternater wire to the terminal o f the IC regulator as shown b Install the alternator connector with the clamp and screw ...

Page 304: ...asher on terminal B dl Install the two nuts together with t h e alternator con nector wi Ie Regu latod al P lace the brush holder cover on t h e reChfier end frame bl P lace the terminal insulator and rubber washer on term inal B e Install the two nuts 1 0 INSTALL V AC U U M PUMP a I n S l a l i a n e w G r i n g o n t h e rect i f ier end frame bl Inslall the vacuum pump with the three bolls Torq...

Page 305: ...or 2 INSPECT RESISTANCE BETWEEN TERMINALS a Using an ohm meter measure the resistance between terminals IG and F Resistance Vollage regulatod At rest 0 n Pulled in 1 2V type 1 0 6 n 24V type 200 n b Measure the resistance between terminals E and L Resistance Voltage relay At rest 0 n Pul led in 1 2v type 1 02 n 24V type 1 99 n e MeaslIre the resistance between terminals B and E Resistance Voltage ...

Page 306: ...e 1 2V type Approx 24 n 24V type Appro x 1 02 n II any of the above checks are nOI positive replace the atternator reg ulator VO LTA GE ADJ USTMENT OF ALTE RNATOR REGU LATOR 1 ADJUST VOLTAGE REGULATOR Bend the reg ulator adjusting arm to adjust Regulating voltage 1 2V type 1 3 8 1 4 8 V 24V type 27 0 29 0 V 2 ADJUST VOLTAGE RELAV Bend the relay adjusting arm to adjust Relay actuating voltag e 1 2V...

Page 307: ... thai there is continuity bl Connect the oh mmeter positive 1 probe to terminal 4 and the negat ive I I probe to terminal 3 and check that there is no continuity Ie Check that there is no continuity between terminals 1 and 2 II continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION al Connect the positive 1 lead from the battery to ter minal 3 Con nect the negative I lead to te...

Page 308: ... that there is contmuity between terminals 1 and 2 b Check that there is continuity between terminals 1 and 4 If continuity is not as specif ied replace the relay 2 INSPECT RELAY OPERATION I C onnect lhe positive 1 1 lead trom the b lttery 10 ter minal 4 Connect the negalive 1 lead to terminal t o terminal 1 b Check that there i s n o continuity between terminals 1 and 2 If operation is not as spe...

Page 309: ...relay box 1 I N SPECT RELAY CONTI N U ITY a Check that there is continuity between terminals 1 and 3 b Check t h a t there is no continuity between terminals 2 and 4 I f continUity is nOI as specified replace the relay 2 I NSPECT RELAY OPERATION lal Apply battery voltage acrOSs terminals 1 and 3 b Check that there is coolinuity between terminals 2 and 4 If operation is 001 as specified replace the...

Page 310: ...A 1 S E RV I C E S PECI FICAT I O N S ENGINE MECHANICAL FUEl SYSTEM COOLING SYSTEM LUBRICATION SYSTEM STARTING SYSTEM CHARGING SYSTEM Page A 2 A S A 1 7 A 1 S A 1 9 A 1 9 ...

Page 311: ...US qts 8 6 US qts 1 0 3 US qts 1 0 9 US qts 3 6 Imp qts 2 5 Imp qts 7 1 Imp qts 8 5 Imp qts 9 1 Imp q t s 1 2 5 1 2 7 when fully charged at 20Ge 168QF 1 2 7 1 2 9 when fully charged at 20 C Be F 1 2 5 1 2 7 when fully charged II 20 C 168 Fi 1 1 5 15 Ib 1 2 5 2 J lb 1 0 1 3 mm 0 39 0 5 1 in 8 9 mm 0 3 1 0 35 in 1 0 5 1 2 5 kg cm 1 493 1 7 7 8 psi 1 0 2 9 6 1 2 2 5 8 kPa 1 1 5 1 2 5 kg em 1 6 3 6 1 ...

Page 312: ... to shaft oil clearance 2 B O g cm 398 psi 2 7 4 6 kPa or more 30 0 kg cm2 427 PSI 2 9 4 2 kPa or more 20 0 kg cm 2 84 psi 1 9 6 1 kPa 2 0 k9 cm 28 psi 1 96 kPa o _ _ e _ _ _ _ I 0 39 0 53 kg cmt 5 5 7 3 psi 38 5 2 kPa 0 1 3 mm 10 00 5 1 in or less 0 20 mm 0 0079 i n 0 20 mm 0 0079 in 30 4 5 600 30 4 5 7 5 0 4 5 1 4 2 0 mm 0 055 0 079 in 9 0 1 0 9 030 mm 0 3547 0 35 5 5 in 4 02 3 1 4 04 1 mm 0 5 5...

Page 313: ... 035 mm 2 0089 2 0092 in No 2 50 8 2 5 50 8 3 5 m m 2 00 1 0 2 00 1 4 in No 3 50 625 50 635 mm 1 993 1 1 9935 in No 4 50 4 2 5 50 435 m m 1 9 8 5 2 1 9 8 5 6 in U S 0 25 No 1 50 900 50 9 1 0 mm 2 0039 2 0043 in No 2 50 700 50 7 1 0 mm 1 9 9 6 1 1 9965 in No 3 50 500 50 5 1 0 mm 1 9 8 8 2 1 9886 in No 4 50 300 50 3 1 0 mm 1 9803 1 9807 in Bearing Inside diame ter STD size No 1 5 1 2 00 5 1 265 mm 2...

Page 314: ...ifter diameter TO size 2 2 1 7 2 2 1 9 mm 0 8728 0 8736 in O S 0 05 2 2 2 2 22 24 mm 0 8748 0 8756 in Cylinder block Warpage Limit 0 20 mm 0 00 7 9 in Cylinder bore diameter STD STO size 9 1 000 9 1 030 m m 3 7008 3 7020 in limit STO size 9 1 23 mm 6 5686 in OIS 0 50 9 1 7 3 rnrn 6 6046 in Piston and Piston diameter piston ring 2H STD size 90 930 90 960 m m 3 5 7 9 9 3 5 8 1 i n als 0 5 0 9 1 4 3 ...

Page 315: ...ter w lil S T D sue 1 STD size 2 Limit Main journal and crank pin Limil 0 040 0 240 m m 0 3 0 m m 2 930 2 980 mm 2 993 3 04 3 mm 3 055 3 1 0 5 mm 69 980 7 0 000 mm 69 730 69 740 mm 69 0480 6 9 490 rom 6 9 2 3 0 6 9 2 4 0 mm 6 8 9 S 0 6 8 9 9 0 mm 0 032 0 068 mm 0 1 0 mm 1 9 8 1 1 9 8 5 mm t 9 8 5 1 9 8 9 rom 1 9 8 9 1 9 9 3 mm 54 980 55 000 mm 54 730 5 4 7 40 mm 5 4 4 8 0 54 490 mm 5 4 2 3 0 5 4 2...

Page 316: ... Cylinder head 2 0 5 2 1 Intake manifold x Cylinder head 8 5 3 8 Fuel filter bracket x Cylinder head 3 7 5 2 7 37 F u e l pipe x Injection pump 2 80 20 28 Fuel hose x Injection pump 1 1 2H T 280 20 2 8 Glow plug x Cylinder head 2H 2 5 9 1 2 Camshaft timing gear x Camshaft 4 5 0 3 3 44 Automatic timer drive gear x Automatic Timer t 1 2H T 2 30 1 7 2 3 N o I i d l e g e a r x Cylinder block 4 7 5 3 ...

Page 317: ...n 0 80a mm 0 850 mm 0 900 mm 0 950 mm 0 9 7 5 mm 1 000 mm 1 0 2 5 mm 1 050 mm 1 0 7 5 mm 1 1 00 mm 1 1 2 5 mm 1 1 50 mm 1 1 7 5 mm 1 200 mm 1 2 2 5 mm 1 2 5 0 mm 1 2 1 5 mm 1 300 mm 1 325 mm 1 3 5 0 mm 1 3 7 5 mm 1 400 mm 0 03 94 in 0 04 1 3 in 0 0433 in 0 0453 in 0 04 7 2 in 0 049 2 in 0 05 1 2 in 0 0 5 3 1 in 0 05 5 1 in 0 05 7 1 in 0 0591 in 0 06 1 0 in 0 0630 in 0 0 6 5 0 in 0 0669 in 0 06B9 i...

Page 318: ...0 rpm Fuel must discharge within 40 seconds Discharge test Pressure at 600 rpm Discharge nozzle diameter Volume at 1 000 rpm Drive gear thrust clearance 1 8 2 2 kg cm 26 31 pSi 1 7 7 2 1 6 kPa 1 54 mm 0 0606 in 900 ccfmin 54 9 cu in lmin or more A 9 Automatic timer 12Hl STD Limit 0 0 1 0 0 200 mm 0 30 m m 0 0004 0 0 0 7 9 i n 0 0 1 1 8 in Drive gear thrust washer thickness Timer spring hee length ...

Page 319: ...washer thickness I 0 0 1 0 0 200 mm 0 30 mm 0 1 mm 0 35 mm 0 5 mm 58 8 mm 0 50 or less 5 5 6 5 0 5 m m 0 6 mm 0 7 mm 0 8 mm 0 9 m m 1 0 mm 0 0004 0 00 7 9 i n 0 0 1 1 8 in 0 004 in 0 0 1 4 in 0 020 in 2 3 1 5 in 0 020 in 0 024 in 0 028 In 0 031 in 0 035 in 0 039 in Clockwise as seen drive side 0 03 0 05 mm 0 1 mm 0 1 0 mm 0 1 2 mm 0 1 4 mm 0 1 6 mm 0 1 8 mm 0 50 mm 1 20 9 4 2 oz or less 0 00 1 2 0...

Page 320: ...30 9 m m 3 1 1 mm 3 1 3 mm 3 1 5 mm 3 1 7 mm 3 1 9 mm 0 02 0 1 0 m m 1 60 mm 1 6 5 mm 1 70 m m 1 7 5 mm 1 80 mm 1 8 5 mm 1 90 mm 1 9 5 mm 2 00 mm 2 1 0 mm 2 20 mm 2 30 m m 0 0 5 0 2 0 m m 0 1 m m 0 2 m m 0 5 m m 0 0 3 0 0 5 mm 0 1 m m 0 1 0 m m 0 1 2 m m 0 1 4 mrf 0 1 6 mm 0 1 8 mm 0 50 mm 0 1 0 mm 0 1 5 mm 0 30 mm 0 50 m m 1 00 mm 1 5 0 mm 1 20 g 14 2 oz or less 0 059 0 079 in 1 9 5 7 1 9 7 2 In ...

Page 321: ...O 24 A ON 1 2 SO 1 2 A 1 5 1 25 kg cm2 1 1 6 3 6 1 7 7 8 pSI 1 1 2 7 8 1 2 258 kPal 1 70 1 80 kg emt 12 4 1 8 2 S60 psi 1 6 6 7 1 7 6 5 1 kPa 6 0 mm 2 0 mm 600 mm 2S mm 0 98 in or more 0 236 in 0 079 in 23 6 in 40 4S C 1 04 1 1 3cF 2H 0 5 kg cm 7 1 psi 28 4 psi 49 kPa 1 96 kPa ___ _ _ _ 2 _ _ T _ _ _ _ _ _ _ _ _ _ _ 2 0 kg cm Control Rack Sliding resistance Pump al 0 rpm 20 g 4 2 oz or less _ _ _ ...

Page 322: ... 0 200 10 4451 7 9 390 500 f 1 6 0 1 00 200 10 6301 1 2 H T MIT 1 0 7 1 1 00 200 I Cold weather 0 4 2 1 0 7 ISpeC 1 750 200 B 9 340 500 10 3501 0 0433 in 0 04 7 2 in 0 05 1 9 in 0 05 5 1 in Injection olume ee CU in 1 2 8 1 5 0 0 7 8 0 92 4 1 5 3 10 2 5 0 32 8 2 9 2 0 5 0 0 56 8 5 1 0 1 0 52 0 6 2 2 0 5 0 0 1 2 0 3 1 1 9 8 1 2 0 0 60 0 73 4 1 5 3 0 2 5 0 32 8 2 9 2 10 50 0 5 6 8 5 1 0 1 0 5 2 0 6 2...

Page 323: ...2 1 0 69 0 7 5 1 0 7 1 7 5 0 200 1 1 3 1 2 5 1 2 0 07 10 4 2 1 10 69 0 76 1 8 9 3 90 500 g 6 I I 1 5 0 091 10 350 I njection Pump Adjustment Governor 2H MIT Vacuum chamber Pressure drop _______ _ 1 0 seconds or more Main spring Speed control sprmg Idle spring Pump rpm Vacuum 1 6 00 6 2 g 3 g Rack position m m in 1 0 3 1 0 9 0 406 0 4 29 I c _ _ _ I_ ___ _ __ 7 Adjusting s h i m 1 h ickness 0 5 mm ...

Page 324: ...7 5 23 31 1 000 258 282 11 5 7 1 7 2 I njection Pump Adjustment Governor 2H AIT and 1 2H T Rack positiOn mm in 1 1 3 0 4 4 5 Or more 7 7 7 9 0 303 0 3 1 1 l 5 6 6 6 0 220 0 2 60 1 5 9 1020 0232 3 4 4 8 0 1 34 0 1 89 1 2 9 1 3 7 10 508 0 539 8 6 9 2 10 3 3 9 0 3621 6 9 8 3 0 2 7 2 0 327 6 0 6 8 0 2 3 6 0 268 4 3 5 7 1 0 6 9 0 2 2 41 1 2 4 1 3 0 10 488 0 5 1 2 1 I 8 7 9 3 10 343 0 366 7 6 9 0 0 299 ...

Page 325: ... 2 5 2 or less Boosl 800st compensator Adjusting Pump rpm comp nsator Rack position 1 2H T lever position pressure m m finJ IcgJcm psi kPa 0 9 8 1 0 4 0 3 8 6 OA09 MaJO imum 500 0 1 2 1 7 1 2 1 0 3 1 1 1 0 406 0 43 7 Total injection Adjusting Boot compensator Pump Measuring Total injection volume volume Ilem Pressure of each cvlinder lever position kg cm psi kPal pm strokes cc leu in 500 1 000 2 1...

Page 326: ...l COOLING SYSTEM Specifications ne cO lant capacity Thermostat Valve opening temperature S2 C type 88 C type Valve opening travel 32 mm bolt head 82 C type al 9 5 C 203 F Radiator B8 C type at OO C 1 2 1 2 F Relief v llve opening pressure STO Limit Torque Spec ifications Part lightened kg em f t Ib N m 700 5 1 350 25 700 5 1 1 8 5 1 3 500 36 1 25 300 2 2 5 0 0 3 6 1 500 1 09 5 00 36 9 5 82 in Ib 2...

Page 327: ...pan x Cylinder block Oi l pan x Timing gear case Oil pan x Reilr oil seal retainer Oil cooler x Oil cooler case Oil cooler case x Cylinder block Oil filter bracket x Oil cooler case Plug 01 oil cooler rehef valve 011 nozzle x Cylinder block ee pag A_ 2 _ _ _ _ _ _ _ _ _ _ 0 3 kg cm 14 3 psi 29 k P a l or more 2 5 6 0 kgicm 1 36 85 psi 2 4 5 5 8 8 kPa 0 1 44 0 2 1 9 mm 0 0057 O OAO mm 0 035 0 090 m...

Page 328: ... 4 0 kg 7 1 8 8 Ib 3 1 39 N 3 6 mm 1 42 i n 35 m m 1 38 i n 0 7 mm 0 028 in 0 2 mm 0 008 in 0 05 mm 0 0020 in CHARGING SYSTEM Battery specific gravity Drive bell tension or deflection Alternator Alternator regulator Rated output Rotor coil resistance wlo Ie regulator wI Ie regulator Slip ring diameter Brush Il posed lenglh 1 2V type 24V type 1 2V type 24V type STO limit STO limit Regulating voltag...

Page 329: ...B 1 STA N DARD B O LT TO RQ U E S P EC I F ICAT I O N S Page STAN DARD BOLT TORQUE SPECIFICATIONS 8 2 ...

Page 330: ... _ _ _ I_ __ __ M _ _ _ k___t _ C _ _ _ j He _ I Bolt 4 4T Stud boll heod bolt 0 head NO _ _ NO mark 7 7T 1 o No m 4T ob 1t I 0 0 hexagon boll w washer U No mark T r r Hexagon head bolt Two U d j n g 5T S I Q CJ Two h I protruding 6T wlwas er n hnes h6Kagon bolt 1 Hexagon head boh Three protruding lines 7T Welded bolt 4T 6T 4T ...

Page 331: ... 6 0 5 5 7 5 8 50 6 1 8 3 1 6 1 5 1 1 5 0 8 3 1 1 3 6 1 6 5 5 6 in Ib 6 4 8 1 2 5 1 6 0 1 2 1 6 1 0 I 1 2 5 330 2 4 3 2 6T 1 2 1 2 5 600 4 3 5 9 1 4 1 5 930 6 7 9 1 1 6 I 1 5 1 400 1 0 1 1 3 7 I 6 80 69 in Ib 7 8 I 90 78 in Ib 8 8 8 1 2 5 9 5 1 4 1 9 2 1 5 1 6 2 6T 1 0 1 2 5 400 29 39 I 440 3 2 43 1 2 1 2 5 730 53 72 8 1 0 5 9 7 9 1 4 1 5 1 2 5 0 9 0 1 2 3 I 6 1 1 0 8 1 1 1 2 0 9 1 2 8 1 2 5 2 60 ...

Page 332: ...SST AND S S M SST ISPECIAl SERVICE TOOLS SSM ISPECIAl SE RVICE MATERIALS C l Page C 2 C 7 ...

Page 333: ...60 1 1 oigo 092 15 00 1 00 09215 001 20 I 092 1 5 001 3Ql NOTE Classification A SST required for vehicle inspections and minor repairs and multipurpose SST B SST required for major r pairs involving disassembly of com ponents C SST required for rather special less frequent work not of classifiable as either A or B OltPt Seall Culter r n lOmm eR mo h ullev I Sh tl Pulley flf ul Y a ar le A 1 Bonl A...

Page 334: ...921 5 00160 Shatt A 1 092 1 5 001601 P I II 09215 00210 ltmover t Fleplacef 0921 5 00280 Iftemover AltplaclI l 09222 61010 connect ngROd u er B 09223 56010 g P B o 09228 3401 0 IOil f lter Wrench A 09228 600 10 Oil Fil eot Wrenchl A o O c c 09231 00101 v ft U OISI B t i237 00010 V I e J 109237 00020 lBaaring Suwl c J 109231 l100301 86 011 Sta 109237 00040 IShait A 1 ...

Page 335: ...C _ I_ G I m9260 O I01 I IROO NO W I V 109260 780201 I Screw Plug W mc hl 09262 1601 0 7A e 09267 7601 1 I lricTIme 09267 76020l AUlomalU TImet Re nove I109210 1601 01 1 Del very V JIve I Holder Wrench I I 0927 1 7601 1 DellV I I Varvft e u Clo 09272 1601 11 Tappet Roller CllImpl 09273 7601 t ITappe t Ciampi lO9274 4601 1 l Tllppel tflsenl a d 09275 4601 0 P1uf l je C amp ...

Page 336: ...11 09287 58010 109288 46 111 O9289 OO101 09260 58010 9267 760301 09268 4 Ul 09278 54012 09283 76021 Plunger Spring Hold Irj Adjll iog Wrench geHolder s tioe m Camshah El eanng COM RepjllCM c o OOP mo Camsh afl S an Cuo Pul er InjectiOn pumo I Cam hart 80ilring Puller AdjUlhng nieel onpump Camlhal Beanng C up Aeplacer I I lo oclKln Pump Tool S1 1 I IBuShing nle ShaH HOId r g t I wtLOC C B B A EM FU...

Page 337: ...9308 10010 09330 00021 r A 09608 12010 Q e Q9608 000401 8 09608 3501 4 1 D9601l 0604tI 09960 2001 7 09992 00023 U OD 09992 00240 1nI6ChOnCamShOft Belring COM Replacer ujl r rSe O l Cup Aomo ed OilSeal Pwl rl n O llnoe front Hub 8 OrNe OB u U u Plac r AKIOHUb Driv P nlOn Bearing Tool Set flontHublnoel ge nng Cone Rep ce I Un lersaI Puller tS5ion r 8 C A A B A A EM FU CO LU ST ...

Page 338: ...SST A N D SSM SSM Special Service Materials C 7 SSM SPECIAL SERVICE MATERIALS P a r t Name Use etc Seal packing black Engine oil pan and stiffening plate ...

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