SERVICE MANUAL &

TECHNICAL BULLETIN
3.3 ltr DIESEL ENGINE
Model L01/L02 series
 FOREWORD
This manual contains maintenance and repair procedures for Nissan FORKLIFT, model L01
and L02 series.

In order to assure your safety and the efficient functioning of the lift truck, this manual
should be read thoroughly. It is especially important that the PRECAUTIONS in the GI
section be completely understood before starting any repair task.

All information in this manual is based on the latest product information at the time of
publication. The right is reserved to make changes in specifications and methods at any time
without notice.
This SERVICE MANUAL does not include the information for GASOLINE engine and
VEHICLE.
For repair procedure and maintenance of GASOLINE engine and VEHICLE, please refer to
the following SERVICE MANUAL.
・NISSAN FORKLIFT
SERVICE MANUAL & TECHNICAL BULLETIN GASOLINE ENGINE
(Pub. No. SM03E-L0KG0)

・NISSAN FORKLIFT
SERVICE MANUAL & TECHNICAL BULLETIN VEHICLE
(Pub. No. SM03E-L012G0)

IMPORTANT SAFETY NOTICE

The proper performance of service is essential for both the safety of the mechanic and the
efficient functioning of the lift truck.
The service methods in this Service Manual are described in such a manner that the service
may be performed safety and accurately.
Service varies with the procedures used, the skills of the mechanic and the tools and parts
available. Accordingly, anyone using service procedures, tools or parts which are not
specifically recommended by NISSAN must first completely satisfy himself that neither his
safety nor the lift truck’s safety will be jeopardized by the service method selected.
 Foreword

The specification, the service procedure, and the adjustment procedure of the
3.3L-4C engine are described in this Service Manual.
Correct handling and regular maintenance, and proper operation such as
disassembly, inspection and correction, and assembly are necessary to use this
engine safely while maintaining the good performance for many years.
Read this manual carefully before starting disassembly, inspection and correction,
and assembly of the engine, and fully understand the procedures about the work.
The content has been described about the production title machine when issuing
it.
A part of the content might change by the improvement afterwards. Please agree
and understand this in advance.
 How to Use This Manual
The specification, service standard, adjustment procedure of the 3.3L-4C engine, and the service procedure such
as disassembly, inspection and correction, and assembly are described for each group.
The details of the injection pump and the governor are published in another manual.
The main content of each group is described for the total contents, and the contents of each group have been
described ahead of each group.
Refer to Service Manual for driving and regular maintenance procedure. Refer to Part Catalog for components and
supplement part order procedure. And refer to various Training Manuals about the structure and function.

1. Description
(1) The symbol in the Component Parts Location numbers it in order of the disassembly.

(2) Inspection done while disassembling has been described in in the Component Parts Location.

(3) The service standard in the inspection and correction has been described to group № 2 as a table at the same
time as describing it to the corresponding section in the text.
(4) Order of assembly is described under Component Parts Location with the following procedure: (5)→(2)→(4)
→(3)→(1)
(5) Cautions have been especially described by using the following marks in the text about the safety so on.

DANGER････Danger with high probability of causing death or serious injury is possible if this information is
not obeyed.
WARNING･･･Potential danger with possibility of causing death or serious injury is possible if this
information is not obeyed
CAUTION････Potential danger with possibility of causing a slight injury or a mid-level is possible if this
information is not obeyed.
CAUTION････Potential danger with possibility of causing the physical loss or damage is possible if this
information is not obeyed.
NOTE･･･････An important matter is emphasized, and worthwhile information on driving and maintenance is
displayed.
(6) The part of the engine oil applying in the tightening torque is marked with "WET". The part not directed is
judged as a dry condition.
(7) The units given are the SI units, and those given in the ( ) are the conventional unit system (metric system).

2. Term
Name value･････Standard nominal sizes of measured parts are shown.
Standard･･･････Size, clearance or standard performances of single parts are shown. However, it is not a design
numerical value because it has been brought together within the range necessary for checking
the numerical value.
Repair limit ････If it reaches this numerical value, replace parts with the new ones or repair.

Group name
General
Service standard
Special service tools
General of disassembly and
assembly
Entire disassembly
Inspection and correction of
engine mechanism
Engine mechanism assembly
Fuel system
Oil system
Cooling system
Inlet and exhaust system
Electrical system
Adjustment of engine,
accustoming driving, and
performance test
Guidance of trouble diagnosis
Total Contents
Content of description Group №
Outside drawings, engine No. and engine type, specifications 1
Service standard table, tightening torque table, sealant applying
2
table, maintenance
Special service tools 3
Judgement at overhaul time, measurement of compression
pressure, disassembly and assembly, disassembly and assembly 4
of general parts
Preparation, electrical system,
fuel system, oil system, cooling system, 5
inlet and exhaust system, engine mechanism
Cylinder head and valve mechanism, flywheel
timing gear, piston and connecting rod, 6
crankshaft and crankshaft case and tappet
Piston and connecting rod,
crankshaft and crankshaft case and tappet,
7
timing gear, flywheel, cylinder head and
valve mechanism
Description of fuel system
8
Fuel filter, injection nozzle
Description of oil system
9
Oil pump, oil filter, relief valve
Description of cooling system
10
Water pump
Description of inlet and exhaust system
11
Exhaust manifold
Starter, alternator, glow plug, magnetic valve 12
Adjustment of engine, accustoming driving, and performance
13
test
Trouble diagnosis and corrections 14
 INTRODUCTION
This service manual has been prepared to provide necessary information concerning the
maintenance and repair procedures for the NISSAN FORKLIFT L01 and L02 series.
Any changes effected in the series after publication of this service manual will be
announced in a technical bulletin. It is, therefore, recommended that each relevant technical
bulletin be inserted in front of each section and be used together with the service manual as a
reference.
If a new model requires different service method or has undergone a major change, revised
sections will be issued to replace the applicable sections. Each revised section will include the
description of how to service the parts for the former specifications. The publication of a
revised section will be announced in the technical bulletin.
This service manual consists of eight sections as shown in the following table, which gives
the updated symbols. When a revised service manual is issued, this ‘‘INTRODUCTION”
sheet should be replaced with a revised one.

Engine

2.5L – 4C
3.3L – 4C

Edition: August 2003

Printing: August 2003 (01)
Publication: SM03E-L0DG0

Printed in Japan
 General

1. Description ........................................................................................................................................................................................ 1 - 2
1.1 Outside drawings ....................................................................................................................................................................... 1 - 2
1.2 Engine No...................................................................................................................................................................................... 1 - 3

2. Specifications ................................................................................................................................................................................. 1 - 4
General

1. Description
1.1 Outside drawings

Air inlet Injection nozzle

Oil level gauge
Inlet manifold

Fuel filter
Fan

Stop solenoid
Water pump
(coolant inlet)
Engine coolant drain plug

Front side Rear side

Governor
Oil filter
Crankshaft pulley

Fuel injection pump Flywheel

Oil drain plug

Left side

Exhaust outlet
Oil inlet Hanger Engine coolant outlet

Hanger
Thermostat case

Exhaust manifold

Alternator

Rear side Front side

Fuel inlet

Fuel outlet
V belt
Starter

Oil pan

Right side

1-2
 General

1.2 Engine No.

Engine No. is stamped on the crankshaft case side.
Engine No.

Stamped location of engine No.

1-3
 General

2. Specifications

Engine type 3.3L-4C

Type MITSUBISHI Diesel Engine
Cooling type Water cooling
Cycle 4
Number of cylinder - layout 4 - Series
Combustion type Swirl chamber type
Valve mechanism Overhead valve type
Main specifications

Cylinder diameter×Bore diameter 94×120 mm (3.70×4.72 in)

Total exhaust 3.3312(2-7/8 Imp qt)
Compression ratio 22:1
Fuel in use Kerosene (JIS K2204 2 or equivalent)
Injection sequence 1-3-4-2
Rotating direction Counterclockwise in view of the flywheel side
Total length 753 mm (29.65 in)
Dimension
Total width 544 mm (21.42 in)
(with fan)
Total height 753 mm (29.65 in)
Mass (dry) 245 kg (540 lb)
Cylinder sleeve Type Dry (integrated with block)
Compression ring: 2
Piston ring Quantity
Oil ring: 1 (with expander)
Engine body

Open 30° (BTDC)

Intake valve
Close 50° (BBCD)
Valve timing
Exhaust Open 74° (BBCD)
valve Close 30° (BTDC)
Starting type Starter
Starting auxiliary device Glow plug
Type Distribution type (Bosch VE)
Fuel injection pump
Plunger diameter 10 mm (0.39 in) dia.

Fuel feed pump Type Bosch, vane type

System Centrifugal
Governor
Fuel system

Type DENSO, all speed

Fuel injection nozzle
Fuel filter
Type DENSO, throttle type
Number of injection hole 1
Nozzle diameter 1 mm (0.04 in) dia.
Injection angle 0°
Valve opening pressure 11.768 kPa (117.7 bar, 120 kg/cm2, 1,706 psi)
Filtration type Cartridge type paper element (with water separator)

1-4
 General

Engine type 3.3L-4C

Lubrication type Compulsion circulation type (oil pump force feed)

Standard
(API service CD class or more, viscosity with SAE30
classification)
Engine oil
Entire engine: 102(2-1/4 Imp gal)
Capacity Oil pan inside: 92(7-7/8 Imp qt) (High level),
Filters: 12(7/8 Imp qt)
Oil system

Type Trochoid
Rotation ratio with
Oil pump 0.73
crankshaft
28.62(6-1/4 Imp gal)/min/2230 min-1 (Pump
Discharge amount
rotation) at 300 kPa (3.0 bar, 3.06kg/cm2, 43.5 psi)
Type Piston valve
Relief valve
304 – 402 kPa
Valve opening pressure
(3.04 – 4.02 bar, 3.1 – 4.1 kg/cm2, 44 – 58 psi)
Oil filter Type Cartridge type paper element

Engine coolant level 5.52(4-7/8 Imp qt) (Engine water jacket)

Type Centrifugal swirl type

Rotation ratio with
Water pump 1.1
crankshaft
Cooling system

1602(35-1/4 Imp gal)/min/3600 min-1 (Pump

Discharge amount
rotation) at 750 kPa (7.50 bar, 7.65kg/cm2, 109 psi)
Cooling fan Type Pusher (φ400)

V-belt Type Low edge cog A type V-belt×1

Type Wax
Thermostat
74.5-78.5℃ (166-173ºF)
Valve opening pressure
(Fully open: 88.5-91.5℃ (191-197ºF)

1-5
 General

Engine type 3.3L-4C

Voltage - Polarity 12V - Ground

Type Mitsubishi Electric, M8T75171

Pinion mating type Pinion shift

Starter
Output 12 V-2.2 kW
Number of pinion
10/122
teeth/ring gear teeth
Mitsubishi Electric, 3-phase alternating-current
Type
generator (with rectifier)
Output 12 V-50 A

Usable rotation speed 1000～18000 min-1

Electrical system

Alternator
Rated output rotation
5000 min-1
speed
Allowable rotation speed 22000 min-1
Rotation ratio with
2.1
crankshaft
Type Seized type
Glow plug
Rated voltage - Current 10.5 V-9.7 A (Impressed for 30 seconds)

Rated voltage 12 V

Consumptive voltage 20 W
Magnetic valve
Starting voltage 6.3 V or less
(Stop solenoid)
Return voltage 2.5 V or more

Coil resistance 8Ω

1-6
 Service Standard

1. Service standard table............................................................................................................................................................. 2 - 2

2. Tightening torque table ........................................................................................................................................................... 2 - 6

2.1 Tightening torque of main bolt............................................................................................................................................... 2 - 6
2.2 Tightening torque of general bolt.......................................................................................................................................... 2 - 7
2.3 Embedding torque of general stud........................................................................................................................................ 2 - 7
2.4 Tightening torque of general plug ......................................................................................................................................... 2 - 7

3. Sealant applying table .............................................................................................................................................................. 2 - 8

4. Maintenance ..................................................................................................................................................................................... 2 - 9
Service Standard

1. Service standard table

Unit: mm (in)
Division

Part Name value Standard Repair limit Remarks

Maximum rpm (no load) 2460 min-1 ±20 min-1

The lowest rotational speed (no Adjust by governor
750 min-1 ±20 min-1
load)
With the temperature
3,236 kPa (32.4 bar, 2,844 kPa (28.4
of oil and the water
Compression pressure 33 kg/cm2, 469 psi) bar, 29 kg/cm2,
temperature
(300 min-1) 412 psi)
20 - 30℃ (68 – 86゜F)
294 – 490 kPa
147 kPa (1.47
(2.94 – 4.90 bar,
At 1500 min-1 bar, 4.0 kg/cm2, Oil temperature
3 – 5 kg/cm2,
Engine oil 56.8 psi) 70 - 90℃
43 – 71 psi)
Engine General

pressure (158 – 194゜F)

98 kPa 49 kPa (0.49
At idle (0.98 bar, 1 kg/cm2, bar, 0.5 kg/cm2,
14 psi) or more 7 psi)
Intake OPEN 30° (BTDC)
Intake CLOSED 50° (ABDC)
Exhaust OPEN 74° (BBCD)
Valve timing
Exhaust 30° (ATDC)
CLOSED ±3°(crankshaft
angle)
Valve clearance (Cold) Intake/Exhaust
5° (STD) before compression TDC at
Period when it begins to inject fuel
0.5 injection pump camshaft lift point
Bend of 98 N (10 kg,
V-Belt tension Approx. 13 (0.51) 22 lb) when strongly
pushing with thumb
Crankshaft Warp of the Within 0.05 Re-grinding of a small
0.20 (0.0079)
case upper surface (0.0020) amount
94.200 (3.7087)
Perform honing so as
94.000 - 94.035 (Repair)
Inner diameter 94 (3.70) dia. to keep the standard
(3.7008 - 3.7022) 94.700 (3.728)
as oversize +0.25
(Replace)
Cylinder (+0.0098), +0.50
0.01 (0.0004) or
Roundness (+0.0197) against name
less
value. Use oversized
Out-of- 0.015 (0.0006) or
piston and piston ring.
roundness less
Crankshaft case mechanism

Replace bearing until

0.200 (0.0079)
repair limit. Grind
(Repair)
crankshaft journal
At crankshaft
Clearance with again and use
0.050 - 0.110 journal outer
crankshaft undersized bearings
(0.0020 - 0.0043) diameter [78
journal -0.25 (-0.0098), -0.50
Main bearing (3.07) dia.]
(-0.0020), -0.75
0.900 (0.035)
(-0.0295) if it exceeds
(Replace)
repair limit.
Width of thrust
0.100 - 0.264
receiving part 0.300 (0.0118) Replace thrust plate.
(0.0039 - 0.0104)
(Thrust gap)
14.000 - 14.018
Inner diameter 14 (0.55) dia. 14.100 (0.5551)
Tappet guide (0.5512 - 0.5519)
hole Clearance with 0.016 - 0.052
0.08 (0.0031) Replace tappet
tappet (0.0006 - 0.0020)
Rebore journals, insert
Clearance with 0.070 - 0.110 bushing, or replace
Camshaft hole 0.150 (0.0059)
camshaft journal (0.0028 - 0.0043) camshaft if it exceeds
repair limit.

2-2
 Service Standard

Unit: mm (in)
Division

Part Name value Standard Repair limit Remarks

Re-grinding of a small
Warp of the lower side Within 0.05 (0.0020) 0.20 (0.0079)
amount
Cylinder head
Thickness of gasket with cylinder 1.15 - 1.25
1.2 (0.047)
head bolts tightened (0.0453 - 0.0492)
7.940 - 7.955
Intake 8 (0.31) dia. 7.900 (0.3110)
Valve stem part (0.3126 - 0.3132)
outside diameter 7.920 - 7.940
Exhaust 8 (0.31) dia. 7.850 (0.3091)
(0.3118 - 0.3126)
Valve and 0.065 - 0.095
Clearance between Intake 0.150 (0.0059)
valve guide (0.0026 - 0.0037)
valve stem part and
0.080 - 0.115
valve guide Exhaust 0.200 (0.0079)
(0.0031 - 0.0045)
13.9 - 14.1
Valve guide installation length 14 (0.55)
(0.547 - 0.555)
Valve seat angle 30°
0.3 - 0.5
Intake 0.4 (0.016)
Amount of valve (0.012 - 0.020)
1.0 (0.039)
Cylinder head mechanism

sinking 0.4 - 0.6

Exhaust 0.5 (0.020)
(0.016 - 0.024)
Valve seat
1.26 - 1.54
Width of seat 1.4 (0.055) 1.8 (0.0709)
(0.0496 - 0.0606)
Reface and up
Valve margin 2.13 (0.0839) to 1.83
(0.0720)
48.85
Free length 47.60 (1.874)
(1.9232)
Angle imprecision margin
Tilt 1.5° to centerline on both
Valve springs
ends side
installation
Installation length 43 (1.69)
177 – 196 N
147 N
Load (18 – 20 kg,
(15 kg, 33 lb)
40 – 44 lb)
19.010 - 19.030
Inside diameter of rocker bushing 19 (0.75) dia.
(0.7484 – 0.7492)
18.980 - 19.000
Rocker arm Rocker shaft outer diameter 19 (0.75) dia.
(0.7472 – 0.7480)
Clearance between rocker 0.010 - 0.050
0.070 (0.0028)
bushing and shaft (0.0004 – 0.0020)
Runout when supporting
by centerline of both end
Push rod Bend 0.3 (0.012) or less
spherical surfaces
(Reading of dial indicator)
Bend 0.02 (0.0008) or less 0.05 (0.0020)
77.850 (3.0650)
77.955 - 77.970 (Repair)
Crankshaft journal outer diameter 78 (3.07) dia.
(3.0691 – 3.0697) 77.100 (3.0354)
(Replace)
57.955 - 57.970
Crankshaft pin outer diameter 58 (2.28) dia. 57.800 (2.2756)
Main moving mechanism

(2.2817 – 2.2823)
Distance between journal and pin
60 (2.36) ±0.04 (±0.0016)
center
Maximum pin runout
Crankshaft Pin/journal parallelism
0.01 (0.0004) or less
Pin/journal roundness Within 0.01 (0.0004) 0.03 (0.0012)
Pin/journal out-of-roundness Within 0.01 (0.0004) 0.03 (0.0012)
Pin/journal corner R Ｒ3 (0.12) ±0.2 (0.0079)
Replace thrust plate until
repair limit. Replace with
End play 0.100 - 0.264 oversized thrust plate if it
31 (1.22) 0.300 (0.0118)
(Shaft thrust bearing width) (0.0039 – 0.0104) exceeds repair limit.
+0.15 (+0.0059), +0.30
(+0.0118)

2-3
Service Standard

Unit: mm (in)
Division

Part Name value Standard Repair limit Remarks

93.955 - 93.985 93.770

S.T.D
(3.6990 – 3.7002) (3.6917)
Outer diameter 0.25 (0.0098) 94.205 - 94.235 94.020
94 (3.70) dia.
(skirt) O.S (3.7089 – 3.7100) (3.7016)
Piston
0.50 (0.0197) 94.455 - 94.485 94.270
O.S (3.7187 – 3.7199) (3.7114)
Amount of projection from -0.25 to 0.15
Check bearing clearance.
crankcase (-0.0098 to 0.0059)
0.07 - 0.11
No. 1 ring 0.200 (0.0079)
(0.0028 – 0.0043)
Clearance
0.045 - 0.085
with ring No. 2 ring 0.150 (0.0059)
(0.0018 – 0.0033)
groove
0.020 - 0.060
Oil ring 0.150 (0.0059)
(0.0008 – 0.0024)
Piston ring
0.30 - 0.50
No. 1 ring
(0.0018 – 0.0197)
Main moving mechanism

Ring end 0.50 - 0.70

No. 2 ring 1.50 (0.0591)
clearance (0.0197 – 0.0276)
0.30 - 0.50
Oil ring
(0.0118 – 0.0197)
29.994 - 30.000
Outer diameter 30 (1.18) dia.
(1.1809 – 1.1811)
0.000 - 0.016
Piston pin Clearance with piston 0.050 (0.0020)
(0.0000 – 0.0006)
Clearance with connecting rod 0.020 - 0.051
0.080 (0.0031)
bushing (0.0008 – 0.0020)
30.020 - 30.045
Bushing inner diameter 30 (1.18) dia.
(1.1819 – 1.1829)
0.05 (0.0020)/100
Bend and twist rod
(3.94) or less
Replace bearing or grind
Connecting
crankshaft pin again and
rod Clearance between crankpin and 0.030 - 0.090
0.200 (0.0079) replace with undersized
rod bearing (0.0012 – 0.0035)
bearing (undersize) if it
exceeds usable limit.
0.150 - 0.350
End play 33 (1.30) 0.50 (0.0197) Replace connecting rod.
(0.0059 – 0.0138)
Flatness Within 0.15 (0.0059)
Flywheel
Runout Within 0.15 (0.0059)
Bend 0.02 (0.0008) or less 0.05 (0.0020) Repair bending, or replace
6.684 6.384 - 6.784
Intake 6.184 (0.2435)
(0.2631) (0.2513 – 0.2671)
Camshaft profile
(D1-D2) 6.720 6.420 - 6.820
Exhaust 6.220 (0.2449)
(0.2646) (0.2528 – 0.2685)
Camshaft
Timing gear mechanism

53.94 - 53.96
Journal outer No.1, 2 54 (2.13) 53.90 (2.1220)
(2.1236)
diameter
No. 3 53 (2.09) 52.94 - 52.96 (2.0842) 52.90 (2.0827)
0.10 - 0.25
End play 5 (0.20) 0.30 (0.0118) Replace thrust plate.
(0.0039 - )
Clearance between bushing and 0.009 - 0.050
0.100 (0.0039) Bushing replacement
shaft (0.0004 – 0.0020)
0.05 - 0.20
Idler Idler gear end play 4.5 (0.177) 0.35 (0.0138) Replace thrust plate.
(0.0020 – 0.0079)
Tightening length of shaft and 0.021T - 0.076T
35 (1.38)
crankcase hole (0.0008T – 0.0030T)
0.05 - 0.15
Backlash of timing gear 0.25 (0.0098) Replace gear.
(0.0020 – 0.0059)

2-4
 Service Standard

Unit: mm (in)
Division

Part Name value Standard Repair limit Remarks

11,768 kPa 11,768 – 12,749 kPa Adjust at shim.

Valve opening (111.7 bar, (117.7 – 127.5 bar, 981 kPa (9.8 bar,
pressure 120 kg/cm2, 120 – 130 kg/cm2, 10 kg/cm2, 142 psi) per
1,706 psi) 1,706 – 1,849 psi) shim 0.1 mm (0.004 in)
Replace nozzle chip
after washing it with
Fuel system

Fuel clean kerosene to

injection Angle of spray 0° check with hand tester
nozzle [kerosene about 20℃
(68゜F)] if
malfunctioning.
1,961 kPa (19.6 bar, 20 kg/cm2, 284 psi)
Oil is close in the from valve opening pressure. Clean or replace
needle valve sheet. Apply low oil pressure, and then keep for 10 nozzle tip.
seconds.
Outside diameter of 31.8 - 32.2
32 (1.26) dia. 31.4 (1.236)
commutator (1.252 – 1.268)
Length 18 (0.71) 11 (0.43)
26 – 36 N 15 N
Brush Spring 31 N
(2.7 – 3.7 kg, (1.5 kg,
pressure (3.2 kg, 7.1 lb)
Electrical system

Starter 6.0 – 8.2 lb) 3.3 lb)

12 V- 0.5 - 2.0 (0.020 –
Pinion gap
2.2 kW 0.079)
At no load
Rotational
Voltage Current
speed
3800 min-1 or
Characteristic 11 V 130 A or less
more
Brush length 18.5 (0.728) 5 (0.20)
Alternator
Resistance between
12 V-50 A 2.7 - 3.2Ω 20℃ (68゜F)
slipping rings
Clearance between 0.20 - 0.30 Replace oil pump
0.50 (0.0197)
outer rotor and case (0.0079 – 0.0118) assembly.
Main shaft outer 15.985 - 16.000
16
diameter (case side) (0.6293 – 0.6299)
Main shaft outer
13.957 - 13.975
diameter (oil pump 14
(0.5495 – 0.5502)
bushing side)
Clearance between 0.032 - 0.074 0.150 Replace pump
main shaft and case (0.0013 – 0.0029) (0.0059) assembly.
Oil pump Clearance between
Oil system

0.025 - 0.111 0.200 Replace bushing or

main shaft and oil
(0.0010 – 0.0044) (0.0079) pump assembly.
pump bushing
Clearance between
0.13 - 0.15 Replace outer rotor
inner rotor and outer 0.20 (0.0079)
(0.0051 – 0.0059) and shaft assembly.
rotor
Rotor and case end 0.04 - 0.09 Replace pump
0.15 (0.0059)
play (0.0016 – 0.0035) assembly.
Inner rotor inner 15.951 - 15.968 (Shrink fit with
16 (0.63) dia.
diameter (0.6280 – 0.6287) mainshaft)
304 – 402 kPa
Relief Valve opening 353 kPa (3.53 bar, (3.04 – 4.02 bar,
valve pressure 3.6kg/cm2, 51 psi) 3.1 - 4.1kg/cm2,
44 – 58 psi)

2-5
Service Standard

2. Tightening torque table

2.1 Tightening torque of main bolt
Screw Width Tightening torque Remarks
Installation parts Diameter × pitch across
flat ft-lb
mm N・m kg-m
mm *in-lb
Cylinder head bolt M12×1.75 19 113 - 123 11.5 - 12.5 83 – 90
Cylinder head plug M16×1.5 14 39.2 - 49.0 4.0 - 5.0 29 – 36
Rocker cover M8×1.25 12 10.0 - 13.0 1.0 - 1.3 87 – 113*
Rocker shaft bracket bolt
(long) M8×1.25 12 10.0 - 20.0 1.0 - 2.0 87 - 174*
The main bearing cap M14×2.0 19 98 - 108 10.0 - 11.0 72 – 80
Connecting rod cap nut M10×1.0 14 49.0 - 59.0 5.0 - 6.0 36 – 43
Flywheel M12×1.25 17 78.5 - 88.3 8.0 - 9.0 58 – 65
Camshaft thrust plate M8×1.25 12 10.0 - 13.0 1.0 - 1.3 87 – 113*
Reception desk plate M8×1.25 12 10.0 - 13.0 1.0 - 1.3 87 – 113*
Timing gear case cover M8×1.25 12 17.0 - 20.0 1.7 - 2.0 12 - 14
Crankshaft pulley M30×1.5 46 480 - 500 49 - 51 354 – 369
Idler thrust plate M10×1.25 14 29.0 - 39.0 3.0 - 4.0 22 – 29
Oil pan M8×1.25 12 10.0 - 13.0 1.0 - 1.3 87 – 113*
Rear plate M10×1.25 14 54.0 - 65.7 5.5 - 6.7 40 – 48
Fuel injection pump delivery
valve holder M14×1.5 14 44.0 - 54.0 4.5 - 5.5 33 – 40
Fuel injection pump gear nut M12×1.75 19 58.8 - 68.6 6.0 - 7.0 43 – 51
Fuel return pipe nut M12×1.5 17 20.6 - 24.5 2.1 - 2.5 15 – 18
Fuel return pipe flare nut M10×1.25 14 17.7 - 21.6 1.8 - 2.2 13 – 16
Fuel injection pump overflow
valve M12×1.0 17 20.0 - 29.0 2.0 - 3.0 14 – 22
Injection pipe nut M12×1.5 17 26.5 - 32.4 2.7 - 3.3 20 – 24
Oil pump gear M10×1.25 14 28.0 - 38.0 2.9 - 3.9 21 – 28
Oil pan drain plug M14×1.5 17 34.0 - 44.0 3.5 - 4.5 25 – 33
Relief valve M22×1.5 27 44.1 - 53.9 4.5 - 5.5 33 – 40
Water drain plug 1/4-18 NPTF 14 35.3 - 43.1 3.6 - 4.4 26 – 32
Thermo switch M16×1.5 19 20.6 - 24.5 2.1 - 2.5 15 – 18
Exhaust manifold M8×1.25 12 27.5 - 33.3 2.8 - 3.4 20 – 25
Starter terminal B M8×1.25 12 9.8 - 11.8 1.0 - 1.2 87 – 104*
Alternator pulley M17×1.25 24 98 - 137 10.0 - 14.0 72 - 101
Glow plug (body) M10×0.7 12 15.0 - 20.0 1.5 - 2.0 11 – 14
Glow plug (terminal) M4×0.7 7 1.0 - 1.5 0.10 - 0.15 9 – 13*
Nozzle tip retaining nut (to
engine) M20×1.5 21 53.0 - 64.7 5.4 - 6.6 39 – 48
Thermostat case M8×1.25 12 17.0 - 20.0 1.7 - 2.0 12 – 14

2-6
 Service Standard

2.2 Tightening torque of general bolt

Tightening torque
Screw
diameter 4T 7T
mm ft-lb ft-lb
N・m kg-m *in-lb N・m kg-m *in-lb
M6 2.94 - 4.90 0.3 - 0.5 26 – 43* 7.85 - 9.80 0.8 - 1.0 69 – 87*
M8 9.80 - 12.7 1.0 - 1.3 87 – 113* 14.7 - 21.6 1.5 - 2.2 11 – 16
M10 17.7 - 24.5 1.8 - 2.5 13 – 18 29.4 - 41.2 3.0 - 4.2 22 – 30
M12 29.4 - 41.2 3.0 - 4.2 22 - 30 53.9 - 73.5 5.5 - 7.5 40 - 54

2.3 Embedding torque of general stud

Embedding torque
Screw
diameter Embedding in aluminum Embedding in iron
mm ft-lb ft-lb
N・m kg-m *in-lb N・m kg-m *in-lb
M8 4.90 - 5.90 0.50 - 0.60 43 – 52* 11.8 - 13.7 1.2 - 1.4 9 – 10
M10 12.7 - 14.7 1.3 - 1.5 9 – 11 21.6 - 25.5 2.2 - 2.6 16 – 19

2.4 Tightening torque of general plug

Tightening torque
Screw
diameter Tightening in aluminum Tightening in iron
mm ft-lb ft-lb
N・m kg-m N・m kg-m
*in-lb *in-lb
NPTF 1/16 4.90 - 7.85 0.5 - 0.8 43 – 69* 7.85 - 11.8 0.8 - 1.2 69 – 104*
R 1/8 7.85 - 11.8 0.8 - 1.2 69 – 104* 14.7 - 21.6 1.5 - 2.2 11 – 16
R 1/4,
19.6 - 29.4 2.0 - 3.0 14 – 22 34.3 - 44.1 3.5 - 4.5 25 – 33
NPTF 1/4
R 3/8 ― ― ― 53.9 - 73.5 5.5 - 7.5 40 - 54

NOTE: (a) This table describes tightening torque of standard nuts and bolts.
(b) This is the value when using spring/washer.
(c) This table shows the standard. Allowance is ±10％.
(d) Use the tightening torque shown in this table excluding a special indication.
(e) Do not apply oil to thread area. (Dry condition)

2-7
Service Standard

3. Sealant applying table

Sealant spreading part Other mating parts Use sealant Applying procedure

Apply the sealant to oil

Oil pan Crankshaft case Three Bond 1207C pan sealing surface

Bearing cap insertion part on Apply to the corner

rear-end of crankshaft case Rear-end bearing cap Three Bond 1212 before inserting cap.

Crankshaft case Insert after applying to

Side seal Rear-end bearing cap Three Bond 1211 side seal.

Cylinder head water hole peco Paint on the hole, and

plug Cylinder head Three Bond 1386D input the peco plug.

Paint on the hole, and

Crankcase water hole peco plug Crankshaft case Three Bond 1386D input the peco plug.

Crankcase oil Paint on the hole, and

Gallery peco plug Crankshaft case Three Bond 1386D input the peco plug.

Crankshaft case oil return hole Paint on the hole, and

peco plug Crankshaft case Three Bond 1386D
input the peco plug.

Apply to crankshaft tip

Crankshaft tip thread area Crankshaft pulley nut Three Bond 1212 thread area and tighten
nut.
Connection between crankshaft Connection between
case rear end surface and Rear gasket Three Bond 1212 crankshaft case and
bearing cap rear end surface bearing cap rear end
surface

2-8
 Service Standard

4. Maintenance
(1) Execute the maintenance interval according to the
time of the service meter.
(2) Execute it ahead of time at the time of the service
meter when it seems that maintenance is necessary.
(Execute referring to the following time, and increase
and decrease the interval properly while seeing
results because a proper maintenance interval of the
engine changes by the state etc. of the usage, the
usage condition, and the fuel and oil.)
(3) Execute the included item at the same time when the
last maintenance interval in the maintenance interval
has already been contained.
Example) Perform "10 hours and 50 hours" at the
same time for 250 hours.
○: Inspection, cleaning, washing, and
adjustment, etc.
●: Part replacement
S: Consult the shop or the specified service
factory when it is not possible to maintain it
privately.
*: Perform for engines which have been stored
for a long time, engines which have been
overhauled, and for new engines in the first 50
hours.

Maintenance table
Inspection interval
Every
Every Every Every
three
Division
Device

day or week or month Every

Contents months Remarks
every every or every 1000
or every
10 50 200 hours
500
hours hours hours
hours
Check of amount of
○
Engine oil oil
system

*
Oil

Replace. ● S
Oil filter
(cartridge type)
Replace. * ● S
Check of amount of
Fuel tank ○
oil
S: Every six months
system

Fuel filter Replace. or every 1200

Fuel

hours
S: Every twelve
Injection nozzle Inspection months or every
2400 hours
Coolant amount
○
Cooling system

inspection
Engine coolant Every twelve
Replace. months or every
2400 hours
Radiator fin Clean ○
Air cleaner Element Every two weeks or
(paper element type) Clean every 100 hours
system
Inlet

Every six months

Element
or every 1200
Replace.
hours
Fluid amount Supply distilled
Battery ○
Electrical

inspection water properly.

system

Alternator Inspection ○ S

Starter Inspection ○ S

V belt Tension inspection ○

2-9
 Special Service Tools

Special service tools ....................................................................................................................................................................... 3 - 2

Special Service Tools

Special service tools

Tool name Part No. Shape Application
Valve spring pusher NF30691-04500 For removing and
installing valve spring

Valve guide remover NF32A91-00300 For valve guide

piercing

Valve guide installer NF32A91-00100 For valve guide

pressure

Stem seal installer NF32A91-10200 For installing stem

seal

Valve seat insert Intake For valve seat

caulking tool NF36791-00200 pressure
Exhaust
NF34491-03020

Piston ring pliers NF31391-12900 For removing and

installing piston ring

Piston installer NF34491-00200 For piston insertion

Idler bushing installer NF30091-07300 For removing and

installing idler gear
bushing

3-2
 Special Service Tools

Tool name Part No. Shape Application

Idler shaft puller NFMH061077 For pulling out idler
shaft

Oil seal sleeve installer NF30691-13010 For crankshaft rear

set side oil seal sleeve
pressure

Gauge adopter NF30691-21100 For engine

compression pressure
measurement

Compression gauge NF33391-02100 For compression

pressure
measurement

Socket for turning NF58309-73100 For engine turning

Socket NF34491-00300 For camshaft thrust

plate and rocker
bracket installation

Connecting rod bushing NFMH061236 For connecting rod

puller bushing installation

Camshaft bushing NF30691-00010 For removing and

installer set installing camshaft
bushing

3-3
Special Service Tools

Tool name Part No. Shape Application

Oil pump bushing NF32A91-00400 For oil pump bushing
installer installation

3-4
 General of Disassembly and Assembly

1. Judgement at overhaul time ............................................................................................................................................... 4 - 2

2. Measurement of compression pressure..................................................................................................................... 4 - 3

2.1 Inspection preparation ............................................................................................................................................................. 4 - 3
2.2 Inspection...................................................................................................................................................................................... 4 - 3

3. Disassembly and assembly ................................................................................................................................................... 4 - 4

3.1 Disassembly.................................................................................................................................................................................. 4 - 4
3.2 Assembly ....................................................................................................................................................................................... 4 - 4

4. Disassembly and assembly of general parts........................................................................................................... 4 - 5

4.1 Oil seal............................................................................................................................................................................................ 4 - 5
4.2 O-ring ............................................................................................................................................................................................. 4 - 5
4.3 Bearing ........................................................................................................................................................................................... 4 - 6
4.4 Lock plate ..................................................................................................................................................................................... 4 - 6
4.5 Split pin, spring pin .................................................................................................................................................................... 4 - 6
General of Disassembly and Assembly
1. Judgement at overhaul time
In general, the standard judged engine overhaul timing is
judged by the decrease in the compression pressure as
a target, and by the increase of the engine oil
consumption and the increase in the amount of PCV
gas.
Moreover, the standard judged engine overhaul timing is
also judged by engine power deterioration, increase of
fuel consumption, low fuel pressure, difficult starting,
and increase of noise. But they may occur by the
influence of other reasons, and not always become the
standard judged engine overhaul timing.
There are various forms in the outside appearance of
the decrease in this compression pressure as the
symptom, and it is difficult to decide indiscriminately.
The symptom that appears outside
(1) The output decreases.
(2) The fuel input rating increases.
(3) The consumption of the engine oil increases.
(4) The blowing emission of the explosion gas
increases by the wear-out such as cylinders and
pistons, and the amount of PCV gas from breather
increases.
4-2
(5) The number of gas stairwells increases by a
malfunctioning hit of the valve seat of the
inlet/exhaust valve.
(6) The start worsens.
(7) The noise in each part of the engine increases.
These are variously combined.
These are the ones that relate directly and the ones
not necessarily so in regards to wear of the main body
of the engine.
Paragraphs (2) and (6) are influenced by the injection
amount of injection pump, injection timing, plunger
wear, nozzle condition, and conditions of electrical
equipments such as battery, starter, and alternators.
The best standard that judges the overhaul timing is a
compression pressure decrease because of wear-out
related to the cylinder and the piston of (4), and
tempering this with other items and judging it overall are
the most reasonable.
 General of Disassembly and Assembly

2. Measurement of compression pressure

2.1 Inspection preparation
Check the following conditions, and perform
inspection. Compression gauge
(1) The engine oil, the air cleaner, starter, and the adapter

battery, etc. must be normal.

2.2 Inspection
(1) It is a stop position (state of the fuel determination)
as for the control lever.
Measurement of Compression Pressure
(2) Remove glow plug together with all cylinders, and
install compression gauge adaptor (30691-21100)
and compression gauge (33391-02100) in the
cylinder checked.
(3) Read the pressure when the engine is rotated with
Starter, and the indicator of the compression gauge
is steady.
(4) Do the disassembly check when measurements are
below the limit.

CAUTION
(a) Measure all numbers of cylinders.
(b) Measure the rotational speed at the same time
because the compression pressure changes
depending on the engine speed.

Unit: kPa (bar, kg/cm2, psi)

Name value Repair limit
Compression 3,236 2,844
pressure (32.4, 33, 469) (28.4, 29, 412)
NOTE：The engine speed when measuring it is assumed to be
300 min-1. Measure oil temperature, engine coolant
temperature within 20 to 30℃ (68 to 86゜F).

CAUTION
(a) It is important that the compression pressure
measures regularly, and the change is known.
(b) The compression pressure is slightly raised by the
fitting of piston ring and valve seat, etc. with a new
engine and overhauling, after that it decreases by
the wear of each part.

4-3
General of Disassembly and Assembly

3. Disassembly and assembly

The maintenance procedures recommended by NISSAN 3.2 Assembly
are described here, and the precautions for SST and (1) Wash parts except oil seal, O-ring, and rubber
safety are described in operation procedure. seat, etc. thoroughly with the solvents, and dry
However, be careful because precautions exist in all them by compressed air completely.
places, and the content of this manual does not (2) Use applicable tools correctly.
describe all safety items. Refer to this Service Manual (3) Use a suitable good quality oil and grease.
for service operation, and be careful about the following Moreover, apply oil, grease, and sealant to the
points. specified area.
(4) Tighten the part with the torque specification to
3.1 Disassembly the specified torque sing the torque wrench.
(1) Use applicable tools correctly. (5) As a rule, replace all gaskets, O-rings with new
(2) Prepare the arrangement stands etc. of the ones.
worktable and the disassembly parts, and resolve
it in the disassembly order.
(3) Arrange disassembled parts in the correct order
so as not to lose them.
(4) Be careful about the assembly mark when
disassembling it, and then put the assembly mark
if necessary.
(5) Check for malfunctions during disassembling and
washing so as not to miss the malfunctions that
could not be discovered after disassembling and
washing.
(6) Be careful about safety especially in the balance
of the disassembled parts and the movement of
heavy loads. (Use the jack and the chain block if
necessary.)

4-4
 General of Disassembly and Assembly

4. Disassembly and assembly of general parts

4.1 Oil seal
Note the following especially when driving the oil
seal.

When driving to the housing

(1) Check seal lip surface for damage, and turn the lip in
the correct direction.
(2) Apply a small amount of grease to the seal
circumference (joint part with the housing) and drive
it in.
(3) Drive in straight while guiding the seal lip surface as
shown in the figure and using a SST contacted with
seal circumference.
When tapping oil seal directly with the hammer, seal
is damaged. It may cause the oil leakage.

When assembling in the shaft Oil seal driving tool

(1) Apply grease to the seal lip surface.

(2) Use the guide as shown in the figure when
assembling in the part with steps, the spline, the
screw, and the key groove.

Oil seal guide

4.2 O-ring
Use the guide when assembling O-ring into the part
with steps, and the spline, the screw, and the key
groove.
Moreover, apply a small amount of grease.

O-ring guide

4-5
General of Disassembly and Assembly

4.3 Bearing
(1) Drive in the race on the attached side when
assembling the bearing.
(Drive in the inner race for the inner race at the
attached side and the outer race for the outer race
at the attached side.) Moreover, use the driving tool
that contacts with each race as shown in the figure
when driving them in.

Bearing driving tool

(2) Shock can be reduced and work can be securely

performed if it is inserted with a press.

Insertion with press

4.4 Lock plate

Bend various lock plates securely.
The figure on the right shows the quality of how to
bend the typical lock plate.
OK OK NG

4.5 Split pin, spring pin

As a rule, replace various split pins with the new
ones.
NG
Moreover, bend them securely.
Drive various spring pins securely.

OK NG
OK

Bend lock plate

4-6
 Entire Disassembly
1. Operation before disassembly ..................... 5 - 2
1.1 Engine oil discharge ............................................ 5 - 2
1.2 Coolant discharge ................................................ 5 - 2
2. Electrical system .................................................... 5 - 2
2.1 Removal of starter .............................................. 5 - 2
2.2 Removal of alternator ........................................ 5 - 2
2.3 Removal of glow plug.......................................... 5 - 3
3. Fuel system ................................................................ 5 - 3
3.1 Removal of fuel filter .......................................... 5 - 3
3.2 Removal of fuel injection pipe ........................ 5 - 3
3.3 Removal of fuel injection nozzle.................... 5 - 3
3.4 Removal of fuel injection pump...................... 5 - 4
4. Oil system ................................................................... 5 - 4
4.1 Removal of oil filter............................................ 5 - 4
4.2 Removal of side cover ...................................... 5 - 4
5. Cooling system ....................................................... 5 - 5
5.1 Removal of fan ..................................................... 5 - 5
5.2 Removal of water pump.................................... 5 - 5
5.3 Removal of thermostat..................................... 5 - 5
6. Inlet and exhaust system ............................... 5 - 5
6.1 Removal of exhaust manifold ......................... 5 - 5
6.2 Removal of inlet manifold ................................ 5 - 6
7. Disassembly of cylinder head and valve
mechanism ................................................................. 5 - 7
7.1 Removal of rocker shaft assembly .............. 5 - 8
7.2 Disassembly of rocker shaft assembly ...... 5 - 8
7.3 Removal of cylinder head ................................ 5 - 8
7.4 Removal of valve and valve spring............... 5 - 8
8. Disassembly of flywheel .................................. 5 - 9
8.1 Removal of flywheel.......................................... 5 -10
8.2 Removal of oil seal case ................................. 5 -10
8.3 Removal of rear plate ...................................... 5 -10
9. Disassembly of timing gear .......................... 5 -11
9.1 Removal of soundproof cover and gear
case cover ........................................................... 5 -12
9.2 Removal of crankshaft pulley ....................... 5 -12
9.3 Removal of oil pan............................................. 5 -12
9.4 Removal of timing gear case assembly...... 5 -12
9.5 Measurement of backlash and end play ... 5 -13
9.6 Removal of oil pump gear............................... 5 -13
9.7 Removal of idler gear ....................................... 5 -14
9.8 Removal of P.T.O. drive gear ........................ 5 -14
9.9 Removal of camshaft ....................................... 5 -14
9.10 Disassembly of camshaft gear................... 5 -14
9.11 Removal of front plate .................................. 5 -15
10. Disassembly of piston, connecting
rod, crankshaft, crankshaft case, and
tappet ......................................................................... 5 -16
10.1 Removal of connecting rod cap................. 5 -17
10.2 Preparation for piston removal.................. 5 -17
10.3 Removal of piston ........................................... 5 -17
10.4 Removal of piston ring .................................. 5 -17
10.5 Removal of piston pin.................................... 5 -18
10.6 Removal of main bearing cap ..................... 5 -18
10.7 Removal of crankshaft .................................. 5 -18
10.8 Removal of tappet........................................... 5 -18
Entire Disassembly

1. Operation before disassembly

1.1 Engine oil discharge
Remove engine oil drain plug from the bottom of oil
pan, and then drain engine oil from oil pan inside.
Oil pan inside: 9l (7-7/8 Imp qt)
Engine oil amount [Entire engine: Approx. 10l
(8-3/4 Imp qt)]

CAUTION
Engine oil drain
Do not touch hot oil. It may cause burns. plug

Engine oil discharge

1.2 Coolant discharge
Loosen coolant drain plug from crankshaft case LH
side surface, and the drain coolant from engine. Engine coolant
drain plug
Engine coolant level 5.5l (4-7/8 Imp qt)

2. Electrical system Coolant discharge

2.1 Removal of starter
Disconnect harnesses, remove starter mounting nut
(1), and then remove starter (2).

Removal of starter
2.2 Removal of alternator
(1) Disconnect harnesses, and then remove bolt (2) of ԛ
ԙ Ԙ
adjusting plate (1).
(2) Remove alternator mounting bolt (3), and then
Ԝ
Ԛ
remove alternator (4).
(3) Remove V-belt (5).
(4) Remove adjusting plate (1) and bracket (6).
Ԛ

Removal of alternator

5-2
 Entire Disassembly

2.3 Removal of glow plug

Remove connection plate mounting nut (1), and then
remove connection plate (2) and glow plug (3).

Removal of glow plug

3. Fuel system
3.1 Removal of fuel filter
(1) Remove fuel hoses (1) and (2).
(2) Remove fuel filter (3) and bracket (4).

Removal of fuel filter

3.2 Removal of fuel injection pipe
(1) Remove the pipe clamping (1) and remove the
injection pipe (2).
(2) Remove return pipe (3) and fuel pipes (4).
(3) Remove leak off pipe (5).

CAUTION
The joint with the fuel injection pump and the fuel
injection pipe of the nozzle holder is covered with a
rubber cap etc. so as to prevent dust from entering in
the fuel system. Removal of fuel injection pipe

3.3 Removal of fuel injection nozzle

Remove fuel injection nozzle (1) and gasket (2).

Removal of fuel injection nozzle

5-3
Entire Disassembly

3.4 Removal of fuel injection pump

(1) Make sure that injection timing stamp lines are
aligned when removing injection pump. Put a mark on
flange circumference if these lines are not aligned.
Installation should be performed by aligning these
lines.

CAUTION
Always check stamp lines before removing.

Removal of fuel injection pump (1)

(2) Remove fuel injection pump mounting bolt (1), and
then remove brackets (2) and (3).
(3) Remove flange mounting bolt (4), and then remove
fuel injection pump (5) together with gear.

Removal of fuel injection pump (2)

4. Oil system
4.1 Removal of oil filter
Remove oil filter (1) using filter wrench.

Removal of oil filter

4.2 Removal of side cover
Remove side cover mounting bolt (1), and then
remove side cover (2) and gasket (3).

Removal of side cover

5-4
 Entire Disassembly

5. Cooling system
5.1 Removal of fan
Remove fan mounting bolt (1), and then remove plate
(2), fan (3), and pulley (4) in this order.

Removal of fan

5.2 Removal of water pump

(1) Removal thermostat bypass hose (1) connected with
water pump.
(2) Remove water pump mounting bolt (2), and then
remove water pump (3) and gasket (4).
(3) Remove water pump spacer mounting bolt (5), and
then remove water pump spacer (6) and gasket (7).

Removal of water pump

5.3 Removal of thermostat
(1) Remove thermostat case mounting bolt (1), and then
remove thermostat case with thermostat in
assembled condition.
(2) Remove gasket (3).

Removal of thermostat
6. Inlet and exhaust system
6.1 Removal of exhaust manifold
Remove exhaust manifold mounting bolt (1), and then
remove exhaust manifold (2) and gasket (3).

ターボチャージャの取り外し
Removal of exhaust manifold

5-5
Entire Disassembly

6.2 Removal of inlet manifold

(1) Remove breather hose (1).
(2) Remove air inlet pipe mounting bolt (2), and then
remove air inlet pipe (3) and gasket (4).
(3) Remove inlet manifold mounting bolt (5), and then
remove inlet manifold (6) and gasket.

Removal of inlet manifold

5-6
 Entire Disassembly

7. Disassembly of cylinder head and valve mechanism

(1)

Replacement
Screw part damage and
wear of contact face to rod (9)
(3)
(4)

(5)
(2) Wear
Wear and clogging oil (8)
(10)
Wear of contact face to
(7) valve cap and clogging oil
(11)
(15)
Worn out and damage (17)
(16)
(18) (12)
Replace-
ment

Wear
(6) (13)

Wear of both ends and bent

(19)

Cracks, damage and adherence Replacement

of carbon and water scale

Cracks

Uneven wear

(14)

Wear of stem face,

damage and worn out

<Order of disassembly>
(1) Rocker cover (8) Rocker arm (15) Valve cotter
(2) Adjusting screw (9) Rocker shaft spring (16) Valve retainer
(3) Short bolt (10) Rocker shaft (17) Valve stem seal
(4) Long bolt (11) Valve cap (18) Valve spring
(5) Rocker shaft bracket (12) Cylinder head bolt (19) Cylinder head gasket
(6) Push rod (13) Cylinder head
(7) Snap ring (14) Valve ((13) – (14): Remove as a set.)

5-7
Entire Disassembly

7.1 Removal of rocker shaft assembly

(1) Loosen the rocker adjusting screw one turn.
(2) Loosen the short bolt on the rocker shaft bracket
first and then loosen the long bolt to remove the
rocker shaft assembly from the cylinder head.

CAUTION
Loosening the bolts in the reverse order may damage
the rocker shaft bracket.

Removal of rocker shaft assembly

7.2 Disassembly of rocker shaft assembly
Arrange disassembled parts in order so that they can
be reinstalled in the original positions. This can help
avoid changing the clearance between the rocker
shaft and the rocker arm when they are
reassembled.

Disassembly of rocker shaft assembly

7.3 Removal of cylinder head

Remove the cylinder head bolts and raise the
cylinder head to remove it from the crankcase.
NOTE：Be careful not to damage the mounting surface
between cylinder and crankshaft case when
removing gasket from cylinder head.
If there is any malfunction in the cylinder head,
check the cylinder head bolts for any looseness
using a torque wrench, before removing the
Removal of cylinder head
cylinder head bolts.

7.4 Removal of valve and valve spring

Valve spring pusher
Compress the valve spring evenly using the valve
spring pusher (30691-04500) to remove the valve
cotter.
NOTE：If valves can be reused, put identification marks
that indicate installation position so as not to
change combination of each valve seat and valve
guide during assembly.

Removal of valve and valve spring

5-8
 Entire Disassembly

8. Disassembly of flywheel

(6)

(5)

Replace O-ring

(4)

(2) Screw part

(3) damage

Replace gasket

Wear of adherence,
damage and aging

Cracks, malfunction of knock-hole

and damage of gear (1)

<Order of disassembly>
(1) Flywheel (3) Oil seal (5) Rear plate
(2) Oil seal case (4) O-ring (6) Gasket

5-9
Entire Disassembly

8.1 Removal of flywheel

(1) Remove one flywheel attaching bolt.
(2) Screw a safe bar (M12 X 1.25) into the hole from
which the bolt was removed and then remove the
other bolts, and then remove lock washer.
(3) Hold the flywheel tightly with both hands and pull it
out straight while shaking it back and forth.

CAUTION
Care must be taken not to cut hands with the ring gear Removal of flywheel
when pulling out the flywheel.

8.2 Removal of oil seal case

Remove the oil seal case mounting bolts, and then
remove the oil seal case.

CAUTION
Be careful not to damage oil seal.

Removal of oil seal case

8.3 Removal of rear plate

Remove the rear plate attaching bolts and remove
the rear plate.

Removal of rear plate

5 - 10
 Entire Disassembly

9. Disassembly of timing gear

Replace : gasket

(19)
(23)
Damage and
wear (22)

(21)
(6)

(20)

(17)
(13)

(7)
(12)

Replace : O-ring
(14) (16)
Clogging oil and wear (9)
Replace : O-ring
(8)
Wear (11) (15)
(18)

Peeling, uneven contact, (4)

damage, malfunction of Replace : O-ring
key groove and excessive
wear bushing

(1) Replace : gasket

(3)

Crack and malfunction

of knock-hole

(10)
(2)
(5)
Replace : O-ring
Wear belt groove Wear of lip face,
damage and
aging

<Order of disassembly>
(1) Soundproof cover (9) Gasket (17) P.T.O. drive gear
(2) Crankshaft pulley (10) Oil seal (18) P.T.O. drive gear bearing
(3) Bearing case (11) Oil pump gear (19) Camshaft
(4) Bearing case (12) Thrust plate (20) Camshaft gear
(5) Cover (13) Idler gear (21) Thrust plate
(6) Injection pump (14) Oil pipe ((19) - (21): Remove as a set.)
(7) Oil pan (15) P.T.O. drive gear bearing (22) Front plate
(8) Timing gear case (16) P.T.O. bearing case (23) Gasket

5 - 11
Entire Disassembly

9.1 Removal of soundproof cover and gear case cover

(1) Remove mounting bolts, and then remove
soundproof cover.
(2) Remove mounting bolts, and then remove gear case
cover.

Removal of soundproof cover and gear case cover

9.2 Removal of crankshaft pulley

(1) Install two bolts (M12 X 1.25) into the threaded holes
in the rear end of the crankshaft. Put a bar between
the two bolts to prevent the crankshaft from turning.
(2) Remove nuts, and then remove crankshaft pulley.

CAUTION
Extreme care must be taken because the bar may fall
off.

Removal of crankshaft pulley

9.3 Removal of oil pan

Remove the oil pan attaching bolts to remove the oil
pan.

Removal of oil pan

9.4 Removal of timing gear case assembly

Remove timing gear case assembly.

CAUTION
Ensure that the oil seal is not damaged.

Removal of timing gear case assembly

5 - 12
 Entire Disassembly

9.5 Measurement of backlash and end play

Measure backlash and end play of each gear.
As a rule, replace all the gears if any measured
backlash exceeds the repair limit.
Replace thrust plate with new ones if end play
measured value exceeds repair limit.

Unit: mm (in)
Repair
Standard Measurement of timing gear backlash
limit
Backlash between 0.05 - 0.15 0.25
each gear (0.0020 – 0.0059) (0.0098)
0.05 - 0.20 0.35
Idler gear end play
(0.0020 – 0.0079) (0.0138)
0.10 - 0.25 0.30
Camshaft end play
(0.0039 – 0.0098) (0.0118)

Measurement of idler gear end play

Measurement of camshaft end play

9.6 Removal of oil pump gear

Remove gear mounting nut, and then remove oil
pump gear.

Removal of oil pump gear

5 - 13
Entire Disassembly

9.7 Removal of idler gear

Remove the thrust plate mounting bolts, and then
remove the idler gear.

Removal of idler gear

9.8 Removal of P.T.O. drive gear

(1) Install bearing puller, and then remove drive gear
bearing.
(2) Remove bolts, and then remove bearing case with
drive gear.

Removal of P.T.O. drive gear bearing

9.9 Removal of camshaft

(1) Reverse crankshaft case.
(2) Rotate the camshaft gear so that the weight
reduction holes in it are lined up vertically. Remove
the thrust plate tightening bolts, and then remove
camshaft from crankshaft case.

CAUTION
Be careful not to damage the cam of camshaft and the
camshaft axle bearing of crankshaft case. Removal of camshaft

9.10 Disassembly of camshaft gear

Remove camshaft gear from camshaft using puller.
Thrust plate can be removed at this time.
NOTE：Do not disassemble camshaft gear and thrust
plate unless they are malfunctioning.

Disassembly of camshaft gear

5 - 14
 Entire Disassembly

9.11 Removal of front plate

Remove the front plate mounting bolts, and then
remove the front plate from crankshaft case.

Removal of front plate

5 - 15
Entire Disassembly

10.Disassembly of piston, connecting rod, crankshaft, crankshaft case, and tappet

Damage
and
(4) wear Scratches of circumference,
cracks, damage, wear and
(5) Worn out adherence of carbon
(6)
(19)

Wear
(9) Wear
(8)
(7) Cracks and
clogging oil

Wear and
clogging oil
(10)
(14)
Screw part (3)
damage

Cracks and wear

(2) (17)

(18)

(1) (16)
Scratches of inner and
outer edge, welding,
peeling and wear

(15)
adherence of water scale,
corrosion and peeling

Scratches, cracks, dent,

(14)
clogging oil and wear

(13)
Peeling and uneven contact (12)
Scratches of inner
(14)
and outer edge,
welding and
peeling
(11)
Note: When replacing crank case, the parts that
belongs to crank case such as relief valve
Cracks Screw part damage
should carefully remove in order to reuse.

<Order of disassembly>
(1) Nut (8) Piston pin (14) Thrust plate
(2) Connecting rod cap (9) Piston (15) Main bearing (lower)
(3) Connecting rod bearing (10) Connecting rod (16) Crankshaft
(4) No. 1 ring ((4) – (10): Remove as a set.) (17) Main bearing (upper)
(5) No. 2 ring (11) Bearing cap bolt (18) Tappet
(6) Oil ring (12) Main bearing cap (19) Crankshaft case
(7) Snap ring (13) Side seal

5 - 16
 Entire Disassembly

10.1 Removal of connecting rod cap

(1) Remove connecting rod cap tightening nuts, tap the
tightening bolt top with an iron hammer almost
squarely, and then remove cap after removing cap
side reamer.
(2) Identify the connecting rod bearing in a proper way so
that it will not be mixed with the upper bearing and
the bearings for the other cylinders.

Removal of connecting rod cap

10.2 Preparation for piston removal

(1) Turn crankshaft case laterally.
(2) If any carbon is attached on the upper portion of the
cylinder, use sandpaper and a shop cloth to remove
the carbon.

Preparation for piston removal

10.3 Removal of piston
Turn connecting rod to top position and put a
hammer into connecting rod large end, and then pull
out toward the crankshaft case upper surface.

Removal of piston
10.4 Removal of piston ring
Remove the piston ring, using piston ring pliers Piston ring pliers
(31391-12900).

Removal of piston ring

5 - 17
Entire Disassembly

10.5 Removal of piston pin

(1) Using snap ring pliers, remove snap ring.
(2) Pull out the piston pin and then separate the Snap ring pliers

connecting rod from the piston.

(3) If the piston pin is hard to pull out, heat the piston
with a piston heater or hot water.

Removal of piston pin

10.6 Removal of main bearing cap

Remove the main bearing cap attaching bolts and
remove the main bearing cap together with the
bearing (lower).
Remove rear end main bearing cap using puller for
removal.
NOTE：Be careful not to damage each main bearing (lower).
Put the removed main bearings in order so that
they can be reinstalled in their original positions.
Removal of main bearing cap

10.7 Removal of crankshaft

Install hoisting accessories to crankshaft and lift up
horizontality, and then slowly remove crankshaft
upward.
NOTE：Be careful not to damage each main bearing
(upper). Put the removed main bearings in order so
that they can be reinstalled in their original
positions.

Removal of crankshaft

10.8 Removal of tappet

Remove tappet.
NOTE：Put the removed tappets in order so that they can
be reinstalled in their original positions.

5 - 18
 Inspection and Correction of Engine Mechanism
1. Inspection and correction of cylinder
head and valve mechanism ........................ 6 – 2
1.1 Measurement of rocker bushing inner
diameter and rocker shaft outer
diameter .................................................................. 6 - 2
1.2 Measurement of valve stem outer
diameter .................................................................. 6 - 2
1.3 Measurement of clearance between valve
stem and valve guide ......................................... 6 - 2
1.4 Replacement of valve guide............................. 6 - 3
1.5 Inspection of valve face .................................... 6 - 4
1.6 Correction of valve face ................................... 6 - 4
1.7 Correction of valve seat ................................... 6 - 5
1.8 Replacement of valve seat............................... 6 - 5
1.9 Lapping of valve and valve seat..................... 6 - 6
1.10 Measurement of valve spring slant and
free length ........................................................... 6 - 6
1.11 Measurement of lower surface of cylinder
head for distortion............................................. 6 - 7
1.12 Measurement of push rod bend................... 6 - 7
1.13 Replacement of combustion jet................... 6 - 7
2. Inspection and correction of flywheel,
camshaft, timing gear .......................................... 6 – 8
2.1 Measurement of flywheel flatness ................ 6 - 8
2.2 Inspection of ring gear ....................................... 6 - 8
2.3 Replacement of ring gear.................................. 6 - 8
2.4 Measurement of cam height............................ 6 - 8
2.5 Measurement of camshaft bend .................... 6 - 9
2.6 Measurement of camshaft journal
outer diameter and camshaft hole
inner diameter ....................................................... 6 - 9
2.7 Driving of camshaft bushing ............................ 6 - 9
2.8 Measurement of idler bushing inner diameter,
shaft outer diameter.......................................... 6 -10
2.9 Replacement of idler shaft.............................. 6 -10
2.10 Inspection of crankshaft pulley V-belt
groove for wear ................................................. 6 -10
3. Inspection and correction of piston,
connecting rod, crankshaft, crankshaft
case, and tappet .................................................... 6 –11
3.1 Measurement of distortion of upper
crankcase surface.............................................. 6 -11
3.2 Measurement of cylinder inner diameter .. 6 -11
3 3 Measurement of piston outer diameter .... 6 -12
3.4 Measurement of piston ring end gap .......... 6 -12
3.5 Measurement of piston ring groove ............ 6 -12
3.6 Measurement of piston pin hole inner
diameter and piston pin outer diameter .... 6 -12
3.7 Measurement of piston protrusion .............. 6 -13
3.8 Measurement of clearance between
connecting rod bearing and crankshaft
pin ............................................................................. 6 -13
3.9 Measurement of clearance between
connecting rod bushing and piston pin ...... 6 -14
3.10 Replacement of connecting
rod bushing.......................................................... 6 -14
3.11 Inspection of connecting rod for bend and
twist ....................................................................... 6 -14
3.12 Inspection of connecting
rod bearing .......................................................... 6 -15
3.13 Measurement of connecting rod
end play ................................................................ 6 -15
3.14 Measurement of crankshaft journal
outer diameter................................................... 6 -15
3.15 Measurement of crankshaft pin outer
diameter............................................................... 6 -16
3.16 Grinding of crankshaft.................................... 6 -16
3.17 Measurement of crankshaft end play....... 6 -16
3.18 Measurement of crankshaft bend.............. 6 -17
3.19 Replacement of crankshaft gear................ 6 -17
3.20 Inspection of oil seal contact surface ..... 6 -18
3.21 Inspection of main bearing surface........... 6 -19
3.22 Measurement of main bearing
clearance ............................................................. 6 -19
3.23 Inspection of cam contact surface of
tappet.................................................................... 6 -20
3.24 Measurement of clearance between tappet
and tappet guide hole..................................... 6 -20
Inspection and Correction of Engine Mechanism

1. Inspection and correction of cylinder head and valve mechanism

1.1 Measurement of rocker bushing inner diameter and
rocker shaft outer diameter
Measure rocker bushing inner diameter and rocker
shaft outer diameter, and then calculate clearance
between those.
Replace rocker arm until the clearance reaches
repair limit. Replace rocker arm and rocker shaft if it
exceeds the repair limit. Unit: mm (in)
Name
Standard Repair limit
value Measurement of rocker bushing inner diameter and
Rocker bushing inner 19 (0.75) 19.010 - 19.030 rocker shaft outer diameter
diameter dia. (0.7484 – 0.7492)
19 (0.75) 18.980 - 19.000
Rocker shaft outer diameter
dia. (0.7472 – 0.7480)
Clearance between rocker 0.010 - 0.050 0.070
―
bushing and shaft (0.0004 – 0.0020) (0.0028)

1.2 Measurement of valve stem part outer diameter

Measurement
Measure valve stem outer diameter. Replace with
direction
new one if it exceeds the repair limit. Replace as well
if uneven wear is found. . Unit: mm (in)
Repair
Name value Standard
limit
Valve stem 7.920 - 7.940 7.900 Measurement
Intake 8 (0.32) dia.
part (0.3118 – 0.3126) (0.3110) position
outside 7.920 - 7.940 7.850
Exhaust 8 (0.31) dia.
diameter (0.3118 – 0.3126) (0.3091)

Measurement of valve stem part outside diameter

1.3 Measurement of clearance between valve stem and

valve guide Measurement
direction
Measure valve guide inner diameter.
As the valve guide tends to wear out at the upper
and lower ends, measure the inner diameter at both
ends in two directions that are horizontal to each
other.
Measurement
Replace if outside the repair limit. . Unit: mm (in) position
Name
Standard Repair limit
value Measurement of valve guide inner diameter
Clearance 0.065 - 0115 0.150
Intake －
between valve (0.0026 – 0.0045) (0.0059)
stem part and 0.080 - 0.115 0.200
Exhaust －
valve guide (0.0031 – 0.0045) (0.0079)
14 13.9 - 14.1
Valve guide installation length －
(0.55) (0.547 – 0.555)

6-2
 Inspection and Correction of Engine Mechanism

1.4 Replacement of valve guide

Valve guide
(1) Using a valve guide remover (NF32A91-00300), push remover
out the valve guide.

Replacement of valve guide

(2) Using a valve guide installer (NF32A91-00100), push Press

in the valve guide. Valve guide installer

CAUTION 13. 9 - 14.1 mm

Be sure to use the valve guide installer to prevent the (0.547 - 0.555 in)
valve guide from going into the bore too deep. There is
a limit to the length of the valve guide that is allowed to
go into the bore.

Pushing in valve guide

6-3
Inspection and Correction of Engine Mechanism

1.5 Inspection of valve face

Apply red lead to the valve face and check valve
face contact with the valve seat using a valve lapper. Valve lapper
If the valve does not come into contact with the
valve seat evenly or the contact surface is not
acceptable in comparison with the repair limit,
correct or replace the valve and the valve seat
depending on the condition. Red lead

CAUTION:(a) Inspection of the valve face should be

performed after checking or replacing the Inspection of valve face
valve guide.
(b) Do not rotate the valve when pressing the
red-colored valve face against the valve
seat.
(c) After correcting or replacing the valve or
valve seat, be sure to perform lapping
operation for the valve and the valve seat.

OK Malfunction
Unit: mm (in)
Name Repair limit
Standard
value
Contact condition between valve seat and valve
Valve seat angle 30°
0.4 0.3 - 0.5
Valve Intake
(0.016) (0.012 – 0.020)
Valve seat

sinking 1.0
amount 0.5 0.4 - 0.6 (0.004) Seat width
Exhaust
(0.020) (0.016 – 0.024)
1.4 1.26 - 1.54
Width of seat 1.8mm
(0.055) (0.0496 – 0.0606)
2.13 Reface and up to
Valve margin
(0.0839) 1.83 (0.0720)

Valve Valve margins

seat Valve depth
angle

Contact between valve seat and valve

1.6 Correction of valve face

If the valve face is seriously worn out, correct it with
a valve refacer.
CAUTION: (a) Set the valve refacer at the angle of 30
degrees and grind the valve face. Set valve face angle 30 ‹
(b) Valve margin must be kept within the for grinding
repair limit.
If there is no chance of correcting the valve face by
refacing, the valve must be replaced.
Correction of valve face
6-4
 Inspection and Correction of Engine Mechanism

1.7 Correction of valve seat

Use a valve seat cutter or valve seat grinder to grind
the valve seat. After grinding, insert 400-grit
sandpaper between the cutter and the valve seat Valve seat
and sand the valve seat gently. cutter

NOTE: (a) Perform minimum valve seat correction.

(b) If the seat width reaches the point where it
exceeds the repair limit due to excessive
wear or correction, the valve seat must be
replaced.
Correction of valve seat

1.8 Replacement of valve seat

(1) Driving of valve seat
Welding
Weld a stud or a bar to the valve seat as shown in Shaft
the figure. Insert a shaft into the valve guide bore Valve seat
from the cylinder head upper surface and position
its tip to the welded stud, and then drive in the valve
seat by hitting the end of the shaft.
NOTE：Care must be taken not to allow spatters to Stud etc.
contact the machined surface of the cylinder head
Driving of valve seat
when welding.
(2) Installation of valve seat
Before installing a new valve seat, measure the inner
diameter of the opening in which the valve seat is to
0.1

0.1

0.1
0.1

be set, in order to make sure that it is to

8

2
8

specifications.

+0.025 +0.025
45 Dia. 46 0 Dia. 37 0 45
Intake Exhaust
(3) Insert valve seat into cylinder head by shrinkage
fitting with the following procedure. Indentation of valve seat
Refrigerate the new valve seat in liquid nitrogen
[approximately –170℃ (–274゜F)] for four minutes or
longer while the cylinder head is kept at the room Insert caulking
temperature. tool

As an alternative, the new valve seat can be kept

refrigerated in ether or alcohol with dry ice in it while
the cylinder head is heated until it reaches 80 to
100℃ (176 to 212゜F).
Insert cooled valve seat to cylinder head using an
insert caulking tool.
Insert caulking tool
Part No. Insertion of valve seat
Inlet side NF36791-00200
Exhaust side NF34491-03020

6-5
Inspection and Correction of Engine Mechanism

1.9 Lapping of valve and valve seat

(1) After correcting or replacing a valve or valve seat, be
sure to perform lapping operation.
(2) Apply a thin coat of compound to the valve surface
subject for lapping.
NOTE: (a) Care must be taken not to allow any
Compound
compound to contact the valve stem.
(b) Medium compound (120 - 150 mesh) should
be used first and then fine compound (200
mesh or more) should be used next for
finishing. Application of compound
(c) Mixing compound with a small amount of
engine oil helps apply the compound to the
surface evenly.

(3) Lap the valve using a valve lapper. Rub the valve
against the valve seat by giving the valve a slight
rotation. Valve lapper

(4) Rinse away the compound with kerosene.

(5) Apply engine oil to the contact surface and rub the
valve against the valve seat.
(6) Check the valve face for proper condition.

Lapping of valve and valve seat

1.10 Measurement of valve spring slant and free length

Check free length and slant of the valve spring for
any irregularity. Replace if outside the repair limit. Slant
Unit: mm (in)
Standard Repair limit
Free length 48.85 (1.9232) 47.60 (1.874) Free
Slant 1.5゜or less length
Installation length 43 (1.69) －
177 – 196 N 147 N
Installation load
(18 – 20 kg, 40 –44 lb) (15 kg)
Measurement of valve spring slant and free length

6-6
 Inspection and Correction of Engine Mechanism

1.11 Measurement of lower surface of cylinder head for

distortion
Using a straightedge and a feeler gauge, check the
surface for any distorted area. Any distortion that
exceeds the repair limit must be corrected using a
surface grinder. Unit: mm (in)
Standard Repair limit
Distortion of cylinder head Within 0.05 0.20
lower surface (0.0020) (0.0079)
Measurement of lower surface of cylinder head for distortion
1.12 Measurement of push rod bend
Measure push rod bend. Replace with new one if it
exceeds the standard. Unit: mm (in)
Standard
(Repair limit)
Push rod bend Within 0.3 (0.012) Push rod

1/2 1/2

Measurement of push rod bend

1.13 Replacement of combustion jet

Round bar
The combustion jet must be replaced only when
irregularities such as cracks are found.
(1) To push out the combustion jet, insert a round stick 6
mm (0.24) dia. into the glow plug hole and tap the
Combustion
perimeter of the inner jet surface. jet

Replacement of combustion jet

(2) To install a new combustion jet, drive it into place

with the injection nozzle parallel with the mounting
Combustion jet
surface, using a plastic hammer

Nozzle
hole

Installation of combustion jet

6-7
Inspection and Correction of Engine Mechanism

2. Inspection and correction of flywheel, camshaft, timing gear

2.1 Measurement of flywheel flatness
Put the flywheel on a surface plate and measure
flatness of the flywheel friction surface using a dial
indicator.
Grind if the flatness exceeds the repair limit.
Unit: mm (in)
Standard Repair limit
Within 0.15 0.50
Flatness of flywheel
(0.0059) (0.0197)

Measurement of flywheel flatness

2.2 Inspection of ring gear

Check the ring gear for missing teeth or irregular
wear. If any irregularity exists, replace the ring gear
in the following manner:
2.3 Replacement of ring gear
(1) Removal of ring gear
Heat the ring gear evenly with an acetylene torch.
Using a hammer, tap the ring gear out with a proper
stick on the perimeter, as shown in the figure.
Inspection of ring gear

(2) Installation of ring gear

Heat the ring gear with a heater (approximately
100℃ (212゜F)). Install the ring gear to the flywheel,
starting with the non-chamfered side.
NOTE：Do not heat ring gear excessively.

2.4 Measurement of cam height Measurement

D1 position
Using a micrometer, measure the long and short
diameters of each cam. If any cam is outside of the D2

repair limit, replace it with a new one. Measurement

direction
Unit: mm (in)
Name Repair
Standard
value limit
Intake 6.684 6.384 - 6.784 6.184
Camshaft
camshaft (0.2631) (0.2513 – 0.2671) (0.2435)
profile
Exhaust 6.720 6.420 - 6.820 6.220
(D1-D2)
camshaft (0.2646) (0.2528 – 0.2685) (0.2449)
Measurement of cam height

6-8
 Inspection and Correction of Engine Mechanism

2.5 Measurement of camshaft bend

Measure camshaft bend. If the degree of bend
exceeds the repair limit, straighten the camshaft
using a press or replace it with new one.
NOTE：Use a dial indicator. Observe the readings of the
dial indicator while rotating the camshaft a full turn.
The difference between the maximum value and
the minimum value must be halved to obtain the
degree of bend. Unit: mm (in)
Measurement of camshaft bend
Repair
Standard
limit
Camshaft bend 0.02 (0.0008) or less 0.05 (0.0020) Measurement
D1 position
2.6 Measurement of camshaft journal outer diameter and
D2
camshaft hole inner diameter
Measurement
Replace the camshaft with the new one when the direction
camshaft journal outer diameter is measured, and it
exceeds the repair limit. Unit: mm (in)
Repair
Name value Standard
limit
53.94 - 53.96 53.90
Camshaft No.1, 2 54 (2.13) dia.
(2.1236 – 2.1244) (2.1220)
journal outer
52.94 - 52.96 52.90 Measurement of camshaft journal outer diameter
diameter No.3 53 (2.09) dia.
(2.0842 – 2.0850) (2.0827)
Clearance between camshaft journal 0.07 - 0.11 0.15
and camshaft hole (0.0028 – 0.0043) (0.0059)

Measurement of camshaft hole inner diameter

2.7 Driving of camshaft bushing Adapter

＋０．０１９
(1) Bore camshaft hole with φ 57H6 ０
１２．５Ｓ
if Bushing Piece Bushing
▽▽
Adapter
clearance between camshaft journal and camshaft
hole exceeds the repair limit, and then drive bushing.
(2) Drive camshaft bushing using a camshaft bushing
installer set (30691-00010).
Rod
(3) Align oil hole from oil gallery and bushing oil hole when Rod Oil hole
installing bushing. Punching Tapping

Driving of camshaft bushing

6-9
Inspection and Correction of Engine Mechanism

2.8 Measurement of idler bushing inner diameter, shaft

Measurement
outer diameter direction
Measure idler bushing inner diameter and idler shaft Measurement
position
outer diameter. Replace idler gear or idler shaft if
these clearances exceed the repair limit. Unit: mm (in)
Standard Repair limit
Clearance between
0.009 - 0.050 0.100
idler bushing and
(0.0004 – 0.0020) (0.0039)
shaft

Measurement of idler bushing inner diameter, shaft

outer diameter

2.9 Replacement of idler shaft Idler shaft puller

Pull out idler shaft using an idler shaft puller

(NFMH061077).

Replacement of idler shaft

2.10 Inspection of crankshaft pulley V-belt groove for wear

Check the V-belt groove of the pulley for wear. Put
a new V-belt around the pulley tightly and check the
height of the upper belt surface relative to the pulley
perimeter.
1.6 mm
If the upper V-belt surface is higher than the pulley (0.063 in)
perimeter, the pulley can continue to be in service. or more
If the upper V-belt surface is lower than the pulley
perimeter by 1.6 mm (0.063 in) or more due to
excessive wear, the pulley cannot be reused and Inspection of crankshaft pulley V-belt groove for wear
must be replaced with a new one.

6 - 10
 Inspection and Correction of Engine Mechanism

3. Inspection and correction of piston, connecting rod, crankshaft, crankshaft case, and tappet
3.1 Measurement of distortion of upper crankcase surface
Place a straightedge on crankshaft case upper
surface. Measure distortion using a feeler gauge.
Grind using surface grinder to repair if it exceeds
the repair limit. Be careful not to grind excessively.
Unit: mm (in)
Standard Repair limit
Distortion of crankshaft 0.20
0.05 (0.0020) or less
upper surface (0.0079)

Measurement of distortion of upper crankcase surface

3.2 Measurement of cylinder inner diameter

(1) Measure cylinder inner diameter at the three points Measurement
direction
such as upper (stepped wear is frequent), middle,

11
80
lower areas of crankshaft direction and its right

150(5.91)
angle direction. Unit: mm (in)
Standard Repair limit
Repair limit: 94.200 (3.7087)
Cylinder bore 94.000 - 94.035 Measurement
Replace limit: 94.700
inner diameter (3.7008 – 3.7022) position
(3.7283)
Roundness 0.01 (0.0004) or less
0.015 (0.0006) or
Out-of-roundness Measurement of cylinder inner diameter
less

(2) Bore cylinder to be +0.25 mm (+0.0098 in) or +0.5mm

(+0.020 in) oversized if measured value is less than
replace limit and reaches repair limit. Honing after
boring is finished within an accuracy of 0 to 0.035
mm (0 to 0.0014 in).
(3) Use oversized piston and piston ring so as to match
with oversized cylinder.
(4) Check cylinder for uneven wear. Select the size so
that the cylinder will be completely round in
consideration of maximum wear limit.
All cylinders should be the same size.
(5) If only piston ring is replaced because cylinder wear is
slight, grind the parts worn out with steps of cylinder
upper using a ridge reamer and perform honing if
necessary.

Correction by ridge reamer

6 - 11
Inspection and Correction of Engine Mechanism

3.3 Measurement of piston outer diameter

Using a micrometer, measure piston pin right angle
direction of the piston skirt.
Replace if outside the repair limit. Unit: mm (in)
Standard Repair limit
93.955 - 93.985 93.770
S.T.D
(3.6990 – 3.7002) (3.6917)
Piston
0.25 94.205 - 94.235 94.020
outer
O.S (3.7089 – 3.7100) (3.7016)
diameter
0.50 94.455 - 94.485 94.270
O.S (3.7187 – 3.7199) (3.7114)
Measurement of piston outer diameter

3.4 Measurement of piston ring end gap

Put the piston ring into a gauge or a new crankshaft
case horizontally and measure the end gap.
Replace the piston rings as a set if outside the Thickness
gauge
repair limit.
Gauge inner diameter: 94.000 – 94.035 mm (3.7008-
3.7022 in) dia. Unit: mm (in)
Standard Repair limit Gap
No. 1 ring, 0.30 - 0.50
Piston ring end Oil ring (0.0118 – 0.0197) 1.50
gap (0.0591) Measurement of piston ring end gap
0.50 - 0.70
No. 2 ring
(0.0197 – 0.0276)
3.5 Measurement of piston ring groove
Insert piston ring for measuring thickness into ring
groove, and then put a straightedge onto it and
insert a feeler gauge to measure piston ring groove.
Replace if outside the repair limit. Unit: mm (in)
Standard Repair limit
0.07 - 0.11
No. 1 ring 0.200 (0.0079)
Clearance (0.0028 – 0.0043)
between ring 0.045 - 0.085
No. 2 ring 0.150 (0.0059)
and ring (0.0018 – 0.0033)
groove 0.020 - 0.060
Oil ring 0.150 (0.0059) Measurement of piston ring groove
(0.0008 – 0.0024)
3.6 Measurement of piston pin hole inner diameter and
piston pin outer diameter
Measure inner diameter of the piston pin hole and
outer diameter of the piston pin. Replace with a new
one if outside the repair limit. Unit: mm (in)
Measurement Measurement
Name direction
Standard Repair limit position
value
Piston pin outer 30 (1.18) 29.994 - 30.000
―
diameter dia. (1.1089 – 1.1811)
Clearance between
0.000 – 0.016 0.050
piston pin hole and ―
(0.0000 – 0.0006) (0.0020)
piston pin
Measurement of piston pin hole inner diameter and
piston pin outer diameter
6 - 12
 Inspection and Correction of Engine Mechanism

3.7 Measurement of piston protrusion

Measure piston protrusion with the following
procedure. Check clearance between each part if
the measured value is outside the standard.
(1) Look for the top dead center of the piston using a
dial indicator.
(2) Put a dial indicator onto crankshaft case upper
surface, and then adjust 0 point.
Measure the height at three points on the upper
surface of the piston and obtain the average value.
To determine the clearance between the top
surface of the cylinder and the cylinder head,
subtract the obtained value, or the height of the Measurement of piston protrusion
protrusion, from the thickness of the gasket with the
cylinder head bolts tightened.
Unit: mm (in)
Standard
Piston protrusion from crankshaft case -0.25 to 0.15 (-0.0098 to 0.0059)
Thickness of gasket with cylinder
1.15 - 1.25 (0.0453 – 0.0492)
head bolts tightened

CAUTION
Piston protrusions must be within the specified range
because any improper protrusion may result in poor
engine performance or cause the piston to interfere
with valves.

3.8 Measurement of clearance between connecting rod

Measurement Measurement 54 5 N-m
bearing and crankshaft pin position {5.5 0.5 kgf-m}
direction
Measure crankshaft pin outer diameter and
connecting rod bearing inner diameter. Replace
bearing with a new one if the clearance exceeds the
repair limit. Grind crankshaft pin and use undersized
bearing if there is excessive wear and unusual wear
to crankshaft pin.
There are three undersized connecting rod bearings:
-0.25 mm, -0.50 mm, -0.75 mm.
NOTE：Do not confuse bearing upper side and lower side
when measuring bearing inner diameter. Assemble
the bearing into connecting rod, and tighten the Measurement of clearance between connecting rod
cap to the specified torque to measure. bearing and crankshaft pin
Unit: mm (in)
Name
Standard Repair limit
value
Crankshaft pin outer 58(2.28) 57.955 - 57.970 57.800
diameter dia. (2.2817 – 2.2823) (2.2756)
Clearance between
0.030 - 0.090 0.200
crankshaft pin and －
(0.0012 – 0.0035) (0.0079)
connecting rod bearing

6 - 13
Inspection and Correction of Engine Mechanism

3.9 Measurement of clearance between connecting rod

bushing and piston pin Measurement
direction
Measure inner diameter of the connecting rod
bushing and outer diameter of the piston pin.
Replace with a new one if outside the repair limit.
Measurement
Unit: mm (in) position
Name
Standard Repair limit
value
Rod bushing inner 30.020 - 30.045
30 (1.18) －
diameter (1.1819 – 1.1829)
Clearance between rod 0.020 - 0.051 0.080 Measurement of connecting rod bushing inner diameter
－
bushing and piston pin (0.0008 – 0.0020) (0.0031)

3.10 Replacement of connecting rod bushing Matching mark side

(1) To replace the connecting rod bushing, use a
connecting rod bushing puller (MH061236).
(2) Align the bushing oil hole with the connecting rod oil Oil hole
hole. Make sure that the bushing alignment mark is
in the position shown in the figure.
(3) After pushing the bushing into place, insert the piston
pin and check that it moves smoothly without any Bushing joint
rattle.
Replacement of connecting rod bushing

3.11 Inspection of connecting rod for bend and twist

(1) Measure C and l as shown in the figure. Using a press, C 0.05 (0.0020)
C 100 (3.94)
repair the connecting rod if it exceeds the repair
0.05
limit. Unit: mm (in) C (0.0020)
Piston pin C
100
Standard Repair limit
(3.94)
Connecting rod for bend 0.05 (0.0020)/ 0.15 (0.0059)/ Connecting rod
and twist (C/2) 100 (3.94) 100 (3.94) Twist
Connecting rod
Bend Unit: mm (in)

Inspection of connecting rod for bend and twist

(2) In general, check connecting rod for bend and twist

using a connecting rod aligner.
NOTE：Before inspecting for bend, tighten the connecting
rod cap to the specified torque.
49.0 - 59.0 N･m
Tightening torque
(5.0 – 6.0 kg-m, 36 – 43 ft-lb)

Measurement by connecting rod aligner

6 - 14
 Inspection and Correction of Engine Mechanism

(3) When measuring with the piston installed, put the

piston on a surface plate with the top on the plate.
Insert a round stick equivalent to the crank pin and
measure round stick height from the surface plate
with a dial indicator.

Bend measurement by dial indicator

3.12 Inspection of connecting rod bearing
Check connecting rod bearing inner surface for dent
or damage by foreign materials. Replace with a new
one if necessary.
Scratch
Peeling
Welding

Inspection of connecting rod bearing

3.13 Measurement of connecting rod end play
Measure clearance (end play) between connecting
rod and crankshaft arm using a feeler gauge after
installing connecting rod to applicable crankshaft pin
and tightening to the specified torque. Replace
connecting rod with a new one if it exceeds the
repair limit. Unit: mm (in)
Standard Repair limit
End play 0.15 - 0.35 (0.0059 – 0.0138) 0.50 (0.0197)

Measurement of connecting rod end play

3.14 Measurement of crankshaft journal outer diameter
Measure crankshaft journal outer diameter in
vertical and horizontal direction using a micrometer.
Check roundness, out-of roundness, and clearance Measurement Measurement
direction position
with bearing. Grind and repair it to be undersized if it
exceeds the repair limit. Replace with a new one if
outside the repair limit. Unit: mm (in)
Name
Standard Repair limit
value
Crankshaft Repair limit: 77.850
77.955 - 77.970
journal Outer 78 (3.07) (3.0650)
(3.0691 –
diameter dia. Replace limit: 77.100
3.0697)
(3.0354)
Measurement of crankshaft journal outer diameter
Roundness Within 0.01 (0.0004) 0.03 (0.0012)
Out-of-
Within 0.01 (0.0004) 0.03 (0.0012)
roundness

6 - 15
Inspection and Correction of Engine Mechanism

3.15 Measurement of crankshaft pin outer diameter

Measure crankshaft pin outer diameter in vertical
and horizontal direction using a micrometer. Check
Measurement Measurement
roundness, out-of roundness, and clearance with direction position
bearing. Grind and repair it with a new one to be
undersized if it exceeds the repair limit. Unit: mm (in)
Name
Standard Repair limit
value
Outer 58 (2.28) 57.955 - 57.970 57.800
diameter dia. (2.2817 – 2.2813) (2.2756)
Crankshaft Within 0.01 0.03 Measurement of crankshaft pin outer diameter
Roundness
pin (0.0004) (0.0012)
Out-of- Within 0.01 0.03
roundness (0.0004) (0.0012)

3.16 Grinding of crankshaft

R 3mm R 3mm
Grind crankshaft according to main bearing and
connecting rod bearing undersize.
Grind so as not to change fillet-roll area and width.
Harden again if its surface hardness is excessively R 3mm

low, and then perform magnetic detection. Specified

hardness is 620 or more (Vickers hardness test).
Grinding specifications to be applied to crankshaft for use
of undersized bearing Unit: mm (in)
Finished dimensions of fillet R
Undersize Finished dimensions
0.25 (0.0098) 77.705 - 77.720 (3.0592 – 3.0598)
Crankshaft journal 0.50 (0.0197) 77.455 - 77.470 (3.0494)
0.75 (0.0295) 77.205 - 77.220 (3.0396 – 3.0402)
0.25 (0.0098) 57.705 - 57.720 (2.2718 – 2.2724)
Crankshaft pin 0.50 (0.0197) 57.455 - 57.470 (2.2620 – 2.2626)
0.75 (0.0295) 57.205 - 57.220 (2.2522 – 2.2528)

CAUTION
When grinding crankshaft journal or pin, be sure to
grind all the other crankshaft journals or pins to the
same size as the modified pin.
After finishing, fillet R must be 3 mm (0.12 in).

3.17 Measurement of crankshaft end play

(1) Replace thrust plate with new one if crankshaft end
play exceeds the repair limit.
NOTE：Crankshaft end play means clearance between
crankshaft thrust bearing width and thrust plate
width assembled into bearing cap.
Crankshaft thrust bearing width

6 - 16
 Inspection and Correction of Engine Mechanism

(2) Use oversized thrust plate when it exceeds the repair

limit if a new thrust plate is used. Two type thrust
plates [+0.15 (+0.0059), +0.30 mm (+0.0118 in)] are
prepared as oversize.
In general, crankshaft rear thrust bearing wear is too
large. Only rear thrust plate is oversized, the
malfunction may be repaired. Unit: mm (in)
Standard Repair limit
0.100 - 0.264 0.300
Crankshaft end play
(0.0039 – 0.0104) (0.0118) クランクシャフトのエンドプレー測定
Measurement of crankshaft end play
Unit: mm (in)
O.S. (One
O.S. (Both sides) Tolerance
side)
＋0.15 (+0.0059) O.S. 31.15 (1.2342) 31.30 (1.2323)
+0.039 (+0.0015)
＋0.30 (+0.0118) O.S. 31.30 (1.2323) 31.45 (1.2382)
0 (0)
─ ─ 31.60 (1.2441)
O.S. = Oversize

3.18 Measurement of crankshaft bend

Use V-blocks to support the crankshaft journals at
the front and the rear of the crankshaft. Measure
runout of the center journal with a dial indicator.
Compare the result with specifications. Use grinding
technique to correct minor runout. Major runout
must be corrected using a press. Replace crankshaft
with new one if it exceeds the standard.
Unit: mm (in)
Measurement of crankshaft bend
Standard Repair limit
Crankshaft bend 0.02 (0.0008) or less 0.05 (0.0020)

3.19 Replacement of crankshaft gear

(1) Pull out gear from crankshaft using a gear puller.
NOTE：Do not tap gear when pulling out.

Replacement of crankshaft gear

6 - 17
Inspection and Correction of Engine Mechanism

(2) Warm it to approximately 100℃ (212゜F) with a gear

heater.
Position crankshaft so that the crankshaft key is
inserted to gear cutout. Tap gear end surface using Joint position

a copper hammer to assemble.

Installation of crankshaft gear

3.20 Inspection of oil seal contact surface

Check crankshaft rear end oil seal contact surface.
If there is wear on the crankshaft due to contact
with the oil seal, use after-market oil seal and an oil
Oil seal
seal sleeve.

Contact face
of oil seal

Inspection of oil seal contact surface

(1) Installation of sleeve

Apply oil to the inner surface of the sleeve and drive Sleeve installer

it into place using an oil seal sleeve installer set

(NF30691-13010). Guide
(NF30691-13100)
CAUTION
Care must be taken not to scratch or damage the
sleeve perimeter.
Installer
(NF30691-13200)

Installation of sleeve
Run the engine and check the oil seal sleeve for
wear. If it is worn, remove the oil seal sleeve in the
following manner and install new after-market oil
seal and oil seal sleeve.
Oil seal

Oil seal
sleeve

Inspection of oil seal contact surface

6 - 18
 Inspection and Correction of Engine Mechanism

(2) Removal of sleeve

Put a chisel on three ends of the sleeve (one end at
a time) at a right angle to it and tap the chisel with a
hammer. When the tension of the sleeve is relaxed,
remove the sleeve.
If this operation does not work, put the chisel on the
sleeve axially and tap the chisel gently to extend the
sleeve. When tightening margin is eliminated, remove
the sleeve.
Removal of sleeve
CAUTION
Care must be taken not to damage the crankshaft
when using a chisel.
3.21 Inspection of main bearing surface
Check crankshaft contact surface for scratch,
corrosion, and peeling by contact and entry of Scratches of
foreign materials. Check back bearing contact inner and outer
edge, corrosion
surface of crankshaft case, main bearing cap, and and peeling

bearing.

Inspection of main bearing surface

3.22 Measurement of main bearing clearance

(1) Measure the average bearing inner diameter at two
points (front/rear) in the crankshaft longer side
when assembling main bearing to crankshaft case
and main bearing cap and tightening main bearing
cap to the specified torque. Obtain clearance of
main bearing. Unit: mm (in)
Standard Repair limit
Clearance between main bearing 0.050 - 0.110 0.200 98 - 108 N-m
and crankshaft journal (0.0020 – 0.0043) (0.0079) (10.0 - 11.0 kg-m, 72 - 80 ft-lb)

Measurement of main bearing inner diameter

(2) Replace main bearing with new one until clearance
between main bearing and crankshaft journal
reaches repair limit. Grind crankshaft again and use
undersized bearings [-0.25 (-0.0098), -0.50
(-0.0197), -0.75 (-0.0295)] if it exceeds the repair
limit.
(3) If it is grinded to the specified dimension as main
bearing hole standard, seating after installation is
not necessary.

6 - 19
Inspection and Correction of Engine Mechanism

3.23 Inspection of cam contact surface of tappet

Check the camshaft contact surface of the tappet
for uneven wear. If the wear is not acceptable,
replace the tappet with a new one.

OK Malfunction Malfunction

Contact surface between tappet and camshaft

3.24 Measurement of clearance between tappet and Measurement

Measurement direction
tappet guide hole position
Replace tappet with new one if clearance between
tappet and tappet guide hole exceeds the repair
limit.
Unit: mm (in)
Name
Standard Repair limit
value
14.000 - 14.018 14.100
Tappet hole 14 (0.55)
(0.5512 – (0.5551)
diameter dia. Measurement of clearance between tappet and tappet
0.5519)
Clearance between 0.016 - 0.052 guide hole
0.08
tappet and tappet ― (0.0006 –
(0.0031)
hole 0.0020)

6 - 20
 Engine Mechanism Assembly

1. Assembly of crankcase, tappet, crankshaft, piston, and connecting rod ........................................ 7 - 2

1.1 Installation of main bearing, thrust plate, and tappet................................................................................................ 7 - 2
1.2 Installation of crankshaft ...................................................................................................................................................... 7 - 2
1.3 Installation of main bearing cap ......................................................................................................................................... 7 - 2
1.4 Installation of main bearing cap bolts .............................................................................................................................. 7 - 3
1.5 Measurement of crankshaft end play .............................................................................................................................. 7 - 3
1.6 Assembly of piston and connecting rod ......................................................................................................................... 7 - 3
1.7 Installation of piston ring ...................................................................................................................................................... 7 - 4
1.8 Preparation for piston installation..................................................................................................................................... 7 - 4
1.9 Installation of connecting rod fastening bolts and bearing ..................................................................................... 7 - 5
1.10 Distribution of piston ring abutment joint.................................................................................................................... 7 - 5
1.11 Installation of piston............................................................................................................................................................. 7 - 5
1.12 Installation of connecting rod cap .................................................................................................................................. 7 - 5

2. Assembly of timing gear ......................................................................................................................................................... 7 - 6

2.1 Installation of front plate ...................................................................................................................................................... 7 - 6
2.2 Installation of camshaft gear and thrust plate............................................................................................................. 7 - 6
2.3 Installation of camshaft ......................................................................................................................................................... 7 - 6
2.4 Installation of idler gear......................................................................................................................................................... 7 - 6
2.5 Installation of oil pump gear................................................................................................................................................. 7 – 7
2.6 Inspection and adjustment after installing the timing gear..................................................................................... 7 - 7
2.7 Installation of oil seal.............................................................................................................................................................. 7 - 7
2.8 Installation of timing gear case .......................................................................................................................................... 7 - 8
2.9 Installation of oil pan .............................................................................................................................................................. 7 - 8
2.10 Installation of crankshaft pulley....................................................................................................................................... 7 - 8

3. Assembly of flywheel ................................................................................................................................................................ 7 - 9

3.1 Installation of rear plate ........................................................................................................................................................ 7 - 9
3.2 Installation of oil seal.............................................................................................................................................................. 7 - 9
3.3 Installation of flywheel ........................................................................................................................................................... 7 - 9

4. Assembly of cylinder head and valve mechanism ............................................................................................. 7 -10

4.1 Installation of stem seal ....................................................................................................................................................... 7 -10
4.2 Installation of valve and valve spring.............................................................................................................................. 7 -10
4.3 Installation of cylinder head................................................................................................................................................ 7 -11
4.4 Assembly of rocker arm and rocker shaft assembly................................................................................................ 7 -11
4.5 Insertion of push rod ............................................................................................................................................................. 7 -11
4.6 Installation of rocker shaft assembly.............................................................................................................................. 7 -12
4.7 Check of No. 1 cylinder compression top dead center position ......................................................................... 7 -12
4.8 Adjustment of valve clearance.......................................................................................................................................... 7 -13
Engine Mechanism Assembly

1. Assembly of crankcase, tappet, crankshaft, piston, and connecting rod

1.1 Installation of main bearing, thrust plate, and tappet
(1) Aligning with the crankcase lug groove, press in the
main bearing (upper). Oil groove
With this, the oil hole of the main bearing and oil
hole of the crankcase will coincide.
(2) Apply a small amount of engine oil to the interior
surface of the main bearing.
(3) Facing the thrust plate's oil groove to the outside,
attach it to the rear surface of the crankcase.
Installation of main bearing
(4) Apply engine oil to the tappet. Then insert it into the
crankcase.

1.2 Installation of crankshaft

(1) Carefully wash the crankshaft with treated oil. Then
clean by blowing with high-pressure air.
(2) Supporting the crankshaft horizontally, gently insert
it into the crankcase.
(3) Apply a small amount of engine oil to the crankshaft
journal.

Installation of crankshaft

1.3 Installation of main bearing cap

Apply Three Bond 1201
(1) Apply engine oil to each bearing. Then attach the
cap.
(2) Before attaching the main bearing cap, apply Three
Bond 1212 to the corners of the rear-end cap.
(3) Assemble the main bearing cap such that the rear
surface of the crankcase and rear surface of the
main bearing cap are flush. Apply Three Bond 1211

Installation of main bearing cap

7-2
 Engine Mechanism Assembly

(4) Apply Three Bond 1211 to the side seal. Then insert
it into the main bearing cap groove. Side
Crank case Bearing cap seal
At the rounded part R of the side seal, insert in the
outward direction, pressing in by hand a certain
distance. Push in completely, being careful not to
bend flat surfaces.
(5) Apply Three Bond 1211 around the side seal.
NOTE: When attaching the main bearing cap, insert from
the front side in the order of the numbers R part

stamped on the main bearing cap.

Insertion of side seal
1.4 Installation of main bearing cap bolts
(1) Using the specified torque, tighten the main bearing
cap bolts that were lubricated with engine oil.
98 – 108 N･m
Tightening torque
(10.0 - 11.0 kg-m, 72 – 80 ft-lb)
(2) Rotate the crankshaft by hand to check for smooth
rotation.

Installation of main bearing cap bolts

1.5 Measurement of crankshaft end play
After attaching the main bearing cap, measure the
crankshaft's end play. Confirm that it is within the
standard. Unit: mm (in)
Standard Repair limit
0.100 - 0.264 0.300
Crankshaft end play
(0.0039 – 0.0104) (0.0118)

Measurement of crankshaft end play

1.6 Assembly of piston and connecting rod A view A

(1) When combining the piston and connecting rod,
ensure that the piston's matching mark and the Front
mark
connecting rod's matching mark are on the same
connecting rod cap
Matching mark to

side.
Matching mark of mass
(2) Apply engine oil to the piston pin, and then insert it.
Connect the piston and connecting rod.

Assembly of piston and connecting rod

7-3
Engine Mechanism Assembly

(3) Using ring pliers, insert the snap ring into the piston
ring groove.
Carefully note the snap ring's tension and its fit into
the groove.
NOTE: Align the snap ring's split opening in the direction
of the piston bottom.

Installation of snap ring

1.7 Installation of piston ring

Mark of top face
(1) Using piston ring pliers (31391-12900), attach the Top ring
R
compression ring and oil ring to the piston.
NOTE: When installing the compression ring, align the
Second ring
"T" mark of the top ring and the "2T" mark of
the second ring with the top face of the piston.
Oil ring
The oil ring has no top and bottom sections.

(2) Install the oil ring such that the coil spring makes an
Combination of piston and piston ring
abutment joint at the double-end abutment and
180゜ diagonal position. Coil spring double-end
abutment

180

Oil ring abutment

1.8 Preparation for piston installation

Oil ring abutment position
(1) Set the crankcase horizontally.
(2) Clean the cylinder's interior surfaces with a rag.
Then apply engine oil.

Preparation for piston installation

7-4
 Engine Mechanism Assembly

1.9 Installation of connecting rod fastening bolts and bearing

(1) Before installing the bearing, properly insert the Rug groove
notched face of the head of the connecting rod cap
fastening bolt.
(2) Aligning with the lug groove, insert the rod bearing
(upper) into the large end of the connecting rod.
Apply engine oil to the interior surface.

Installation of connecting rod fastening bolts and bearing

1.10 Distribution of piston ring abutment joint
Camshaft side
Thrust direction
Apply engine oil to the piston ring. Distribute the
180 No.1 Ring gaps
piston ring abutment joints, avoiding the pin
direction and thrust/counter-thrust directions.

No.2
Ring gaps
Oil ring end gap
60 60
Thrust reverse Combustion chamber side
direction

Distribution of piston ring abutment joint

1.11 Installation of piston

(1) Place the crank pins (for assembling the piston) into
the top position. Facing the piston's front mark (○)
toward the engine front, insert the piston into the
cylinder, using a piston installer (NF34491-00200).
(2) Closely connect the large end of the connecting rod
to the crank pin. While pressing on the piston head, Front Piston
turn the crankshaft 180 degrees to a position where mark installer

the cap can easily be attached.

Installation of piston

1.12 Installation of connecting rod cap

(1) Install the connecting rod bearing (lower) in line with
the lug groove of the connecting rod cap. Apply
engine oil to the interior surface.
(2) Tighten the cap mounting nuts to the specified
torque.
49.0 - 59.0 N･m
Tightening torque
(5.0 - 6.0 kg-m, 36 – 43 ft-lb)
Apply engine oil
CAUTION
Confirm that the cap matching mark and connecting rod
Installation of connecting rod cap
matching mark are on the same side.

7-5
Engine Mechanism Assembly

2. Assembly of timing gear

2.1 Installation of front plate
(1) Attach the gasket in line with the crankcase dowel
pin.
(2) Fasten the front plate to the crankcase to the
specified torque.
10.0 - 13.0 N･m
Tightening torque
(1.0 - 1.3 kg-m, 87 – 113 in-lb)
(3) Using a cutter, cleanly cut off the gasket protruding
from the crankcase bottom.
Installation of front plate

2.2 Installation of camshaft gear and thrust plate

When installing the camshaft gear, warm and then
install the gear, without forgetting the thrust plate.

CAUTION
Be careful not to damage the camshaft cam and
bushing.
Thrust plate
Camshaft gear

Installation of camshaft gear and thrust plate

2.3 Installation of camshaft

(1) Apply engine oil to the camshaft journal and cam.
(2) Gently insert the camshaft into the crankcase.
(3) Tighten the thrust plate mounting bolts to the
specified torque.
10.0 - 13.0 N･m
Tightening torque
(1.0 - 1.3 kg-m, 87 – 113 in-lb)

2.4 Installation of idler gear Installation of camshaft

(1) While aligning the matching marks of each gear,
install the idler gear.
(2) Install the thrust plate. Tighten the bolts to the
specified torque.
29.0 - 39.0 N･m
Tightening torque
(3.0 - 4.0 kg-m, 22 – 29 ft-lb)

Installation of idler gear

7-6
 Engine Mechanism Assembly

(3) The matching marks of the gears coincide at the No.1

Camshaft gear Idler gear
piston compression top dead center position as shown Drive gear

n the figure.

22

3
2

33
11
1

Injection pump
gear
Crankshaft gear Oil pump gear

Timing gear matching mark

2.5 Installation of oil pump gear

(1) Attach the oil pump gear to the oil pump shaft.
(2) Tighten the jam nut to the specified torque.
28.0 - 38.0 N･m
Tightening torque
(2.9 - 3.9 kg-m, 21 – 28 ft-lb)

Installation of oil pump gear

2.6 Inspection and adjustment after installing the timing gear
After disassembling and reassembling the timing
gear, check and make adjustments for backlash and
end play in the gears.
Repair
Standard
limit
0.05 - 0.15 0.25
Backlash between each gear
(0.0020 – 0.0059) (0.0098)
0.05 - 0.20 0.35
Idler gear end play
(0.0020 – 0.0079) (0.0138)
0.10 - 0.25 0.30
Camshaft end play
(0.0039 – 0.0098) (0.0118) Inspection of backlash

2.7 Installation of oil seal

Apply a small amount of grease to the oil seal. Then
using an installer, drive it into the timing gear case.

Installation of oil seal

7-7
Engine Mechanism Assembly

2.8 Installation of timing gear case

(1) Attach the gasket in line with the crankcase dowel
pin.
(2) Apply engine oil to the oil seal lip.
(3) Install the timing gear case. Tighten the bolt to the
specified torque.
17.0 - 20.0 N･m
Tightening torque
(1.7 - 2.0 kg-m, 12 – 14 ft-lb)

Installation of timing gear case

2.9 Installation of oil pan

(1) Clean the crankcase, timing gear case, and oil pan
mounting surface.
(2) Squeeze out a 4 mm (0.16 in) diameter thickness of
Three Bond 1207C (32A91-05100: liquid gasket),
and apply around the entire circumference of the oil
pan flange.
(3) Within five minutes after the liquid gasket application,
attach the oil pan to the crankcase.
Application point of liquid gasket
(4) Tighten the mounting bolts to the specified torque.
10.0 - 13.0 N･m
Tightening torque
(1.0 - 1.3 kg-m, 87 –113 in-lb)

Cut
NOTE: (a) When squeezing out the 4 mm diameter
liquid gasket, cut off the end of the liquid
gasket tube's nozzle at the position illustrated.
(b) If the liquid gasket is difficult to use, a gasket
that is in service in the department
(NF32A13-03200) can be used.

Nozzle tip of liquid gasket tube

2.10 Installation of crankshaft pulley

Attach two safety bars (M12×1.25) to the screw
holes at the crankshaft rear. Engage the bars to
prevent the crankshaft from rotating.
Tighten the crankshaft pulley to the specified
torque.
480 – 500 N･m
Tightening torque
(49 – 51 kg-m, 354 – 369 ft-lb)

CAUTION
The bar might slip from its position, so give sufficient
Installation of crankshaft pulley
attention to safety.

7-8
 Engine Mechanism Assembly

3. Assembly of flywheel
3.1 Installation of rear plate
(1) Apply Three Bond 1212 to the joint between the rear
end of the crankcase and rear end of the bearing
cap.
(2) Aligning with the crankcase dowel pin, install the rear
plate via the gasket.
(3) Tighten the rear plate mounting bolts to the
specified torque.
54 – 65.7 N･m
Tightening torque Installation of rear plate
(5.5 – 6.7 kg-m, 40 – 48 ft-lb)

3.2 Installation of oil seal

(1) Install the oil seal to the oil seal case.
(2) Apply engine oil to the oil seal lip.
(3) Attach the oil seal case to the rear plate via the
O-ring.
(4) Tighten the oil seal case mounting bolts.

3.3 Installation of flywheel Installation of oil seal

(1) Aligning with the crankshaft dowel pin, install the
flywheel.
(2) Tighten the flywheel mounting bolt via the lock
washer to the specified torque.
After tightening, bend the corner of the lock washer
to prevent the bolt from loosening.
78.5 – 88.3 N･m
Tightening torque
(8.0 – 9.0 kg-m, 58 – 65 ft-lb)

(3) Check the flywheel's surface runout. Confirm that it Installation of flywheel

meets the standard.

If it does not meet the standard, retighten the bolt.
Unit: mm (in)
Standard Repair limit
Flywheel runout Within 0.15 (0.0059) 0.50 (0.0197)

Check of flywheel runout

7-9
Engine Mechanism Assembly

4. Assembly of cylinder head and valve mechanism

4.1 Installation of stem seal
After installing the valve, attach the stem seal to
the valve guide, using the stem seal installer Stem seal
installer Bulb
(32A91-10200).

CAUTION
Stem seal
Do not apply a liquid seal to the joint between the
stem seal and valve guide. Also, to secure initial Valve guide

lubrication at the stem seal lip, apply engine oil to the

valve stem and then insert the stem seal. Installation of stem seal
To prevent the lip from getting damaged, do not
remove the valve after attaching the stem seal.

4.2 Installation of valve and valve spring Valve spring pusher

(1) Install the valve spring and retainer into the valve
guide. Using the valve spring pusher
(NF30691-04500), attach the valve cotter.

Installation of valve and valve spring

(2) Using a soft hammer, lightly tap the top of the valve
stem several times. Confirm that the valve spring
and valve cotter are securely installed.

Check valve cotter installation

7 - 10
 Engine Mechanism Assembly

4.3 Installation of cylinder head

(1) Ensure that the cylinder head gasket does not slip
from position by aligning it with the two dowel pins
Dwell pin
on the crankcase's top face.
(2) Aligning with the dowel pins, install the cylinder head.
Then fasten the cylinder head bolts.

CAUTION
Do not use liquid packing.
Confirm that the crankcase top is free from dents Installation of cylinder head
and nicks.

(3) Tighten the cylinder head bolts to the specified

torque uniformly in the order shown in the figure.
113 – 123 N･m
Tightening torque Front 12 4 5 13
(11.5 - 12.5 kg-m, 83 – 90 ft-lb)
16 8 1 9 17
14

15 11 7 3 2 6 10

Bolts: 17

Tightening order of cylinder head bolts

4.4 Assembly of rocker arm and rocker shaft assembly

A s s e m bl y m a r k
When assembling the rocker arm, make sure that the
mark on the shaft faces toward the front of the
engine as shown in the figure.
Check that the rocker arm can slightly move after it
is assembled.

Assembly of rocker shaft assembly

4.5 Insertion of push rod

Insert the push rod into the push rod hole in the
cylinder head.
Check that the push rod ball end rests on the arc
portion of the tappet.

7 - 11
Engine Mechanism Assembly

4.6 Installation of rocker shaft assembly

(1) Install the valve cap.
(2) Attach the rocker shaft assembly to the cylinder
head. Then tighten the long bolt to the specified
torque.
10.0 – 20.0 N･m
Tightening torque
(1.0 - 2.0 kg-m, 87 – 174 in-lb)
NOTE: Fasten the rocker shaft bracket bolts in the
reverse order of removal. Fasten the long bolt
first, and then fasten the short bolt. Installation of rocker shaft assembly

4.7 Check of No. 1 cylinder compression top dead center

position
(1) Engage the turning socket (NF58309-73100) to the
crankshaft pulley nut. Then turn it in the engine's
normal direction of rotation (clockwise when viewed
from the front of the engine).
(2) Stop rotating at the point where the "0" mark
engraved in the circumference of the crankshaft
pulley is aligned with the timing gear case pointer.
Check of No. 1 cylinder compression top dead center
position (1)

(3) At this time, move the rocker arms of the No. 1

cylinder's inlet/exhaust valves up and down.
Confirm that the push rods are not pushing up the
inlet/exhaust rocker arms together.
The condition in which the inlet and exhaust are not
pushed upward together (there is clearance) is the
No. 1 cylinder's compression top dead center.
If either rocker arm is still in the up position, rotate
the crankshaft one additional turn.
Check of No. 1 cylinder compression top dead center
position (2)

7 - 12
 Engine Mechanism Assembly

4.8 Adjustment of valve clearance

(1) Insert a thickness gauge between the rocker arm
and the valve cap to measure clearance.
Unit: mm (in)
Standard
Intake 0.25 (0.0098)
Valve clearance (Cold)
Exhaust 0.25 (0.0098)

(2) Loosen the lock nut and turn the adjusting screw Adjustment of valve clearance
clockwise or counterclockwise until desired
clearance is obtained. The thickness gauge should
be caught tightly between the arm and the valve cap
when the specified clearance is obtained.
(3) Tighten the lock nut securely and measure clearance
again.
(4) Rotate the engine by a specified angle and repeat
the steps above to adjust valve clearance for the
other cylinders.
Adjusting sequence and rotation angle are as
follows:
Order (cylinder No.) Rotational angle
1-3-4-2 180°

CAUTION
After adjusting the valve clearance after disassembly,
rotate the crankshaft 2-3 times. Then reconfirm that
it meets the standard.

7 - 13
 Fuel System

1. Description of fuel system ............................................................................................................................. 8 - 2

2. Fuel filter................................................................................................................................................................ 8 - 2
Disassembly and inspection ........................................................................................................................................................... 8 - 2

3. Injection nozzle.................................................................................................................................................... 8 - 3
3.1 Disassembly.................................................................................................................................................................................. 8 - 3
3.2 Inspection and Adjustment .................................................................................................................................................... 8 - 4
3.3 Assembly ....................................................................................................................................................................................... 8 - 6

4. Fuel system air bleeding.................................................................................................................................. 8 - 6

Fuel filter................................................................................................................................................................................................ 8 - 6
Fuel System

1. Description of fuel system

Fuel filter

Fuel inlet Leak off pipe

Ignition nozzle

Return pipe

Fuel
outlet

Injection pump

2. Fuel filter
Disassembly and inspection

Crack, screw part damage

(3)

Air relief plug

(2)

Replace every 500 hours or

when clogging or cracking

(1)

<Order of disassembly>
(1) Level sensor assembly (2) Filter element (3) Bracket

8-2
 Fuel System

3. Ignition nozzle
3.1 Disassembly

Wear
(7)

Worn out and slant (6)

(5)

(4)
Damage and wear (3)
(2)
Adherence of carbon
and clogging nozzle hole
(1)

<Order of disassembly>
(1) Retaining nut (4) Pressure pin (7) Body
(2) Nozzle tip (5) Pressure spring
(3) Piece (6) Washer

8-3
Fuel System

3.2 Inspection and Adjustment

(1) Inspection adjustment of nozzle injection valve
opening pressure
(a) Install the nozzle in the nozzle tester, move a
manual steering wheel up and down several times,
and pull out air in the pipe and the nozzle.
(b) Check the steering wheel and check the
measurement of the pressure gauge jetting the
nozzle by quietly operating the complete process
cycle.
Inspection of nozzle injection valve opening pressure
(c) The indicator of the pressure gauge of the tester
rises slowly and descends suddenly when the
steering wheel of the nozzle tester is moved up
and down at the speed of one time or more per
second. It is usual that the indicator of the
pressure gauge under the jet vibrates in detail, and
read the jet injection-valve opening pressure by
the measured pressure of the beginning swing the
indicator.
Unit: kPa (bar, kg/cm2, psi)
Name value Standard
11,768 – 12,749
Jet injection-valve 11,768
(117.7 – 127.5, 120 –130,
opening pressure (117.7, 120, 1,706)
1,706 – 1,849)
Standard shows adjusting value at newly
established edition.

C A U T I O N
Do not touch injection while testing the nozzle
injection.

(d) Increase and decrease the washer in the body and

adjust the injection valve opening pressure.
Adjusting washer thickness: 1.25 to 1.7 mm (0.0492
to 0.0669 in) at 0.05 mm (0.0020 in) intervals (10
types)
NOTE：The injection valve opening pressure changes 981
kPa (9.8 bar, 10 kg/cm2, 142 psi) for each 0.1 mm
(0.004 in) increase and decrease of the shim.

8-4
 Fuel System

(2) Nozzle injection inspection

(a) Check clogging, the state of injection, and for fuel
leakage from injection hole, etc. at the same time
when adjusting pressure with the nozzle tester.
(b) Confirm whether the atomization is generated OK Injection Droop Malfunction Spay
angle rear of injection beard
when the steering wheel of the tester is operated high direction shape
at the speed of about one time per second.

State of nozzle injection

(3) Washing and replacing for poor injection

(a) Loosen retaining nut, remove nozzle tip, and wash
Top of nozzle tip
needle valve and body.

CAUTION
Do not tap the tip of the nozzle tip when pulling out the
nozzle tip.

Removal of retaining nut

(b) After washing them using clean mineral oils, the
solvents combine with the needle valve and the
body in clean kerosene.
NOTE：Be careful when handling, and never change the
combination because precision is finished up in
needle valve and the body.
(c) Tighten retaining nut for the nozzle tip tightening
to the specified torque. Needle
valve
Body
Tightening 34.3 - 39.2 N･m
torque (3.5 - 4.0 kg-m, 25 –29 ft-lb) Washing of nozzle tip
(d) Replace nozzle tip with a new one when injection
does not improve after adjusting and washing
NOTE：The rubbing face of the needle valve must never
be touched with hands.
Remove the seal peel (plastic film), slide the
nozzle and the needle valve in clean mineral oils,
and remove the applied anticorrosive oil
completely when replacing the nozzle tip with new
one. After washing it, the solvents combine with
the needle valve and the body in clean kerosene.

8-5
Fuel System

3.3 Assembly

(7)

(6)

(5) Retaining nut

Tightening torque to body
34.3 - 39.2 N-m
(3.5 - 4.0 kg-m, 25 - 29 ft-lb)
(4)

(3) Tightening torque to engine

53.0 - 64.7 N-m
(2) (5.4 - 6.6 kg-m, 39 - 48 ft-lb)
(1)

Order of assembly

(7)→(6)→(5)→(4)→(3)→(2)→(1)

4. Fuel system air bleeding

Fuel filter
(1) Loosen the air pulling out plug of the fuel filter.
(About 1.5 rotations) Priming button
(2) Move the priming button of the fuel filter up and down.
Tighten the plug when fuel that does not contain
bubbles comes out from the air pulling out plug.
Air relief plug

Fuel system air bleeding

8-6
 Oil System

1. Description of oil system ....................................................................................................................................................... 9 - 2

2. Oil pump .............................................................................................................................................................................................. 9 - 2

2.1 Disassembly.................................................................................................................................................................................. 9 - 2
2.2 Inspection...................................................................................................................................................................................... 9 - 3
2.3 Assembly ....................................................................................................................................................................................... 9 - 4

3. Oil filter ................................................................................................................................................................................................ 9 - 5

Disassembly and inspection ........................................................................................................................................................... 9 - 5

4. Relief valve........................................................................................................................................................................................ 9 - 5
Inspection............................................................................................................................................................................................... 9 - 5
Oil System

1. Description of oil system

Valve mechanism
Push rod

Tappet
Piston
Camshaft

Relief valve
Idler gear

Oil pump

Oil filter

Oil strainer

Oil pan

2. Oil pump
2.1 Disassembly

Replace O-ring

(1)

(3)

(2)

(4)

(5)

<Order of disassembly>
(1) O-ring (3) Inner rotor (5) Pump case
(2) Mainshaft (4) Outer rotor
((2) – (3): Remove as a set.)

9-2
 Oil System

2.2 Inspection
(1) Measurement of clearance between outer rotor and
inner rotor
Replace the outer rotor and shaft assembly with new
ones as a set when the clearance in the outer rotor
and inner rotor is measured, and the repair limit is
exceeded. Unit: mm (in)
Repair
Standard
limit
Clearance between outer 0.13 - 0.15 0.20
rotor and inner rotor (0.0051 – 0.0059) (0.0079) Measurement of clearance between outer rotor and pump case

(2) Measurement of end play between rotor and case

Replace the oil pump with new one when the end
play of the rotor and the case is measured, and the
repair limit is exceeded. Unit: mm (in)
Standard Repair limit
End play measurement 0.04 - 0.09 0.15
of rotor and case (0.0016 – 0.0035) (0.0059)

End play measurement of rotor and case

(3) Measurement of clearance between outer rotor and

pump case
Replace the oil pump with new one when the
clearance in the outer rotor and the case is
measured, and the repair limit is exceeded.
Unit: mm (in)
Standard Repair limit
Clearance between 0.20 - 0.30 0.50
outer rotor and case (0.0079 – 0.0118) (0.0197)
Measurement of clearance between outer rotor and inner rotor

(4) Measurement of clearance between shaft and pump

case
Calculate the clearance by the mainshaft outer
diameter and the case inner diameter, and when the
repair limit is exceeded, replace the oil pump with
new one as an assembly. Unit: mm (in)
Standard Repair limit
Mainshaft outer diameter 15.985 - 16.000
―
(case side) (0.6293 – 0.6299)
Clearance between shaft 0.032 - 0.074 0.150
and case (0.0013 – 0.0029) (0.0059) Measurement of clearance between shaft and pump case

9-3
Oil System

(5) Measurement of clearance between shaft and

bushing
Calculate the clearance by the mainshaft and the oil
pump bushing inner diameter of crankshaft case, and
when the repair limit is exceeded, replace the
bushing with a new one or the oil pump with new one
as an assembly. Unit: mm (in)
Standard Repair
limit
Mainshaft outer
13.957 - 13.975
diameter (pump bushing ―
(0.5495 – 0.5502) Measurement of clearance between shaft and bushing
side)
Clearance between
0.025 - 0.111 0.200
mainshaft and pump
(0.0010 – 0.0044) (0.0079)
bushing

(6) Push of oil pump bushing

Push the oil pump bushing with the oil pump bush
installer (NF32A91-00400).

CAUTION
Push a new idler bushing with the idler bushing installer
until the bushing becomes flush with the front face of
the crankcase.

2.3 Assembly

(5)

(1)

(3)

Flush with the case end

Flush with the case end

(4)
(2)

Order of assembly

(5)→(4)→(3)→(2)→(1)

9-4
 Oil System

3. Oil filter
Disassembly and inspection

When installing gasket,

apply engine oil

(1)

Clogged, cracks,
replace every
250 hours

(1) Filter element

4. Relief valve
Inspection
(1) Check relief valve and valve seat for contact, and Tightening
torque
spring for breakage and damage. 44 - 54 N-m
(2) Adjust the relief valve with the shim when the valve (4.5 - 5.5 kg-m,
33 - 40 ft-lb)
opening pressure of the relief valve is measured, and
the standard is exceeded.
Unit: kPa (bar, kg/cm2, psi)
Standard
Valve opening 304 – 402
Shim Cap bolts
pressure (3.04 – 4.02, 3.1 – 4.1, 44 - 58)
Inspection of relief valve

9-5
 Cooling System

1. Description of cooling system .........................................................................................................................................10 - 2

2. Water pump and fan .................................................................................................................................................................10 - 3

Inspection.............................................................................................................................................................................................10 - 3

3. Thermostat inspection...........................................................................................................................................................10 - 4
Cooling System

1. Description of cooling system

Engine coolant outlet Cylinder head

Bypass pipe

Water pump Water jacket

Coolant water inlet

10 - 2
 Cooling System

2. Water pump and fan

Inspection
(5)

Ware of V belt
groove and damage (4)

Deformed fan blade

and cracks (3)

Replace gasket

(1)
Corrosion, cracks, damage

Elongation of belt,
aging and cracks
(2)

(1) V belt (3) Pulley (5) Spacer

(2) Fan (4) Water pump assembly

Basically, do not disassemble water pump, and the replacement judgment is performed by the check from outside.
Check for water leakage, unsmooth rotation, and cracks. Replace the malfunctioning water pump assembly with
new one if necessary.
If the fan blades are deformed or have cracks, replace with a new fan.

10 - 3
Cooling System

3. Thermostat inspection
For the operation test of the thermostat, soak the mm (in)

thermostat in the container where water was put 9

Valve lift
(0.35)

in, heat while measuring the water temperature Temperature

( )
0 74.5 - 78.5 90
with the thermometer, and then measure the (0) (166 -173) (194)

temperatures such as beginning valve opening

temperature and temperature that valve lift
becomes 8 mm (0.31 in) or more. Replace it for the
new ones when the difference with the standard is
large.
Thermostat inspection
Standard
Beginning valve opening 74.5 – 78.5℃
temperature (166 – 173゜F)
Temperature that valve lift
90℃ (194゜F)
becomes 9mm (0.35 in) or more

NOTE: (a) Stir the warm water in the container with the
stick so that it is always uniform.
(b) Surely do after confirming the stamp of the
temperature of an open valve on the
thermostat installation flange when building
in the thermostat.

10 - 4
 Service Bulletin
Issue : SB 0408
Date : August 2004

Applied model: All

Subject: Coolant/Antifreeze used for aluminum radiators and/or other aluminum parts.

Introduction:
We have received several complaints for leaking of radiators.
After investigation of several radiators, it was found that most of the radiators were leaking
because of internal corrosion.
This internal corrosion was caused due to the fact that the coolant/antifreeze is not meeting the
specification for aluminum radiators.

During the investigation it was found that when mixing concentrate coolant/antifreeze with tap
water, the corrosion protection is reduced and will cause internal corrosion, even though the
coolant/antifreeze supplier describes on the label that mixing with tap water is allowed.

Instruction (for all models):

• Use ready-mix coolant/antifreeze which is suitable for aluminum radiator and engine.
o Coolant/antifreeze specifications: Ethylene glycol base

SB0408-Coolant spec.doc Page 1 of 1 2/12/2008

 Inlet and Exhaust System

1. Description of inlet and exhaust system ................................................................................................................11 - 2

2. Exhaust manifold ........................................................................................................................................................................11 - 2

Inspection.............................................................................................................................................................................................11 - 2
Inlet and Exhaust System

1. Description of inlet and exhaust system

Exhaust manifold
Inlet manifold

2. Exhaust manifold
Inspection
(1) Check if flange has any cracks or not.
(2) Check distortion on flange face. Repair flange, if
the distortion level is over the standard limit.
Unit: mm (in)

Standard
Distortion of exhaust manifold 0.2 (0.008) or less

Mesurement of distortion of exhaust manifold

11 - 2
 Electrical System

1. Starter ................................................................................................................................................................................................12 - 2
1.1 Inspection before disassembly (assembly) ....................................................................................................................12 - 2
1.2 Disassembly................................................................................................................................................................................12 - 4
1.3 Inspection....................................................................................................................................................................................12 - 6
1.4 Assembly ....................................................................................................................................................................................12 -10
1.5 Inspection and adjustment after assembly...................................................................................................................12 -12

2. Alternator ........................................................................................................................................................................................12 -13

2.1 On board inspection...............................................................................................................................................................12 -13
2.2 Disassembly...............................................................................................................................................................................12 -15
2.3 Inspection...................................................................................................................................................................................12 -17
2.4 Assembly ....................................................................................................................................................................................12 -19
2.5 Installation..................................................................................................................................................................................12 -20

3. Glow plug .........................................................................................................................................................................................12 -20

3.1 Inspection...................................................................................................................................................................................12 -20
3.2 Installation..................................................................................................................................................................................12 -20

4. Magnetic valve (stop solenoid).......................................................................................................................................12 -21

4.1 Inspection...................................................................................................................................................................................12 -21
4.2 Installation..................................................................................................................................................................................12 -21
Electrical System

1. Starter
1.1 Inspection before disassembly (assembly)
Adjust, or disassemble and correct if it is
malfunctioning.
(1) Pinion gap
(a) Connect battery positive terminal to starter Lightly press
terminal S and negative terminal to starter body, backwards

and then pinion is popped out.

CAUTION + -
Do not energize continuously for 10 seconds or more. Battery
12V
0.5 - 2.0mm
(b) Lightly push the tip of the pinion shaft popped out Starter
(0.020 - 0.079 in)
with a finger to the original position, and measure
the return amount (amount of the movement). Inspection of pinion gap
(c) Adjust by increasing and decreasing the number of
sheets of packing of a magnetic switch when
measured value is outside the range between 0.5 to
2.0 mm (0.020 to 0.079 in). When the number of
sheets is increased, the pinion gap becomes small.

(2) No load test Switch

(a) Connect the ammeter, the voltmeter, the
Ammeter
tachometer, and the battery as shown in the figure. A
(b) If the pinion pops out and starter rotates more than
the specified rpm when the switch is turned ON, it Starter V
is normal. Tachometer
Disassemble starter, and check and correct, except - +
Battery
when the current or the rpm are outside the 12V
standard.
No load test
CAUTION
(a) Use thick wire if possible, and tighten each terminal Item Standard
sufficiently. Starter name M8T75171
(b) As for the rotation sound, do not misidentify it Official output V-kW 12-2.2
Terminal
V 11
characteristic

because the sound has risen compared with the voltage

No load

mechanism without the reduction gear.

Current A 130 or less
(c) Be careful that the pinion pops out when operating
Rotational
while performing the rotation detection in the tip of min-1 3800 or more
speed
the pinion.

12 - 2
 Electrical System

(3) Inspection of magnetic switch

Perform the following check, and replace a magnetic S
switch at the malfunction. M

(a) Remove the connector of terminal M.

(b) Suction test + -
If the pinion pops out when the battery is Battery
12V
connected with magnetic switch terminal S to M
Disconnect connecting
side and the switch is turned on, it is normal. wire of terminal M

CAUTION Suction test

Do not energize continuously for 10 seconds or more.

(c) Maintenance test

Draw out the pinion fully by hand with the battery Disconnect connecting S
connected between the magnetic switch terminal S wire of terminal M

and the body. It is normal if it is released and it M

does not return.

+ -
CAUTION
Battery
Do not energize continuously for 10 seconds or more. 12V

Maintenance test

(d) Return test

Draw out the pinion fully by hand with the battery Disconnect connecting
wire of terminal M
connected between magnetic switch terminal M M
and the body.
If the pinion returns at once when releasing it, it is
+ -
normal.
Battery
12V
CAUTION
Do not energize continuously for 10 seconds or more.

Return test

12 - 3
Electrical System
1.2 Disassembly
Replace: snap ring
Breakage and
wear of gear
Smoothness, fixing
<Order of disassembly>
(1) Pinion set
(2) Magnetic switch
(3) Rear bracket
(4) Brush holder assembly
(5) Yoke assembly
(6) Armature
12 - 4
Contaminated commutator surface,
seizure, wear, wear and damage of
gear, open circuit for ground
Rough rotation
Rough rotation
Adhesion of brush powder, uneven wear,
movement of brush in holder
Replace: washer
Wear and damage
of gear Attachment state of
pole and field coil
(7) Bearing (13) Gear shaft
(8) Ball (14) Internal gear
(9) Packing set (15) Overrunning clutch
(10) Gear (16) Front bracket
(11) Lever assembly (17) Bearing
(12) Washer set (18) Oil seal
 Electrical System

Disassembly
Always disassemble after removing the pinion first when
the following parts are disassembled or replaced.

Parts disassembled after removing pinion

(a) Front bracket or its bearing, oil seal
(b) Deceleration gear part
(c) Overrunning clutch

(1) How to remove pinion

S1
Supply power to the switch, and remove the pinion
that popped out. Remove terminal M connector and B S2
+
connect the battery with starter as shown in the M
S
figure. Pop out the pinion by closing switches S1 and Battery
S2, and then stop the pinion rotation by opening Starter

switch S2. Set a pipe tool to the pinion stopper, tap -

the tool with the hammer lightly, and remove the

pinion stopper. However, the stopper might not be
How to remove pinion
removed when tapping, and the pinion returns to the
original position. Perform again from the beginning in
that case.

(2) Ball
Do not lose the ball that becomes a bearing in the
direction of thrust of the armature. It may be stuck
on the grease of the tip of the shaft when pulling out
the armature.

12 - 5
Electrical System

1.3 Inspection
Inspection
(1) Short-circuit test of armature coil
Iron chips
Check the armature coil by using growler tester, and Growler tester
replace the one with the short-circuit.
Inspection procedure:
(The deposits of the armature coil should be
removed.) Rotate the armature coil slowly while
attaching a piece of iron to the armature coil in
parallel. At this time, it is normal if the piece of iron
is not suctioned or vibrated.
Short-circuit test of armature coil

(2) Ground test of armature coil

Check continuity between commutator segment and
armature coil.
Replace the armature if continuity should exist.

Ground test of armature coil

(3) Runout measurement of commutator

Using a dial indicator, measure commutator runout.
Replace the armature with a new one when the
runout exceeds repair limit. Repair with sandpaper
(#300-500) when the commutator surfaces are
getting rough.
When worn out with steps, replace the armature with
a new one because it is not possible to repair.
Unit: mm (in)
Runout measurement of commutator
Standard Repair limit
Commutator runout 0.05 (0.0020) 0.10 (0.0039)

12 - 6
 Electrical System

(4) Measurement of commutator outside diameter O

dia uter
Replace the armature with a new one when the m
et
er
commutator outside diameter is measured, and the
repair limit is exceeded.
Unit: mm (in)
Standard Repair limit
Outside diameter of 31.8 - 32.2 31.4
commutator (1.252 – 1.268) (1.236)

Measurement of commutator outside diameter

(5) Measurement of undercutting depth between

segments
Undercut
Clean the groove between segments, and measure Segment
the undercutting depth. Repair if it exceeds repair Mica
limit. Unit: mm (in)
Standard Repair limit
Undercutting depth 0.4 - 0.6 0.2
between segments (0.016 – 0.024) (0.008)

Measurement of undercutting depth

(6) Inspection of armature gear

Check armature gear for excessively wear and
breakage. Replace the armature with new one if
necessary.

(7) Disconnection test of yoke coil

Check continuity between terminal lead line and
brush positive terminal. Replace the yoke assembly
with new one if continuity should not exist.

Disconnection test of yoke coil

12 - 7
Electrical System

(8) Ground test of yoke coil

Check continuity between yoke and brush positive
terminal. It is grounded if continuity should exist.
Check insulation conditions. Replace the yoke
assembly with new one if it cannot be repaired.

Ground test of yoke coil

(9) Inspection of magnetic switch

Perform the next continuity test. Replace a magnetic Terminal S

switch with new one if necessary.

(a) Disconnection test of coil Terminal M
Terminal B
Check continuity between terminals S and Terminal
M, terminal S and ground (case). Between terminal
B and the ground, continuity should not exist.
(b) Welding check of point of contact
Check continuity between terminal B and terminal
Inspection of magnetic switch
M.
(10) Measurement of brush length
Brush
Replace the brush with new one when the length of
the brush is measured, and it reaches the repair limit.
Repair with sandpaper (♯300-500) when the brush
is worn unevenly and contact surfaces are getting
rough. Unit: mm (in)
Name value Repair limit
Brush length 18 (0.71) 11 (0.43)

Measurement of brush length

(11) Measurement of brush spring tension

Measure the installation tension in the brush spring.
Take a reading the moment when spring separates
from the brush. Replace the brush spring with new
one when the tension reaches the repair limit.
Unit: N (kg, lb)
Repair
Standard
limit
26 – 36 15
Brush spring tension
(2.7 – 3.7, 6.0 – 8.2) (1.5, 3.3) Measurement of brush spring tension

12 - 8
 Electrical System

(12) Insulation inspection of blush holder

Check continuity between brush holder positive side Brush holder

and brush holder negative side using a tester.

Replace the brush holder with new one when
continuity should exist.

(13) Inspection of bearing

Replace ones that do not rotate smoothly and the
one that make noise sounds.
Insulation inspection of blush holder

(14) Inspection of overrunning clutch

(a) Confirm the smooth rotation when it locks when
the pinion shaft is rotated in a direction, and that it
rotates in the opposite direction.
(b) Check pinion shaft for unsmooth rotation, wear, and
damage. Replace overrunning clutch (pinion shaft
assembly) with new one if necessary.

CAUTION
Do not wash overrunning clutch with mineral oils. Inspection of overrunning clutch

(15) Front bracket

Replace ball bearing together with front bracket
when the ball bearing does not rotate smoothly and
makes noise sounds.
NOTE：Replace the oil seal at each disassembly.

(16) Reduction gear

Check for damage and wear. Replace if necessary.

12 - 9
Electrical System

1.4 Assembly
Assembly
Note the following, and assemble in the reverse
order of disassembly.
(1) Application of grease
Apply grease to all sliding parts, gears, and bearings
shown in the following figure when overhauling
starter.

B C A E D
F

Parts to which grease is applied when assembling starter

A Armature shaft gear C Reduction gear F Pinion shaft bearing

B Armature back bearing D Pinion shaft gear G Pinion
(Apply a little grease so as not to enter E Lever sliding area of magnetic H Oil seal
commutator.) switch

12 - 10
 Electrical System

(2) Installation of stopper ring

Pull the pinion stopper with a pulling out tool after
fixing the stopper ring into the ring groove of the
pinion shaft, and set the stopper ring in the ring
groove of the stopper.

Installation of stopper ring

(3) End play adjustment of pinion shaft

Reduction
Put adjusting washer between the center bearing Adjusting washer gear

bracket and the reduction gear and adjust the end

Washer
play (thrust gap) to 0.5 mm (0.020 in) or less.
(a) Assemble the pinion shaft, the reduction gear, the Snap ring

washer, and the snap ring to the center bearing End play
bracket. Max 0.5 mm
(b) Axially move the pinion shaft and measure the end (0.020 in)

play.
End play adjustment of pinion shaft
Increase and adjust the number of sheets of
adjusting washer when the end play exceeds 0.5
mm (0.020 in).

(4) Installation of lever

Be careful of the lever direction when installing. Front bracket
Lever

Lever spring

Installation of lever

12 - 11
Electrical System

1.5 Inspection and adjustment after assembly

Perform the following inspection and test after
assembling starter.
(1) Inspection of pinion gap
Lightly push the pinion shaft edge side with a finger Lightly press
at the position in which the pinion popped out backwards S
completely and measure the returned amount.
Increase and decrease the number of sheets of
+ -
packing in the magnetic switch installation part to Battery
12V
adjust when the gap is outside the range between 0.5 0.5 - 2.0mm
Starter
(0.020 - 0.079 in)
to 2.0 mm (0.020 to 0.079 in). Increase the number of
sheets of packing when the pinion gap is too large,
Adjustment of pinion gap
and decrease it when it is small.

CAUTION
Do not energize continuously for 10 seconds or more.

(2) No load test

Connect the meter between starter and battery, and
confirm the no load characteristic after adjusting the Ammeter
Switch
pinion gap as shown in the figure.
Battery
Switch
CAUTION
Voltmeter Starter
Use thick wire if possible, and tighten each terminal
sufficiently.

Voltage Current Rotational speed No load test

No load 130 A or 3800 min-1 or
11 V
characteristic less more

12 - 12
 Electrical System

2. Alternator
For charge system inspection, detect the
malfunctioning parts according to the following
conditions. If the inspection could not be performed
under the condition that the alternator is installed on
the work bench, perform inspection and corrections
after removing.
The adjustment value of the voltage regulator
Overcharge

is high.
Battery malfunction
Alternator inspection
The adjustment value of the voltage relay is
low.
Overelectrical
discharge

Alternator output malfunction

Power consumption is excessively high.
A special load is used.
Wiring malfunction

2.1 On board inspection

(1) Precautions
Handle the parts with extra caution because
improper handling causes breakage and malfunctions.
(a) Do not connect the battery in reverse. However, (-)
is ground.
(b) Do not use the high voltage tester such as Megger.
(c) Remove the battery cable when charging with the
battery.
(d) Do not remove the lead line from terminal B of the
alternator while running the engine.
(e) Do not ground it because the battery voltage is
always supplied to alternator terminal B.
(f) Do not short or ground terminal L. (Type with
built-in IC regulator)
(g) Prevent steam from hitting the alternator directly
when using the steam cleaner.

12 - 13
Electrical System

(2) Inspection of adjusting voltage (with built-in IC

Clamp ammeter
regulator) Ammeter
+ -
(a) Remove terminal and connect the ammeter A

between those. Or, clamp alternator terminal B Switch

L
harness if ammeter is clamp type. + -
R
(b) Connect the voltmeter between terminal L and
+ Battery
ground. V Voltmeter 12V
(c) The indication of the voltmeter must be 0 when
starter switch is at OFF.
Inspection of adjusting voltage (with built-in IC
Indicate the value whose indication of the regulator)
voltmeter is considerably lower than the battery
voltage when starter switch is ON (engine not
started). (About 1 to 4 V)
(d) Short-circuit the ammeter terminal and start the
Standard V-A
engine.
Adjustment
(e) Measure voltmeter indication value (adjusting voltage 14.7±0.3 V 12-50
voltage) when ammeter indication value is 5 A or [20℃ (68゜F) time]
less and engine speed is 1800 min-1, 2500 min-1, and
lamp switches are OFF.

(3) Output inspection (with built-in IC regulator)

(a) Apply all loads such as lamps.
(b) Engine speed must increase, and measure the
maximum output current at a prescribed alternator
rotational speed by the voltmeter indication value
13.5 V.
If it is within the standard, it is normal.
NOTE：If load current, such as lamps, has not reached the
Output performance
value shown in the table on the right, measure
Standard
again after battery is discharged. Items Type name Voltage of Rotational
terminal/current speed
13.5 V/33 A or
2500 min-1
characteristic

more
Output
(Hot)

A7TA0477A
13.5 V/47 A or
5000 min-1
more

12 - 14
 Electrical System

2.2 Disassembly

(5)
Contaminated snap ring,
damage, seizure and coil resistance
Rough rotation (10)

(4)

(3)

Status of sliding
brush and wear

(2)
Rough
rotation
(1)

(7)

(9) Short and open circuit

(8)

(6) Open circuit for coil and ground

<Order of disassembly>
(1) Nut (5) Rotor assembly (9) Rectifier assembly
(2) Pulley and spacer (6) Stator (10) Nut set
(3) Screw (7) Rear bracket
(4) Front bracket assembly (8) Regulator assembly

12 - 15
Electrical System

Disassembly
(1) Separation of stator core and front bracket
(a) Insert a screwdriver into the clearance between
stator core and front bracket, and raise up.

CAUTION
Be careful that the screwdriver is not inserted too
deeply because it may cause damage to stator core.

Disassembly of alternator

(2) Removal of pulley

(a) Secure rotor wrapped with the application cloth
using a vise, and pull out pulley and spacer after
removing pulley nut.
(b) Pull out rotor from front bracket.

Removal of pulley

(3) Removal of stator core and rectifier

(a) Remove soldering of the lead line where stator core
ties to rectifier, and remove stator core.

CAUTION
Quickly perform removal of soldering.
Diode is destroyed when it is heated for long periods of
time.

(b) Remove the rectifier mounting screw, and then Removal of stator core
remove rectifier.

12 - 16
 Electrical System

2.3 Inspection
Inspection
(1) Inspection of rectifier Trio diode
Heat sink (-)
Check resistance between diode lead and heat sink
for each diode. Measurement is performed when
connecting test lead line positive side to diode and
connecting test lead line negative side to diode. It is
open when both have resistance of infinity, and it is
shorted when both have resistance near 0. When
Heat sink (+) Lead wire for diode
open or short-circuited, diode is malfunctioning.
Replace rectifier.
Inspection of rectifier
For each trio diode, check resistance between lead
lines (terminals). If it is open or shorted, replace
rectifier with new ones.

(2) Inspection of field coil

(a) Check resistance between snap rings. Replace
rotor with new one if it is outside the standard.
Standard
Resistance between snap rings 2.7～3.2Ω

Field coil continuity test

(b) Check continuity between slip ring and shaft (core).

Replace rotor with new one if continuity should
exist.

Field coil ground test

12 - 17
Electrical System

(3) Inspection of stator core

(a) Check continuity between each lead line of stator
core. Replace the stator with new one if continuity
should not exist.

Stator core continuity test

(b) Check continuity between each lead line of stator

core and stator core. Replace stator with new one
if continuity should exist.

Stator core ground test

(4) Inspection of brush

(a) Replace the brush that is worn near the wear repair
limit . Unit: mm (in)
Standard Repair limit
5 mm (0.20 in)
Brush length 18.5 (0.728) 5 (0.20) 18.5 mm
Wear limit line
(0.728 in)

Inspection of brush

12 - 18
 Electrical System

(b) If soldering the lead line of the brush is removed,

the brush and spring can be removed.

Replacement of brush

(c) Solder the lead line after it pushes it so that the

brush may enter the holder as shown in the figure
when installing a new brush.

Replacement of brush

2.4 Assembly
Assemble in reverse order of disassembly. However,
be careful about the following.
Assembly
(1) Press-fit it heating the rear bracket to 50 to 60℃
(122 to 140゜F) when press-fitting rear bearing to the
rear bracket.
(2) To lift the brush before the rotor is installed in the
Wire
rear bracket, pass a wire through the small hole
provided in the rear bracket, and then remove the
wire after assembly.

Rear bracket

Brush

Wire

Assembly of alternator

12 - 19
Electrical System

2.5 Installation
(1) Hang a belt (fan belt) to alternator, and install it to
engine.
At this time, tighten all bolts temporarily.
(2) Insert a stick between the alternator and the
crankcase, use the stick as a lever, and put the belt
on.
Tighten the bolt that fixes the alternator to the
adjusting plate under this condition.
Installation of alternator

(3) Check belt tension. Loosen the bolt and perform step )
98N g, 22 lb
(2) again if it is outside the standard. Bolt (10 k Water pump pulley

Standard
Belt tension Approx. 13 mm (0.51 in) Adjusting ox.
plate Appr
(Crankshaft pulley to alternator [Measured by pressing 13 m m
in)
pulley) with 98 N (10 kg, 22 lb)] Alternator (0.51
pulley
(4) Tighten all bolts that fix the alternator when belt Bolt
Crankshaft pulley

tension is within the standard.

Belt tension inspection

3. Glow plug
3.1 Inspection
Check continuity between terminal and body as
shown in the figure, and replace ones without
continuity and ones with a large resistance with new
ones.
Standard
Resistance (reference) Approx. 0.2 Ω

Inspection of glow plug

3.2 Installation
(1) Install the glow plug in the cylinder head to the
specified torque.
15.0 - 20.0 N･m
Tightening torque
(1.5 - 2.0 kg-m, 11 – 14 ft-lb)
(2) Install connection plate to glow plug, and tighten
suppression nut to the specified torque.
1.0 - 1.5 N･m
Tightening torque
(0.10 - 0.15 kg-m, 9 –13 in-lb)

12 - 20
 Electrical System

4. Magnetic valve (stop solenoid)

4.1 Inspection
(1) Check continuity between terminal and body as
shown in the figure, and replace ones without
continuity and ones that are lower than the standard
resistance with new ones.
Standard
Resistance
[Ambient temperature: 18 - 28℃ 8 - 9.2Ω
(64 – 82゜F)]
Inspection of magnetic valve (1)

(2) Visually check rubber on the top of armature for

peeling and scratches. Slide armature by hand and
check for it getting stuck.

Armature

Inspection of magnetic valve (2)

4.2 Installation
Install magnetic assembly to distributor to the
Magnetic valve
specified torque. assembly

15 – 25 N･m
Tightening torque
(1.5 - 2.5 kg-m, 11 – 18 ft-lb)

Injection pump
distributor head

Installation of magnetic valve

12 - 21
 Adjustment of Engine, Accustoming Driving, and
Performance Test

1. Engine adjustment .....................................................................................................................................................................13 - 2

1.1 Check and adjustment of valve clearance...................................................................................................................13 - 2
1.2 Draining of fuel system........................................................................................................................................................13 - 3
1.3 Air bleeding of fuel system ................................................................................................................................................13 - 3
1.4 Adjustment of period when it begins to inject fuel ..................................................................................................13 - 4
1.5 Check and adjustment of V belt tension......................................................................................................................13 - 4
1.6 Adjustment of governor.......................................................................................................................................................13 - 5

2. Accustoming driving.................................................................................................................................................................13 - 6
2.1 Start of engine ........................................................................................................................................................................13 - 6
2.2 Check while engine is running...........................................................................................................................................13 - 6
2.3 Accustoming driving time....................................................................................................................................................13 - 6
2.4 Check and adjustment after accustoming driving ....................................................................................................13 - 6

3. Performance test .......................................................................................................................................................................13 - 7

3.1 Engine equipment...................................................................................................................................................................13 - 7
3.2 Test item and purpose.........................................................................................................................................................13 - 7
3.3 Other inspections...................................................................................................................................................................13 - 7
3.4 Engine output correction ....................................................................................................................................................13 - 7
Adjustment of Engine, Accustoming Driving, and Performance Test

1. Engine adjustment
1.1 Check and adjustment of valve clearance
Check and adjust valve clearance when engine is cold.
Unit: mm (in)
Standard
Intake 0.25
Valve clearance (Cold)
Exhaust (0.0098)

(1) Check of valve clearance

(a) Follow injection sequence to check valve
clearance. Rotate crankshaft 180°in the regular
rotation direction and position each cylinder at
compression TDC.
Injection sequence
Cylinder No. 1-3-4-2
(b) Attach socket and ratchet handle to crankshaft
pulley nut in order to turn crankshaft. Check compression TDC (1)
(Turning socket: 58309-73100)
Double-faced width of
46 (1.81)
crankshaft pulley nut
(c) The “0” mark engraved in the circumference of
the crankshaft pulley is aligned with the timing
gear case pointer, and push rod does not push
out rocker arm with both intake and exhaust
valve when No. 1 cylinder is at compression
TDC.
(d) Insert a thickness gauge between the rocker arm
Check compression TDC (2)
and the valve cap to measure clearance.

(2) Adjustment of valve clearance

(a) Loosen the lock nut and turn the adjusting screw
clockwise or counterclockwise until desired
clearance is obtained. The thickness gauge
should be caught tightly between the arm and the
valve cap when the specified clearance is
obtained.
(b) Tighten the lock nut securely and measure
clearance again.
Adjustment of valve clearance

13 - 2
 Adjustment of Engine, Accustoming Driving, and Performance Test

1.2 Draining of fuel system

Fuel and water may be mixed in fuel system, if there
is water over standard quantity at bottom of fuel
filter.
Drain water with the following procedure.
(1) Loosen drain plug on bottom of fuel filter.

Drain plug

Fuel filter water draining

(2) Push manual pump repeatedly (about 7 times), and
transmit fuel to drain rapidly.
(3) Secure drain plug after draining.
(4) Always bleed air after draining.

CAUTION
The drainage includes fuel in addition to water. Wipe Manual pump
away any fuel spilt on the surrounding components.

Fuel filter water draining

1.3 Air bleeding of fuel system
(1) Loosen plug for air bleeding of fuel filter with spanner.

Air bleeding plug

Fuel lifter bleeding air

(2) Attach cloth at plug for air bleeding and push manual
pump repeatedly.
When there are no bubbles from plug for air bleeding,
air bleeding is complete.
(3) Secure air bleeding plug.
Manual pump

Fuel filter bleeding air

13 - 3
Adjustment of Engine, Accustoming Driving, and Performance Test

1.4 Adjustment of period when it begins to inject fuel

When period to begin injecting fuel is early, tilt When slow
injection pump to opposite side of crankcase. (carry forward)

When period to begin injecting fuel is late, tilt injection When fast
(carry backward)
pump to crankcase.

Adjustment of period when it begins to inject fuel

1.5 Check and adjustment of V belt tension

Push center of belt with thumb to check bending.
Loosen bolts fixing alternator and adjust tilting of
alternator to adjust V belt.
Unit: mm (in)
Standard
V belt deflection Approx. 13 (0.51)

Check and adjustment of V belt tension

13 - 4
 Adjustment of Engine, Accustoming Driving, and Performance Test

1.6 Adjustment of governor

Check and adjustment of the no load lowest rotation (low
idling) and the highest rotation

CAUTION
(a) The set bolt is sealed after the output of each
engine is confirmed on the test bench, and this
check adjustment can be executed only at the
service factories specified by the company.
(b) After adjusting the each governor part, seal all
external stoppers when shipping from the factory.
(c) When the engine malfunction occurs, this seal
becomes very important for judgement standards
when there is a complaint. Apply the seal to the
specified seal part securely without forgetting.
(d) When the check is adjusted, prepare it in
consideration of overrunning the engine
(overspeed) to operate the engine stop lever by
hand.
Do after machine is driven enough after the engine
starts, and the engine coolant temperature and the
temperature of oil become 70℃ or more when
checking the adjustment.
(1) Engine started Idling
(a) Pull the speed control lever to a high-speed side, and adjusting
operate starter switch. screw
(b) Maintain it at 800 to 1000 min-1 by operating the
speed control lever because the rotational speed of
the engine detonates with about 150 min-1, and the
turn increases.
(c) Return the speed control lever to the low idling Maximum speed
rotation position when the engine rotation is adjusting screw
steady.
(2) Low idling set (no load lowest rotational speed set) Engine adjustment
Fix the speed control lever to become a no load
lowest rotational speed, and set it with the idling
adjustment screw.

CAUTION
Avoid the rotational speed when the tensional vibration
dangerous rotational speed region exists.
(3) Governor set (highest rotational speed set)
(a) Maintain the speed control lever at the directed
highest rotational speed position.
(b) Adjust to the rotational speed directed by the
maximum speed adjustment screw (highest
rotational speed set screw) while keeping the
position, and set it.

13 - 5
Adjustment of Engine, Accustoming Driving, and Performance Test

2. Accustoming driving
Install the engine in the dynamometer, hold the 2.3 Accustoming driving time
accustoming driving concurrently, and check each part The relation between the load and the driving time
when overhauling the engine. of the accustoming driving is as follows.

Accustoming driving time

2.1 Start of engine rpm (min-1) Load (kW) Time (min)
(1) Check the amount etc. of engine coolant, the engine 1 1000 No load 30
oil, and the fuel before starting the engine, and 2 1500 25％ 30
perform the air pulling out from the fuel and the Ratings rotational
3 25％ 10
speed
coolant system.
4 (2300) 50％ 10
(2) Crank the engine with starter for about 15 seconds
5 75％ 30
with the fuel determined to apply the engine oil in the
6 100％ 20
engine each part.
(3) Move the speed control lever in the direction of a
2.4 Check and adjustment after accustoming driving
slight fuel increase (It is not good to move the lever
(a) Check each bolt and nut for looseness
to full injection position), and turn the key of starter
(b) Adjustment of valve clearance
switch to "START" position to start.
(c) Check at period when it begins to inject fuel
(4) The no load low speed must rotate by operating the
speed control lever after it starts (low idle).

2.2 Check while engine is running

Discontinue driving, confirm the cause, and
perform appropriate treatment when the following
condition is noted, and malfunction is found during
the process of the accustoming driving.
(1) Oil pressure 294 – 490 kPa (2.94 – 4.90 bar, 3 – 5
kg/cm2, 43 –71 psi) (at 1500 min-1), pressure 98 kPa
(0.98 bar, 1 kg/cm2, 14 psi) (at 750 min-1)
(2) Engine coolant temperature [Approx. 75 - 85℃
(167 – 185゜F)]
(3) Engine oil temperature [70 - 90℃ (158 - 194゜F)]
(4) There is no oil, coolant, and fuel leakage.
(5) The knock sound must not disappear with the rise of
the engine coolant temperature, and, additionally,
there must not be malfunctioning sound.
(6) Check for the presence of the exhaust color and the
smell.

13 - 6
 Adjustment of Engine, Accustoming Driving, and Performance Test

3. Performance test (2) Calculation of corrected output

There are various methods of testing the performance. Multiply measured shaft output and axis torque and
In this text: "Earth-moving machinery -Engines- Part1: correct the diesel engine correction coefficient
Test code of net power (JIS D0006-1)" calculated from the count type.
and "Earth-moving machinery -Engine- Part2: Standard Corrected output = measurement axis (αc) ×
format of specifications and tests methods of diesel output of correction coefficient
engines (JIS D0006-2)" are shown. ･Atmospheric conditions during test
It is necessary to add other examination items according Temperature (T): 283 K [10℃ (50゜F)] ≦T≦313
to the usage. Synthesize the examination result and K [40℃ (104゜F)]
judge the performance of the engine. Dry atmospheric pressure (P): 80kPa (800 mbar,
600 mmHg, 23.62 inHg) ≦P≦110kPa (1,100 mbar,
3.1 Engine equipment 825 mmHg, 32.48 inHg)
Attach necessary devices for the engine such as
the fan, the air cleaners, and alternators while (3) Calculation of correction coefficient (αc)
installed. αc=(fa)fm
fa: Atmospheric coefficient
3.2 Test item and purpose
fm: Coefficient of engine
(1) Load test when working
(a) Calculation of atmospheric coefficient (fa)
It knows the performance of the output in various (1) For no supercharging and the machine type
loads, the torques, the fuel input ratings, and the
supercharging engine
governor. 99 T 0.7
(2) Continuous load test
fa= ( )(
Pd ･ 298 )
(2) For the turbo supercharging engines with the
Continuously drive ten hours in 90% load of the
intake air cooler or without intake cooler
official net axis output (continuous load) in the 99 0.7 T 1.2
rotational speed of the engine corresponding to the
fa= ( ) Pd (
･ 298 )
(3) For the turbo supercharging engine with intake
official net axis output, know the fuel input rating
liquid cooling machine
and the driving situation, and confirm whether 99 0.7 T 0.7
continuous driving is possible.
fa= ( )Pd (
･ 298 )
(b) Calculation of coefficient (fm) of engine
(3) No load lowest rotational speed test
fm＝0.036qc-1.14
Confirm whether steady driving is possible in a
qc: Amount of correction fuel supply
regulated no load lowest rotational speed. (1) qc＝ q
r
3.3 Other inspections
(z)×(flowing quantity of fuel g/s)
Check for gas leakage, coolant leakage, nasty smell, q＝
(Swept volume 2)×(Engine speed min-1)
oil leakage, hunting. Correct if necessary.
z=120000(4 cycle engine)
r: Exit pressure of supercharger or intercooler and
3.4 Engine output correction
ratio of the atmospheric pressure
The output of the diesel engine is controlled by the
(The no supercharging engine is r=1.)
atmospheric pressure, the temperature, and
(2) Coverage of coefficient (fm) of engine
humidity. Therefore, it is necessary to correct the
37.2 ≦qc≦65mg/(2cycle)
output to a standard atmospheric condition.
qc≦37.2mg/(2cycle): fm=0.2 (constant)
(1) Standard atmospheric condition
65 mg/(2cycle): ≦qc:fm=1.2 (constant)
Standard temperature: 298 K [25℃ (77゜F)]
Total atmospheric pressures: 100 kPa (1,000 bar,
(c) Limit of correction type use
750 mmHg, 29.53 inHg)
The range of correction coefficient ( α c) is
Standard dry air atmospheric pressure: 99 kPa (990
assumed to be 0.9≦αc≦1.1.
mbar, 743 mmHg, 29.25 inHg)
Indicate the corrected value, and record the test
condition in the test record when this range is
exceeded.
13 - 7
 Guidance of Trouble Diagnosis

Trouble diagnosis and corrections...................................................................................................................................................14 - 2

Guidance of Trouble Diagnosis

Trouble diagnosis and corrections

There is

The Glow plug doesn't heat red.

There is irregularity in the noise

Engine Exhaust smoke an

The scorch of the Glow plug is

Allophone generation in engine

The knock of the noise during
Breakdown or
Poor starting Poor power non-standard engine
malfunction output condition hunting
cap.
Does not start The engine

Small amount of extra

though the does not At work

Exhaust fumes: large

Exhaust fumes: large

operation is large.
Starter does not go

during operation.
engine rotates. rotate.

The rotation of

The crank turns

The crank does

exhaust fumes.

amount, white

amount, black
of extra fumes

of extra fumes
Large amount

with the hand.

Small amount

not turn with

There is no

At work
the hand.

At Idle

At Idle
White

Black
early.

fumes
Condition

up.
The fuel supply to the
injection pump is ○ ○ ― ― ― ― ― ― ○ ― ― ― ― ― ― ― ― ― ―
malfunctioning.
Injection pump imbalance is
large. ― ― ○ ― ― ― ― ― ― ― ○ ○ ― ○ ○ ― ○ ○ ○
Malfunctioning injection
pump and oil seal ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ―

Poor fuel injection amount ○ ○ ― ― ― ― ― ― ○ ― ― ― ― ― ― ― ― ― ―

The fuel oil consumption is
excessive. ― ― ― ― ― ― ― ― ― ― ― ― ― ○ ― ― ― ― ―
Injection nozzle poor
― ― ○ ― ― ― ― ― ― ― ○ ○ ○ ○ ○ ― ○ ○ ○
Fuel system

injection
The return is excessive of
the jet nozzle. ― ○ ― ― ― ― ― ― ○ ― ― ― ― ― ― ― ○ ○ ―
Advancement at period too
much when it begins to ― ― ○ ― ― ― ― ― ― ○ ― ― ○ ○ ○ ― ― ― ―
inject fuel
Too late at period when it
begins to inject fuel ― ― ○ ― ― ― ― ― ― ― ○ ○ ― ― ― ― ○ ○ ―
The rotation of the engine
is too low. ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ○ ―
The engine stop is
imperfect. ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ―

Poor fuel ― ― ○ ― ― ― ― ― ― ○ ○ ○ ○ ○ ○ ― ― ― ―

Size of viscosity of fuel ○ ○ ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ―

Poor oil quality ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ―

High viscosity oil ― ― ― ― ○ ― ― ― ― ― ― ― ― ― ― ― ― ― ―

Low viscosity oil ― ― ― ― ― ― ― ― ― ― ― ― ○ ― ― ― ― ― ―

Insufficient hydraulic
Oil system

pressure ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ―

There are a lot of oil leaks. ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ―

There is much oil up. ― ― ― ― ― ― ― ― ― ― ― ― ○ ○ ○ ― ― ― ―

Clogged/restricted oil filter ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ―

Breakdown of oil pressure
indicator lamp switch ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ―
or the lamp.

14 - 2
 Guidance of Trouble Diagnosis

(●: Refer to the attached table.)

Engine Malfunc-

Do not rotate at high speed and

The rotation of the engine does

There is a lot of consumption of

The return to low speed is bad. Oil system coolant tioning
The throb of an engine is large.

malfunction temperature alternator

Excessive fuel consumption

malfunction charge

The water temperature

The water temperature

The engine is reversed.

The lamp lights at high

Cause the engine stall.

The lamp lights in low

during engine stopped

during engine stopped

Water mixes with oil.
Oil is diluted by fuel.

Light at high speed.

Does not turn ON

Does not turn ON

Corrective action

Excessive PCV

(over heat)
do not stop.

is too high.

is too low.
not go up.

speed.

speed.
oil.

― ○ ― ○ ― ― ― ― ― ― ― ― ― ― ― ― ― ― ●

○ ○ ― ― ― ― ○ ― ― ― ― ― ― ― ― ― ― ●
Disassembly or
― ― ― ― ― ― ― ― ○ ― ― ― ― ― ― ― ― ― replacement if necessary
― ○ ― ○ ― ― ― ― ― ― ― ― ― ― ― ― ― ― ●

― ― ― ― ― ― ○ ― ○ ― ― ― ― ― ○ ― ― ― ●

○ ○ ― ― ― ― ○ ― ○ ― ― ― ― ― ― ― ― ― ●

― ○ ― ― ― ― ○ ― ― ― ― ― ― ― ― ― ― ― Nozzle chip replacement

○ ○ ― ― ― ― ○ ― ― ― ― ― ― ― ― ― ― ― ●

― ○ ― ― ― ― ○ ― ― ― ― ― ― ― ○ ― ― ― ●

○ ○ ― ― ― ― ― ― ― ― ― ― ○ ― ― ― ― ―

― ― ― ― ― ○ ― ― ― ― ― ― ― ― ― ― ― ―

― ○ ― ― ― ― ○ ― ― ― ― ― ― ― ― ― ― ― ●
Replace it with the fuel for
― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― the cold area.
Replace it with good quality
oil.
― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― Replace it with the oil of a
suitable viscosity for the
temperature.
― ― ― ― ― ― ― ― ― ― ― ― ― ○ ― ― ― ―

― ― ― ― ― ― ― ○ ― ― ○ ― ○ ― ― ― ― ― Ditto

― ― ― ― ― ― ― ― ― ― ― ― ○ ― ― ― ― ― ●
Tighten, and replace
― ― ― ― ― ― ― ○ ― ― ― ― ― ― ― ― ― ― packing.
― ― ― ― ― ― ― ○ ― ― ― ― ― ― ― ― ― ― ●
Replace element and oil
― ― ― ― ― ― ― ― ― ― ― ― ― ○ ― ― ― ― replace at the same time.
― ― ― ― ― ― ― ― ― ― ― ○ ○ ― ― ― ― ― Ditto

14 - 3
Guidance of Trouble Diagnosis

Engine Exhaust There is

The scorch of the Glow plug is

Breakdown or smoke an engine
Poor starting Poor power

There is irregularity in the noise

malfunction non-standard hunting

The Glow plug doesn't heat red.

Allophone generation in engine

output

The knock of the noise during

condition cap.
Does not start The engine
though the does not At work

The rotation of Starter

Exhaust fumes: large

Exhaust fumes: large

engine rotates. rotate.

operation is large.
turn with the hand.

during operation.
The crank doesn't

Small amount of
does not go up.
exhaust fumes.

exhaust fumes
The crank turns

amount, white

amount, black
Large amount
Small amount

with the hand.

There is no

of exhaust

of exhaust

At work
At Idle

At Idle
fumes

fumes

White

Black
early.
Condition
Shortage of amount of suction air ― ― ○ ― ― ― ― ― ― ― ○ ― ― ○ ― ― ― ― ―
Air system

Compression pressure shortage ― ― ○ ― ― ― ― ― ― ○ ○ ○ ○ ○ ○ ― ○ ○ ○

The temperature is high or the
atmospheric pressure is low in the high ― ― ― ― ― ― ― ― ― ― ○ ― ― ○ ― ― ― ― ―
ground.
Because the engine was too cold ― ― ○ ○ ― ― ― ― ― ― ― ○ ― ― ○ ― ― ― ―

The cooling action of the radiator ― ― ― ― ― ― ― ― ― ○ ― ○ ○ ― ○ ― ― ― ―

Cooling system

is excessive.
Insufficient amount of coolant ― ― ― ― ― ― ― ― ― ― ○ ― ― ○ ― ― ― ― ―

Cooling action shortage of radiator ― ― ― ― ― ― ― ― ― ― ○ ― ― ○ ― ― ― ― ―

Water leak of cylinder head gasket ― ― ― ― ― ― ― ― ― ○ ― ○ ○ ― ― ― ○ ― ―

Crankcase water jacket crack ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ―

A starting switch is malfunctioning. ― ― ― ― ○ ― ○ ― ― ― ― ― ― ― ― ― ― ― ―

Starter magnetic switch is ― ― ― ― ○ ― ― ― ― ― ― ― ― ― ― ― ― ― ―
malfunctioning.
Starter is malfunctioning. ― ― ― ○ ○ ― ― ― ― ― ― ― ― ― ― ― ― ― ―

Starter free foil is malfunctioning. ― ― ― ○ ○ ― ― ― ― ― ― ― ― ― ― ― ― ― ―

Electrical system

Drive gear and pinion gear ― ― ― ― ○ ― ― ― ― ― ― ― ― ― ― ― ― ― ―

Decrease of voltage of battery ― ― ○ ○ ○ ― ○ ― ― ― ― ― ― ― ― ― ― ― ―

Glow plug or pilot lamp ― ― ○ ― ― ― ○ ― ― ― ― ― ― ― ― ― ― ― ―
disconnection
Glow plug short-circuit ― ― ○ ― ― ― ― ○ ― ― ― ― ― ― ― ― ― ― ―

Alternator breakdown ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ―

The relay is malfunctioning. ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ―

Wiring malfunction ― ― ○ ○ ○ ― ― ○ ― ― ― ― ― ― ― ― ― ― ―

Burning of movement part ― ― ― ○ ― ○ ― ― ― ― ○ ― ― ○ ― ○ ○ ― ―

Cylinder, piston, and piston ring ― ― ○ ― ― ― ― ― ― ○ ― ○ ○ ― ○ ○ ― ― ―
wear-out
Worn piston ring ― ― ○ ― ― ― ― ― ― ○ ― ○ ○ ― ○ ― ― ― ―

Oil clearance size ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ○ ― ― ―

Engine Mechanical

Looseness of connecting rod cap bolt ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ○ ― ― ―

Interference with valve and piston ― ― ― ― ― ○ ― ― ― ― ― ― ― ― ― ○ ― ― ―

Breakage in valve spring ― ― ○ ― ― ― ― ― ― ○ ― ○ ○ ― ― ○ ○ ○ ○

The valve clearance is excessive. ― ― ― ― ― ― ― ― ― ― ○ ― ― ○ ― ○ ○ ○ ○

Foreign material enters in the ― ― ― ― ― ○ ― ― ― ― ― ― ― ― ― ○ ― ― ―
cylinder.
The gear backlash is excessive. ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ○ ― ― ―

14 - 4
 Guidance of Trouble Diagnosis

(●: Refer to the attached table.)

Engine Malfunc-
Oil system coolant tioning

There is a lot of consumption of oil.

malfunction temperature alternator

Do not rotate at high speed and

The return to low speed is bad.

malfunction charge
The throb of an engine is large.

Excessive fuel consumption

The rotation of the engine

Does not turn ON during

Does not turn ON during

The water temperature

The water temperature

The engine is reversed.

The lamp lights at high

Cause the engine stall.

is too high.(over heat)

The lamp lights in low
Corrective action

Water mixes with oil.

Oil is diluted by fuel.

Light at high speed.

engine stopped

engine stopped
does not go up.

Excessive PCV
do not stop.

is too low.
speed.
speed.
― ○ ― ○ ― ― ○ ― ― ― ― ― ― ― ― ― ― ― ●

― ○ ― ― ― ― ○ ― ― ― ― ― ― ― ― ― ― ― ●

― ― ― ― ― ― ○ ― ― ― ― ― ― ― ○ ― ― ― (It is necessary to squeeze a full

loading set of the fuel.)
― ○ ― ― ― ― ― ― ― ― ― ― ― ○ ― ― ― ― Do enough from the oil pan after it
heats, and it starts when starting.
― ― ― ― ― ― ○ ― ― ― ― ― ― ― ― ○ ― ― ●

― ― ― ― ― ― ― ○ ― ― ○ ― ○ ― ○ ― ― ― ●

― ― ― ― ― ― ― ○ ― ― ○ ― ○ ― ○ ― ― ― ●

― ― ― ― ― ― ― ― ― ○ ― ― ― ― ― ― ― ― Tightening or gasket replacement if

necessary
― ― ― ― ― ― ― ― ― ○ ― ― ― ― ○ ― ― ― Disassembly and crankcase
replacement
Disassemble and check contact,
― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― and then repair or replace if
necessary.
― ― ― ― ― ○ ― ― ― ― ― ― ― ― ― ― ― ― Disassemble and repair or replace if
necessary.
― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― Ditto

― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― Disassemble and repair or replace

starter if necessary.
― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― Ring gear correction or replacement
and pinion gear replacement
― ― ― ― ― ○ ― ― ― ― ― ○ ― ― ― ― ○ ― Charge or replace. Heat if it is the
low temperature.
― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― Part replacement

― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― Copper packing replacement, if

necessary replace glow plug
― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ○ Replace alternator if necessary.

― ― ― ― ― ○ ― ― ― ― ― ― ― ― ― ― ○ ○ Adjust or replace if necessary.

― ― ― ― ― ― ― ― ― ― ― ○ ― ― ― ― ○ ― Connect wires securely and

correctly.
― ○ ― ○ ― ― ○ ○ ― ― ○ ― ― ― ○ ― ― ― ●

― ○ ― ― ― ― ○ ○ ○ ― ○ ― ― ― ― ― ― ― Overhaul and part replacement

― ○ ― ― ― ― ○ ○ ○ ― ○ ― ○ ○ ― ― ― ― Ditto

― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― Disassemble, bearing replacement.

If necessary undersized.
― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― Additionally tighten
Engage timing gear correctly, and
― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― assume the amount of sinking of
the valve to be proper.
○ ○ ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― Part replacement

○ ○ ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― Adjust to 0.25 mm.

― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― Overhaul
― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― Gear or idler bushing replacement

14 - 5
 Guidance of Trouble Diagnosis

Condition Possible causes Corrective action

The fuel supply to the injection
pump is malfunctioning. The cock of the fuel tank shuts. Open the cock.

The fuel tank is empty. Fueling

Blocking of tube on fuel S The pipe adjustment or the inside is washed by

air.
Air inhalation in system on fuel S Tightening installation part or pipe
replacement
Fuel leakage It tightens hard in the correct direction.

Clogged fuel filter Disassemble and clean, or element

replacement
Malfunctioning bleeding. Bleeding.
Excessively high injection pump
imbalance Agglutination of plunger Disassembly and part replacement

Wear-out of plunger Ditto

Wear-out of bearing Ditto

Plunger spring breakage Ditto

Loosening of plunger pinion Tighten hard while aligning to stamp line.

The exhalation valve is malfunctioning. Part replacement

Breakage in exhalation valve spring Ditto

Poor fuel injection amount Stop lever link caught Connect the linkage and put the lever position
(It is possible to put it on the in neutral.
injection pump.)
Rack does not move. Refueling or overhaul

Agglutination of plunger Disassembly and part replacement

Wear-out of plunger Ditto

Wear-out of bearing Ditto

Loosening of plunger pinion Tighten hard while aligning to stamp line.

The fuel oil consumption is
excessive.
Because the full loading set does not move
The stop lever is pushed to the increase side.
Loosening of full loading set
Do a correct fuel set with the pump
adjustment stand.
Correct the link, and put the lever on a neutral
position.
Do a correct fuel set with the pump
adjustment stand.

Loosening of plunger pinion Tighten hard while aligning to stamp line.

Injection nozzle spray Disassemble nozzle, and replace parts if
malfunction Needle agglutination of nozzle tip
necessary.
The seat of the nozzle tip is malfunctioning. Ditto

Breakage in nozzle spring Part replacement

Advancement at period too
much when it begins to inject
fuel
Injection pressure decrease
Packing nozzle point carbon adhesion
The installation angle of the injection pump is
malfunctioning.
Improper matching timing gear
Replace adjustment shim to become standard
injection beginning pressure with the nozzle
tester.
Remove carbon.
Correctly align stamp lines of the injection
pump and the flange.
Timing gears should be engaged correctly.

14 - 6

Condition
Too late at period when it
begins to inject fuel
Poor fuel
Insufficient hydraulic pressure
There is much oil up.
Shortage of amount of
inhalation air
Compression pressure
shortage
Insufficient amount of coolant
Possible causes
Installation angle of injection pump
non-standard condition
Injection timing control is inaccurate.
Wear-out of bearing of injection pump
The fuel is inferior.
Moisture mixing with fuel
Shortage of amount of oil pan oil
Air inhalation from oil strainer
Oil pump is malfunctioning.
Oil system pipe blocking
Relief valve malfunction
Clogged oil filter
Oil leakage from the oil system is frequent.
The amount of the oil pan oil is too large.
Cylinder, piston, and piston ring wear-out
Agglutination of piston ring
Worn valve guide(s)
Because a no load was driven for a long time
Clogged air cleaner stopped up
Blocking of suction pipe
Valve seat malfunction
Valve stem agglutination
The valve is depressed in the rocker.
Cylinder, piston, and piston ring wear-out
Agglutination of piston ring
Gas leakage of cylinder head gasket
Breakage in valve spring
Poor starter rotation (at starting)
Pouring water amount shortage
Overheat
Unit seal water leak of water pump
It is a crack in the water jacket of the crankcase.
Other water leaks
Guidance of Trouble Diagnosis
Corrective action
Correctly align stamp lines of the injection
pump and the flange.
Timing gears should be engaged correctly.
Disassembly and part replacement
Replace with the good quality one.
Ditto
Oil is replenished with a regular level.
Replace and tighten if pipe is damaged, flange
packing is improperly tightened
Overhaul
Disassembly washing
Disassemble and check spring if it is broken
and caught foreign materials.
Replace element and oil replace at the same
time.
Overhaul
Oil is exhausted to a regular level.
Overhaul and part replacement
Ditto
Ditto
Smoke doesn't disappear if it is not driven for
a while. It is overhauled when oil comes out
from the exhaust tube voluminously.
Element cleaning or replacement
Check and cleaning
Disassembly correction
Ditto
The valve clearance is adjusted to 0.25 mm.
Overhaul and part replacement
Overhaul and part replacement
Tighten or replace gasket with a new one if
necessary.
Disassembly and part replacement
Ditto
The volume of water is replenished with a
proper level.
Disassembly and part replacement
14 - 7
 Guidance of Trouble Diagnosis

Condition Possible causes Corrective action

Cooling action shortage of The air outtake is imperfect in the cooling water The air bleeder valve, the drain valve or the
radiator system. hose clamp is loosened and it executes the
air outtake.
Radiator internal rust and scale adhesion Wash it.

Garbage adhesion outside of radiator Ditto

There is a lot of slipping of the fan belt. Adjust the belt tension.

Thermostat malfunction (Close) Part replacement

The cooling action is
excessive of the radiator. Temperature is low.

Because it has not covered the radiator. Cover the radiator.

Thermostat malfunction (Open) Part replacement

Burning of movement part Burning of cylinder, piston, piston ring burning, Overhaul and part replacement
and the main bearing and connecting rod bearing
Idler bushing burning Ditto

14 - 8