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Mitsubishi S16R Service Manual
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Mitsubishi S16R Service Manual

Mitsubishi S16R Service Manual

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SERVICE MANUAL
1COVER
October 2010
Pub. No. 99249-36150
TP-6856 10/10

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  • Page 1 SERVICE MANUAL 1COVER October 2010 Pub. No. 99249-36150 TP-6856 10/10...
  • Page 3 FOREWORD This service manual describes the maintenance and adjustment procedures, and specifi- cations for Mitsubishi diesel engines. To maintain the performance of the engine for many years and to ensure safe operation, it is important to use the engine correctly and conduct scheduled inspection and mainte- nance, and it may also be necessary to take appropriate measures which involve in disas- sembly, inspection, repair and assembly work of the engine and engine parts.
  • Page 4 HOW TO USE THIS MANUAL This service manual consists of several chapters, which will give you quick references to specifications, maintenance standards, adjustment and service procedures including practices to disassemble, inspect, repair and assemble the Mitsubishi diesel engines. A short summary describing the contents of each chapter is given in the CHAPTER INDEX page, and there is also a detailed table of contents at the beginning of each chapter.
  • Page 5 FOREWORD Terms used in this manual Nominal value means the basic nominal size of a part to be measured. Standard value means the quantitative requirement for dimension of a part, clearance between parts and performance.The values are rounded off for the inspection job, and do not necessarily conform to the design values. Limit value means the limit value, which the measured value reaches, the part needs repair or replacement with a new one.
  • Page 6 FOREWORD Safety Cautions Fire and Explosion Precautions Pay Attention to Fuel, Oil and Exhaust Gas Keep Flames Away Leak Do not use flames near the engine (in the engine room).The flame is dan- If any fuel, oil or exhaust gas leakage is found, imme- gerous to ignite combustibles and diately take corrective measures to stop it.Such leak- cause a fire.Wipe off spilled fuel, oil...
  • Page 7 FOREWORD Stay Away From Rotating and Moving Parts Lockout and Tagout Install Protective Covers Over Rotating Be sure to lockout and tagout before starting inspec- Parts After Inspection and Maintenance tion and maintenance. Lockout and tagout are effec- Work tive methods of cutting off machines and equipment Check the covers over engine rotating from energy sources.
  • Page 8 FOREWORD Be Careful of Falling Be Careful of Exhaust Gas Poison- Lift Engine Carefully Be careful of Ventilation to Operate Engine Use slings or wire ropes strong enough to lift the load considering the If the engine is installed in an engine weight.To lift the engine, hitch enclosed area, and the exhaust gas is the proper slings to the lifting hangers...
  • Page 9 FOREWORD Be Careful of Burns Be Careful When Handling Fuel, Engine Oil or LLC Do Not Touch the Engine During or Immedi- Use Specified Fuel, Engine Oil and Long- ately After Operation Life Coolant (LLC) Only Do not touch any parts of the engine during or immediately after opera- Use the fuel, oil and LLC specified in this manual only, tion.You can get burned.Before start-...
  • Page 10 FOREWORD When Abnormality Occurs Battery Do Not Add Cooling Water Immediately Be Careful with Battery ŒNever use flames or generate After a Sudden Stop Due to Overheating sparks near the battery.The bat- If the engine stops suddenly due to overheating, or tery gives off highly flammable you suddenly stop the engine by any reason, do not hydrogen gas and oxygen gas.Any...
  • Page 11 FOREWORD Other Cautions Never Break the Seals Do Not Tamper To ensure the proper engine operation, the fuel control If tampered, the warranty is totally void even in the link is provided with seals that protect the fuel injection warranty period.Tampering with the engine can not volume and rotation speed settings against tamper- only damage the engine but also may lead to personal ing.If the seal is tampered, no guarantee will be pro-...
  • Page 12 FOREWORD Use Care to Protect Engine From Water Warm-up the Engine Before Use Use care to protect engine from water such as rain After starting the engine, run the engine at a low idling entering through the air inlet or exhaust openings.Do speed for 5 to 10 minutes for warming-up.
  • Page 13 FOREWORD Cautions for Engine Transportation Observe Safety Rules at Work Site To road-transport the engine, consider the engine Observe the safety rules established at the workplace weight, width and height, and obey applicable laws when operating and maintaining the engine.Do not and regulations such as road traffic laws, vehicle road operate the engine if you are in bad health.
  • Page 14 FOREWORD Warning Labels Maintenance of Warning Labels Make sure all warning/caution labels are legible. Clean or replace the warning or caution label when the description or illustration is not clear to read. For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvent, gasoline or other chemicals to prevent the label from fading and peering.
  • Page 15 FOREWORD Points on Assembling Points on Disassembling and As- Œ Wash all engine parts, except such parts as oil seals, O- sembling rings and rubber seats, in cleaning oil and dry them with This service manual contains the recommended practices to compressed air.
  • Page 17 GENERAL CONTENTS Chapter 1 GENERAL 1. External View 2. Outline of Systems 3. Contents of Plate and Label 4. Specifications Chapter 2 SERVICE DATA 1. Maintenance service data 2. Tightening torque table Chapter 3 SERVICE TOOLS 1. Special Tools Chapter 4 OVERHAUL INSTRUCTIONS 1.
  • Page 18 Chapter 8 FUEL SYSTEM 1. Fuel system - Remove and inspect 2. Fuel system - Disassemble and inspect 3. Fuel system - Install Chapter 9 LUBRICATION SYSTEM 1. Lubrication system - Remove and inspect 2. Lubrication system - Disassemble, inspect and assemble 3.

  • Page 19: Table Of Contents

    Chapter 1 GENERAL External View ......................1-3 Outline of Systems ....................1-17 Outline of Fuel System ......................1-17 Outline of Lubrication System....................1-18 Outline of Cooling System ...................... 1-19 Outline of Inlet and Exhaust System..................1-23 Contents of Plate and Label ................. 1-24 Name Plate ..........................

  • Page 21: External View

    Chapter 1 GENERAL Chapter 1 GENERAL 1. External View S16R-PTA with fan spec Cooling water outlet Cooling water outlet Thermostat case Thermostat case Water pump Breather Oil pump Engine oil drain port Damper Oil pan Note: Configuration may differ depending on the customization and specifications.
  • Page 22 Chapter 1 GENERAL S16R-PTA with fan spec Rear hanger Fuel filter Front hanger Thermostat case Fuel injection pump Breather Governor Front Rear Water drain cock Damper Fuel feed pump Bypass oil filter Starter Oil cooler Oil filler Fuel return port...
  • Page 23 Chapter 1 GENERAL S16R-PTK-2 Engine Engine cooling water cooling water outlet outlet Thermostat case Thermostat case Water pump Breather Oil pump Engine oil drain port Damper Oil pan Note: Configuration may differ depending on the customization and specifications. Engine Front View...
  • Page 24 Chapter 1 GENERAL S16R-PTK-2 Fuel filter Fuel injection pump Oil cooler Front hanger Rear hanger Intercooler cooling water inlet Governor oil filter Stop lever Bypass oil filter Governor Front Rear Fuel feed pump Damper Oil filter Starter Relief valve Oil filler...
  • Page 25 Chapter 1 GENERAL S16R-PTK2 Engine Engine cooling water cooling water outlet outlet Thermostat case Thermostat case Water pump Breather Oil pump Damper Engine oil drain port Oil pan Note: Configuration may differ depending on the customization and specifications. Engine Front View...
  • Page 26 Chapter 1 GENERAL S16R-PTK2 Fuel injection pump Fuel filter Oil cooler Rear hanger Front hanger Stop lever Governor Bypass oil filter actuator Front Rear Fuel feed pump Damper Starter Oil filter Relief valve Oil filler Oil level gauge Fuel return port Fuel inlet Note: Configuration may differ depending on the customization and specifications.
  • Page 27 Chapter 1 GENERAL S16R-Y2PTAW Air cooler thermostat case Air cooler cooling water outlet Engine cooling water outlet Engine cooling water outlet Thermostat case Thermostat case Air cooler water pump Water pump Damper Oil pump Oil pan Engine oil drain port Note: Configuration may differ depending on the customization and specifications.
  • Page 28 Chapter 1 GENERAL S16R-Y2PTAW Fuel filter Fuel injection pump Oil cooler Rear hanger Front hanger Stop lever Bypass oil filter Actuator (Governor) Front Rear Air cooler cooling water inlet Fuel feed pump Damper Oil filter Starter Relief valve Oil filler Oil level gauge Note: Configuration may differ depending on the customization and specifications.
  • Page 29 Chapter 1 GENERAL S16R-Y1PTAA2 Engine cooling water outlet (To radiator) Thermostat case Air outlet (To radiator) Water pump Damper Oil pump Oil pan Engine cooling water inlet (From radiator) Air inlet (From radiator) Engine oil drain port Note: Configuration may differ depending on the customization and specifications.
  • Page 30 Chapter 1 GENERAL S16R-Y1PTAA2 Rear hanger Fuel filter Exhaust pipe Front hanger Exhaust gas outlet Rear Front Stop lever Oil cooler Actuator (Governor) Fuel injection pump Bypass oil filter Starter Fuel feed pump Oil filter Oil filler Oil level gauge...
  • Page 31 Chapter 1 GENERAL S16R-C2MPTK Engine cooling water outlet Engine cooling water outlet Thermostat case Thermostat case Breather Water pump Oil pump Crankshaft pulley Oil pan Engine oil drain port Damper Note: Configuration may differ depending on the customization and specifications.
  • Page 32 Chapter 1 GENERAL S16R-C2MPTK Fuel filter Air cooler cooling water outlet Governor oil filter Oil cooler Air cooler cooling water inlet Stop lever Fuel feed pump Governor Front Rear Damper Water drain cock Starter Bypass oil filter Fuel injection pump...
  • Page 33 Chapter 1 GENERAL S16R2-PTAW Air cooler coolant outlet Engine coolant thermostat case Engine coolant outlet Air cooler water pump Air cooler thermostat case Engine water pump Oil pump Damper Oil pan Note: Configuration may differ depending on the customization and specifications. Engine Front View S16R2-PTAW Exhaust pipe...
  • Page 34 Chapter 1 GENERAL S16R2-PTAW Rear hanger Fuel filter Front hanger Intake air inlet Bypass oil filter Air cooler Actuator coolant inlet Front Rear Fuel feed pump Fuel injection pump Damper Starter Oil filter Breather Fuel feed pump Note: Configuration may differ depending on the customization and specifications. Left Side View S16R2-PTAW Rear hanger...

  • Page 35: Outline Of Systems

    Chapter 1 GENERAL 2. Outline of Systems 2.1 Outline of Fuel System Fuel leak-off pipe Fuel injection nozzle Fuel injection pump Fuel feed pump Fuel injection pipe To right side of engine From right side of engine Fuel filter To fuel tank From fuel tank Outline of Fuel System Engine with trochoid fuel feed pump spec...

  • Page 36: Outline Of Lubrication System

    Chapter 1 GENERAL 2.2 Outline of Lubrication System Woodward PSG, EG-3P or EG-B2P type governor spec Rocker shaft Piston Camshaft Main gallery Turbocharger Relief valve Governor oil filter Timing gear Oil cooler Piston cooling nozzle Water pump Oil thermostat Governor Safety valve Fuel injection pump Oil pump...

  • Page 37: Outline Of Cooling System

    Chapter 1 GENERAL S16R2( spec) External oil cooler Piston Rocker shaft Camshaft Main gallery Relief valve Turbocharger Oil cooler Timing gear Water pump Oil thermostat Piston cooling nozzle Oil pump Fuel injection pump External oil cooler Crankshaft Oil strainer Oil filter Bypass oil filter Safety valve Outline of Lubrication System...
  • Page 38 Chapter 1 GENERAL PTA spec with external cooling water method Engine Engine cooling water cooling water Water jacket inlet outlet Water outlet pipe Oil cooler Water pump (Rocker case) Thermostat Bypass pipe Oil cooler Water jacket Air cooler (After cooler) Outline of Cooling System PTAW spec with double cooling system Air cooler...
  • Page 39 Chapter 1 GENERAL TAA spec Air cooler (From exhaust manifold to cylinder head) (Air to air type) Oil cooler Water jacket Water pump Water outlet pipe Thermostat (Rocker case) Bypass pipe Oil cooler Water jacket (From turbocharger) Radiator Outline of Cooling System PTAW with double cooling system radiator spec Air cooler cooling water Engine...
  • Page 40 Chapter 1 GENERAL PTK spec Water pump Inlet Outlet Water outlet pipe Outlet Inlet (Rocker case) Water Oil cooler jacket Intercooler Thermostat Water outlet pipe Bypass pipe Oil cooler Water jacket (Rocker case) Outline of Cooling System M(P)TK spec with fresh water cooling system Cooling water outlet or seawater cooling system Water...

  • Page 41: Outline Of Inlet And Exhaust System

    Chapter 1 GENERAL 2.4 Outline of Inlet and Exhaust System PTA PTK PTAW M(P)TK spec Inlet Exhaust gas outlet Exhaust Exhaust pipe Turbocharger Turbocharger From air cleaner From air cleaner Air cooler Cylinder Outline of Inlet and Exhaust System PTAA spec Inlet Exhaust pipe Exhaust...

  • Page 42: Contents Of Plate And Label

    Chapter 1 GENERAL 3. Contents of Plate and Label 3.1 Name Plate The name plate is attached on the lateral side of the engine, and shows the following information: Left ŒEngine serial number ŒManufactured date ŒTotal displacement Rear Front ŒEngine output ŒRated speed Right Cylinder No.

  • Page 43: Specifications

    Chapter 1 GENERAL 4. Specifications Engine model S16R S16R2 Type Water cooled, four stroke cycle diesel, turbo charged No. of cylinders - Arrange- 16-V ment Combustion system Direct injection system Valve mechanism Overhead Cylinder bore × stroke 170×180 mm [6.69×7.09 in.] 170×220 mm [6.69×8.66 in.]...
  • Page 44 Chapter 1 GENERAL S16R S16R2 Equipment Specification name name Overlap 61° Compression ratio (37517-30101) Overlap 93° Compression ratio 13.5 (37517-07700) Overlap 108° Compression ratio (37517-10600) Overlap 108° Compression ratio (37517-10401) Overlap 93° Piston Compression ratio (37517-07600) Overlap 108° Compression ratio 14.5...
  • Page 45 Chapter 1 GENERAL S16R S16R2 Equipment Specification name name Stub (37725-14301) shaft Standard (37721-00060) Light weight type Flywheel (37721-17013) MCS coupling (37721-02011) Double damper Double damper Damper with spacer Triple damper with spacer Fuel Standard pipe Injection Double pipe pipe...
  • Page 46 Chapter 1 GENERAL S16R S16R2 Equipment Specification name name Trochoid Trochoid Fuel Fuel feed Feed pump pump type Stop : RUN OFF Stop : RUN ON Solenoid Start rack control : RUN OFF ø60 exhaust pipe ø80 exhaust pipe Exhaust ø120 exhaust...
  • Page 47 Chapter 1 GENERAL S16R S16R2 Equipment Specification name name Fresh water (37855-21001) Fresh water (big size) (37855-28001) Fresh water (big size) (37855-04010) Air cooler Fresh water two stages (37855-10050) Sea water (37855-20031) Built-in radiator (37847-11300) D1530, PUSHER (37848-03500) D1828, PUSHER...
  • Page 49 Chapter 2 SERVICE DATA Maintenance service data ..................2-3 Engine general ......................... 2-3 Basic engine ..........................2-4 Fuel system ..........................2-11 Lubrication system........................2-14 Cooling system ........................2-15 Electrical system........................2-17 AIR START SYSTEM ......................2-20 Tightening torque table..................2-21 Tightening torque for Basic engine ..................

  • Page 51: Maintenance Service Data

    Chapter 2 SERVICE DATA Chapter 2 SERVICE DATA 1. Maintenance service data 1.1 Engine general Item Nominal Standard Limit Remarks 1.8 MPa 1.27 MPa Cranking Compression pressure {18.4 kgf/cm {13 kgf/cm (approx 120 min [261.1 psi] [184.2 psi] 0.49 to 0.64 MPa 0.29 MPa When oil temp is at 90 to Rated...

  • Page 52: Basic Engine

    Chapter 2 SERVICE DATA 1.2 Basic engine Unit: mm [in.] Item Nominal Standard Limit Remarks ø36 36.000 to 36.040 36.090 Rocker bushing inside diameter [1.42] [1.4173 to 1.4189] [1.4209] Rockers ø36 35.966 to 35.991 35.940 Rocker shaft outside diameter [1.42] [1.4160 to 1.4170] [1.4150] ø10...
  • Page 53 Chapter 2 SERVICE DATA Unit: mm [in.] Item Nominal Standard Limit Remarks 88.12 Free length 90.6 [3.567] [3.4693] A = 2.0°or less B = 3.7 Part number: Inner Squareness B = less than 3.2 [0.126] [0.146] over 37504-10600 spring Lf = 90.6 [3.567] entire length Set length/load 56.0 [2.205]/...
  • Page 54 [0.024 to 0.031] [0.078] 0.6 to 0.8 No.2 compression [0.024 to 0.031] Piston End gap ring 0.3 to 0.45 S16R [0.012 to 0.0177] [0.078] 0.3 to 0.5 S16R2 [0.012 to 0.020] ø70 69.987 to 70.000 69.970 Piston pin Outside diameter [2.76]...
  • Page 55 Chapter 2 SERVICE DATA Unit: mm [in.] Item Nominal Standard Limit Remarks ø70 70.020 to 70.040 70.070 Inside diameter of the connecting rod bushing [2.76] [2.7567 to 2.7575] [2.7587] 0.05/100 Bend and twist [0.0020 / 3.94] or less 0.6 to 0.9 End play 1.4 [0.055] [0.024 to 0.035]...
  • Page 56 Chapter 2 SERVICE DATA Unit: mm [in.] Item Nominal Standard Limit Remarks Crank gear and front idler gear backlash 0.11 to 0.28 Front idler gear and water pump gear backlash 0.50 [0.0197] [0.0043 to 0.0110] Water pump gear and oil pump gear backlash Front ø50 50.000 to 50.025...
  • Page 57 Chapter 2 SERVICE DATA Unit: mm [in.] Item Nominal Standard Limit Remarks 124.930 to 124.950 124.890 Standard [4.9185 to 4.9193] [4.9169] 124.680 to 124.700 124.640 0.25 [0.0098] [4.9087 to 4.9094] [4.9071] Crankpin outside ø125 124.430 to 124.450 124.390 0.50 [0.0197] diameter [4.92] [4.8988 to 4.8996]...
  • Page 58 Chapter 2 SERVICE DATA Unit: mm [in.] Item Nominal Standard Limit Remarks 67.00 to 67.03 Standard [2.6378 to 2.6390] 0.25 67.25 to 67.28 [0.0098] [2.6476 to 2.6488] 0.50 67.50 to 67.53 [0.0197] [2.6575 to 2.6587] 0.75 Part number: 67.75 to 67.78 67 [2.64] [0.0295] 37820-10103...

  • Page 59: Fuel System

    Chapter 2 SERVICE DATA 1.3 Fuel system Unit: mm [in.] Item Nominal Standard Limit Remarks Free length of nozzle spring 30 [1.18] Squareness of nozzle spring 0.6 [0.024] or less Parallelism of top and bottom nozzle spring 0.1 [0.004] or less 34.32 to 34.81 MPa 34.32 MPa {350 to 355 kgf/cm...
  • Page 60 Chapter 2 SERVICE DATA Unit: mm [in.] Item Nominal Standard Limit Remarks 89.987 to 90.022 ø90 [3.54] [3.5428 to 3.5442] Inside diameter of case bearing housing 99.987 to 100.022 ø100 [3.94] [3.9365 to 3.9379] 89.985 to 90.000 Small ø90 [3.54] [3.8970 to 3.5433] Outside diameter...
  • Page 61 Chapter 2 SERVICE DATA Unit: mm [in.] Item Nominal Standard Limit Remarks Bearing fitting inside diameter in 51.988 to 52.018 ø52 [2.05] drive shaft side case [2.0468 to 2.0479] 51.987 to 52.000 Outside diameter ø52 [2.05] [2.0467 to 2.0472] Drive shaft side bearing 24.990 to 25.000 Inside diameter...

  • Page 62: Lubrication System

    Chapter 2 SERVICE DATA 1.4 Lubrication system Unit: mm [in.] Item Nominal Standard Limit Remarks 0.100 to 0.200 Drive gear and driven gear backlash 0.400 [0.0157] [0.0039 to 0.0079] 0.100 to 0.148 Clearance between gear teeth and case 0.350 [0.0138] [0.0039 to 0.0058] Clearance between gear width and case 0.040 to 0.116...

  • Page 63: Cooling System

    Chapter 2 SERVICE DATA 1.5 Cooling system Unit: mm [in.] Item Nominal Standard Limit Remarks 61.970 to 62.000 Inside diameter of pulley bearing fit ø62 [2.44] [2.4398 to 2.4409] 61.987 to 62.000 Outside diameter ø62 [2.44] [2.4404 to 2.4409] Tension pulley Bearing 24.990 to 25.000 Inside diameter...
  • Page 64 Chapter 2 SERVICE DATA Unit: mm [in.] Item Nominal Standard Limit Remarks 109.995 to 110.030 Inside diameter of case bearing housing ø110 [4.33] [4.3305 to 4.3319] 109.985 to 110.000 Outside diameter ø110 [4.33] [4.3301 to 4.3307] Seawater pump Part number: Bearing for air cooler 45353-94600...

  • Page 65: Electrical System

    Chapter 2 SERVICE DATA 1.6 Electrical system Unit: mm [in.] Item Nominal Standard Limit Remarks Front shaft outside ø19 18.90 to 18.94 diameter [0.75] [0.7441 to 0.7457] Front bearing inside ø19 19.000 to 19.033 diameter [0.75] [0.7480 to 0.7493] Pinion bearing inside ø19 19.000 to 19.033 diameter...
  • Page 66 Chapter 2 SERVICE DATA Unit: mm [in.] Item Nominal Standard Limit Remarks (reference At pull starting 0.066 [0.0026] Coil at 20°C) resistance (reference Magnetic switch Hold condition 1.07 [0.0421] at 20°C) 1.35 to 2.05 [0.0531 Contactor deflection to 0.0807] Part number: or higher 37766-20200 Commutator...
  • Page 67 Chapter 2 SERVICE DATA Unit: mm [in.] Item Nominal Standard Limit Remarks 29 A or more 2500 (when engine Rotating Output is hot) current speed 35 A or more (at 27 V) (min 5000 (when engine is hot) Regulator adjusting voltage External 28.5 ±...

  • Page 68: Air Start System

    Chapter 2 SERVICE DATA 1.7 AIR START SYSTEM Unit: mm [in.] Item Nominal Standard Limit Remarks ø15 0.016 to 0.052 0.100 Clearance between valve and valve guide [0.59] [0.0006 to 0.0020] [0.0039] Starter valve Valve spring free length [1.42] [1.34] 21.85 to 21.95 21.75 Distributer valve height...

  • Page 69: Tightening Torque Table

    40 ± 2.0 289.12 ± 14.45 Right side front mounting Front mounting bracket 20 × 1.5 bracket(S16R front row lower 245 ± 12.3 25 ± 1.25 180.70 ± 9.07 1 bolt and S16R2 front row lower and middle 2 bolts) Rear mounting bracket 20 ×...
  • Page 70 Chapter 2 SERVICE DATA Note:(a) For torque-angle tightening method of cylinder head bolts, follow the steps in sequence given below: 1) Tighten it with a snug torque 294 ± 14.7N·m {30 ± 1.5kgf·m} [66.09±3.3 lbf·ft]. 2) Tighten to the angle 65± 3°. 3) Loosen all bolts, and then retighten them in the sequence shown in the above 1) and 2).(Two time tightening) For tightening procedure, refer to "Cylinder head bolt - Tighten"...

  • Page 71: Tightening Torque For Fuel System

    Chapter 2 SERVICE DATA 2.2 Tightening torque for Fuel system Tightening torque Dia × Pitch Description Remarks (M-thread) N·m kgf·m lbf·ft Accessory drive case 12 × 1.25 108 ± 5.4 11 ± 0.55 80 ± 4.0 Accessory 30 × 1.5 490 ±...

  • Page 72: Tightening Torque For Cooling System

    Exhaust pipe V clamp 1/4-28 UNF 9 ± 0.45 0.9 ± 0.045 6.64 ± 0.33 Unify screw T bolt type : used only in S16R-2 Air duct clamp 6 × 1.0 4.9 ± 0.49 0.5 ±0.05 3.61 ± 0.36 and S16R-TAA Air cooler 10 ×...

  • Page 73: Tightening Torque For Electrical System

    Chapter 2 SERVICE DATA 2.6 Tightening torque for Electrical system Tightening torque Dia × Pitch Description Remarks (M-thread) N·m kgf·m lbf·ft Starter - Install 12 × 1.25 59 ± 5.9 6 ± 0.6 43.52 ± 4.35 Magnetic switch 6 × 1.0 4.5 ±...

  • Page 74: Tightening Torque For Standard Bolts And Nuts

    Chapter 2 SERVICE DATA 2.8 Tightening torque for Standard bolts and nuts Thread size Width across Strength classification Threads Dia × Pitch flats 10.9 (M-thread) (mm) [in.] N·m kgf·m N·m kgf·m 8 × 1.25 12 [0.47] 10 × 1.25 14 [0.55] 12 ×...

  • Page 75: Tightening Torque For Standard Eyebolts

    Chapter 2 SERVICE DATA 2.9 Tightening torque for Standard eyebolts Strength classification Thread size Width across flats Dia. × Pitch (mm) [in.] (M-thread) N·m kgf·m lbf·ft 8 × 1.25 12 [0.47] 8 ± 1 0.8 ± 0.1 5.90 ± 0.73 10 ×...
  • Page 77 Chapter 3 SERVICE TOOLS Special Tools......................3-3...
  • Page 79 Chapter 3 SERVICE TOOLS 1. Special Tools Chapter 3 SERVICE TOOLS Maintenance Tool name Part No. Illustration Usage item Basic engine Rocker bushing tool 37591-02600 Rocker Bushing - Replace Bushing inside diam : ø36 X 40 mm [1.38 X1.57 in.] Front 32591-02500 Front Idler Bushing - Replace...
  • Page 80 Chapter 3 SERVICE TOOLS Maintenance Tool name Part No. Illustration Usage item Basic engine Front seal 37591-05010 Front oil seal - install Installer assembly Rear seal installer assembly 37791-06010 Rear oil seal - install Slinger installer 37491-02100 Rear slinger - Press-in With installer guide installer guide 37491-02200...
  • Page 81 Chapter 3 SERVICE TOOLS Maintenance Tool name Part No. Illustration Usage item Basic engine Connecting rod 37591-01010 Connecting rod bushing - Install and bushing installer remove Nozzle remover 33591-10101 Fuel injection nozzle - remove Connecting rod Sheet thick- Connecting rod end play - Set gauge ness : 0.5 mm [0.02 in.]...
  • Page 82 Chapter 3 SERVICE TOOLS Maintenance Tool name Part No. Illustration Usage item Basic engine Valve seat cutter Shaft Valve Seat - Reface 37591-06400 Width across flats: 32 mm [1.26 in.] Applicable seat inside/outside diame- ø10 mm ter: ø45 to 66 [1.77 to 2.60 in.] W1 1/8 Cutter 37591-06430...
  • Page 83 Chapter 3 SERVICE TOOLS Maintenance Tool name Part No. Illustration Usage item Fuel Nozzle tester 83091-03301 Fuel injection nozzle opening pressure system - measure Socket 58309-73100 Fuel injection Pump gear and water pump gear - install/remove Fuel 37591-06100 Fuel injection pump coupling clear- Injection pump coupling ance - adjust gauge...
  • Page 84 Chapter 3 SERVICE TOOLS Maintenance Tool name Part No. Illustration Usage item Cooling Impeller remover 37591-03200 Water pump impeller - pull-out system M18 × 1.5 mm [0.059 in.] Ring remover 37791-03400 Water pump Unit Seal - Remove Unit seal 37191-06300 Water pump unit seal - Press-in installer Ring installer...
  • Page 85 Chapter 3 SERVICE TOOLS Maintenance Tool name Part No. Illustration Usage item Inspection and Belt gauge 32591-09100 Belt tension - measure measurement...
  • Page 87 Chapter 4 OVERHAUL INSTRUCTIONS Determining Overhaul Timing ................4-3 Compression Pressure - Measure................4-4...
  • Page 89 Chapter 4 OVERHAUL INSTRUCTIONS Chapter 4 OVERHAUL INSTRUCTIONS 1. Determining Overhaul Timing In most cases, the engine should be overhauled when the compression pressure of the engine decrease. An increase in engine oil consumption and blow-by gas should be considered when evaluating the engine condition. Such symptoms as the output decrease, fuel consumption increase, oil pressure decrease, engine starting difficulty and noise increase should be considered to evaluate overhaul timing, although these symptoms are often affected by various causes, and are not always effective to consider overhaul timing.
  • Page 90 Chapter 4 OVERHAUL INSTRUCTIONS 2. Compression Pressure - Measure Compression gauge Compression gauge (a) Be sure to measure the compression pressure of P/N:33A91-01700 P/N:33A91-01700 all cylinders. It is not a clever way to measure the compression pressure of only two or three Gauge adapter Gauge adapter P/N:37591-02200...
  • Page 91 Chapter 5 DISASSEMBLY OF BASIC ENGINE Cylinder heads and valve mechanisms - Disassemble and inspect....5-3 Fuel inlet connector - Remove....................5-4 Nozzle assembly - Remove ...................... 5-4 Valve clearance - Inspect ......................5-4 Fuel injection timing - Inspect ....................5-5 Rocker shaft assembly - Remove.....................
  • Page 92 Chapter 5 DISASSEMBLY OF BASIC ENGINE Cylinder liner, piston and connecting rod - Disassemble and inspect .... 5-19 Piston protrusion - Measure....................5-20 Connecting rod end play - Measure..................5-20 Hard carbon deposits on the upper part of cylinder liner - Remove ........5-20 Connecting rod cap - Remove ....................

  • Page 93: Cylinder Heads And Valve Mechanisms - Disassemble And Inspect

    Chapter 5 DISASSEMBLY OF BASIC ENGINE Chapter 5 DISASSEMBLY OF BASIC ENGINE 1. Cylinder heads and valve mechanisms - Disassemble and inspect Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the efficient work.

  • Page 94: Fuel Inlet Connector - Remove

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 1.1 Fuel inlet connector - Remove Remove the fuel inlet connector. Fuel inlet connector Fuel inlet connector - Remove 1.2 Nozzle assembly - Remove Nozzle gland Gasket When removing the nozzle assembly using a nozzle remover, be careful not to get caught your fingers between the nozzle remover weight and bar and plate.

  • Page 95: Fuel Injection Timing - Inspect

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 1.4 Fuel injection timing - Inspect Inspect the fuel injection timing, and know the current con- dition. Pointer For the inspection procedures, refer to "Fuel injection tim- ing - Check and adjust" of "ASSEMBLY OF BASIC Line mark on ENGINE.

  • Page 96: Valve Bridge - Remove

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 1.7 Valve bridge - Remove Remove the valve bridge and bridge cap. Bridge cap Note: Be careful not to drop the bridge cap into the cylinder Screw head. Valve bridge - Remove 1.8 Rocker case - Remove (1) Remove the snap ring of water outlet connector.

  • Page 97: Valve And Valve Spring - Remove

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 1.11 Valve and valve spring - Remove Using a valve spring pusher, compress the valve spring evenly and remove the valve cotters. Valve spring pusher Note: If valves are reusable, mark each valve seat and the P/N:33591-04500 mating valve for identifying their original positions.

  • Page 98: Rear Mechanism - Disassemble And Inspect

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 2. Rear mechanism - Disassemble and inspect Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the efficient work. Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with any job.

  • Page 99: Flywheel Face And Radial Runouts - Measure

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 2.1 Flywheel face and radial runouts - Measure Measure the face and radial runouts of the flywheel, and know the current condition. Face runout measuring For the measurement procedure, refer to "Flywheel face and plane radial runouts - Measure"...

  • Page 100: Rear Idler Shaft Thrust Collar - Remove

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 2.4 Rear idler shaft thrust collar - Remove (1) Remove the cover from the timing gear case. (2) Install the bolts (M6 × 1.0 mm) into the dedicated bolt holes for removal of rear idler shaft thrust collar, and remove the rear idler shaft thrust collar.

  • Page 101: Rear Idler Gear - Remove

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 2.8 Rear idler gear - Remove (1) Remove the oil seal slinger from the crankshaft. (2) Remove the thrust plate. (3) Remove the rear idler gears (right and left). Thrust plate Rear idler gear Slinger Rear idler gear - Remove 2.9 Accessory drive - Remove...

  • Page 102: Camshaft - Remove

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 2.12 Camshaft - Remove Support the camshaft with a wood stick or the like through the side cover. Remove the camshaft paying attention not to damage the crank case and camshaft bushing. (1) Remove the thrust plate. (2) Support the camshaft from the side cover mounting sec- Camshaft Thrust plate...

  • Page 103: Front Mechanism - Disassemble And Inspect

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 3. Front mechanism - Disassemble and inspect Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the efficient work. Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with any job.

  • Page 104: Fan Drive Assembly - Remove

    Raise using a rope, etc. Crankshaft pulley Jack bolt Be careful not to drop or bump the damper. It can, (S16R: M14 × 1.5 mm) (S16R2: M12 × 1.25 mm) not only cause damage to the part, but also lead to personnel injuries.

  • Page 105: Fan Drive Idler Gear Backlash - Measure

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 3.4 Fan drive idler gear backlash - Measure (With fan spec) Measure the fan drive idler gear backlash, and know the current condition. For the measurement procedure, refer to "Fan drive idler gear backlash - Measure" of "ASSEMBLY OF BASIC ENGINE.

  • Page 106: Pump Plate (For Water Pump And Oil Pump) - Remove

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 3.7 Pump plate (for water pump and oil pump) - Remove Install two jack bolts evenly into the jack bolt holes, and remove the pump plate. Note: Remove the oil pump and water pump, then remove the pump plate.

  • Page 107: Water Pump Bearing Cover And Oil Pump Bearing Cover - Remove

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 3.11 Water pump bearing cover and oil pump bearing cover - Remove Remove the water pump bearing cover and oil pump bear- ing cover from the front plate. Water pump bearing cover Oil pump bearing cover Water pump bearing cover oil pump bearing cover - Remove 3.12 Front idler gear backlash - Measure...

  • Page 108: Front Idler Shaft - Remove

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 3.15 Front idler shaft - Remove Do not remove the front idler shaft unless it is necessary. If necessary, screw two jack bolts evenly into bolt holes, and remove the front idler shaft. Jack bolt (M10×1.25 mm) Front idler shaft - Remove 3.16 Coupling - Remove...

  • Page 109: Cylinder Liner, Piston And Connecting Rod - Disassemble And Inspect

    3 Lower connecting rod bearing 9 Piston pin 4 Upper connecting rod bearing 10 Piston 5 No. 1 compression ring 11 Connecting rod 6 No. 2 compression ring 12 Cylinder liner (S16R: approx 16 kg [35 lb]) (S16R2: approx 19 kg [42 lb]) 5-19...

  • Page 110: Piston Protrusion - Measure

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 4.1 Piston protrusion - Measure Measure the piston protrusion, and know the current condi- Piston protrusion tion. For the measurement procedure, refer to "Piston protrusion - Measure" of "ASSEMBLY OF BASIC ENGINE." Piston protrusion - Measure 4.2 Connecting rod end play - Measure Measure the connecting rod end play, and know the current condition.

  • Page 111: Piston - Remove

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 4.5 Piston - Remove When holding the connecting rod with your hand to prevent it from swinging, be very careful, as you may suffer hand injuries from accidental movement of the connecting rod. (a) When pulling-out the piston, be careful not to drop the upper connecting rod bearing. (b) Use care not to damage the cylinder liner by the swing of the connecting rod when pulling-out the piston and connecting rod from the cylinder liner.

  • Page 112: Piston Ring - Remove

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 4.5.2 Removing the piston with pushing-up the con- Eyebolt P/N: 37591-02500 necting rod big end (M10 × 1.25 mm) (1) Remove the connecting rod cap and rotate the crank- shaft to bring the piston to the top dead center position. (2) Install the eye bolt to the threaded hole on the piston top, and support the piston to prevent from falling down.

  • Page 113: Piston Pin And Piston - Remove

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 4.7 Piston pin and piston - Remove (1) Remove the snap ring using ring pliers. (2) Place a piece of wood against the end face of piston pin and lightly tap with a hammer to remove the piston pin, and separate the piston from the connecting rod.

  • Page 114: Crankcase, Crankshaft And Main Bearing - Disassemble And Inspect

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 5. Crankcase, crankshaft and main bearing - Disassemble and inspect Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the efficient work. Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with any job.

  • Page 115: Crankcase - Invert

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 5.1 Crankcase - Invert Using a turn table, invert the crankcase. When the turn table Weight of crankcase and is not available, hitch slings to the crankcase using wood crankshaft assembly: approx 2615 kg [5765 lb] pieces and cloth pads, and raise the crankcase with a hoist or crane and lay it on the wooden block with its side facing...

  • Page 116: Crankshaft - Remove

    Chapter 5 DISASSEMBLY OF BASIC ENGINE 5.5 Crankshaft - Remove Crankshaft assembly (a) Before removing the crankshaft, remove the front side upper thrust plate first, and be careful not to let it fall into the crankcase. (b) When placing the crankshaft onto a pallet or other stands, be careful not to damage the crankshaft.
  • Page 117 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE Cylinder head and valve mechanism - Inspect and repair........6-3 Rocker bushing inside diameter and rocker shaft outside diameter - Measure......6-3 Rocker bushing - Replace ......................6-3 Valve stem outside diameter and valve guide inside diameter - Measure........ 6-4 Valve guide - Replace.......................
  • Page 118 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.17 Connecting rod bend and twist - Inspect ................6-24 Crankcase and crankshaft - Inspect and repair..........6-25 Crankcase top surface distortion - Measure ................6-25 Inside diameter of main bearing housing bore - Measure ............6-25 Cylinder liner fitting section in crankcase - Inspect..............

  • Page 119: Chapter 6 Inspection And Repair Of Basic Engine

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE Chapter 6 I N SPECTI O N AND REPAI R OF BASI C ENGI N E 1. Cylinder head and valve mechanism - Inspect and repair 1.1 Rocker bushing inside diameter and rocker shaft outside diameter - Measure Measure the inside diameter of the rocker bushing and the Measurement Measurement direction...

  • Page 120: Valve Stem Outside Diameter And Valve Guide Inside Diameter - Measure

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.3 Valve stem outside diameter and valve guide inside diameter - Measure Measure the outside diameter of the valve stem and the inside diameter of the valve guide at the top and bottom Measurement direction sliding ends in orthogonal direction as shown, as the sliding...

  • Page 121: Valve Face - Inspect

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.5 Valve face - Inspect Inspect the valve face after the valve guide is inspected or Seat width replaced. Lap the valve and valve seat whenever the valve is refaced or replaced. Valve margin Valve sinkage Valve face - Inspect...

  • Page 122: Valve Seat - Reface

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.7 Valve seat - Reface If any damage or inclusions are found, grind the sheet face. (1) Use the valve seat cutter or valve seat grinder to reface the valve seat. After refacing, insert sand paper of Socket approx 400 grit between the cutter and valve, and sand (width across flats...
  • Page 123 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.8.3 Valve seat - Install Unit: mm [in.] (1) Before installing the valve seat, measure the inside Cylinder head diameter of the valve seat counterbore of cylinder head and the outside diameter of the valve seat to make sure 8 [0.31] that the interference is within the range of standard 3.6 [0.14]...

  • Page 124: Valve And Valve Seat - Lap

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.9 Valve and valve seat - Lap Lap the valve against the valve seat whenever the valve seat is refaced or the valve is replaced. (1) Apply a thin coat of lapping compound evenly to the valve face.

  • Page 125: Squareness And Free Length Of Valve Spring - Measure

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.11 Squareness and free length of valve spring - Measure Measure the squareness and free length of valve spring. If Spring squareness the free length or squareness exceeds the limit, replace a valve spring with a new one.

  • Page 126: Pushrod Runout - Measure

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 1.13 Pushrod runout - Measure Measure the runout of push rod at TIR. If the runout exceeds the standard, replace the push rod with a new one. Item Standard Remarks Pushrod runout 0.50 mm [0.0197 in.] or less V-block Push rod...

  • Page 127: Rear Mechanism - Inspect And Repair

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 2. Rear mechanism - Inspect and repair 2.1 Rear idler bushing inside diameter and rear idler shaft outside diameter - Measure Measure the rear idler bushing inside diameter and the rear idler shaft outside diameter.If the value exceeded the limit, Measurement direction replace the rear idler gear assembly or rear idler shaft with a...

  • Page 128: Cam Lift Of Cam Lobe - Measure

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 2.3 Cam lift of cam lobe - Measure Measure the major diameter and minor diameter of cam lobe to determine cam lift. If the value exceeds the limit, replace the camshaft with a new one. Major axis Item Part No.

  • Page 129: Camshaft Bushing - Inspect

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 2.6 Camshaft bushing - Inspect (1) Check the inside surface of each bushing for damage, corrosion, flaking and other abnormalities. If any defect is found, replace the camshaft bushing with a new one. (2) Measure the camshaft bushing inside diameter with the Measurement bushing installed in the crankcase.

  • Page 130: Front Mechanism - Inspect And Repair

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 3. Front mechanism - Inspect and repair 3.1 Damper - Inspect visually Check the damper for cracks around the outer periphery, swelling in the end plate, silicone oil leakage, and discolor- ation and separation of coating due to overheating. If any defect is found, replace the damper with a new one.

  • Page 131: Fan Drive Idler Bushing - Replace

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 3.4 Fan drive idler bushing - Replace (With fan spec) Lower than gear boss end face (1) Using the removing side of the idler bushing puller, by 1 mm [0.04 in.] Idler bushing puller remove the fan drive idler bushing.

  • Page 132: Front Idler Bushing Inside Diameter And Front Idler Shaft Outside Diameter - Measure

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 3.6 Front idler bushing inside diameter and front idler shaft outside diameter - Measure Measure the front idler bushing inside diameter and the Measurement front idler shaft outside diameter. If the value exceeds the direction limit, replace the front idler gear assembly or front idler shaft with a new one.

  • Page 133: Piston And Connecting Rod - Inspect And Repair

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4. Piston and connecting rod - Inspect and repair 4.1 Piston - Inspect visually Check the combustion surface, piston pin bore, ring groove, sliding surface and bottom surface of the piston. If any defect are found, replace the piston with a new one.

  • Page 134: Piston Ring Groove - Inspect

    0.6 to 0.8 mm compression [0.024 to 0.032 in.] Piston ring end Piston Ring End Gap - Measure 0.3 to 0.45 mm S16R [0.012 to 0.0177 in.] 2.0 mm [0.078 in.] 0.3 to 0.5 mm S16R2 [0.012 to 0.020 in.]...

  • Page 135: Piston Pin Outside Diameter - Measure

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.8 Piston pin outside diameter - Measure Measure the piston pin outside diameter. Measurement If the value exceeds the limit, replace the piston pin with a direction new one. Item Nominal Standard Limit Piston pin outside ø70 mm...
  • Page 136 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.10.2 Connecting rod bushing - Remove Press (1) Apply engine oil to the inner surface of connecting rod bushing. Mandrel (2) Attach the collar A to the mandrel and insert the man- drel into the connecting rod bushing while aligning the Collar A match mark (red line) on the collar A with the mark on...
  • Page 137 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.10.3 Connecting rod bushing - Press-in (a) Make sure that the match marks (red lines) on col- Connecting rod bushing oil hole lars A and B are in alignment. (b) Make sure that the oil hole of the connecting rod Collar A bushing is in alignment with the match mark (red match mark...

  • Page 138: Connecting Rod Assembly Weight Rank

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE (4) Measure the inside diameter of the connecting rod 1.6S Bushing inner surface roughness bushing. If the value exceeds the limit, replace the connecting Connecting rod bushing inside diameter rod with a new one and measure the diameter again. Connecting rod bushing Item Standard...

  • Page 139: Side Face Width Of Connecting Rod Big End - Measure

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.13 Side face width of connecting rod big end - Measure (1) Inspect the side face of connecting rod big end visually. If there is any defect such as wear or flaw, replace the connecting rod with a new one.

  • Page 140: Connecting Rod Bearing Thickness - Measure

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 4.16 Connecting rod bearing thickness - Measure Measure the thickness of connecting rod at its center. If the value exceeds the limit, replace both upper and lower connecting rod bearing shells with new ones as a set. Measurement at the center When the crankshaft is subject to re-grinding due to wear of...

  • Page 141: Crankcase And Crankshaft - Inspect And Repair

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5. Crankcase and crankshaft - Inspect and repair 5.1 Crankcase top surface distortion - Measure Straight edge Refacing depth of crankcase should be minimum. Excessive grinding of the crankcase may result in defects such as defective combustion and stamping between piston and valve.

  • Page 142: Cylinder Liner Fitting Section In Crankcase - Inspect

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.3 Cylinder liner fitting section in crankcase - Inspect (1) Inspect the counterbore in crankcase. Check for the Fitting bore of Counterbore in crankcase cracks in edges, uneven contact between the counter- cylinder liner in crankcase bore and the bottom face of cylinder liner flange.
  • Page 143 Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.5.1 Crankpin and crank journal - Grind When using the undersize bearing, grind to the standard value corresponding to the undersize bearing to be used. Do not change the fillet radius and the bearing journal width when grinding.

  • Page 144: Crankpin And Rearmost Crank Main Journal Width - Measure

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.6 Crankpin and rearmost crank main journal width - Measure (1) Inspect the ends of crankshaft for harmful flaw and wear. Rearmost crank Crankpin (2) Measure the crankpins and rearmost crank main journal journal width width width.

  • Page 145: Crankshaft Runout - Measure

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.7 Crankshaft runout - Measure Support the crankshaft at the front and rear main journals with V-blocks, and measure the crankshaft runout at the V-block center main journal using a dial gauge. If the runout devi- ates slightly from the standard, correct the crankshaft by grinding.

  • Page 146: Oil Seal Slinger - Inspect

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.9.2 Crankshaft gear - Install Rear gear engaged position (a) Make sure the correction installation direction and position of crankshaft gear. (b) To shrinkage-fit the crankshaft gear to crankshaft, heat the crankshaft gear evenly to the specified temperature.

  • Page 147: Main Bearing - Inspect

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.11.2 Oil seal slinger - Install ID mark ID mark (1) Measure the outside diameter of crankshaft and inside (37425-08201) (37411-04200) diameter of oil seal slinger, and check the interference. (2) Heat the oil seal slinger evenly to the temperature of 110ºC [230°F] or less.

  • Page 148: Thickness Of Main Bearing Shell - Measure

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.13 Thickness of main bearing shell - Measure Measure the thickness of main bearing shell at its center. If the value exceeds the limit, replace both upper and lower main bearing shells with new ones as a set. Measurement at the center When the crankshaft is subject to re-grinding due to wear of...

  • Page 149: Thickness Of Thrust Plate - Measure

    Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE 5.15 Thickness of thrust plate - Measure Measure the thickness of thrust plate. If the value exceeds the limit, replace the thrust plate with a new one. When the crankshaft is subject to re-grinding due to wear, use the oversize thrust plate.
  • Page 151 Chapter 7 ASSEMBLY OF BASIC ENGINE Crankshaft and main bearing - Install..............7-3 Crankcase - Invert ........................7-3 Piston cooling nozzle - Install ....................7-3 Upper main bearing - Install...................... 7-4 Rear upper thrust plate - Install ....................7-4 Crankshaft - Install........................7-5 Front upper thrust plate - Install....................
  • Page 152 Chapter 7 ASSEMBLY OF BASIC ENGINE Rear mechanism - Assemble................7-24 Rear plate - Install........................7-24 Rear idler shaft - Install......................7-24 Camshaft - Install........................7-24 Camshaft gear - Install......................7-25 Camshaft end play - Measure....................7-25 Fuel injection pump accessory drive - Install ................7-25 Rear Idler Gear - Install ......................

  • Page 153: Crankshaft And Main Bearing - Install

    Chapter 7 ASSEMBLY OF BASIC ENGINE Chapter 7 ASSEMBLY OF BASIC ENGINE 1. Crankshaft and main bearing - Install 1.1 Crankcase - Invert Using a turn table, invert the crankcase. When the turn table Weight of crankcase and is not available, hitch slings to the crankcase using wood crankshaft assembly: approx 2615 kg [5765 lb] pieces and cloth pads, and raise the crankcase with a hoist or...

  • Page 154: Upper Main Bearing - Install

    Chapter 7 ASSEMBLY OF BASIC ENGINE 1.3 Upper main bearing - Install (a) Do not apply engine oil to the back faces of the main bearing shells and main bearing fitting bores in the crank- case when installing the main bearings. Install the main bearings only after cleaning off foreign matters, oil and grease from these surfaces using cleaning solvent.

  • Page 155: Crankshaft - Install

    Chapter 7 ASSEMBLY OF BASIC ENGINE 1.5 Crankshaft - Install (1) Make sure that the sliding surfaces of the upper main bearing shells installed in the crankcase are evenly coated with clean engine oil. (2) Thoroughly wash the crankshaft with cleaning oil, and blow off the oil with compressed air.

  • Page 156: Main Bearing Cap - Install

    Chapter 7 ASSEMBLY OF BASIC ENGINE 1.8 Main bearing cap - Install Be sure to observe the specified tightening sequence when tightening the main bearing cap bolts and side bolts. (1) Make sure that the main bearings and thrust plates "FRONT"...

  • Page 157: Crankshaft End Play - Measure

    Chapter 7 ASSEMBLY OF BASIC ENGINE 1.9 Crankshaft end play - Measure (1) Verify the smooth rotation of the crankshaft. (2) Attach a dial gauge probe to the rear end face of crank- shaft. (3) Using a bar, move the crankshaft fully to the front and rear to read the each measurement.

  • Page 158: Cylinder Liner, Piston And Connecting Rod - Assemble

    Chapter 7 ASSEMBLY OF BASIC ENGINE 2. Cylinder liner, piston and connecting rod - Assemble 2.1 Cylinder liner protrusion - Measure (1) Place the dial gauge probe on the top surface of the cyl- Height of protrusion inder liner flange, and zero the dial gauge. (2) Slide the probe to measure the protrusion of the cylin- der liner at four places.

  • Page 159: Cylinder Liner - Install

    Chapter 7 ASSEMBLY OF BASIC ENGINE (5) Calculate the cylinder liner flange protrusion by sub- tracting the depth of counterbore in crankcase from the Crankcase Shim thickness of the cylinder liner flange. Cylinder liner If the value exceeds the limit, insert a shim under the cylinder liner flange.

  • Page 160: Cylinder Liner Flange Protrusion - Measure (Cylinder Liner Installed)

    Chapter 7 ASSEMBLY OF BASIC ENGINE 2.4 Cylinder liner flange protrusion - Measure (cylinder liner installed) (1) Remove the dust and dirt from the crankcase top face Bolt, P/N:37591-06300 Cylinder liner and the cylinder liner top end face to measure. Tightening torque flange protrusion 98 N·m {10 kgf·m}...

  • Page 161: Piston And Connecting Rod - Assemble

    Chapter 7 ASSEMBLY OF BASIC ENGINE 2.6 Piston and connecting rod - Assemble (1) Apply engine oil to the piston pin, and assemble the View A piston and the connecting rod. The orientation of piston Piston weight and connecting rod is shown in the illustration. Note: The piston and piston pin are made for a clearance fit.

  • Page 162: Crankshaft - Turn

    Chapter 7 ASSEMBLY OF BASIC ENGINE 2.8 Crankshaft - Turn (1) Install two bolts to the flywheel mounting holes of the crankshaft. (2) Using the bolts, turn the crankshaft with a bar. Bolt (M22 × 1.5 mm) Crankshaft Crankshaft Crankshaft - Turn 2.9 Piston installation - Prepare (1) Turn the crankshaft to a position where the connecting rod big end does not hit the crankpin on the piston...

  • Page 163: Piston- Install

    Chapter 7 ASSEMBLY OF BASIC ENGINE 2.11 Piston - Install Punch mark on piston top face CAM When installing the piston, install the eye bolt to the Eyebolt P/N:37591-02500 threaded hole on the piston top, and lift the piston with (M10 ×...
  • Page 164 Chapter 7 ASSEMBLY OF BASIC ENGINE (5) Install piston into cylinder liner by tapping the piston head with a soft-head hammer. Note: Make sure that the piston is not caught in the cylinder liner, or the connecting rod big end does not hit the crank pin.

  • Page 165: Connecting Rod Cap - Install

    Chapter 7 ASSEMBLY OF BASIC ENGINE 2.12 Connecting rod cap - Install Lower connecting rod Connecting rod bolt bearing (a) Verify that the matching numbers on the connect- Lug groove ing rod and the connecting rod cap are same and on the same side.

  • Page 166: Connecting Rod End Play - Measure

    Chapter 7 ASSEMBLY OF BASIC ENGINE (6) Measure the connecting rod end play, and adjust the Tightening torque: end play to the range of the standard value. Bolt ID mark "AL" and "AU" 637 ± 31.9 N·m {65 ± 3.25 kgf·m} (7) Tighten the connecting rod bolts to the specified torque.

  • Page 167: Piston Protrusion - Measure

    Chapter 7 ASSEMBLY OF BASIC ENGINE 2.14 Piston protrusion - Measure Piston protrusion Piston protrusion must always meet the standard, as the amount of protrusion not only influences engine performance, but it also prevents valve stamping. Measure the protrusion of each piston, following the instructions below.

  • Page 168: Front Mechanism - Assemble

    Chapter 7 ASSEMBLY OF BASIC ENGINE 3. Front mechanism - Assemble 3.1 Coupling - Install (With tachometer spec) (1) Install the coupling aligning the dowel pin on the cam- shaft front end, and tighten the bolt. (2) Install the oil seal and O-ring to the oil seal case, and Oil seal case tighten the bolt.

  • Page 169: Front Idler Gear Backlash - Measure

    Chapter 7 ASSEMBLY OF BASIC ENGINE 3.5 Front idler gear backlash - Measure Measure the backlash of the front idler gears by either of the following methods : measure the gear backlash with a dial gauge applied to a tooth flank on the pitch circle at a right angle to the tooth axis, or measure the clearance between gears by inserting a thickness gauge between the engaging gear teeth.

  • Page 170: Fan Drive Idler Gear And Fan Drive Idler Shaft - Install

    Chapter 7 ASSEMBLY OF BASIC ENGINE 3.9 Fan drive idler gear and fan drive idler shaft - Install (With fan spec) Gear case flange assembly (1) With the small gear of the fan drive idler gear facing spec out side, install the fan drive idler gear through the mounting hole, and hold the fan drive idler gear by 59 ±...

  • Page 171: Front Gear Case - Install

    Chapter 7 ASSEMBLY OF BASIC ENGINE 3.12 Front gear case - Install (1) Apply sealant (ThreeBond 1211) to the front gear case Eyebolt 05930-00200 packing mounting surface of the crankcase, and install (M12 × 1.25 mm) the packing.Apply the same sealant (ThreeBond 1211) to the packing, and then install the front gear case.

  • Page 172: Breather Case, Thermostat Bracket - Install

    Chapter 7 ASSEMBLY OF BASIC ENGINE 3.15 Breather Case, Thermostat Bracket - Install (Without fan spec) PTAW Install the breather case or thermostat bracket to the front gear case. Thermostat bracket Breather case Breather Case, Thermostat Bracket - Install 3.16 Damper and crankshaft pulley - Install (1) Install the guide bolt to the damper mounting thread on Guide bolt the crankshaft.

  • Page 173: Damper Face And Radial Runouts - Measure

    Chapter 7 ASSEMBLY OF BASIC ENGINE 3.17 Damper face and radial runouts - Measure Measure the face and radial runouts of the damper. If the value exceeds the limit, check the assembling condi- tion such as bolt looseness or accumulation of foreign sub- stances on the mounting faces.

  • Page 174: Rear Mechanism - Assemble

    Chapter 7 ASSEMBLY OF BASIC ENGINE 4. Rear mechanism - Assemble 4.1 Rear plate - Install (1) Install the nozzle plates. Nozzle plate (2) Apply sealant (ThreeBond 1211) to the rear plate pack- ing mounting surface of the crankcase, and install the packing.

  • Page 175: Camshaft Gear - Install

    Chapter 7 ASSEMBLY OF BASIC ENGINE 4.4 Camshaft gear - Install (1) Install the camshaft gear by aligning its hole with the dowel pins on the camshaft. Camshaft gear (2) Tighten the bolts to the specified torque. (3) Verify the camshaft smooth rotation. 12T bolt (black): 127 ±...

  • Page 176: Rear Idler Gear - Install

    Chapter 7 ASSEMBLY OF BASIC ENGINE 4.7 Rear Idler Gear - Install (1) Turn the crankshaft to move the No. 1 cylinder to the Application of Molykote to the entire inner peripheral top dead center. surface of rear idler bushing (2) Apply engine oil to the idler shaft.

  • Page 177: Timing Gear Backlash - Measure

    Chapter 7 ASSEMBLY OF BASIC ENGINE 4.9 Timing gear backlash - Measure Measure the backlash of the timing gears using either method : measure the gear backlash with a dial gauge probe Camshaft gear Injection pump gear applied to a tooth flank on the pitch circle at a right angle to the tooth axis, or measure the clearance between gears by inserting a thickness gauge between the engaging gear teeth.

  • Page 178: Rear Oil Seal - Install

    Chapter 7 ASSEMBLY OF BASIC ENGINE 4.12 Rear oil seal - Install Use the rear seal installer assembly to install the rear oil Insert bolt seal. Guide flange (1) Apply clean engine oil evenly to the oil seal lip. Insert Swing washer Note: Pay attention to the mounting side of oil seal, and be careful not to damage the oil seal.

  • Page 179: Flywheel Face And Radial Runouts - Measure

    Chapter 7 ASSEMBLY OF BASIC ENGINE 4.15 Flywheel face and radial runouts - Measure Measure the face and radial runouts of the flywheel. If the value exceeds the limit, check the assembling condi- Face runout measuring tion such as bolt looseness or accumulation of foreign sub- plane stances on the mounting faces.

  • Page 180: Cylinder Head And Valve Mechanism - Assemble

    Chapter 7 ASSEMBLY OF BASIC ENGINE 5. Cylinder head and valve mechanism - Assemble 5.1 Cylinder head - Assemble Guide and seal installer Guide and seal installer P/N:37591-12300 P/N:37191-11500 (a) Be careful when inserting the valve through the Valve stem stem seal, as the edge of the valve can cause Stem seal damage to the stem seal lip.

  • Page 181: Valve Sinkage - Measure

    Chapter 7 ASSEMBLY OF BASIC ENGINE 5.2 Valve sinkage - Measure Measure the valve sinkage. Seat width If the value exceeds the limit, replace the valve or valve seat with a new one. Lap the valve and valve seat whenever the valve or valve seat is refaced or replaced.

  • Page 182: Cylinder Head Gasket - Install

    Chapter 7 ASSEMBLY OF BASIC ENGINE 5.5 Cylinder head gasket - Install (1) Wipe off oil, grease and other contamination from the cylinder head bottom surface and the crankcase top sur- face. (2) Install the cylinder head gasket coated with liquid gas- ket onto the crankcase with the dowel pin and the hole in alignment.

  • Page 183: Rocker Case - Install

    Chapter 7 ASSEMBLY OF BASIC ENGINE 5.8 Rocker case - Install (1) Install O-rings on water outlet connector. Apply grease Connector Connector mounting to the O-ring sliding surface. mounting Snap ring groove hole hole (deep side) (2) Apply grease to connector mounting hole of rocker case.

  • Page 184: Clearance Between The Bottom Face Of Valve Bridge Pusher And The Top Face Of Valve Rotator - Inspect

    Chapter 7 ASSEMBLY OF BASIC ENGINE 5.11 Clearance between the bottom face of valve bridge pusher and the top face of valve rotator - Inspect Hold down the top of bridge by hand. Be sure to secure the standard clearance between Valve bridge Bridge cap valve bridge and valve rotator.

  • Page 185: Valve Clearance - Check And Adjust

    Chapter 7 ASSEMBLY OF BASIC ENGINE 5.13 Valve clearance - Check and adjust Adjust the valve clearance. Adjust the valve clearance when the engine is cold. Note:(a) The inlet valves are on the left side and the exhaust valves are on the right side when the cylinder head is viewed from the camshaft side.
  • Page 186 Chapter 7 ASSEMBLY OF BASIC ENGINE 5.14.2 Fuel injection timing - Check (1) Turn the crankshaft in the normal direction, and stop the turning when the No. 1 cylinder is positioned at approx 10° before the specified fuel injection timing. Check that the "0"...

  • Page 187: Valve Timing - Inspect

    Chapter 7 ASSEMBLY OF BASIC ENGINE 5.15 Valve timing - Inspect The specified valve timing is automatically achieved, pro- vided that the gears are assembled by aligning match marks and that the valve clearance is adjusted to the specified value. For verification, check the valve timing as follows : 5.15.1 Valve timing at normal valve clearance (no Rocker arm thickness gauge insertion)
  • Page 188 Chapter 7 ASSEMBLY OF BASIC ENGINE Overlap 61° spec 10.5° 24° Exhaust valve closed 37° Inlet valve open 2.5° Exhaust valve closed Inlet valve open Rotation direction Rotation direction Exhaust valve open Exhaust valve open 57° Inlet valve closed 44° 26°...

  • Page 189: Fuel Injection Nozzle Assembly - Install

    Chapter 7 ASSEMBLY OF BASIC ENGINE Overlap 108° spec Inlet valve open 45° Exhaust valve closed 63° Exhaust valve closed Inlet valve open Rotational direction Rotation direction Exhaust valve open Inlet valve closed Exhaust valve open 53° 35° Inlet valve closed Overlap 108°...
  • Page 191 Chapter 8 FUEL SYSTEM Fuel system - Remove and inspect................ 8-3 Fuel injection pipe and fuel leak-off pipe - Remove and inspect ..........8-3 Fuel filter and fuel pipe - Remove and inspect ................. 8-5 Stop solenoid - Remove and inspect ..................8-8 Fuel control link - Remove and inspect...................

  • Page 193: Fuel System - Remove And Inspect

    Chapter 8 FUEL SYSTEM Chapter 8 FUEL SYSTEM 1. Fuel system - Remove and inspect 1.1 Fuel injection pipe and fuel leak-off pipe - Remove and inspect Replace Replace Right side fuel injection pump Replace Replace Left side cylinder head Replace Replace Right side...
  • Page 194 Chapter 8 FUEL SYSTEM Double injection pipe type fuel injection pipe spec Replace Replace Replace Replace Replace Left side cylinder head Replace Replace Right side cylinder head Replace Left side fuel injection pump Front Right side fuel injection pump Replace Replace Fuel leakage sensor Fuel injection pipe and fuel leak-off pipe - Remove and inspect...

  • Page 195: Fuel Filter And Fuel Pipe - Remove And Inspect

    Chapter 8 FUEL SYSTEM 1.2 Fuel filter and fuel pipe - Remove and inspect Replace Replace Front Replace Replace Replace Left side Right side Fuel filter and fuel pipe - Remove and inspect Removing sequence 1 Flexible pipe 7 Fuel filter bracket 13 Left fuel pipe 2 Fuel pipe 8 Pipe stay...
  • Page 196 Chapter 8 FUEL SYSTEM Change over type fuel filter spec Replace Front Replace Replace Left side Replace Replace Right side Replace Replace Fuel filter and fuel pipe - Remove and inspect Removing sequence 1 Flexible pipe 7 Fuel filter bracket 13 Left fuel pipe 2 Fuel pipe 8 Pipe stay...
  • Page 197 Chapter 8 FUEL SYSTEM Trochoid pump type fuel feed pump spec S16R2 Timing gear case Right side fuel injection pump Attach on the top of left side fuel injection pump accessory drive. Left side fuel injection pump S16R2 Front S16R2 Replace: Sealing washer Fuel filter and fuel pipe - Remove and inspect Removing sequence...

  • Page 198: Stop Solenoid - Remove And Inspect

    Chapter 8 FUEL SYSTEM 1.3 Stop solenoid - Remove and inspect Stop solenoid RUN OFF spec Control shaft Stop solenoid - Remove and inspect Removing sequence 1 Link 4 Ball bearing 7 Stop solenoid 2 End plate 5 Stop lever 8 Bracket 3 Snap ring 6 Follower...
  • Page 199 Chapter 8 FUEL SYSTEM Stop solenoid RUN ON spec Control shaft Control shaft Control shaft Replace: Rubber cushion Replace: Rubber cushion Stop solenoid - Remove and inspect Removing sequence 1 Follower 3 Plate 2 Stop solenoid 4 Bracket...
  • Page 200 Chapter 8 FUEL SYSTEM Starting rack restrict solenoid spec Replace: Rubber cushion Replace: Rubber cushion Replace: Rubber cushion Replace: Rubber cushion Stop solenoid - Remove and inspect Removing sequence 1 Follower 6 End plate 11 Start rack restrict solenoid 2 Stop solenoid 7 Snap ring 12 Plate 3 Plate...

  • Page 201: Fuel Control Link - Remove And Inspect

    Chapter 8 FUEL SYSTEM 1.4 Fuel control link - Remove and inspect Looseness, wear Looseness, wear Settling, deformation Looseness, wear a. Oil pressure governor spec b. PROACT spec Replace To governor c. SG4017 spec lever d. DYNA8000 or equivalent spec Looseness, wear Starting rack limit solenoid spec Stop solenoid...

  • Page 202: Governor And Actuator - Remove And Inspect

    Chapter 8 FUEL SYSTEM 1.5 Governor and actuator - Remove and inspect Oil pressure governor spec Replace a. PSG b. EG-3P a. Woodward PSG type governor c. EG-B2P b. Woodward EG-3P type governor c. Woodward EG-B2P type governor Governor - Remove and inspect Removing sequence 1 Governor lever 2 Governor...
  • Page 203 Chapter 8 FUEL SYSTEM SG4017 spec actuator DYNA8000 or equivalent spec actuator a. SG4017 DYNA8000 or equivalent Replace : Rubber cushion Replace Replace : Rubber cushion a. TOHO SEISAKUSYO SG4017 type actuator b. Woodward DYNA8000 type actuator Actuator - Remove and inspect Removing sequence 1 Governor lever 3 Bracket...
  • Page 204 Chapter 8 FUEL SYSTEM Actuator spec Replace ： Rubber cushion Replace ： Rubber cushion * Woodward PROACT type actuator Actuator - Remove and inspect Removing sequence 1 Stopper bolt 4 Bracket 2 Governor lever 5 Plate 3 Actuator 8-14...

  • Page 205: Fuel Injection Pump - Remove And Inspect

    Chapter 8 FUEL SYSTEM 1.6 Fuel injection pump - Remove and inspect Fuel injection pump - Remove and inspect Removing sequence 1 Coupling cover 4 Fuel injection pump (approx. 68 kg [149 lb]) 2 Cover stay 5 Shim (Record the installing position and thickness.) 3 Stay 6 Bracket 8-15...

  • Page 206: Fuel System - Disassemble And Inspect

    Chapter 8 FUEL SYSTEM 2. Fuel system - Disassemble, inspect and assemble 2.1 Fuel filter (paper element) - Disassemble, inspect and assemble Air vent plug 9 ± 1 N·m {0.9 ± 0.1 kgf·m} [6.6 ±0.7 lbf·ft] Replace Crack, flaw Fuel filter bracket Filter wrench Fuel filter cartridge Use the filter wrench to remove...
  • Page 207 Chapter 8 FUEL SYSTEM Change over type fuel filter spec Air vent plug Replace 9 ± 1 N·m {0.9 ± 0.1 kgf·m} [6.6 ±0.7 lbf·ft] Filter wrench Crack, flaw Use the filter wrench to remove the fuel filter. (Use only when removing) Replace Dent Fuel filter (paper element) - Disassemble, inspect and assemble...
  • Page 208 Chapter 8 FUEL SYSTEM 2.1.1 Fuel filter cartridge - Install (a) Make sure that there is no flame around the area before handling fuel. (b) Wipe any spilled fuel to prevent a fire. (c) Do not use the fuel filter cartridge that has a dent on the case. If the case has a dented, it can cause damage to the fuel filter cartridge, leading to fuel leaks during operation, and results in a fire.

  • Page 209: Fuel Injection Nozzle - Disassemble And Inspect

    Chapter 8 FUEL SYSTEM 2.2 Fuel injection nozzle - Disassemble and inspect Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the efficient work. Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with any job.

  • Page 210: Fuel Injection Nozzle - Inspect And Adjust

    Chapter 8 FUEL SYSTEM 2.3 Fuel injection nozzle - Inspect and adjust 2.3.1 Fuel injection start pressure - Inspect and adjust Nozzle tester P/N:83091-03301 Never touch the fuel injection nozzle orifice during nozzle injection test. (1) Install the fuel injection nozzle to the nozzle tester. (2) Push down the handle at a speed of one stroke a second and measure the pressure when injection starts.
  • Page 211 Chapter 8 FUEL SYSTEM 2.3.3 Nozzle tip - Clean and replace (a) Be careful not to hit the nozzle tip. (b) The needle valve and body are precision parts. Handle them carefully, and do not change the original valve and body combination. (1) Remove the retaining nut.
  • Page 212 Chapter 8 FUEL SYSTEM 2.3.5 Push rod - Inspect Spring seating face Inspect the push rod visually. If its spring seat wears local wear unevenly, or its needle valve contact surface wears remark- ably, or the cavitation occurs on its tapered area, replace the push rod with a new one.

  • Page 213: Fuel Injection Nozzle - Assemble

    Chapter 8 FUEL SYSTEM 2.4 Fuel injection nozzle - Assemble TE type 39 ± 5 N·m Do not hit with a hammer, etc. {4 ± 0.5 kgf·m} when installing into cylinder head. [29 ± 3.7 lbf·ft] 73.5 ± 4.5 N·m Application of engine oil to both sides {7.5 ±...
  • Page 214 Chapter 8 FUEL SYSTEM T type 39 ± 5 N·m Do not hit with a hammer, etc. {4 ± 0.5 kgf·m} when installing into cylinder head. [29 ± 3.7 lbf·ft] 73.5 ± 4.5 N·m Application of engine oil to both sides {7.5 ±...

  • Page 215: Fuel Injection Pump Accessory Drive - Disassemble And Inspect

    Chapter 8 FUEL SYSTEM 2.5 Fuel injection pump accessory drive - Disassemble and inspect Deformation, lip surface wear Wear, flaw Rotation Wear, flaw Rotation Peeling, wear Fuel injection pump accessory drive - Disassemble and inspect Disassembling sequence 1 Nut 4 Snap ring 7 Bearing 2 Washer 5 Drive shaft...
  • Page 216 Chapter 8 FUEL SYSTEM Trochoid fuel feed pump spec Replace Deformation, lip surface wear Rotation Peeling, wear Replace Deformation, lip surface wear Replace Wear, flaw Wear, flaw Peeling, wear Rotation Rotation Fuel injection pump accessory drive - Disassemble and inspect Disassembling sequence 1 Coupling 8 Washer...

  • Page 217: Outside Diameter And Inside Diameter Of Accessory Drive Bearing Fit - Inspect

    Chapter 8 FUEL SYSTEM 2.6 Outside diameter and inside diameter of accessory drive bearing fit - Inspect (1) Rotate the bearing and if the rotation is not smooth, replace the bearing with a new one. Fuel injection pump gear (2) Inspect the fit of drive shaft and bearing. If significant wear is found, replace them with new ones.

  • Page 218: Fuel Injection Pump Accessory Drive - Assemble

    Chapter 8 FUEL SYSTEM 2.7 Fuel injection pump accessory drive - Assemble 490 ± 24.5 N·m {50 ± 2.5 kgf·m} [361 ± 18.1 lbf·ft] Application of engine oil to lip portion Application of engine oil Fuel injection pump accessory drive - Assemble 8-28...
  • Page 219 Chapter 8 FUEL SYSTEM Trochoid fuel feed pump spec Adjust using shim so that backlash of drive gear to driven gear falls between 0.10 to 0.20 mm [0.0039 to 0.0079 in.] Chamfered side M30×1.5 For Nut (37525-09900) Tightening torque: 490 ± 24.5 N·m {50 ±...
  • Page 220 Chapter 8 FUEL SYSTEM 2.7.1 Ball bearing press-fit to driven gear (Trochoid fuel feed pump) Ball bearing Attach the gear stand to the driven gear when press-fit the ball bearing to the gear. Driven gear Gear stand P/N:37891-06100 Ball bearing press-fit to driven gear 2.7.2 Backlash between drive gear and driven gear - Backlash tool Measure (Trochoid fuel feed pump)

  • Page 221: Governor Drive - Disassemble And Inspect

    Chapter 8 FUEL SYSTEM 2.8 Governor drive - Disassemble and inspect Oil pressure governor spec PSG governor MAX 1450 rpm spec Flaw, wear Wear Rotation Flaw, wear Rotation Wear PSG or EG-3P governor MIN 1460 rpm spec Spline defect, wear Replace Flaw, wear PSG or EG-3P...
  • Page 222 Chapter 8 FUEL SYSTEM Oil pressure governor spec MAX 1450 rpm spec Flaw, wear Wear Rotation Flaw, wear Rotation Wear Replace Flaw, wear MAX 1450 rpm spec Wear Deformation, crack, deterioration Rotation * Woodward EG-B2P type governor Governor drive - Disassemble and inspect Disassembling sequence 1 Bolt 5 Drive shaft A...

  • Page 223: Outside Diameter And Inside Diameter Of Bearing Fit

    Chapter 8 FUEL SYSTEM 2.9 Outside diameter and inside diameter of bearing fit (Oil pressure governor spec) Rotate the bearing and if the rotation is not smooth, replace the bearing with a new one. Inspect the fit of drive shaft, idler shaft and bearing. If sig- nificant wear is found, replace them with new ones.

  • Page 224: Governor Drive - Assemble

    Chapter 8 FUEL SYSTEM 2.10 Governor drive - Assemble Oil pressure governor spec Shrink fit (200 [392゜ F] or below) Backlash 0.12 to 0.18 mm [0.0047 to 0.0071 in.] Shrink fit (200 [392゜ F] or below) 108 ± 5.4 N·m {11 ±...
  • Page 225 Chapter 8 FUEL SYSTEM Oil pressure governor spec Backlash 0.12 to 0.18mm [0.0047 to 0.0071 in.] Shrink fit 200  [392 F] or below * Woodward EG-B2P type governor Governor drive - Assemble 2.10.1 Drive gear and idler gear backlash - Measure Measure the drive gear and idler gear backlash.

  • Page 226: Fuel System - Install

    Chapter 8 FUEL SYSTEM 3. Fuel system - Install Install the parts in the reverse order of the disassemble sequence. (Refer to the illustration for disassembling.) Clean and dry well the fuel passage. 3.1 Fuel injection pump - Install 108 ± 5.4 N·m {11.0 ±...
  • Page 227 Chapter 8 FUEL SYSTEM 3.1.1 Checking before installing fuel injection pump Pointer Ensure the correct mounting position of drive coupling. "0" line mark on flywheel If it is installed 180 degrees out of position, the fuel injection timing cannot be adjusted. (1) Turn the crankshaft.
  • Page 228 Chapter 8 FUEL SYSTEM 3.1.2 Fuel injection pump - Install (a) Install new shims of the same thickness (t=0.25 mm [0.0098 in.]) to the removed ones on the bracket installing surfaces of right bank fuel injection pump. And install the pump to the right bank bracket. (No shims on the left bank bracket) (b) First, tighten the bolts (long) to connect the drive coupling and laminated plates to the specified torque, and then loosen the bolts.
  • Page 229 Chapter 8 FUEL SYSTEM (7) Install the stay between the fuel injection pump case and crankcase. (8) Refill engine oil through the oil drain pipe mounting hole of cam chamber. (9) Install the oil pipe and fuel pipe. Refill engine oil through oil drain pipe mounting hole.

  • Page 230: Fuel Control Link - Install

    Chapter 8 FUEL SYSTEM 3.2 Fuel control link - Install 3.2.1 Control shaft - Install If the bearings at both ends of control shaft are not properly installed, or if the bearings do not rotate smoothly, it could result in a hunting or other malfunctions. Cover Control shaft O-ring...
  • Page 231 Chapter 8 FUEL SYSTEM 3.2.3 Fuel control link - Install and adjust PSG spec PSG spec Distance from the end of fuel Stop lever injection pump to the end of rack: 68 ± 0.5 mm [2.68 ± 0.020 in.] Variable length Variable length control link control link C...
  • Page 232 Chapter 8 FUEL SYSTEM Fixed length (239 mm [9.41 in.]) Fixed length control link for the right bank (239 mm [9.41 in.]) Fixed length control link for the right bank (239 mm [9.41 in.]) control link B-1 Control link Control link Control link lever Control shaft lever 65 ±...
  • Page 233 Chapter 8 FUEL SYSTEM (5) Install the variable-length control link between the con- trol shaft lever and the governor lever. Fine adjust the distance from the end of fuel injection pump to the end of rack to be 67 mm [2.64 in.] when the angle scale of the governor output shaft reads "0"...

  • Page 234: Stop Solenoid - Install

    Chapter 8 FUEL SYSTEM 3.3 Stop solenoid - Install 3.3.1 Stop solenoid RUN OFF type : Turned OFF during the engine running, when turned ON, the solenoid is activated to stop the engine. RUN ON type : Turned ON during the engine running, when turned OFF, the solenoid is deactivated to stop the engine. 3.3.2 Start rack restrict solenoid RUN OFF type : Turned OFF during the engine starting, when turned ON during engine running, the solenoid releases the restriction.
  • Page 235 Chapter 8 FUEL SYSTEM 3.3.4 Stop solenoid (RUN OFF) - Adjust RUN OFF stop system spec Variable length Clearance: 0 mm (contact) control link Stop solenoid ON: 68 ± 0.5 mm [2.68 ± 0.020 in.] Play: approx 3 mm [0.12 in.] Section A-A Stop solenoid (RUN OFF) - Adjust (1) Pull the stop solenoid manually to the stop solenoid ON position (engine stop).
  • Page 236 Chapter 8 FUEL SYSTEM 3.3.5 Stop solenoid (RUN ON), start rack restrict solenoid (RUN OFF) - Adjust RUN ON stop system, Adapter Stop solenoid Follower Follower Follower starting rack control spec (RUN ON) Lever Lever Lever Link Link Link (variable length) (variable length) (variable length) Clearance: 0 mm (contact)
  • Page 237 Chapter 8 FUEL SYSTEM 3.3.6 Stop solenoid (RUN OFF), start rack restrict solenoid (RUN ON) - Adjust RUN OFF stop system, Starting rack restrict solenoid Follower Clearance: 0 mm (contact) starting rack control spec Adapter (RUN ON) Link Follower (variable length) Lever See bracket Clamping...
  • Page 238 Chapter 8 FUEL SYSTEM 3.3.7 Stop solenoid (RUN ON), start rack restrict solenoid (RUN ON) - Adjust Stop solenoid RUN ON stop system Adapter Follower starting rack control spec (RUN ON) Lever Lever Lever Link (variable length) Clearance: 0 mm (contact) See bracket Clamping Clamping...
  • Page 239 Chapter 8 FUEL SYSTEM 3.3.8 Solenoid function - Verify Verify the solenoid functions of start, running and emergency stop of the engine and check the fuel injection pump rack posi- tions. Stop solenoid Specification Chapter Engine starting Engine running Engine emergency stop Stop solenoid Plunger position (spring condition) Compressed...
  • Page 241 Chapter 9 LUBRICATION SYSTEM Lubrication system - Remove and inspect............9-3 Oil pipe and right oil cooler - Remove and inspect ..............9-3 Oil pump, oil filter, oil pan and left oil cooler - Remove and inspect ......... 9-5 Breather and oil filler - Remove and inspect................9-6 Governor oil filter - Remove and inspect ..................

  • Page 243: Lubrication System - Remove And Inspect

    Chapter 9 LUBRICATION SYSTEM Chapter 9 LUBRICATION SYSTEM 1. Lubrication system - Remove and inspect 1.1 Oil pipe and right oil cooler - Remove and inspect Trochoid fuel feed pump spec Oil filter Front Accessory drive Accessory drive Crankcase S16R2 a.
  • Page 244 Chapter 9 LUBRICATION SYSTEM 2 Turbo spec Replace: O-ring Oil filter Packing Sealing washer Front Accessory drive Crankcase Oil cooler Crankcase Oil pan Crankcase Accessory drive Oil pipe and right oil cooler - Remove and inspect 1 Right drain pipe 6 Right oil cooler (approx.

  • Page 245: Oil Pump, Oil Filter, Oil Pan And Left Oil Cooler - Remove And Inspect

    Chapter 9 LUBRICATION SYSTEM 1.2 Oil pump, oil filter, oil pan and left oil cooler - Remove and inspect Replace Replace Replace S16R2 Replace Clogging Replace Replace Replace Replace Replace S16R2 Replace Replace Replace Replace Replace Flaw, crack Oil pump, oil filter, oil pan and left oil cooler - Remove and inspect Removing sequence 1 Bypass drain pipe 5 Oil pipe...

  • Page 246: Breather And Oil Filler - Remove And Inspect

    Chapter 9 LUBRICATION SYSTEM 1.3 Breather and oil filler - Remove and inspect Breather attaching on Breather attaching on Breather attaching on gear case spec timing gear case spec side cover spec Replace Replace Replace Replace Replace Replace Replace Replace Breather and oil filler - Remove and inspect Removing sequence 1 Breather...

  • Page 247: Governor Oil Filter - Remove And Inspect

    Chapter 9 LUBRICATION SYSTEM 1.4 Governor oil filter - Remove and inspect Oil pressure governor spec Replace Replace To governor drive case To turbocharger oil pipe Replace *Woodward PSG, EG-3P or EG-B2P type governor To timing gear case To timing gear case To timing gear case Replace Replace...

  • Page 248: Lubrication System - Disassemble, Inspect And Assemble

    Chapter 9 LUBRICATION SYSTEM 2. Lubrication system - Disassemble, inspect and assemble 2.1 Oil pump and safety valve - Disassemble and inspect Replace Settling, break, wear Flaw, crack Replace Replace Spline flaw, wear Flaw, wear Contact, peeling, wear Flaw, wear Replace Replace Flaw, crack...
  • Page 249 Chapter 9 LUBRICATION SYSTEM S16R2 expanded discharge spec) Replace Settling, break, wear Flaw, crack Flaw, wear Replace Replace Spline flaw, wear Replace Contact, peeling, wear Flaw, wear Replace Replace Flaw, crack Oil Pump and Safety Valve - Disassemble and Inspect Disassembling Sequence 1 Oil pump cover 3 Drive gear...

  • Page 250: Oil Pump And Safety Valve - Inspect

    Chapter 9 LUBRICATION SYSTEM 2.2 Oil pump and safety valve - Inspect 2.2.1 Drive gear and driven gear backlash - Measure Measure the drive gear and driven gear backlash. If the value exceeds the limit, replace the gears with new ones. Item Standard Limit...
  • Page 251 Chapter 9 LUBRICATION SYSTEM 2.2.5 Oil pump safety valve - Inspect Stopper Valve Valve spring Item Standard 1.3 ± 0.13 MPa Safety valve opening pressure {13 ± 1.3 kgf/cm [188 ± 18.9 psi] O-ring (1) Inspect the oil pump safety valve spring, and if any deformation, wear, or damage is found, or if the mea- sured value exceeds the limit, replace it with a new one.

  • Page 252: Oil Pump And Safety Valve - Assemble

    Chapter 9 LUBRICATION SYSTEM 2.3 Oil pump and safety valve - Assemble 33 ± 3.3 N·m {3.4 ± 0.34 kgf·m} [24 ± 2.4 lbf·ft] 88 ± 10 N·m {9 ± 1.0 kgf·m} [65 ± 7.4 lbf·ft] O-ring Application of engine oil Apply ThreeBond 1215 to cover and case.

  • Page 253: Oil Filter, Oil Filter Alarm, Relief Valve And Left Oil Cooler - Disassemble And Inspect

    Chapter 9 LUBRICATION SYSTEM 2.4 Oil filter, oil filter alarm, relief valve and left oil cooler - Disassemble and inspect Clogging, crack Replace Replace Replace Crack, deformation Replace Crack, deformation Replace Replace Replace Replace Deformation, deterioration, breakage, wear Deterioration, wear, crack Wear, crack Replace Oil filter, oil filter alarm, relief valve and left oil cooler - Disassemble and inspect...
  • Page 254 Chapter 9 LUBRICATION SYSTEM Remote bypass oil filter spec Clogging, crack Replace Replace Replace Crack, deformation Replace Crack, deformation Replace Replace Replace Deformation,deterioration, breakage, wear Deterioration, wear, crack Wear, crack Replace Oil filter, oil filter alarm, relief valve and left oil cooler - Disassemble and inspect Disassembling sequence 1 Full-flow oil filter 5 Connector...
  • Page 255 Chapter 9 LUBRICATION SYSTEM Changeover-type oil filter spec Replace Clogging, crack Replace Replace Replace Replace Replace Deformation, deterioration, Replace breakage, wear Replace Replace Deterioration, wear, crack Wear, crack Replace Oil filter, oil filter alarm, relief valve and left oil cooler - Disassemble and inspect Disassembling sequence 1 Full-flow oil filter 7 Cock...
  • Page 256 Chapter 9 LUBRICATION SYSTEM Changeover-type oil filter Replace Remote bypass oil filter spec Clogging, crack Replace Replace Replace Replace Replace Deformation, deterioration, Replace breakage, wear Replace Replace Deterioration, wear, crack Wear, crack Replace Oil filter, oil filter alarm, relief valve and left oil cooler - Disassemble and inspect Disassembling sequence 1 Full-flow oil filter 6 Oil filter alarm...

  • Page 257: Oil Filter - Inspect

    Chapter 9 LUBRICATION SYSTEM 2.5 Oil filter - Inspect When replacing the oil filter, sample the oil (500 ml [0.13 U.S. gal.]) and check for metal and other particles. If metal or other particles are found, cut and unfold the element, and inspect the color and shape of metal particles trapped in the element to identify the cause.

  • Page 258: Oil Thermostat - Inspect

    Chapter 9 LUBRICATION SYSTEM 2.9 Oil thermostat - Inspect 2.9.1 Oil thermostat seal - Inspect Thermostat seal (1) Inspect the oil thermostat seal for deterioration and cracks. If defects are found, replace the seal with a new one. Mounting direction (2) Refer to the illustration for the correct orientation of seal installation.

  • Page 259: Oil Filter, Oil Filter Alarm, Relief Valve, And Left Oil Cooler - Assemble

    Chapter 9 LUBRICATION SYSTEM 2.10 Oil filter, oil filter alarm, relief valve, and left oil cooler - Assemble To assemble, follow the disassembly sequence in reverse. Thoroughly clean oil passages with wash oil, and dry the cleaned parts with compressed air. 2.11 Oil filter cartridge - Install (a) To install the oil filter cartridge, tighten the oil fil- ter cartridge by hand.

  • Page 260: Right Oil Cooler - Disassemble And Inspect

    Chapter 9 LUBRICATION SYSTEM 2.12 Right oil cooler - Disassemble and inspect Clogging, rupture, crack Aging, wear, crack Replace Replace Replace Replace Wear, crack Replace Replace Crack, deformation Replace Replace Right oil cooler - Disassemble and inspect Disassembling sequence 1 Connector 3 Oil cooler cover 5 Thermostat seal 2 Oil thermostat...

  • Page 261: Governor Oil Filter - Disassemble And Inspect

    Chapter 9 LUBRICATION SYSTEM 2.15 Governor oil filter - Disassemble and inspect Oil pressure governor spec Replace Clogging, crack Replace * Woodward PSG, EG-3P or EG-B2P governor Governor oil filter - Disassemble and inspect Disassembling sequence 1 Center bolt 3 Spring seat 5 Case 2 Element 4 Spring...

  • Page 262: Governor Oil Filter - Assemble

    Chapter 9 LUBRICATION SYSTEM 2.16 Governor oil filter - Assemble Oil pressure governor spec 9.8 ± 2.0 N·m {1 ± 0.2 kgf·m} [7 ± 1.5 lbf·ft] Replace Clogging, crack 9.8 ± 2.0 N·m {1 ± 0.2 kgf·m} 34.3 ± 6.9 N·m [7 ±...

  • Page 263: Lubrication System - Install

    Chapter 9 LUBRICATION SYSTEM 3. Lubrication system - Install ŒInstall the parts in the reverse order of the disassemble sequence. (Refer to the illustration for disassembling.) ŒThoroughly clean and dry the oil passage. 3.1 Oil pan - Install (1) Install the O-ring to the oil passage of the oil pan Replace Replace mounting surface.
  • Page 265 Chapter 10 COOLING SYSTEM Cooling system - Remove and inspect..............10-3 External cooling system - Remove and inspect..............10-3 Air cooler water pump - Remove and inspect................. 10-6 Heat exchanger - Remove and inspect .................. 10-7 Water pipe - Remove and inspect ..................10-9 Thermostat case and water pipe - Remove and inspect ............

  • Page 267: Cooling System - Remove And Inspect

    Chapter 10 COOLING SYSTEM Chapter 10 COOLING SYSTEM 1. Cooling system - Remove and inspect 1.1 External cooling system - Remove and inspect Replace: Packing Replace Replace Replace Outlet Replace Mounting position may differ depending on customization or specifications. Inlet Timing gear Timing gear case...
  • Page 268 Chapter 10 COOLING SYSTEM PTAW spec with air cooler water pump S16R2 Air cooler Air cooler S16R2 S16R2 Air cooler water pump Replace: Packing, O-ring External cooling system - Remove and inspect Removing sequence 1 Coupling 11 Water pipe (Front air cooler inlet) 2 Water pipe (Thermostat inlet) 12 Coupling 3 Coupling...
  • Page 269 Chapter 10 COOLING SYSTEM MPTK spec with seawater pump Air cooler Air cooler Heat exchanger Seawater pump Replace: Packing External cooling system - Remove and inspect Removing sequence 1 Coupling 3 Water pipe 2 Water pipe 4 Water pipe 10-5...

  • Page 270: Air Cooler Water Pump - Remove And Inspect

    Chapter 10 COOLING SYSTEM 1.2 Air cooler water pump - Remove and inspect PTAW spec MPTK spec Wear, flaw Wear, flaw S16R2-PTAW spec Stretch the belt when installing and adjusting. Crankshaft Wear, flaw Tension pully Water pump Air cooler water pump - Remove and inspect Removing sequence 1 Belt 3 Tension pulley assembly...

  • Page 271: Heat Exchanger - Remove And Inspect

    Chapter 10 COOLING SYSTEM 1.3 Heat exchanger - Remove and inspect MPTA spec Replace Replace Replace Front gear case Replace Heat exchanger - Remove and inspect Removing sequence 1 Coupling 6 Water pipe 2 Water pipe 7 Heat exchanger (approx 30 kg [66 lb]) 3 Water pipe 8 Bracket (approx 26 kg [57 lb]) 4 Coupling...
  • Page 272 Chapter 10 COOLING SYSTEM MPTK spec MPTK spec Replace Replace Replace Replace Replace Replace Replace Replace Front Front gear case gear case Replace Replace Replace Replace Heat exchanger - Remove and inspect Removing sequence 1 Coupling 6 Water pipe 11 Water pipe 2 Water pipe 7 Coupling 12 Water pipe...

  • Page 273: Water Pipe - Remove And Inspect

    Chapter 10 COOLING SYSTEM 1.4 Water pipe - Remove and inspect PTA URGE MPTA URGE Replace Replace Replace Replace Replace Replace Replace Replace Crankcase Water pipe - Remove and inspect Removing sequence 1 Coupling 5 Left water pipe 2 Right water pipe 6 Water pipe 3 Water pipe 7 Water connector...
  • Page 274 Chapter 10 COOLING SYSTEM PTK spec (Y2)PTAW spec S16R2 Replace Replace Replace Replace Replace S16R2 Replace Replace Replace Crankcase Water pipe - Remove and inspect Removing sequence 1 Water connector 2 Water connector 10-10...
  • Page 275 Chapter 10 COOLING SYSTEM PTAA2 spec Replace Crack, Crack, deterioration deterioration Crack, Crack, deterioration deterioration Crack, deterioration Replace Replace Crack, deterioration Water pipe - Remove and inspect Removing sequence 1 Rubber hose 4 Water pipe 7 Rubber hose 2 Water pipe 5 Rubber hose 8 Water pipe 3 Rubber hose...

  • Page 276: Thermostat Case And Water Pipe - Remove And Inspect

    Chapter 10 COOLING SYSTEM 1.5 Thermostat case and water pipe - Remove and inspect Replace Replace Replace Replace Replace Thermostat case and water pipe - Remove and inspect Removing sequence 1 Coupling 6 Bracket 2 Bypass water pipe 7 Bracket 3 Bypass water pipe 8 Nut 4 Left thermostat case...

  • Page 277: Water Pump - Remove

    Chapter 10 COOLING SYSTEM 1.6 Water pump - Remove Remove the nut with the socket wrench. Socket P/N:58309-73100 Water pump - Remove 10-13...

  • Page 278: Cooling System - Disassemble, Inspect And Assemble

    Chapter 10 COOLING SYSTEM 2. Cooling system - Disassemble, inspect and assemble 2.1 Tension pulley - Disassemble and inspect PTAW spec MPTK spec Wear Wear, flaw Rotation Tension Pulley - Disassemble and Inspect Disassembling Sequence 1 Tension bracket 4 Snap ring 6 Spacer 2 Snap ring 5 Bearing...
  • Page 279 Chapter 10 COOLING SYSTEM S16R2 PTAW spec Wear Wear, flaw Rotation Tension Pulley - Disassemble and Inspect(S16R2 PTAW spec) Disassembling Sequence 1 Tension bracket 4 Snap ring 6 Spacer 2 Snap ring 5 Bearing 7 Bearing 3 Tension pulley 2.1.1 Tension Pulley - Inspect Measure the bearing fit in tension pulley and on shaft.

  • Page 280: Thermostat - Disassemble And Inspect

    Chapter 10 COOLING SYSTEM 2.2 Thermostat - Disassemble and inspect Deformation, deterioration, wear, crack Replace Wear, crack Thermostat - Disassemble and inspect Disassembling sequence 1 Thermostat cover 3 Thermostat 5 Thermostat case 2 Snap ring 4 Thermostat seal 10-16...
  • Page 281 Chapter 10 COOLING SYSTEM Air cooler thermostat spec Replace Deformation, deterioration, wear, crack Wear, crack Replace Thermostat - Disassemble and inspect Disassembling sequence 1 Thermostat cover 4 Thermostat seal 6 Jiggle valve 2 Snap ring 5 Thermostat cover 7 Thermostat case 3 Thermostat 10-17...

  • Page 282: Thermostat For Jacket Water And Air Cooler - Inspect

    Chapter 10 COOLING SYSTEM 2.3 Thermostat for jacket water and air cooler - Inspect 2.3.1 Thermostat seal - Inspect Thermostat seal (1) Inspect the oil thermostat seal for deterioration and cracks. If defects are found, replace the seal with a new one.

  • Page 283: Water Pump - Disassemble And Inspect

    Chapter 10 COOLING SYSTEM 2.4 Water pump - Disassemble and inspect Rotation Replace Peeling, wear Replace Rotation Replace Corrosion, flaw Replace Replace Corrosion, crack, flaw Replace Water pump - Disassemble and inspect Disassembling sequence 1 Snap ring 7 O-ring 13 Unit seal 2 Cover 8 Water pump gear 14 Oil seal...
  • Page 284 Chapter 10 COOLING SYSTEM 2.4.1 Water pump mounted on engine - Inspect Visually check the drain port at the bottom center of water pump case with a finger. If water is oozing out, the unit seal is defective, and if oil is oozing out, the oil seal is defective. Water pump mounted on engine - Inspect 2.4.2 Impeller - Remove Water pump pliers...

  • Page 285: Water Pump - Inspect

    Chapter 10 COOLING SYSTEM 2.4.3 Water pump shaft - Remove (1) Remove the oil seal sleeve. Gear puller (2) Remove the gear and ball bearing together with a gear puller. (3) Remove the ball bearing snap ring on the water pump impeller side.

  • Page 286: Water Pump - Assemble

    Chapter 10 COOLING SYSTEM 2.6 Water pump - Assemble Replace Front plate Bearing case Oil seal 392 ± 19.6 N·m {40 ± 2.0 kgf·m} [289 ± 14.5 lbf·ft] Replace Install so that its chamfered side is on the pulley side. Replace Apply LLC to floating seat outer peripheral Application of LLC...
  • Page 287 Chapter 10 COOLING SYSTEM 2.6.1 Oil seal - Install (1) Tap-in the oil seal with the installer making sure that oil seal surface is flush with the water pump housing face. (2) Apply engine oil to the oil seal lip. Application of engine oil Oil seal - Install 2.6.2 Unit seal (stationary side) - Install...
  • Page 288 Chapter 10 COOLING SYSTEM 2.6.5 Pulley side ball bearing - Install (1) Set the gear to the shaft with the key. (2) Press-in the ball bearing on the pulley nut side with a press. Press-fit Pulley side ball bearing - Install 2.6.6 Water pump impeller - Press-in Flush Press-in the water pump impeller with a press.

  • Page 289: Air Cooler Water Pump - Disassemble And Inspect

    Chapter 10 COOLING SYSTEM 2.7 Air cooler water pump - Disassemble and inspect PTAW spec P/N: 37753-00013 37753-00031 Replace Corrosion, flaw Replace Rotation Corrosion, crack, flaw Wear, flaw S16R2 PTAW spec Air cooler Water pump - Disassemble and Inspect Disassembling sequence 1 Water pump pulley 4 Cover 7 Ball bearing...
  • Page 290 Chapter 10 COOLING SYSTEM 2.7.1 Water pump mounted on engine - Inspect Touch the drain port at the bottom center of water pump case with a finger. If water or oil is oozing out, the unit seal is defective. Water pump mounted on engine - Inspect 2.7.2 Water pump pulley - Remove Install the pulley puller to the holes on the water pump pul- ley, and remove the water pump pulley.
  • Page 291 Chapter 10 COOLING SYSTEM 2.7.4 Water pump shaft - Remove Remove the shaft and ball bearings by pushing the end face of water pump shaft on the impeller side. Water pump shaft Ball bearing Water pump shaft - Remove 10-27...
  • Page 292 Chapter 10 COOLING SYSTEM MPTK spec P/N: 45353-94600 Lip face wear, deformation, deterioration Rotation Spline wear Rotation Replace Wear, deformation, deterioration Deformation, deterioration, crack, flaw Replace Wear, flaw Seawater pump for air cooler - Disassemble and inspect Disassembling sequence 1 Cover 6 Slinger 11 Bearing 2 Water pump impeller...

  • Page 293: Air Cooler Water Pump - Inspect

    Chapter 10 COOLING SYSTEM 2.8 Air cooler water pump - Inspect (PTAW spec) Measure the bearing fit diameters of the water pump bearing housing and the shaft, and the inside and outside diameters of bearing. If any of the measurements is out of the standard, replace the part with a new one. Item Nominal Standard...

  • Page 294: Air Cooler Water Pump- Assemble

    Chapter 10 COOLING SYSTEM 2.9 Air cooler water pump- Assemble PTAW spec P/N: 37753-00013 Replace 37753-00031 Pack 47g (1.66 oz) WPH grease (Kyodo Yushi Co., Ltd). Install so that its chamfered Flush side is on the pulley side. Fill the bearing rolling contact surface with WPH grease (Kyodo Yushi Co., Ltd).
  • Page 295 Chapter 10 COOLING SYSTEM 2.9.1 Unit seal (stationary side) - Install (1) Apply sealant (ThreeBond 1102) to the outer circum- Unit seal installer ference of the unit seal (stationary side). (2) Press-in the unit seal into the water pump case with the unit seal installer.
  • Page 296 Chapter 10 COOLING SYSTEM 2.9.5 Water pump pulley - Install Press-fit Press-in the Water pump pulley to the water pump shaft. Flush Pulley Shaft Water pump pulley - Install 10-32...
  • Page 297 Chapter 10 COOLING SYSTEM MPTK spec P/N:45353-94600 24 ± 2.4 N·m Application of ThreeBond 1102 {2.45 ± 0.24 kgf·m} [17.7 ± 1.77 lbf·ft] Application of ThreeBond 1102 510 ± 51 N·m {52.01 ± 5.2 kgf·m} [376 ± 37.6 lbf·ft] 12 ± 1.2 N·m 24 ±...
  • Page 298 Chapter 10 COOLING SYSTEM 2.9.6 Oil seal - Install (1) Tap-in the oil seal with the installer making sure that oil seal surface is flush with the water pump housing face. Installer (2) Apply grease to the oil seal groove and lips. Application of grease Oil seal Oil seal - Install...
  • Page 299 Chapter 10 COOLING SYSTEM 2.9.9 Water pump shaft - Install Water pump shaft (1) Press-in the ball bearing to the water pump shaft with the installer. Snap ring (2) Press-in the ball bearing and water pump shaft to the holder with the installer. (3) Fit the snap ring to the holder.
  • Page 300 Chapter 10 COOLING SYSTEM 2.9.13 Impeller - Install Tap- in the impeller to the shaft. Blade tip Impeller Note: Place the impeller to bend its impellers in following di- rection to the water pump rotation. Rotation direction Impeller - Install 2.9.14 Cover - Install 12 ±...

  • Page 301: Fan Drive Assembly - Disassemble And Inspect

    Chapter 10 COOLING SYSTEM 2.10 Fan drive assembly - Disassemble and inspect Crack, breakage, bend Crack, flaw, deformation, deterioration Crack, flaw, deformation, deterioration Flaw, wear, deformation Replace Crack, flaw, deformation, deterioration Replace Wear Fan drive assembly - Disassemble and inspect Disassembling sequence 1 Fan plate 7 Fan hub...

  • Page 302: Fan Drive - Inspect

    Chapter 10 COOLING SYSTEM 2.11 Fan drive - Inspect Inspect the fit between the fan drive shaft and fan drive case bearing, and if significant wear is observed, replace them with new ones. Item Nominal Standard ø120 mm [4.72 in.] 119.987 to 120.022 mm [4.7239 to 4.7253 in.] Inside diameter of case bearing housing ø140 mm [5.51 in.]...

  • Page 303: Fan Drive - Assemble

    Chapter 10 COOLING SYSTEM 2.15 Fan drive - Assemble Application of engine oil to oil seal lip portion. Be flush with the case face. 60 ± 3.0 N･m {6.1 ± 0.3 kgf･m} 108 ± 10.8 N･m [44 ± 2.2 lbf·ft] {11 ±...
  • Page 304 Chapter 10 COOLING SYSTEM 2.15.1 Fan drive gear case - Assemble Fan side Gear side (1) Press-in the bearing to the drive shaft with the bearing (Oil seal sleeve side) installer. Ball bearing - Install (2) Install the oil seal to the fan drive case with the Fan drive case installer.
  • Page 305 Chapter 10 COOLING SYSTEM 2.15.2 Fan - Assemble The installation of fan is performed in the final stage of Friction rubber Grommet assembling work. Fan hub Spacer (1) Install the fan hub to the coupling, and tighten the bolts 108 ± 5.4 N·m {11 ±...

  • Page 306: Cooling System - Install

    Chapter 10 COOLING SYSTEM 3. Cooling system - Install ŒInstall the parts in the reverse order of the disassemble sequence. (Refer to the illustration for disassembling). ŒClean and dry well the cooling water passage. 3.1 Water pipe (air cooler) - Install Apply silicone sealant to the both sides of packings between the air cooler in/out connectors and water pipes.
  • Page 307 Chapter 11 INLET AND EXHAUST SYSTEMS Inlet and exhaust systems - Remove and inspect..........11-3 Air duct - Remove and inspect....................11-3 Insulator - Remove and inspect ....................11-9 Exhaust pipe - Remove and inspect ..................11-15 Exhaust manifold - Remove and inspect ................11-18 Inlet and exhaust systems - Disassemble, inspect and assemble ....

  • Page 309: Inlet And Exhaust Systems - Remove And Inspect

    Chapter 11 INLET AND EXHAUST SYSTEMS Chapter 11 INLET AND EXHAUST SYSTEMS 1. Inlet and exhaust systems - Remove and inspect 1.1 Air duct - Remove and inspect Fresh water air cooler spec Crack, flaw, deformation Replace Crack, flaw, deformation Replace Turbocharger Turbocharger...
  • Page 310 Chapter 11 INLET AND EXHAUST SYSTEMS Seawater air cooler spec Replace Crack, flaw, deformation Turbocharger Crack, flaw, deformation Replace Crack, flaw, deformation Replace Turbocharger Replace Turbocharger Crack, flaw, deformation Replace Replace Replace Crack, flaw, deformation Turbocharger Replace Replace Air duct - Remove and inspect Removing sequence 1 Upper air duct 4 Rubber hose...
  • Page 311 Chapter 11 INLET AND EXHAUST SYSTEMS Raised spec Replace Crack, flaw, deformation Crack, flaw, deformation Replace Turbocharger Turbocharger Replace Replace Crack, flaw, deformation Replace Crack, flaw Turbocharger Crack, flaw, deformation Turbocharger Replace Crack, flaw, deformation Crack, flaw, deformation Replace Replace Air cooler Replace Replace...
  • Page 312 Chapter 11 INLET AND EXHAUST SYSTEMS 2 Turbo spec Crack, flaw, deformation Replace Turbocharger Replace Replace Crack, flaw Turbocharger Crack, flaw, deformation Replace Crack, flaw, deformation Air cooler Replace Replace Crack, flaw, deformation Replace Air cooler Air duct - Remove and inspect Removing sequence 1 Air duct 4 Rubber hose...
  • Page 313 Chapter 11 INLET AND EXHAUST SYSTEMS TAA spec Crack, flaw, deformation Replace (Between radiator and turbocharger) Crack, flaw, deformation Replace Turbocharger Crack, flaw, deformation Crack, flaw Turbocharger Crack, flaw, deformation Replace Crack, flaw, deformation Turbocharger Replace Crack, flaw Turbocharger Crack, flaw, deformation Crack, flaw, deformation Replace Replace...
  • Page 314 Chapter 11 INLET AND EXHAUST SYSTEMS TAA spec (Between air cooler and crankcase) Crack, flaw, deformation Crack, flaw Replace Crack, flaw, deformation Crack, flaw Crack, flaw Replace Crack, flaw, deformation Crack, flaw Crack, flaw Crack, flaw, deformation Crack, flaw, deformation Replace Replace Crack, flaw, deformation...

  • Page 315: Insulator - Remove And Inspect

    Chapter 11 INLET AND EXHAUST SYSTEMS 1.2 Insulator - Remove and inspect Exhaust pipe 60 mm [2.36 in.] /4 turbo spec Check for any deformation or flaw. Insulator - Remove and inspect Removing sequence 1 Insulator cover 5 Rear turbo insulator 2 Outer insulator 6 Front turbo insulator 3 Inner insulator...
  • Page 316 Chapter 11 INLET AND EXHAUST SYSTEMS Exhaust pipe 60 mm [2.36 in.] /2 turbo spec Check for any deformation or flaw. Insulator - Remove and inspect Removing sequence 1 Insulator cover 5 Rear turbo insulator 2 Outer insulator 6 Front turbo insulator 3 Inner insulator 7 Stay 4 Insulator...
  • Page 317 Chapter 11 INLET AND EXHAUST SYSTEMS Exhaust pipe 80 mm [3.15 in.] spec Check for any deformation or flaw. Insulator - Remove and inspect Removing sequence 1 Insulator cover 5 Rear turbo insulator 2 Outer insulator 6 Front turbo insulator 3 Inner insulator 7 Stay 4 Insulator...
  • Page 318 Chapter 11 INLET AND EXHAUST SYSTEMS Exhaust pipe 120 mm [4.72 in.] spec Check for any deformation or flaw. Insulator - Remove and inspect Removing sequence 1 Insulator cover 6 Rear turbo insulator 2 Upper insulator 7 Front turbo insulator 3 Middle insulator 8 Stay 4 Lower insulator...
  • Page 319 Chapter 11 INLET AND EXHAUST SYSTEMS Exhaust pipe 150 mm [5.90 in.] spec Check for any deformation or flaw. Insulator - Remove and inspect Removing sequence 1 Insulator cover 6 Rear turbo insulator 2 Upper insulator 7 Front turbo insulator 3 Middle insulator 8 Stay 4 Lower insulator...
  • Page 320 Chapter 11 INLET AND EXHAUST SYSTEMS Exhaust pipe 150 mm [5.90 in.] /TAA spec Check for any deformation or flaw. Insulator - Remove and inspect Removing sequence 1 Insulator cover 5 Rear turbo insulator 2 Outer insulator 6 Front turbo insulator 3 Inner insulator 7 Stay 4 Insulator...

  • Page 321: Exhaust Pipe - Remove And Inspect

    Chapter 11 INLET AND EXHAUST SYSTEMS 1.3 Exhaust pipe - Remove and inspect Exhaust pipe 60, 80, 120 mm [2.36, 3.15, 4.72 in.] spec Pre-cleaner spec Crack, flaw, deformation Replace Replace Crack, flaw, Replace deformation Crack, flaw, deformation Crack, flaw, deformation Replace Replace Replace...
  • Page 322 Chapter 11 INLET AND EXHAUST SYSTEMS Exhaust pipe 60 mm [2.36 in.] /2 turbo spec Pre-cleaner spec Crack, flaw, deformation Replace Crack, flaw, deformation Crack, flaw, deformation Replace Pre-cleaner spec Exhaust pipe - Remove and inspect Removing sequence 1 Silencer assembly 4 Turbocharger 7 Exhaust pipe (approx.
  • Page 323 Chapter 11 INLET AND EXHAUST SYSTEMS Exhaust pipe 150 mm [5.90 in.] spec Pre-cleaner spec Crack, flaw, deformation Replace Replace Crack, flaw, deformation Replace Replace Replace Crack, flaw, deformation Replace Replace Crack, flaw, deformation Replace Crack, flaw, deformation Replace Replace Replace Crack, flaw, deformation...

  • Page 324: Exhaust Manifold - Remove And Inspect

    Chapter 11 INLET AND EXHAUST SYSTEMS 1.4 Exhaust manifold - Remove and inspect Exhaust pipe 60 mm [2.36 in.] spec Crack, flaw, deformation Crack, flaw, deformation Replace: Gasket Exhaust manifold - Remove and inspect Removing sequence 1 Coupling 3 Exhaust manifold 2 Flexible joint 11-18...
  • Page 325 Chapter 11 INLET AND EXHAUST SYSTEMS Exhaust pipe 60 mm [2.36 in.] /2 turbo spec Crack, flaw, deformation Replace: Gasket Exhaust manifold - Remove and inspect Removing sequence 1 Coupling 2 Flexible joint 3 Exhaust manifold 11-19...
  • Page 326 Chapter 11 INLET AND EXHAUST SYSTEMS Exhaust pipe 80 mm [3.15 in.] spec Replace: Gasket Crack, flaw, deformation S16R2 Note: Flexible joints for S16R2 (4 places) are made of different material. Ensure the original locations to assemble. Exhaust manifold - Remove and inspect Removing sequence 1 V clamp 2 Flexible joint...
  • Page 327 Chapter 11 INLET AND EXHAUST SYSTEMS Exhaust pipe 120, 150 mm [4.72, 5.90 in.] spec Crack, flaw, deformation Crack, flaw, deformation Replace Crack, flaw, deformation Crack, flaw, deformation Replace: Gasket Exhaust manifold - Remove and inspect Removing sequence 1 V clamp 2 Flexible joint 3 Exhaust manifold 11-21...

  • Page 328: Inlet And Exhaust Systems - Disassemble, Inspect And Assemble

    Chapter 11 INLET AND EXHAUST SYSTEMS 2. Inlet and exhaust systems - Disassemble, inspect and assemble 2.1 Air cooler - Disassemble, inspect and assemble Fresh water air cooler spec Replace Replace Tighten with stay (8pls) Replace (S16R2 only) Replace Apply Chemi-Seal S-283-B or equivalent to the gasket Replace Apply Chemi-Seal S-283-B...
  • Page 329 Chapter 11 INLET AND EXHAUST SYSTEMS 10×1.25 Seawater, fresh water two-stage air cooler spec 60 N·m {6.1 kgf·m} [44 lbf·ft] Replace The gap between the element Fresh water and plate must be sealed with two-stage air cooler spec KE45-W (Shin-Etsu Chemical Co.) or equivalent silicon sealant.

  • Page 330: Pre-Cleaner - Clean

    Chapter 11 INLET AND EXHAUST SYSTEMS 2.1.1 Air cooler - Inspect The air cooler differs in material and structure depend- ing on the application (fresh water or seawater). Pay attention to the difference when handling the air cooler. This cooler is for fresh water. 2.1.2 Air cooler - Clean Blow compressed air (at a pressure of 0.29 to 0.49 MPa {3 Intake side...

  • Page 331: Inlet And Exhaust Systems - Install

    Chapter 11 INLET AND EXHAUST SYSTEMS 3. Inlet and exhaust systems - Install ŒInstall the parts in the reverse order of the disassemble sequence. (Refer to the illustration for disassembling.) ŒThoroughly clean and dry the inlet and exhaust passages. 3.1 Inlet cover and exhaust manifold - Install 3.1.1 Exhaust manifold coupling - Tighten Do not distort the exhaust manifold coupling.
  • Page 333 Chapter 12 AIR START SYSTEM Air start system - Remove ..................12-3 Magnetic valve - Remove ....................... 12-3 Air pipe, starter valve and distributer valve - Remove ............12-4 Air starter - Remove........................ 12-5 Air start system - Disassemble, inspect and assemble ........12-6 Magnetic valve - Disassemble and inspect................

  • Page 335: Air Start System - Remove

    Chapter 12 AIR START SYSTEM Chapter 12 AIR START SYSTEM 1. Air start system - Remove 1.1 Magnetic valve - Remove Air direct starting spec Cylinder head Replace Replace Distributor valve Front Replace Magnetic valve - Remove Removing sequence 1 Air pipe 6 Flexible pipe 2 Air pipe 7 Elbow...

  • Page 336: Air Pipe, Starter Valve And Distributer Valve - Remove

    Chapter 12 AIR START SYSTEM 1.2 Air pipe, starter valve and distributer valve - Remove Air direct starting spec Front Replace: Gasket O-ring Air pipe, starter valve and distributer valve - Remove Removing sequence 1 No.1 to 8 pilot air pipes 3 Distributer valve 2 Main air pipe 4 Starter valve...

  • Page 337: Air Starter - Remove

    Chapter 12 AIR START SYSTEM 1.3 Air starter - Remove Air starter motor starting spec Timing gear case Air starter - Remove Removing sequence 1 Clamp 4 Clamp 2 Auto-muffler 5 Air box (approx 60 kg [132 lb]) 3 Elbow 12-5...

  • Page 338: Air Start System - Disassemble, Inspect And Assemble

    Chapter 12 AIR START SYSTEM 2. Air start system - Disassemble, inspect and assemble 2.1 Magnetic valve - Disassemble and inspect Air direct starting or air starter motor starting spec Disconnection Settling, crack Replace Replace Replace Settling, crack Replace Replace Magnetic valve - Disassemble and inspect Disassembling sequence 1 Magnetic valve...

  • Page 339: Magnetic Valve - Assemble

    Chapter 12 AIR START SYSTEM 2.2 Magnetic valve - Assemble Air direct starting or air starter motor starting spec Magnetic valve - Assemble 12-7...

  • Page 340: Starter Valve - Disassemble And Inspect

    Chapter 12 AIR START SYSTEM 2.3 Starter valve - Disassemble and inspect Air direct starting spec Seat face defect, wear Replace: Gasket, -ring Wear Replace Settling, crack Replace: Gasket Starter valve - Disassemble and inspect Disassembling sequence 1 Eye bolt 5 Nut 2 Cap nut 6 Retainer...

  • Page 341: Starter Valve - Inspect

    Chapter 12 AIR START SYSTEM 2.4 Starter valve - Inspect 2.4.1 Clearance between starter valve and starter valve guide - Measure Measure the clearance between the starter valve and valve guide. If the value exceeds the limit, replace the starter valve or starter valve guide a new one.

  • Page 342: Starter Valve - Assemble

    Chapter 12 AIR START SYSTEM 2.5 Starter valve - Assemble Air direct starting spec Application of engine oil to valve sliding portion 117.6 ± 5.88 N·m {12 ± 0.6 kgf·m} [86.7 ± 4.34 lbf·ft] 19 ± 0.95 N·m {1.94 ± 0.09 kgf·fm} Lapping: [14 ±...

  • Page 343: Distributer Valve - Disassemble And Inspect

    Chapter 12 AIR START SYSTEM 2.6 Distributer valve - Disassemble and inspect Air direct starting spec Replace Settling Wear Replace Crack, wear Crack, wear Distributer valve - Disassemble and inspect Removing sequence 1 Case cover 5 Distributer valve 2 Distributer spacer 6 Bushing 3 Distributer valve, lock pin, E-ring 7 Distributer case...

  • Page 344: Distributer Valve - Inspect

    Chapter 12 AIR START SYSTEM 2.7 Distributer valve - Inspect 2.7.1 Distributer valve height - Measure Measure the distributer valve height. If the value exceeds the limit, replace the valve with a new one. Item Standard Limit 21.85 to 21.95 mm 21.75 mm Distributer valve height [0.8602 to 0.8642 in.]...

  • Page 345: Distributer Valve - Assemble

    Chapter 12 AIR START SYSTEM 2.8 Distributer valve - Assemble Air direct starting spec Rotation direction Match mark Application of oil No. 1 cylinder top (No. 8) Fitting 3° Air inflow 132° Overlap 45° 45° 42° No. 6 cylinder top 90°...

  • Page 346: Air Start System - Install

    Chapter 12 AIR START SYSTEM 3. Air start system - Install Install the parts in the reverse order of the disassemble sequence. (Refer to the illustration for disassembling.) 12-14...
  • Page 347 Chapter 13 ADJUSTMENT AND OPERATION Engine - Adjust ...................... 13-3 Turning gear - Use........................13-3 Valve bridge and adjusting screw - Check................13-4 Valve clearance - Check......................13-4 Fuel injection timing - Check....................13-4 Fuel system - Bleed air ......................13-4 Belt and belt tension - Inspect and adjust................

  • Page 349: Engine - Adjust

    Chapter 13 ADJUSTMENT AND OPERATION Chapter 13 ADJUSTMENT AND OPERATION 1. Engine - Adjust 1.1 Turning gear - Use Before starting the engine, ensure the turning gear in the operation position. If the engine is started while the turning gear is engaged (pushed-in position), it will result in the personal injury as well as damage to the ring gear. (1) Loosen two bolts, and remove the plate from the slot of the shaft.

  • Page 350: Valve Bridge And Adjusting Screw - Check

    Chapter 13 ADJUSTMENT AND OPERATION 1.2 Valve bridge and adjusting screw - Check Check the adjustment of the valve bridge and adjusting screw. If it is not adjusted, adjust it to the standard value. For the adjusting procedure, refer to "Valve bridge and adjusting screw - Adjust"...
  • Page 351 Chapter 13 ADJUSTMENT AND OPERATION 1.5.2 Fuel injection pump - Bleed air (1) Loosen the air vent plugs of the fuel injection pump by approx 1.5 turns. (2) Feed fuel by moving the priming pump up and down. Air vent plug (3) When fuel flowing from the vent holes no longer con- 15 ±...

  • Page 352: Belt And Belt Tension - Inspect And Adjust

    Chapter 13 ADJUSTMENT AND OPERATION 1.6 Belt and belt tension - Inspect and adjust If any defects such as cuts or surface separations are found during inspection, replace the belt with a new one. Keep oil and grease off the belt. Oil or grease on the belt causes the belt to slip and shorten the service life. Excessive belt tension can cause rapid wear of the alternator bearing and shorten the service life of the belt.
  • Page 353 Chapter 13 ADJUSTMENT AND OPERATION Ribbed belt tension (N) table Belt straight distance (mm) [in.] Num- Item ber of 300 [11.81] or more than 300 more than 400 more than 500 to 600 more than 600 ribs below [11.81] to 400 [15.75] [15.75] to 500 [19.69] [19.69 to 23.62] [23.62]...

  • Page 354: Break-In Operation

    Chapter 13 ADJUSTMENT AND OPERATION 2. Break-in operation 2.1 Preparation before engine starting ŒCheck the levels of fuel, engine oil, and coolant, and also bleed air from the fuel system and cooling system. ŒInspect the link between the governor output lever and the fuel injection pump rack. Check that the fuel control rack is at the no-injection position when the engine is stopped.
  • Page 355 Chapter 13 ADJUSTMENT AND OPERATION 2.3.2 Inspection while the engine is running During the break-in operation, pay attention to followings and make sure that there are no abnormalities. ŒOil pressure and oil temperature ŒExhaust temperature ŒCoolant temperature and level ŒDifferences between right and left banks ŒAny leakage of oil, water, fuel, or gas (air) ŒBlow-by gas (amount and color) ŒNoise and vibration...

  • Page 356: Engine-Test And Adjustment

    Chapter 13 ADJUSTMENT AND OPERATION 3. Engine-Test and adjustment (a) Engine test, adjustment and seal shall be performed at the certified maintenance shop only. When the seal of engine is performed at a service shop other than the certified shops, ask an certified shop for the presence of qualified person for test, adjustment and seal.

  • Page 357: Seal

    Chapter 13 ADJUSTMENT AND OPERATION 3.6 Seal After all performance tests and adjustments are completed, stop the engine, and seal the specified part between governor actua- tor and fuel injection pump rack. 3.6.1 Tamper proof - Remove Inner nut Tamper proof nut is composed of double structure, and can- not be removed by rotating.
  • Page 359 Engine inspection record sheet (SR series) No. 1 Cylinder liner bore inside diameter - measure No. 2 Cylinder liner flange protrusion - measure No. 3 Valve guide inside diameter and Vale stem diameter - measure No. 4 Cylinder head valve sinkage, seat width, and valve margin - measure No.
  • Page 360 170.000 to 170.040 [6.69] [6.6929 to 6.6945] 37507-55600 liner 170.100 inside [6.6968] 37507-22700 170.020 to 170.040 diameter [6.69] [6.6937 to 6.6945] 37807-05700 S6R2 S12R S16R S16R2 30[1.18] 30[1.18] 30[1.18] 30[1.18] 30[1.18] 100[3.94] 180[7.09] 100[3.94] 100[3.94] 185[7.28] 250[9.84] 250[9.84] 250[9.84] 250[9.84] 340[13.39]...
  • Page 361 Standard Item to be measured Standard 0.16 to 0.24 Cylinder S6R,S6R2 [0.0063 to 0.0094] liner flange S12R,S16R, 0.11 to 0.20 protrusion S16R2 [0.0043 to 0.0079] Measured value Item Cylinder liner bore flange protrusion Average value Approved by Checked by Measured by...
  • Page 362 No.3(1/3) INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Valve guide inside diameter and Valve stem diameter - Item Unit mm[in.] measure (1/3) Measuring location Standard Item to be measured Standard Limit Nominal 10.000 to 10.015 10.060 Valve guide inside diameter (same for inlet and exhaust) [0.39] [0.3937 to 0.3943]...
  • Page 363 No.3(2/3) INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Valve guide inside diameter and Valve stem diameter - Item Unit mm[in.] measure (2/3) Measuring location Standard Item to be measured Standard Limit Nominal 10.000 to 10.015 10.060 Valve guide inside diameter (same for inlet and exhaust) [0.39] [0.3937 to 0.3943]...
  • Page 364 No.3(3/3) INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Valve guide inside diameter and Valve stem diameter - Item Unit mm[in.] measure (3/3) Measuring location Standard Item to be measured Standard Limit Nominal 10.000 to 10.015 10.060 Valve guide inside diameter (same for inlet and exhaust) [0.39] [0.3937 to 0.3943]...
  • Page 365 No.4(1/2) INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Cylinder head valve sinkage, seat sidth, and valve margin - Item Unit mm[in.] measure (1/2) Measuring location Standard Item to be measured Standard Limit Valve seat angle -0.1 to 0.1 Valve sinkage [-0.039 to 0.039] [0.039]...
  • Page 366 No.4(2/2) INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Cylinder head valve sinkage, seat sidth, and valve margin - Item Unit mm[in.] measure (2/2) Measuring location Standard Item to be measured Standard Limit Valve seat angle -0.1 to 0.1 Valve sinkage [-0.039 to 0.039] [0.039]...
  • Page 367 No.5 INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Item Unit mm[in.] Cylinder head bottom face distortion - measure Measuring location Standard Item to be Standard Limit measured Distortion of 0.03[0.0012] 0.07 cylinder head or less [0.0028] bottom surface Measured value Cylinder head bottom face distortion Item...
  • Page 368 No. 6(1/2) INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Connecting rod bushing inside diameter and connecting rod Item Unit mm[in.] big-end bore diameter - measure (1/2) Measuring location Standard Item to be measured Nominal Standard Limit Roundness Connecting rod bushing 70.020 to 70.040 70.070[2.7587] inside diameter...
  • Page 369 No.6(2/2) INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Connecting rod bushing inside diameter and connecting rod Item Unit mm[in.] big-end bore diameter - measure (2/2) Measuring location Standard Item to be measured Nominal Standard Limit Roundness Connecting rod bushing 70.020 to 70.040 70.070[2.7587] inside diameter...
  • Page 370 No. 7(1/2 INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Rocker bushing inside diameter and rocker shaft outside Item Unit mm[in.] diameter - measure (1/2) Measuring location Standard Nominal Standard Limit Item to be measured Rocker bushing 36.000 to 36.040 36.090 inside diameter [1.42]...
  • Page 371 No.7(2/2) INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Rocker bushing inside diameter and rocker shaft outside Item Unit mm[in.] diameter - measure (2/2) Measuring location Standard Nominal Standard Limit Item to be measured Rocker bushing 36.000 to 36.040 36.090 inside diameter [1.42]...
  • Page 372 No. 8(1/2) INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Piston pin bore inside diameter and piston pin outside Item Unit mm[in.] diameter - measure (1/2) Measuring location Standard Nominal Standard Limit Item to be measured Piston pin bore 70.002 to 70.015 70.040 inside diameter...
  • Page 373 No.8(2/2) INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Piston pin bore inside diameter and piston pin outside Item Unit mm[in.] diameter - measure (2/2) Measuring location Standard Nominal Standard Limit Item to be measured Piston pin bore 70.002 to 70.015 70.040 inside diameter [2.76]...
  • Page 374 No. 9 INSPECTION RECORD SHEET Engine Model Customer Date Serial No. Item Unit mm[in.] Valve clearance - measure Measuring location Standard Item to be measured Standard Inlet 0.6[0.024] Valve clearance (A) Exhaust 0.8[0.031] Measured value Valve clearance Valve clearance Inlet Exhaust Inlet Exhaust...
  • Page 375 33.83 to 35.79 37560-32000 {345 to 365}[4907 to 5191] type {350}[4978] S12R Screw adjust 34.32 34.32 to 34.81 {350 to 355}[4978 to 5049] S16R,S16R2 type {350}[4978] Measured value Injection pressure Injection pressure Injection pressure Injection pressure Service hours Service hours...
  • Page 376 84.100 S6R,S6R2 84[3.31] [3.3079 to 3.3108] [3.3110] Camshaft bushing inside diameter S12R 84.000 to 84.035 84.100 84[3.31] S16R,S16R2 [3.3071 to 3.3085] [3.3110] 83.920 to 83.940 83.870 Camshaft journal bore outside diameter 84[3.31] [3.3039 to 3.3047] [3.3020] Measured value Item Clearance...
  • Page 377 84.100 S6R,S6R2 84[3.31] [3.3079 to 3.3108] [3.3110] Camshaft bushing inside diameter S12R 84.000 to 84.035 84.100 84[3.31] S16R,S16R2 [3.3071 to 3.3085] [3.3110] 83.920 to 83.940 83.870 Camshaft journal bore outside diameter 84[3.31] [3.3039 to 3.3047] [3.3020] Measured value Item Clearance...
  • Page 378 0.300 to 0.520 0.600 S6R,S6R2 [0.0118 to 0.0205] [0.0236] Crankshaft 0.200 to 0.400 0.500 S12R end play [0.0079 to 0.0157] [0.0197] 0.200 to 0.500 S16R,S16R2 [0.0079 to 0.0197] Measured value Before disassembly After reassembly Approved by Checked by Measured by Remark...
  • Page 380 TP-6856 10/10...

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