Komatsu Mamual de Taller Serie SA12V140Z-1

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ShopManual

This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or dis-closed except in accordance with written authorization from Komatsu America International Company.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to makechanges or add improvements at any time without incurring any obligation to install such changes on products soldpreviously.

Due to this continuous program of research and development, periodic revisions may be made to this publication.It is recommended that customers contact their distributor for information on the latest revision.

Copyright 2000 KomatsuDataKom Publishing Corporation

SA12V140Z-1 SERIES

DIESEL ENGINE

August 2000

CEBM002602

FOREWORD CONTENTS

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CONTENTS

01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

11 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . .11-1

12 TESTING, ADJUSTING AND TROUBLESHOOTING. . . . . . . 12-1

13 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . 13-1

14 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

15 REPAIR AND REPLACEMENT OF PARTS . . . . . . . . . . . . . . 15-1

pubinfok.fm 10/12/99

PRODUCT PUBLICATIONS INFORMATIONVarious product Parts and Service Publications are available to all KOMATSU construction equipment owners, including operation and maintenance manuals, parts books and service manuals.

Special publications, such as service tool, air conditioning and turbocharger service manuals are also available as well as selected Operation and Service manuals in foreign languages.

The Publications listed below are available for this particular machine(s).

DESCRIPTION FORM NUMBER

PARTS BOOK - PAPER:Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application

PARTS BOOK - MICROFICHE:Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application

OPERATION AND MAINTENANCE MANUAL:Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application

SHOP MANUALChassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific ApplicationEngine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM002602

SAFETY MANUAL

Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the Komatsu America International Company Parts Inventory Processing System (PIPS).

If the PIPS system is not available at the distributor location, then the following Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown on the reverse side of this page.

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REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS

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IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINESERIAL NUMBER MUST BE SHOWN.

QTY. PUBLICATION FORM NO. P-Paper MODEL NUMBER SERIAL NUMBER PARTS BOOK

M-Microfiche

PUBLICATIONDESCRIPTION

KDC91E 072199 CURRENT PRICES WILL BE CHARGED

FOREWORD

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FOREWORD

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FOREWORD

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FOREWORD SAFETY

SAFETYSAFETY NOTICE

GENERAL PRECAUTIONS

Mistakes in operation are extremely dangerous. Readthe OPERATION & MAINTENANCE MANUAL carefullyBEFORE operating the machine.

1. Before carrying out any greasing or repairs, readall the precautions given on the decals which arefixed to the machine.

2. When carrying out any operation, always wearsafety shoes and helmet. Do not wear loose workclothes, or clothes with buttons missing.

• Always wear safety glasses when hitting parts witha hammer.

• Always wear safety glasses when grinding partswith a grinder, etc.

3. If welding repairs are needed, always have atrained, experienced welder carry out the work.When carrying out welding work, always wearwelding gloves, apron, glasses, cap and otherclothes suited for welding work.

4. When carrying out any operation with two or moreworkers, always agree on the operating procedurebefore starting. Always inform your fellow workersbefore starting any step of the operation. Beforestarting work, hang UNDER REPAIR signs on thecontrols in the operator's compartment.

5. Keep all tools in good condition and learn the cor-rect way to use them.

6. Decide a place in the repair workshop to keep toolsand removed parts. Always keep the tools andparts in their correct places. Always keep the workarea clean and make sure that there is no dirt or oilon the floor. Smoke only in the areas provided forsmoking. Never smoke while working.

PREPARATIONS FOR WORK

7. Before adding oil or making repairs, park themachine on hard, level ground, and block thewheels or tracks to prevent the machine from mov-ing.

8. Before starting work, lower blade, ripper, bucket orany other work equipment to the ground. If this isnot possible, insert the safety pin or use blocks toprevent the work equipment from falling. In addi-tion, be sure to lock all the control levers and hangwarning signs on them.

9. When disassembling or assembling, support themachine with blocks, jacks or stands before start-ing work.

10. Remove all mud and oil from the steps or otherplaces used to get on and off the machine. Alwaysuse the handrails, ladders or steps when getting onor off the machine. Never jump on or off themachine. If it is impossible to use the handrails,ladders or steps, use a stand to provide safe foot-ing.

PRECAUTIONS DURING WORK

11. When removing the oil filler cap, drain plug orhydraulic pressure measuring plugs, loosen themslowly to prevent the oil from spurting out. Beforedisconnecting or removing components of the oil,water or air circuits, first remove the pressure com-pletely from the circuit.

12. The water and oil in the circuits are hot when theengine is stopped, so be careful not to get burned.Wait for the oil and water to cool before carryingout any work on the oil or water circuits.

13. Before starting work, remove the leads from thebattery. ALWAYS remove the lead from the nega-tive (-) terminal first.

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for the safe operation of your machine. The service and repairtechniques recommended and described in this manual are both effective and safe methods of operation. Someof these operations require the use of tools specially designed for the purpose.

To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cau-tions accompanying these symbols should always be followed carefully. If any dangerous situation arises or maypossibly arise, first consider safety, and take the necessary actions to deal with the situation.

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FOREWORD SAFETY

14. When raising heavy components, use a hoist orcrane. Check that the wire rope, chains and hooksare free from damage. Always use lifting equip-ment which has ample capacity. Install the liftingequipment at the correct places. Use a hoist orcrane and operate slowly to prevent the compo-nent from hitting any other part. Do not work withany part still raised by the hoist or crane.

15. When removing covers which are under internalpressure or under pressure from a spring, alwaysleave two bolts in position on opposite sides.Slowly release the pressure, then slowly loosen thebolts to remove.

16. When removing components, be careful not tobreak or damage the wiring, Damaged wiring maycause electrical fires.

17. When removing piping, stop the fuel or oil fromspilling out. If any fuel or oil drips on to the floor,wipe it up immediately. Fuel or oil on the floor cancause you to slip, or can even start fires.

18. As a general rule, do not use gasoline to washparts. In particular, use only the minimum of gaso-line when washing electrical parts.

19. Be sure to assemble all parts again in their originalplaces. Replace any damaged part with new parts.

• When installing hoses and wires, be sure that theywill not be damaged by contact with other partswhen the machine is being operated.

20. When installing high pressure hoses, make surethat they are not twisted. Damaged tubes are dan-gerous, so be extremely careful when installingtubes for high pressure circuits. Also check thatconnecting parts are correctly installed.

21. When assembling or installing parts, always usethe specified tightening torques. When installingprotective parts such as guards, or parts whichvibrate violently or rotate at high speed, be particu-larly careful to check that they are installed cor-rectly.

22. When aligning two holes, never insert your fingersor hand. Be careful not to get your fingers caught ina hole.

23. When measuring hydraulic pressure, check thatthe measuring tool is correctly assembled beforetaking any measurements.

24. Take care when removing or installing the tracks oftrack-type machines. When removing the track, thetrack separates suddenly, so never let anyonestand at either end of the track.

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FOREWORD GENERAL

GENERAL

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accu-rate understanding of the product and by showing him the correct way to perform repairs and make judgements.Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service work-shop. For ease of understanding, the manual is divided into the following sections. These sections are furtherdivided into each main group of components.

GENERAL

This section lists the general machine dimensions, performance specifications, component weights, andfuel, coolant and lubricant specification charts.

STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-standing of the structure, but also serves as reference material for troubleshooting.

TESTING, ADJUSTING AND TROUBLESHOOTING

This section explains checks to be made before and after performing repairs, as well as adjustments to bemade at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are alsoincluded in this section.

DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or assemblingeach component, as well as precautions to be taken for these operations.

MAINTENANCE STANDARD

This section gives the judgement standards when inspecting disassembled parts.

NOTICE

The specifications contained in this shop manual are subject to change at any time and without any advancenotice. Contact your distributor for the latest information.

00-5 1

FOREWORD HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

VOLUMESShop manuals are issued as a guide to carrying outrepairs. They are divided as follows:

Chassis volume: Issued for every machinemodel

Engine volume: Issued for each engine series

Electrical volume: Each issued as one to coverall models

Attachment volume: Each issued as one to coverall models

These various volumes are designed to avoid duplica-tion of information. Therefore to deal with all repairs forany model, it is necessary that chassis, engine, electri-cal and attachment be available.

DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will besent to your distributors. Get the most up-to-date infor-mation before you start any work.

FILING METHOD

1. See the page number on the bottom of the page.File the pages in correct order.

2. Following examples show how to read the pagenumber:Example:

10 - 3

Item number (10. Structure and Function)

Consecutive page number for each item

3. Additional pages: Additional pages are indicated bya hyphen (-) and numbered after the page number.File as in the example.Example:

10-410-4-1

Added pages10-4-210-5

REVISED EDITION MARK

When a manual is revised, an edition mark (123…) isrecorded on the bottom outside corner of the pages.

REVISIONS

Revised pages are shown at the LIST OF REVISEDPAGES between the title page and SAFETY page.

SYMBOLS

So that the shop manual can be of ample practical use,important places for safety and quality are marked withthe following symbols.

Symbol Item Remarks

SafetySpecial safety precautions are necessary when perform-ing the work.

� Caution

Special technical precau-tions or other precautions for preserving standards are necessary when performing the work.

Weight

Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc.

Tightening torque

Places that require special attention for tightening torque during assembly.

CoatPlaces to be coated with adhesives and lubricants etc.

Oil, waterPlaces where oil, water or fuel must be added, and the capacity.

DrainPlaces where oil or water must be drained, and quantity to be drained.

00-6 1

FOREWORD HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONSHOISTING

• If a part cannot be smoothly removed from themachine by hoisting, the following checks shouldbe made:

1. Check for removal of all bolts fastening the part tothe relative parts.

2. Check for existence of another part causing inter-face with the part to be removed.

WIRE ROPES1. Use adequate ropes depending on the weight of

parts to be hoisted, referring to the table below:

� The allowable load value is estimated to be 1/6 or1/7 of the breaking strength of the rope used.

2. Sling wire ropes from the middle portion of thehook.

Slinging near the edge of the hook may cause the ropeto slip off the hook during hoisting, and a serious acci-

dent can result. Hooks have maximum strength at themiddle portion.

3. Do not sling a heavy load with one rope alone, butsling with two or more ropes symmetrically woundon to the load.

Slinging with one rope may cause turning ofthe load during hoisting, untwisting of the rope,or slipping of the rope from its original windingposition on the load, which can result in a dan-gerous accident.

4. Do not sling a heavy load with ropes forming awide hanging angle from the hook. When hoisting aload with two or more ropes, the force subjected toeach rope will increase with the hanging angles.The table below shows the variation of allowableload (kg) when hoisting is made with two ropes,each of which is allowed to sling up to 1000 kg ver-tically, at various hanging angles. When two ropessling a load vertically, up to 2000 kg of total weightcan be suspended. This weight becomes 1000 kgwhen two ropes make a 120° hanging angle. Onthe other hand, two ropes are subject to an exces-sive force as large as 4000 kg if they sling a 2000kg load at a lifting angle of 150°.

Heavy parts (25 kg or more) must be liftedwith a hoist etc. In the DISASSEMBLY ANDASSEMBLY section, every part weighing 25kg or more is indicated clearly with the symbol

Wire ropes(Standard “Z” or “S” twist ropes without galvanizing)

Rope diameter Allowable load

mm kN tons

10 9.8 1.0

11.2 13.7 1.4

12.5 15.7 1.6

14 21.6 2.2

16 27.5 2.8

18 35.3 3.6

20 43.1 4.4

22.4 54.9 5.6

30 98.1 10.0

40 176.5 18.0

50 274.6 28.0

60 392.2 40.0

00-7 1

FOREWORD COATING MATERIALS

COATING MATERIALS� The recommended coating materials prescribed in the shop manuals are listed below.test

Category Code Part No. Quantity Container Main applications, features

Adh

esiv

es

LT-1A 790-129-9030 150 g Tube• Used to prevent rubber gaskets, rubber

cushions and cork plugs from comingout

LT-1B 790-129-905020 g

(2 pes.)Polyethylene

container

• Used in places requiring an immediatelyeffective, strong adhesive.

• Used for plastics (except polyethylene,polypropylene, tetrafluoroethylene, andvinyl chloride), rubber, metal and non-metal.

LT-2 09940-00030 50 gPolyethylene

container

• Features: Resistance to heat, chemi-cals

• Used for anti-loosening and sealantpurposes for bolts and plugs.

LT-3

790-129-9060(Set of adhe-sive and hard-ening agent)

Adhesive:1 kg

Hardening agent:500 g

Can• Used as adhesive or sealant for metal,

glass or plastic.

LT-4 790-129-9040 250 gPolyethylene

container• Used as sealant for machined holes.

HoltzMH 705

790-126-9120 75 g Tube• Used as heat-resisting sealant for

repairing engine.

Three bond 1735

179-129-9140 2 gPolyethylene

container

• Quick hardening type adhesive.• Cure time: within 5 sec. to 3 min.• Used mainly for adhesion of metals,

rubbers, plastics and woods.

Aron-alpha201

790-129-9130 50 gPolyethylene

container

• Quick hardening type adhesive.• Quick cure type (max. strength after 30

minutes).• Used mainly for adhesion of rubbers,

plastics and metals.

Loctite 648-50

79A-129-9110 50 ccPolyethylene

container

• Features: Resistance to heat, chemi-cals

• Used at joint portions subject to hightemperature.

Gasket sealant

LG-1 790-129-9010 200 g Tube• Used as adhesive or sealant for gas-

kets and packing of power train case,etc.

LG-3 790-129-9070 1 kg Can

• Features: Resistance to heat• Used as sealant for flange surfaces and

bolts at high temperature locations;used to prevent seizure.

• Used as sealant for heat resistant gas-ket for at high temperature locationssuch as engine pre-combustion cham-ber, exhaust pipe.

00-8 1

FOREWORD COATING MATERIALS

Gasket sealant

LG-4 790-129-9020 200 g Tube

• Features: Resistance to water, oil• Used as sealant for flange surface,

thread.• Also possible to use as sealant for

flanges with large clearance.• Used as sealant for mating surfaces of

final drive case, transmission case.

LG-5 790-129-9080 1 kgPolyethylene

container

• Used as sealant for various threads,pipe joints, flanges.

• Used as sealant for tapered plugs,elbows, nipples of hydraulic piping.

LG-6 09940-00011 250 g Tube

• Features: Silicon based, resistant toheat, cold.

• Used as sealant for flange surface,thread.

• Used as sealant for oil pan, final drivecase, etc.

LG-7 09920-00150 150 g Tube

• Features: Silicon based, quick harden-ing type.

• Used as sealant for flywheel housing,intake manifold, oil pan, thermostathousing, etc.

Three bond 1211

790-129-9090 100 g Tube• Used as heat-resisting sealant for

repairing engines.

Mo

lybd

enum

disu

lphi

de

lubr

ican

t

LM-G 09940-00051 60 g Can• Used as lubricant for sliding parts (to

prevent squeaking).

LM-P 09940-00040 200 g Tube

• Used to prevent seizure or scuffing ofthe thread when press fitting or shrinkfitting.

• Used as lubricant for linkage, bearings,etc.

Grease

G2-LI

SYG2-400LISYG2-350LI

SYG2-400LI-ASYG2-160LI

SYGA160CNLI

Various Various • General purpose type

G2-CA

SYG2-400CASYG2-350CA

SYG2-400CA-ASYG2-160CA

SYG2-160CNCA

Various Various• Used for normal temperature, light load

bearing at places in contact with wateror steam.

Mol

ybde

num

disu

lphi

de

lubr

ican

t

SYG2-400M400 g (10 per case)

Belows type • Used for places with heavy load.

Category Code Part No. Quantity Container Main applications, features

00-9 1

FOREWORD STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of DIS-ASSEMBLY AND ASSEMBLY.

Thread diameter of bolt Width across flats

mm mm Nm kgm

6 10 13.2 ±1.4 1.35 ±0.15

8 13 31.4 ±2.9 3.20 ±0.3

10 17 65.7 ±6.8 6.70 ±0.7

12 19 112 ±9.8 11.5 ±1.0

14 22 177 ±19 18 ±2.0

16 24 279 ±29 28.5 ±3

18 27 383 ±39 39 ±4

20 30 549 ±58 56 ±6

22 32 745 ±78 76 ±8

24 36 927 ±98 94.5 ±10

27 41 1320 ±140 135 ±15

30 46 1720 ±190 175 ±20

33 50 2210 ±240 225 ±25

36 55 2750 ±290 280 ±30

39 60 3280 ±340 335 ±35

Thread diameter of bolt Width across flats

mm mm Nm kgm

6 10 7.85 ± 1.95 0.8 ± 0.2

8 13 18.6 ± 4.9 1.9 ± 0.5

10 14 40.2 ± 5.9 4.1 ± 0.6

12 27 82.35 ± 7.85 8.4 ± 0.8

00-10 1

FOREWORD STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE OF HOSE NUTSUse these torques for hose nuts.

TIGHTENING TORQUE OF SPLIT FLANGE BOLTSUse these torques for split flange bolts.

TIGHTENING TORQUE FOR FLARED NUTS

Use these torques for flared part of nut.

Nominal No.Thread diameter Width across flat Tightening torque

mm mm Nm kgm

02 14 19 24.5 ± 4.9 2.5 ± 0.5

03 18 24 49 ± 19.6 5 ± 2

04 22 27 78.5 ± 19.6 8 ± 2

05 24 32 137.3 ± 29.4 14 ± 3

06 30 36 176.5 ± 29.4 18 ± 3

10 33 41 196.1 ± 49 20 ± 5

12 36 46 245.2 ± 49 25 ± 5

14 42 55 294.2 ± 49 30 ± 5

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

10 14 65.7 ± 6.8 6.7 ± 0.7

12 17 112 ± 9.8 11.5 ± 1

16 22 279 ± 29 28.5 ± 3

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

14 19 24.5 ±4.9 2.5 ±0.5

18 24 49 ±19.6 5 ±2

22 27 78.5 ±19.6 8 ±2

24 32 137.3 ±29.4 14 ±3

30 36 176.5 ±29.4 18 ±3

33 41 196.1 ±49 20 ±5

36 46 245.2 ±49 25 ±5

42 55 294.2 ±49 30 ±5

00-11 1

FOREWORD ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire codetable will help you understand WIRING DIAGRAMS.Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

CLASSIFICATION BY COLOR AND CODE

Nominal number

Copper wireCable O.D.

(mm)Current

rating (A)Applicable circuitNumber of

strandsDia. Of

strand (mm)Cross sec-tion (mm)

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

PriorityCircuits

Classi-fication

Charging Ground Starting Lighting Instrument Signal Other

1

Prim

ary Code W B B R Y G L

Color White Black Black Red Yellow Green Blue

2

Aux

iliar

y

Code WR — BW RW YR GW LW

ColorWhite &

Red—

Black & White

Red & White

Yellow & Red

Green & White

Blue & White

3

Code WB — BY RB YB GR LR

ColorWhite & Black

—Black & Yellow

Red & Black

Yellow & Black

Green & Red

Blue & Red

4

Code WL — BR RY YG GY LY

ColorWhite &

Blue—

Black & Red

Red & Yel-low

Yellow & Green

Green & Yellow

Blue & Yel-low

5

Code WG — — RG YL GB LB

ColorWhite & Green

— —Red & Green

Yellow & Blue

Green & Black

Blue & Black

6

Code — — — RL YW GL —

Color — — — Red & BlueYellow &

WhiteGreen &

Blue—

00-12 1

FOREWORD CONVERSION TABLES

CONVERSION TABLES

METHOD OF USING THE CONVERSION TABLEThe Conversion Table in this section is provided to enable simple conversion of figures. For details of the methodof using the Conversion Table, see the example given below.

EXAMPLE• Method of using the Conversion Table to convert from millimeters to inches.1. Convert 55 mm into inches.

(a) Locate the number 50 in the vertical column at the left side, take this as 1, then draw a horizontal line from1.

(b) Locate the number 5 in the row across the top, take this as 2, then draw a perpendicular line down from2.

(c) Take the point where the two lines cross as 3. This point 3 gives the value when converting from millime-ters to inches. Therefore, 55 millimeters = 2.165 inches.

2. Convert 550 mm into inches.(a) The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to

convert it to 55 mm.(b) Carry out the same procedure as above to convert 55 mm to 2.165 inches.(c) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one

place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

2

Millimeters to inches 1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748

20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142

30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536

40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

3

150 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323

60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717

70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110

80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504

90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

00-13 1


Millimeters to Inches 1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748

20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142

30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536

40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323

60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717

70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110

80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504

90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound 1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89

20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93

30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98

40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07

60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12

70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17

80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21

90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

00-14 1


Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9

0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019

20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661

30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303

40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586

60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228

70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870

80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511

90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

Liter to U.K. Gallon 1 L = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9

0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179

20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379

30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579

40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978

60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178

70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378

80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577

90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

00-15 1


kgm to ft. lb. 1 kgm = 7.233 ft. lb.

0 1 2 3 4 5 6 7 8 9

0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4

20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8

30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1

40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8

60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1

70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4

80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7

90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4

110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7

120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1

130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4

140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0

160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4

170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7

180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0

190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

00-16 1


kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/in2

0 1 2 3 4 5 6 7 8 9

0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2

20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5

30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7

40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2

60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4

70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124

80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266

90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550

110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693

120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835

130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977

140 1991 2005 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262

160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404

170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546

180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688

190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973

210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115

220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257

230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399

240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

00-17 1


TemperatureFahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centi-grade temperature reading or vise versa is to enter the accompanying table in the center or boldface column offigures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired toconvert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit tempera-tures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convertfrom Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and readthe corresponding Fahrenheit temperature on the right.°C °F °C °F °C °F °C °F

-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

00-18 1

pubinfok.fm 10/12/99

PRODUCT PUBLICATIONS INFORMATIONVarious product Parts and Service Publications are available to all KOMATSU construction equipment owners, including operation and maintenance manuals, parts books and service manuals.

Special publications, such as service tool, air conditioning and turbocharger service manuals are also available as well as selected Operation and Service manuals in foreign languages.

The Publications listed below are available for this particular machine(s).

DESCRIPTION FORM NUMBER

PARTS BOOK - PAPER:Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application

PARTS BOOK - MICROFICHE:Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application

OPERATION AND MAINTENANCE MANUAL:Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application

SHOP MANUALChassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific ApplicationEngine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM002601

SAFETY MANUAL

Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the Komatsu America International Company Parts Inventory Processing System (PIPS).

If the PIPS system is not available at the distributor location, then the following Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown on the reverse side of this page.

PURCHASE ORDER NO.

ORDER DATE

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS

COMPLETE FORM

AND RETURN TO << DataKom Publishing Corporation440 North Fairway DriveVernon Hills, IL 60061-8112 U.S.A.Attn: Service PublicationsFax No. (847) 970-4186Tel No. (847) 970-5887

COMPANY NAME

ATTN.

STREET ADDRESS

CITY, STATE, ZIP CODE

COUNTRY

SHIP TO <<

TYPE or PRINTONLY <<

PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE

IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINESERIAL NUMBER MUST BE SHOWN.

QTY. PUBLICATION FORM NO. P-Paper MODEL NUMBER SERIAL NUMBER PARTS BOOK

M-Microfiche

PUBLICATIONDESCRIPTION

KDC91D 022597 CURRENT PRICES WILL BE CHARGED

01-1

01 GENERAL

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2GENERAL ASSEMBLY DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3

VIEW FROM LEFT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3VIEW FROM RIGHT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4VIEW FROM FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5VIEW FROM REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6VIEW FROM LEFT SIDE (CUSTOM CONNECTIONS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7VIEW FROM TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8

ENGINE PERFORMANCE CURVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9WA800-2LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9WA900-1LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10330M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-11

GENERAL SPECIFICATIONS

01-2

SPECIFICATIONSEngine model SA12V140Z-1

Applicable machine WA800-2LE WA900-1LC 330M

Number of cylinder 12

Bore x Stroke mm 140 x 165

Total piston displacement cc 30,480

Firing order R1 – LI – R5 – L5 – R3 – L3 – R6 – L6 – R2 – L2 – R4 –L4

Dim

ensi

ons

Overall length

Overall width

Overall height(excluding exhaust pipe)

mm

mm

mm

1887.7

1320.1

1658

1887.7

1320.1

1658

1887.7

1320.1

1658

Per

form

ance

Flywheel horsepower

Gross horsepower

Maximum torque, gross

Maximum torque, net

High idling speedLow idling speed

Minimum fuel consumption at fullpower

kW(HP)/rpm

kW(HP)/rpm

N•m(lb/ft)/rpm

N•m(lb/ft)/rpm

rpmrpm

g/kW•h(lb/HP•h)

588(789)/2,000

621(833)/2,000

3806(2807)/1,400

3279(2750)/1,400

2,250±50

650

194 (.319)

636(853)/2,000

669(897)/2,000

4100(3024)/1,300

4034(2975)/1,300

2,250±50

650

193 (.317)

753(1010)/2,000

783(1050)/2,000

4628(3414)/1,400

4560(3363)/1,400

2,350±50

650

193 (.317)

Dry weight kg 3,271 3,271 3,271

Fuel injection pump BOSCH RP 39

Governor BOSCH RE 33

Lubricating oil amount (total system)(minimum required)

l(US Gal)

148(39.1)132(34.9)

148(39.1)132(34.9)

148(39.1)132(34.9)

Coolant amount (engine only)(total system)

l(US Gal)

85(22.4)310(81.9)

85(22.4)310(81.9)

85(22.4)228(60.2)

Alternator 24 V, 75 A 24 V, 75 A 24 V, 75 A

Starting motor 24 V, 11kW 50 MT x 1

24 V, 11kW, 50 MT x 1

24 V, 11kW, 50 MT x 1

Battery 12V 200 Ah x 4 12 V 200 Ah x 4 12 V 200 Ah x 4

Turbocharger H x 60 x 2 H x 60 x 2 H x 60 x 2

Air compressor Holset TC676 Holset TC676 Holset TC676

50+

0–

50+

0–

50+

0–

GENERAL GENERAL ASSEMBLY DRAWING

01-3

GENERAL ASSEMBLY DRAWINGVIEW FROM LEFT SIDE


01-4

VIEW FROM RIGHT SIDE


01-5

VIEW FROM FRONT


01-6

VIEW FROM REAR


01-7

VIEW FROM LEFT SIDE (CUSTOM CONNECTIONS)


01-8

VIEW FROM TOP

GENERAL ENGINE PERFORMANCE CURVE

01-9

ENGINE PERFORMANCE CURVEWA800-2LC

Curves above represent gross engine performance capabilities obtained and corrected in accordance with SAEJ1995 conditions of 100 kPa (29.61 in. Hg) barometric pressure [91 m (300 ft.) altitude], 25°C (77°F) inlet air tem-perature, and 1kPa (0.30 in. Hg) water vapor pressure with No. 2 diesel fuel. The engine may be operated withoutchanging the fuel setting up to 3048 m (10,000 ft.) altitude. For sustained operation at high altitudes, the fuel rate ofthe engine will be adjusted to limit performance by 4% per 305 m (1,000 ft.) above 3048 m (10,000 ft.) altitude and2% per 11°C above 38°C (1% per 10°F above 100°F).


01-10

WA900-1LC



01-11

330M


11-1

11 STRUCTURE AND FUNCTION

GENERAL STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3INTAKE AND EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5

INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7AFTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8

ENGINE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10Valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10Rocker arm housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10Fuel injection nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10

CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12Piston cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12Liner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12

MAIN REVOLVING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14Connecting rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14

TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15Front seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16

VALVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17Valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18

FLYWHEEL AND FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19Rear seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19

LUBRICATING OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20Piston cooling, connecting rod, overhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21Front gear train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-23

FULL FLOW LUBRICATING OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24LUBRICATING OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-25

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-25MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-26

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-26OIL COOLER BYPASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-27

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-27Regulator valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-27

LUBRICATING OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-28Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-28Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-28

LUBRICATING OIL BYPASS FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-29Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-29

LUBRICATING OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-31

11-2

STRUCTURE AND FUNCTION TABLE OF CONTENTS

FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-31FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32RIGHT BANK PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-33LEFT BANK PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-34FUEL INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-35

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-35FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-36

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-36COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-37

THERMOSTAT HOUSING FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-38COOLING FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-39WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-41CORROSION RESISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-42

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-42ACCESSORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-43

AIR COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-43Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44Unloader valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-45ALTERNATOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-45ALTERNATOR WITH REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-46STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-47ELECTRICAL INTAKE AIR HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-48

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-48

STRUCTURE AND FUNCTION GENERAL STRUCTURE

11-3

GENERAL STRUCTURE

1. Front cover2. Cylinder block3. Cylinder liner4. Rocker lever housing5. Cylinder head cover6. Exhaust valve7. Intake valve8. Piston

9. Turbocharger10. Cam follower11. Camshaft12. Flywheel13. Flywheel housing14. Main bearing cap15. Crankshaft16. Oil pan

17. Connecting rod18. Connecting rod cap19. Oil strainer20. Lubricating oil pump21. Crankshaft gear22. Vibration damper23. Crankshaft pulley

STRUCTURE AND FUNCTION GENERAL STRUCTURE

11-4

24. Cylinder head25. Intake manifold26. Electrical intake air heater27. Lubricating oil cooler28. Intake connector pipe29. Rocker lever

30. Aftercooler31. Nozzle holder32. Push rod33. Piston cooling nozzle

STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM

11-5

INTAKE AND EXHAUST SYSTEMINTAKE SYSTEM

1. Intake manifold (Right bank)2. Electrical intake air heater 3. Aftercooler cover (Right bank)4. Aftercooler cover (Left bank)5. Intake manifold (Left bank)A. Air intake


11-6

EXHAUST SYSTEM

1. Exhaust manifold (Left bank)2. Exhaust manifold (Right bank)3. Turbocharger (Right bank)4. Turbocharger (Left bank)


11-7

TURBOCHARGER

1. V band clamp2. Turbine Housing3. Turbocharger heat shield4. Drive screw5. Lock nut6. Split ring seal7. Split ring seal8. Dataplate9. Regular hexagon nut10. Thrust collar11. Oil slinger12. Oil seal plate13. V band clamp14. Oil baffle

15. Shaft and wheel16. Turbo thrust bearing17. Turbo compressor impeller18. Compressor housing19. Turbo bearing housing20. Roll pin21. Retaining pin22. Retaining ring23. Turbocharger bearing24. Retaining ring25. O-ring seal26. Oil control sleeve


11-8

AFTERCOOLER

1. Aftercooler cover2. Aftercooler core3. Intake manifold

H The diagram above shows the right bank.

A. Intake air inlet (from turbocharger)B. Intake air outlet (to cylinder head)C. Water inlet (to cylinder head)D. Water outlet (to thermostat)

STRUCTURE AND FUNCTION ENGINE BODY

11-9

ENGINE BODYCYLINDER HEAD

1. Fuel spill tube2. Air vent tube3. Rocker lever housing4. Cylinder head5. Head cover6. Nozzle holder retainer

7. Fuel injection nozzle holder assembly

8. Head cover mounting bolt9. Cylinder head mounting bolt10. Fuel inlet connector

B. Intake C. Exhaustd. To fuel tanke. To radiator


11-10

Specifications• Direct fuel injection type• 4-valve• Divided type (One cylinder head for one cylinder)• Injection nozzle and fuel inlet connector assembled

in rocker arm housing and cylinder head• Cylinder head bolt: Tighten bolts by the plastic

range turning angle method

Valve seat• Press fitted insert for intake and exhaust

Rocker arm housing cover• Floating type seal

Fuel injection nozzle• Mount: Dry type (without sleeve)


11-11

CYLINDER BLOCK

1. Cylinder block2. Cylinder liner3. Crevice seal4. Liner seal5. Liner seal6. Main bearing cap bolt

7. Main bearing cap8. Main bearing9. Piston cooling nozzle10. Thrust bearing


11-12

Specifications• Crankshaft: 7 bearings• Camshaft: 7 bearings• Main bearing cap bolt: Tightening bolts by the

plastic range turning angle method.Piston cooling• With piston cooling nozzle

Cylinder liner• Wet type• Treatment: Plateau honing finish

Tuffride treatedLiner seal• TOP:Crevice seal (Ethylene propylene

rubber)• MIDDLE: O-ring (Ethylene propylene

rubber)• BOTTOM: O-ring (Silicon rubber)


11-13

MAIN REVOLVING SYSTEM

1. Piston2. Piston pin3. Connecting rod bushing4. Top ring5. Second ring6. Oil ring7. Crankshaft pulley8. Vibration damper

9. Crankshaft10. Crankshaft gear (No. of teeth: 45)11. Connecting rod bearing12. Connecting rod cap13. Connecting rod14. Connection rod cap bolt


11-14

Crankshaft• Stamp forging• Journal and filet portion:

Induction hardening

Piston• Ductile cast iron (FCD)

Connecting rod• Stamp forging:

With lubrication hole

Top ring Second ring Oil ring

Both faces key-stone.Barrel face.Hard chrome plating.

Keystone inner cut.Tapered face.Hard chrome plating.

M-shape steel ring.Hard chrome plating with coil expander.


11-15

TIMING GEAR

H Circled numbers indicate spur gear. Other gears are helical.

1. Accessory drive gear (No. of teeth: 22)2. R-Sub-idler gear (No. of teeth: 50)3. R-Idler gear (large) (No. of teeth: 75)4. R-Camshaft gear (No. of teeth: 60)5. Idler gear (small) (No. of teeth: 45)6. L-Camshaft gear (No. of teeth: 60)7. L-Idler gear (large) (No. of teeth: 75)8. L-Sub-idler gear (No. of teeth: 50)9. L-Fuel injection pump drive gear (No. of teeth: 60)

10. Air compressor drive gear (No. of teeth: 30)11. Crankshaft gear (No. of teeth: 45)12. Oil pump drive gear (No. of teeth: 27)13. Water pump drive gear (No. of teeth: 25)14. R-Fuel injection pump drive gear (No. of teeth: 60)15. Front seal

R, L, A, B, B1, B2, C, D: Match marks for timing gears


11-16

Front seal• Single lip with dust seal


11-17

VALVE SYSTEM


11-18

1. Camshaft gear (No. of teeth: 48)

2. Thrust plate3. Camshaft4. Cam follower5. Cam roller6. Rocker arm shaft7. Cam follower shaft8. Rocker arm adjust-

ment screw9. Lock nut10. Push rod11. Rocker arm12. Crosshead adjust-

ment screw

13. Locknut14. Crosshead15. Valve guide16. Exhaust valve17. Valve spring (outer)18. Valve spring (inner)19. Valve spring seat

(lower)20. Valve spring seat

(upper)21. Intake valve22. Cam roller pin

Valve timing

Camshaft• Drawn steel bar• Journal and cam portion: Induction hardening


11-19

FLYWHEEL AND FLYWHEEL HOUSING

1. Ring gear (No. of teeth: 142)2. Flywheel3. Flywheel housing4. Crankshaft rear sealA. Timing sensor pickup portB. RPM sensor port

Rear seal• Dry type: Single lip oil seal• Wet type: Double lip oil seal

STRUCTURE AND FUNCTION LUBRICATING OIL SYSTEM

11-20

LUBRICATING OIL SYSTEM

1. Full flow filter head2. Full flow filter(s)3. Lubricating oil pump4. High pressure regulator5. Suction tube6. Lubricating oil cooler7. Low pressure and lubricating oil cooler bypass reg-

ulator8. Signal line9. Cold oil flow10. Hot oil flow

11. Bypass filters12. Oil cooler bypass valve13. Bypass valve spring14. Regulator valve15. Regulator valve spring16. Valve bodyA. From main gallery (signal line)B. From oil coolerC. To oil panD. To oil filter


11-21

Piston cooling, connecting rod, overhead1. Crankshaft oil drillings2. Main oil drilling3. Connecting rod wrist pin oil supply4. Upper rocker lever oil supply5. Piston cooling oil drilling6. Cam follower oil drilling7. Piston cooling nozzle


11-22

Front gear train1. Right bank (large) idler gear2. Right bank (small) idler gear3. Piston cooling oil supply drillings4. Left bank (large) idler gear


11-23

Turbocharger1. Piston cooling oil supply drilling2. Turbocharger oil supply3. Turbocharger oil drain


11-24

FULL FLOW LUBRICATING OIL FILTERS

1. Oil supply2. Oil drain3. Full flow filters


11-25

LUBRICATING OIL PUMP

1. Pump body2. Pump drive (No. of teeth: 27)3. Drive gear4. Driven gear5. Pump cover

a. Suction (From oil pan)b. Discharge (To oil cooler)

Specifications• Type: Gear pump• Pump speed: Engine speed x 1.67


11-26

MAIN RELIEF VALVE

1. Valve spring2. Main relief valve3. Valve body

Specifications• Cracking pressure:

8.5 ± 0.5 kg/cm2

121 ± 7 psi


11-27

OIL COOLER BYPASS VALVE1. Oil cooler bypass valve2. Bypass valve spring3. Regulator valve4. Regulator valve spring5. Valve bodyA. From main galleryB. From oil coolerC. To oil panD. To oil filter

Specifications• Cracking pressure

(differential pressure)

2.3 ± 0.2 kg/cm2 3.3 ± 2.5 psi

Regulator valve• Cracking pressure:

4.1 ± 0.5 kg/cm2

58 ± 7.1 psi


11-28

LUBRICATING OIL FILTER

1. Filter head2. Filter connector3. Cover4. Cartridge

A. Oil inlet portB. Oil outlet port

Specifications• Filtering area:

3.6 m2 38.75 sq.ft.

Safety valve• Cracking pressure:

2.0 ± 0.2 kg/cm2

28.44 ± 2.8 psi


11-29

LUBRICATING OIL BYPASS FILTER

1. Filter head2. Cartridge

A. Oil inlet portB. Oil outlet port

Specifications• Filtering area: 2.8 m2 [30.1 sq. ft.]


11-30

LUBRICATING OIL COOLER

1. Oil cooler cover2. Cooler element: 12 cores

a. Oil inlet or outletb. Oil inlet or outletc. Cooling water

Specifications• Effective area:

0.986 m2 10.61 sq. ft.

STRUCTURE AND FUNCTION FUEL SYSTEM

11-31

FUEL SYSTEMFLOW DIAGRAM

1. Fuel tank2. Prefilter3. Fuel connection block4. Fuel lift pump5. Fuel filter6. EHAB

7. Fuel injection pump8. Fuel injection nozzle9. Electronic governorA. Fuel supply (From tank)B. Fuel overflow valveC. Fuel gallery outlet

D. Fuel gallery inletE. Fuel out to lift pumpF. Fuel in from fuel filterG. Fuel drain (to tank)


11-32

FUEL INJECTION PUMP

Specifications• Maker:BOSCH• Type:RP39


11-33

RIGHT BANK PIPING

1. Fuel injection pipe (No. 6 cylinder)2. Fuel injection pipe (No. 5 cylinder)3. Fuel injection pipe (No. 4 cylinder)4. Fuel injection pipe (No. 3 cylinder)5. Fuel spill tube6. Fuel injection pipe (No. 2 cylinder)7. Fuel injection pipe (No. 1 cylinder)8. Pump drive gear (No. of teeth: 60)9. Pump drive shaft

10. Housing11. Coupling12. Air bleed plug13. Oil outlet pipe14. Fuel injection pump15. Adapter16. Feed pump17. Emergency stop valve


11-34

LEFT BANK PIPING

1. Fuel injection pipe (No. 1 cylinder)2. Fuel injection pipe (No. 2 cylinder)3. Fuel injection pipe (No. 3 cylinder)4. Fuel spill tube5. Fuel injection pipe (No. 4 cylinder)6. Fuel injection pipe (No. 5 cylinder)7. Fuel injection pipe (No. 6 cylinder)8. Emergency stop valve9. Air bleed plug10. Oil inlet pipe

11. Feed pump12. Fuel injection pump13. Oil outlet pipe14. Hand priming pump15. Coupling16. Pump drive shaft17. Housing18. Pump drive gear (No. of teeth: 60)


11-35

FUEL INJECTION NOZZLE

1. Inlet connector2. Nozzle holder3. Adjusting shim4. Spring5. Spring seat6. Spacer7. Nozzle8. Retaining cap9. Needle10. #1 RB and #1 LB injector with needle lift sensor

a. Fuel inlet (From injection pump)b. Injection (To cylinder)c. Fuel return (To fuel tank)

Specifications• Type: Multi-hole type• Adjusting injection pressure: Shim adjusting type


11-36

FUEL FILTER

1. Filter head2. Cartridge

a. Fuel inlet (From transfer pump)b. Fuel outlet (To injection pump)

H Additional ports are marked indicating flow direc-tion.

Specifications• Filtration area: 2.0 m2 (1.0 x 2 pcs)

STRUCTURE AND FUNCTION COOLING SYSTEM

11-37

COOLING SYSTEM

1. Aftercooler2. Water outlet3. Aftercooler water inlet4. Water pump impeller5. Bypass flow6. Water outlet to block7. Water inlet

8. Bypass flow9. Water filters10. Cylinder liner coolant cavity11. Cylinder head coolant passage12. Oil coolers13. Vent line flow


11-38

THERMOSTAT HOUSING FLOW

1. Thermostat2. Water outlet3. Coolant from block4. Closed thermostat flow5. Open thermostat flow


11-39

COOLING FAN BELT

1. Fan hub2. Air crossover3. Coolant temperature sensor4. Oil pan5. Fan idler tensioner6. Water filters7. Engine barring location8. Full flow oil filters


11-40

WATER PUMP

1. Pump shaft2. Water seal3. Pump body4. Water pump drive gear (No. of teeth: 25)5. Ball bearing6. Oil seal7. Impeller8. Pump cover

a. From thermostatb. From radiator (water inlet)c. To oil cooler (water outlet)

Specifications• Type: Centrifugal gear drive• Pump speed: Engine speed x 1.80


11-41

COOLING FAN

1. Fan 2. Fan pulley3. Fan belt (poly V-belt)4. Crank pulley5. Tension pulley6. Idler pulley

A. Wind direction

Pulley outside diameter (mm)

Fan pulley Crank pulley Tension pulley

405 203 150


11-42

CORROSION RESISTOR

1. Head 2. Cartridge3. Element (Chemicals)4. Valve

a. Water inletb. Water outlet

Specifications• Filtration area:0.373 m2 x 2

4.01 sq. ft. x 2

STRUCTURE AND FUNCTION ACCESSORY

11-43

ACCESSORYAIR COMPRESSOR

1. Cylinder head2. Unloader valve3. Piston4. Piston ring5. Piston pin6. Cylinder7. Connecting rod8. Crankcase9. Crankshaft10. Bushing11. Cover12. Thrust bearings13. Unloading assembly

a. Air inletb. Air outletc. Unload pressure (from air governor)d. Oil inlete. Water inlet or outletf. Water inlet or outletg. Oil outlet

STRUCTURE AND FUNCTION ACCESSORY

11-44

Specifications• Type: Water cooled, two cylinder• Unloader valve method: intake valve, open type• Cylinder O.D. x stroke: 92.08 x 50.8 mm• Discharge volume: 1352 cc/rev• Weight: 33.5 kg

Unloader valve• Governor controlled• Max 125 psi

STRUCTURE AND FUNCTION ELECTRICAL SYSTEM

11-45

ELECTRICAL SYSTEMALTERNATOR MOUNTING

1. Alternator2. Adjustment molt3. Alternator drive pulley4. Alternator bracket

a. Alternator pulleyb. Alternator drive pulley


11-46

ALTERNATOR WITH REGULATOR

1. Alternator2. Alternator pulley


11-47

STARTING MOTOR

DELCO 50MT 24V1. Solenoid2. Pinion gear3. Starting motor


11-48

ELECTRICAL INTAKE AIR HEATER

1. Heater body2. Heater coil3. Terminal

Specifications• Rated voltage: 11V• Rated current: 86A

12 TESTING, ADJUSTING ANDTROUBLESHOOTING

ADJUSTING VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3MEASURING COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5

FUEL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5FUEL PUMP INSTALLATION AND TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7

CHECKING INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12USING PROXIMITY SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12USING FUEL PUMP LOCK PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15

SENSOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18TIMING SENSOR (WITH FLYWHEEL TIMING HOLES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-182ND DESIGN (FLYWHEEL TIMING LUGS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19

FUEL OVERFLOW VALVE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-20ADJUSTING FUEL INJECTION PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-21PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22

ENGINE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22IN SERVICE RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22ENGINE DYNAMOMETER RUN-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22PORTABLE DYNAMOMETER OR LOAD BANK RUN-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22INSITE SERVICE TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22

FUEL FLOW MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-23INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-23MEASUREMENT OF FUEL CONSUMPTION RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-23SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-24

DYNAMOMETER WORKSHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-25ENGINE DYNAMOMETER TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26

SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26COOLANT PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26GENERAL ENGINE TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26ENGINE THROTTLE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-27TESTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-28

ENGINE SPEED (RPM) WITH A VERIFIED TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . 12-28FUEL INLET RESTRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-28FUEL DRAIN LINE RESTRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29INTAKE MANIFOLD PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29INTAKE AIR RESTRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29EXHAUST RESTRICTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29ENGINE BLOWBY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30LUBRICATING OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32COOLANT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32LUBRICATING OIL TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32AIR COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-33STARTING MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-33

ENGINE RUN-IN INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34TEST LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34

TESTING AND ADJUSTING TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-37COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39

CHECKING FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39

12-1 1

12-2

TESTING AND ADJUSTING TABLE OF CONTENTS

330M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39WA800/WA900. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39

ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39CHECKING BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39ADJUSTING BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-40DRIVE BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-40

1

TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE

12ADJUSTING VALVE CLEARANCE

� Adjust clearance between crosshead and rocker arm.

Adjusting method of valve clearance

1. Remove the rocker arm housing cover

2. Rotate the crankshaft in a clockwise direction. While watch-ing the movement of the intake valve of the R6 cylinder,bring the R1 cylinder into the top dead center position of thecompression stroke and align the “R1.6 TOP” line on thevibration damper (1) with the pointer (2).

� Hold with a wrench in position B in the diagram on the right,then crank the engine in the direction of the arrow.

� When the R1 cylinder comes near the top dead center ofthe compression stroke, the R6 intake valve will start tomove (open)

3. Loosen locknut (6) of adjustment screw (5) of R1 cylinder,insert the feeler gauge A corresponding to the specifiedclearance between crosshead (4) and rocker arm (3), andadjust the clearance with the adjustment screw until thethickness gauge can slide lightly.

� Valve clearance (When engine is cold)Intake valve: 0.43 mmExhaust valve: 0.80 mm

4. Tighten locknut in this position, secure adjustment screw.

Locknut: 58.8 ± 5.9 N•m (43.4 ± 4.4 lbf-ft)

5. Follow the same procedure to align the line with the pointerand adjust the valve clearance of each cylinder according tothe firing order.

� Firing order:R1 – L1 – R5 – L5 – R3 – L3 – R6 – L6 – R2 – L2 – R4 – L4

� The lines and marks shown in the diagram are on the out-side circumference of the damper.

12-3 1

TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE

12MEASURING COMPRESSION PRESSURE

Method of measuring compression pressure

Avoid touching the exhaust manifold or muffler when measuring compression. Be careful of rotating parts.Do NOT wear loose fitting or torn clothing. Remove ALL jewelry when working.

� Warm up the engine before measuring the compression pressure. (Oil temperature 40 - 60 °C)

1. Adjust valve clearance.

� For details, see “ADJUSTING VALVE CLEARANCE” on page 12-32. Power to EHAB must be OFF.

3. Remove the nozzle holder assembly from the cylinder to be measured.

4. Install adapter A1 in the mount of the nozzle holder of thecylinder to be measured, then secure with retainer (2).

Mounting bolt: 66.2 ± 7.4 N•m (48.8 ± 5.5 ft-lb)

5. Connect compression gauge A to the adapter.

6. Crank the engine with the starting motor and measure thecompression pressure.

� Measure the compression pressure at the point where thegauge indicator remains steady.

� If the adapter mount is coated with a small amount of oil, itwill prevent leakage.

� For details of the standard values for compression pressure,see Standard value table.

12-4 1

TESTING AND ADJUSTING FUEL SYSTEM

12FUEL SYSTEM

FUEL PUMP REMOVAL� Rotate the crankshaft to the engine timing specification

before removing the right bank fuel pump.

1. Install a protective cover to prevent any dirt or dust from get-ting into the discharge port of the injection pump or the inletport of the nozzle connector. Clean the debris from aroundthe inline fuel injection pump.

2. Remove electrical connections (1) and fuel lines (2).Remove all of the oil lines (3).

� Right bank and left bank pumps are removed and installedat the right bank timing location.

� If the fuel pump is to be reused, remove the timing lock pinand install in the locked position, as shown, to preserve thepump timing.

3. Remove the four capscrews (1), washers and nuts holdingthe pump to the drive housing.

4. Remove the injection pump bracket mounting bolts (2).

� The right bank fuel pump bracket has six mounting bolts.The left bank fuel pump bracket has three mounting bolts.

12-5 1


125. Move pump away from housing. Disengage the pump drive-shaft gear from the spline coupling. Remove the pump fromthe drive housing.

6. If pump is to be recalibrated, remove spline drive gear frompump. Use spline coupling with bar attached to preventpump rotation while removing large nut. Use flange gearpuller to remove gear.

Remove locking pin to prevent damage.

7. Remove capscrews from mounting support and removesupport.

8. Install drive spline after repair. Remove locking pin.

Spine retaining nut:407 N•m (300 ft-lb)

9. Install locking pin and cap.

Locking pin and cap:27 N•m (20 ft-lb)

12-6 1


12FUEL PUMP INSTALLATION AND TIMING

1. Rotate the engine clockwise until the crankshaft damperpointer aligns with the specified engine timing, which is pro-vided on the engine dataplate before TDC for the right bankNo. 1 cylinder on the compression stroke.

� Right bank and left bank pumps are installed at the rightbank setting location.

2. Remove the No. 1 cylinder rocker cover and verify that theNo. 1 cylinder is at TDC, right bank.

3. Remove the fuel injection pump timing pin cap and verifythat the pump is locked.

4. Install the timing pin, plug, and sealing washer.

Timing pin plug:30 N•m (22 ft-lb)

5. Install the mounting bracket onto the fuel pump. Do NOTtighten the capscrews.

6. Install the spline coupling onto the pump drive shaft gear(1).

7. Install new o-rings.

12-7 1


12I

If the pump does not align, do NOT force the pump anddrive into alignment. Forcing will result in fuel pumpdamage.

8. Engage the spine coupling and install the pump drive shaftgear into the drive housing. Install the flange mounting cap-screws (1) and the fuel pump mounting capscrews (2).

� The injection pump assembly MUST be at an angle to theengine block.

� If the pump does not align, remove fuel pump and the coverplate on the front gear cover to gain access to the fuel pumpdrive gear.

9. Loosen (2 to 3 turns) the large nut securing the two-piecedrive gear to the drive shaft. Using the barring tool to holdthe engine in position, remove the two opposing capscrewssecuring the fuel pump drive gear to the hub.

10. Fabricate two jackscrews (M12x1.5) using bolts, Part No.01011-31265. Remove 25mm of thread from the end ofeach capscrew to form a 6mm diameter. The remaining 25mm of thread will be used to install the jackscrews.

11. Install the two jackscrews.

12. Tighten the jackscrews through the gear and hub until mak-ing contact with the thrust plate.

13. Tighten each capscrew with 1/4 turn until the two-piece gearassembly pops off the drive shaft taper.

14. Remove the jackscrews.

12-8 1


1215. Engage the spline coupling and install the pump drive shaftgear into the drive housing. Install the flange mounting cap-screw (1) and the fuel pump mounting screw (2).

� The injection pump assembly MUST be at an angle to theengine block.

16. Tighten the two pumps to bracket capscrews (1).

17. Tighten the four flange mounting capscrews (2).

18. Tighten the fuel pump mounting capscrews (3).

All capscrews:65 N•m (48 ft-lb)

19. Install large nut securing gear to shaft

Gear nut: 24 N•m (17 ft-lb)

20. Remove fuel pump locking pin.

� If locking pin is difficult to remove, install metric capscrewinto end of pin to aid in removal.

12-9 1


1221. Tighten large nut securing gear to shaft.

Large nut: 109 N•m (80 ft-lb)

22. Install and tighten two attaching bolts in gear.

Mounting bolt:14 N•m (84 ft-lb)

23. Rotate the engine clockwise until the crankshaft damperpointer aligns with the specified engine timing, which is pro-vided on the engine dataplate.

24. Install the injector pump lock pin. Verify the timing pin willstill engage.

25. Remove the lock pin.

26. Tighten the large nut securing the two-piece drive gear tothe drive shaft.

Large nut: 407 N•m (300 ft-lb)

27. Install the cover plate on the front gear cover.

28. Tighten the capscrews.

Capscrew: 65 N•m (48 ft-lb)

12-10 1


1229. Install the electronic connections (1) and fuel lines (2) andall the oil lines (3)

High pressure lines:24 N•m (17 ft-lb)

Low pressure lines:27 N•m (20 ft-lb)

30. Install the timing pin, cap and sealing washer in theunlocked position.

Timing pin cap:30 N•m (22 ft-lb)

31. Pass the NBF connector through the hole in the rocker levercover.

32. Press fit the grommet into the rocker lever cover (3).

33. Install the valve cover and gasket (2).

Mounting bolt:7 N•m (62 in-lb)

34. Connect BF connector to ECM connection.

12-11 1

TESTING AND ADJUSTING CHECKING INJECTION TIMING

12CHECKING INJECTION TIMING

USING PROXIMITY SENSOR

A Proximity Sensor and Lights Tool (Bosch # 0 986 612 174) isthe most accurate method of adjusting fuel pump timing. Thetiming marks for the right bank are used to time bothpumps.

1. Remove the rocker cover of right bank cylinder 1. (The leftbank is illustrated.)

� Before barring engine, make sure that the lock pins in bothof the fuel pumps are disengaged, to prevent damage to thefuel pump.

� If a lock pin is difficult to remove from its engaged position,install a metric capscrew into the exposed end of the pin toaid in its removal.

The normal direction of rotation for 12V140Z-1 engines is clock-wise, when viewing from the front of the engine. A wrench maybe used to turn the engine from the center of the engine barringlocation. (A).

If the front barring point is not readily accessible, the optionalbarring tool may be used at the flywheel housing.

12-12 1


2. Rotate the engine to the R 1-6 mark on the crankshaftdamper.

3. Make sure that right bank cylinder 1 is at TDC of the com-pression stroke by checking that both right bank cylinder 1valve rocker levers are loose and the adjusting screws arethe same height. If not, then rotate the engine 360°

4. Rotate the crankshaft counter-clockwise to approximately40 degrees before TDC of the compression stroke for rightbank cylinder 1.

5. Remove the timing pin plug, the timing pin, and the sealingwasher from the pump to be timed.

12-13 1


� Use only compressed air to clean the probe end of the sen-sor to prevent damage.

6. Align the slot in the sensor with the slot in the fuel pump tim-ing window. Securely hand tighten the sensor (A) and installthe ground clamp (B).

7. Slowly bar the engine in the normal direction of rotation.One light on the service tool will illuminate as the pumpnears the injection point. It is not important if this is light A orlight B. The crank angle at which the second light first illumi-nates is the current pump timing.

If timing does not meet specifications, refer to fuel pump timinginstallation section.

8. Double check the pump timing, remove the sensor, andinstall the lock pins in the disengaged position. Install thetiming pin plugs with sealing washers.

Timing pin cap:30 N•m (22 ft-lb)

9. Install needle lift sensor wire (3).

10. Install the rocker cover with a new gasket and tighten thebolts to specification (The left bank is illustrated).

Mounting bolt:7 N•m (62 in-lb)

11. Connect needle lift sensor connector (1)

12-14 1


12USING FUEL PUMP LOCK PIN

If a Proximity Sensor Lights Tool is not available, fuel injectiontiming may be adjusted through the use of the fuel pump lockpins. The timing marks for the right bank are used to timeboth pumps. 1. Remove the rocker cover of right bank cylinder 1. (The left

bank is illustrated.)

� Before barring the engine, make sure that the lock pins inboth of the fuel pumps are disengaged, to prevent damageto the fuel pump.

� If a lock pin is difficult to remove from its engaged position,install a metric capscrew into the exposed end of the pin toaid in its removal.

The normal direction of rotation for 12V140Z-1 engines is clock-wise, when viewing from the front of the engine. A wrench maybe used to turn the engine from the center of the engine barringlocation (A).

If the front barring point is not readily accessible, the optionalbarring tool may be used at the flywheel housing.

12-15 1


2. Rotate the engine to the R 1-6 mark on the crankshaftdamper.

3. Make sure that the right bank cylinder 1 is at TDC of thecompression stroke by checking that both right bank cylin-der 1 valve rocker levers are loose and the adjusting screwsare the same height. If not, then rotate the engine 360°.

4. Rotate the crankshaft clockwise to approximately 6.5degrees before TDC of the compression stroke for rightbank cylinder 1.

5. Bar the engine back and forth near this point until the lockpin can be installed in the engaged position.

12-16 1


If timing does not meet specifications, refer to fuel pump instal-lation section.

12-17 1

TESTING AND ADJUSTING SENSOR INSTALLATION

12SENSOR INSTALLATION

SPEED SENSOR

1. Bar engine to align tooth of flywheel ring gear with center ofsensor mounting hole.

2. Install sensor, hand tighten until contact.

3. Back out sensor 1/4 to 1 1/4 turn for alignment of mountingcapscrew hole.

4. Install capscrew.

Capscrew: 7 N•m (62 in-lb)

5. Connect pin connector to harness.

TIMING SENSOR (WITH FLYWHEEL TIM-ING HOLES)

1. Bar engine and check alignment of reference hole in fly-wheel through mounting hole. Reference hole should NOTbe visible.

12-18 1

TESTING AND ADJUSTING SENSOR INSTALLATION

2. Install sensor. Hand tighten until contact with flywheel sur-face.

3. Back out 1/4 to 1 1/4 turn until alignment with mounting cap-screw hole.



2ND DESIGN (FLYWHEEL TIMING LUGS)

1. Remove sensor mounting assembly.

2. Rotate 180° to place sensor over flywheel surface or barengine until one of seven timing lugs appear in sensor hole.

3. Install sensor. Hand tighten until contact.

4. Back out 1/4 to 1 1/4 turn until aligns with mounting cap-screw hole.



6. Connect harness to sensor.

7. Install sensor cover into housing.

8. Connect harness from sensor to engine harness.

12-19 1

TESTING AND ADJUSTING FUEL OVERFLOW VALVE pressure

12FUEL OVERFLOW VALVE PRESSURE

1. Install pressure gauge between lift pump outlet and fuel fil-ter inlet.

� Lift pump gauge installation will require modified capscrewfor hose connection.

1. Operate engine for 3 - 5 minutes or until pressure is stable.

Minimum: 245 kPa (35 psi)

Maximum: 280 kPa (40 psi)

If overflow valve is defective, fuel pump assembly must be reca-librated with new valve.

If lift pump is defective, main pump calibration is not required.

Capscrew and fuel connection: 24 N•m (17 ft-lb)

12-20 1

TESTING AND ADJUSTING ADJUSTING FUEL INJECTION PRESSURE

12ADJUSTING FUEL INJECTION PRESSURE

1. Remove retaining cap (8).

2. Confirm thickness of adjustment shim (3).

3. Insert correct shim (3) in response to the adjustment valueof injection pressure.

4. Tighten retaining cap (8), then confirm the fuel injectionpressure using nozzle tester.

Retaining cap:83.4 ± 4.9 N•m (61.5 ± 3.6 ft-lb)

� Fuel injection racking pressure:

30 MPa (4350 psi)

� Adjustment value per shim thickness of 0.025 mm: 0.34 MPa (49.3 psi)

� Prepared shims: 0.5 to 1.975 mm (at intervals of 0.025 mm)

� Refer to the parts book for part numbers of theprepared shims.

� 0.031 x 7 hole cup 1600 PPH (725 kgH) flow

1.4

0–

203

0–

12-21 1

TESTING AND ADJUSTING PERFORMANCE TEST

12PERFORMANCE TEST

ENGINE TESTING

This section outlines engine testing and engine run-in recom-mendations for 12V140Z-1 engines. All engines must be run-inafter a rebuild or a repair involving the replacement of one ormore piston ring sets, cylinder liners or pistons.

Incorrect or insufficient break-in of the piston rings willlead to early oil consumption or high blowby complaints.Adherence to these run-in guidelines will allow the fulldurability of new pistons, liners, and rings to be realized.

Before running the engine, make sure the engine is filled withthe proper coolant. Also, make sure the lubricating oil system isfilled and primed.

IN SERVICE RUN

The following in-service run-in guidelines are recommended for 12V140Z-1 engines after a repair involvingreplacement of one or more of the piston ring sets, cylinder liners or pistons where engine or an engine dynamom-eter and/or chassis dynamometer run-in cannot be performed.

The majority of heavy duty diesel applications will provide sufficient run-in under normal loaded operations. How-ever, light load/high rpm operation must be avoided during the run-in period.

ENGINE DYNAMOMETER RUN-IN

This is the preferred method of run-in engines that have been rebuilt out-of-chassis. It is not practical, nor recom-mended that an engine be removed from the application to conduct the run-in after a rebuild or cylinder repair hasbeen performed in-chassis. There is no requirement, nor is it recommended for an engine that has been run-in andtested on an engine dynamometer to be run-in again after it has been reinstalled in the vehicle or equipment.

PORTABLE DYNAMOMETER OR LOAD BANK RUN-IN

When it is not possible to load an engine immediately after rebuild or repair, (example: a standby generator or firepump that cannot be operated because of customer restrictions, a fire truck that cannot be loaded with the waterpump, etc.), the engine must be run-in on a portable dynamometer or load bank following the recommendationsoutlined in the attached procedures.

INSITE SERVICE TOOL

The preferred method of obtaining test information and determining corrective action is using service tool 3886188to read fault codes and engine data. See INSITE information in this section.

12-22 1


12FUEL FLOW MEASUREMENTAccurate fuel flow measurement is important for evaluation of engine performance and troubleshooting on anengine or chassis dynamometer. The only way accurate fuel flow measurement can be obtained is through properuse of available equipment.

INSTALLATION

When installing the fuel measuring device, it is important to reduce the amount of air that can be introduced into thesystem when the device is not in use. Therefore, the plumbing used must include non-restrictive shutoff valves,such as ballcock valves, to contain fuel in the device after each use. Additional installation considerations are:

• A separate fuel supply for use on the dynamometer is recommended. All fuel used in the measuring devicemust be clean for consistent operation.

• Care must be taken to reduce fuel line restriction to and from the engine. Minimum recommended hose sizesare No. 10 for the engine fuel inlet, and No. 8 for the engine fuel drain. The length of either hose must notexceed 15 feet.

• For accurate fuel consumption or flow measurement while testing on a chassis dynamometer, it is recom-mended to use a fuel cooler to maintain inlet temperature to the fuel gear at 49°C (120°F) or below.

MEASUREMENT OF FUEL CONSUMPTION RATIO

1. Measure the length of time required for lowering of the fuellevel from A to B.

• Method for calculation of fuel consumption ratio.g = (r•b)/(P•t) X 3600.g = Fuel consumption ratio (g/kW•h(g/HP•h))r = Specific gravity of fuelb = Fuel consumption (cc) within measuring timeP = Shaft output (kW(HP))t = Fuel consumption time (second)

• Typical measurement at test bench

12-23 1


• Simple measuring method

SPECIFICATIONS

Maintain the following limits during the engine test/run-in procedures:

Due to variations in ratings of different engine models, refer to the specific “Engine Data Sheet” for the particularengine model being tested.

Intake restriction (Maximum at advertised horsepower)

• Clean air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 mm H2O (15 in H2O)• Dirty air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635 mm H2O (25 in H2O)

Exhaust back pressure (Maximum at advertised horsepower) ....................................................75 mm Hg (3 in Hg)

Blowby * (Maximum at advertised horsepower)

• New or rebuilt engines (Maximum 3600 hours). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Tables• Used engines (Over 3600 hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Tables

Oil pressure (With 15W-40 oil at 107°C (225°F))

• Low idle (Minimum allowable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 kPa (20 psi)• At 1200 RPM or torque peak (Minimum allowable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 kPa (36 psi)

Fuel inlet restriction measured at fuel pump inlet (Maximum at advertised horsepower)

• Clean fuel filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 mm Hg (4 in Hg)• Dirty fuel filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 mm Hg (8 in Hg)• Maximum allowable fuel inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71°C (160°F) * Blowby checking tool, Part No. 3822566 - 0.302 inch orifice.

Blowby Limits(using 0.302 inch diameter orifice at rated load and speed)

Engine HP (RPM Rating) New/Rebuilt Used Engine Limit

All ratings305 mm H2O(12 in H2O)

762 mm H2O(30 in H2O)

12-24 1


12DYNAMOMETER WORKSHEET

Date: Repair Order No.: Operator:

ESN: CPL: Fuel Pump Code:

Complaint: SC Code:

PARAMETER CODE SPECIFICATIONS ACTUAL READINGFuel Rate (lb/hr)

Intake Mfd. Pressure (in.Hg) See Fuel Pump Code

Intake Mfd. Temperature

*Intake Air Restriction 25 in H2O Maximum

*Exhaust Air Restriction 3 in Hg, Maximum

*Fuel Inlet Restriction 8 in Hg (Dirty Filter), Maximum

*Fuel Drain Line Restriction 3 psi, Maximum

Engine Blowby See Tables

* - Recorded at Maximum horsepower speed and full load

Road Speed Limit Engine High Speed LimitCheck Oil Level Low High OK Fuel Quality OK Not OK

Engine Speed

Fuel*Rate/Press

Fuel Temp

TurboInlet Air

Temp

IntakeManifold

Temp/Press

Coolant Temp/Press

EngineBlowby

LubeOil

Press

HPor

Torque

* Be sure that the fuel rate is corrected for temperature.

Fuel Temperature Correction for Flow Rate Pressure Conversions

Less than 7°C (45°F)7 to 13°C (45 to 55°F)13.0 to 20.0°C (55 to 68°F)20.0 29°C (68 to 85°F)29 to 42°C (85 to 108°F)42 to 56°C (108 to 132°F)56°C above (132°F)

Flow meter not accurateSubtract 2% from flow rate readingSubtract 1% form flow rate readingNo correctionAdd 1% to flow rate readingAdd 2% to flow rate readingFlow meter not accurate

1 in. H2O = 0.074 in. Hg = 0.036 psi1 in. Hg = 13.514 in. H2O = 0.491 psi1 psi = 2.036 in. Hg = 27.7 in. H2O

12-25 1

TESTING AND ADJUSTING ENGINE DYNAMOMETER TESTING

12ENGINE DYNAMOMETER TESTING

SETUP� Be sure the dynamometer capacity is sufficient to permit

testing at 100 percent of the engine rated horsepower. If thecapacity is not enough, the testing procedure must be modi-fied to the restrictions of the dynamometer.

1. Use engine lifting fixture, Part No. 3375109, to install theengine to the test stand. Align and connect the dynamome-ter. Refer to the manufacturer’s instructions for aligning andtesting the engine.

Refer to Service Bulletin No. 3666005, Dynamometer and Road Engine Testing, for detailed instructions on auxil-iary aftercooling system attachment.

COOLANT PLUMBING

2. Connect the coolant supply to the water inlet connection.

3. Connect the coolant return to the water outlet connection.

4. Connect vent lines.

5. Install the drain plugs and close all of the water drain cocks.

GENERAL ENGINE TEST PROCEDURES

� The lubricating oil system must be primed before operatingthe engine after rebuild to avoid internal component dam-age. Do not prime the system from the bypass filter as thefilter will be damaged.

6. Remove the large plug from the oil cooler housing.

7. Use a pump capable of supplying 205 kPa (30 psi) continu-ous pressure. Connect the pump to the front of the engineoil cooler as shown.

8. Use a supply of clean oil. Turn the pump to the ON position.Check the engine oil pressure gauge. When the gauge indi-cates oil pressure, begin monitoring the oil level in the oilpan.

12-26 1


9. Check the engine coolant level to be sure it is filled to theproper level.

Check the coolant level only when the engine isstopped. Wait until the coolant temperature is below50°C (120°F) before removing the pressure cap. Failureto do so can cause personal injury from heated coolantspray.

Do not add cold coolant to a hot engine. This can causeengine casting damage. Allow the engine to cool below50°C (120°F) before adding coolant.

10. Check the engine lubricating oil level to be sure it is filled tothe proper level.

� Use a known source of good quality No. 2 diesel fuel.

This is very important since No. 1 diesel fuels, along with most other alternate fuels, are lighter (lower specific grav-ity, higher API gravity) than No. 2 diesel fuel. The lighter the fuel, the lower the energy content (BTU) per liter (gal-lon).

ENGINE THROTTLE CONTROLEngines that are run on the engine dynamometer require thatthe engine harness be installed, and connected to the engine.Additionally, a special engine dynamometer version of the OEMwiring harness and throttle control must be installed.

A special wiring harness and throttle control has been devel-oped to enable engine operation out of the chassis.

12-27 1


TESTING PROCEDURETo properly monitor engine performance, record the followingparameters. To limit dynamometer operating time, instrumentthe engine to make as many checks as possible.

• Engine speed rpm with a verified tachometer• Fuel rate (Use service tool, Part No. 337637)• Fuel temperature (if needed to correct fuel rate)• Fuel inlet restriction• Fuel drain line restriction• Intake manifold pressure

• Intake air restriction• Exhaust air restriction• Coolant temperature• Engine blowby• Lubricating oil pressure• Coolant pressure• Inlet manifold air temperature• Turbocharger inlet air temperature

ENGINE SPEED (RPM) WITH A VERIFIED TACHOMETER

1. Use a digital optical tachometer, Part No. 3377462, to checkand verify speed.

FUEL INLET RESTRICTION

2. Measure the fuel inlet restriction. Install a vacuum gauge,Part No. ST-434, between the primary fuel filter and the liftpump inlet.

Do not measure fuel inlet restriction with the fuel measuringdevice installed. This will not measure the inlet restriction of thevehicle’s supply plumbing.

12-28 1


FUEL DRAIN LINE RESTRICTION

3. Use Pressure Gauge, Part No. ST-1273, to measure fueldrain line restriction.

� Do not measure fuel drain line restriction with the fuel mea-suring device installed. This will not measure the drain linerestriction of the vehicle’s return plumbing.

INTAKE MANIFOLD PRESSURE

4. Measure the intake manifold pressure (turbocharger boost).Install pressure gauge, Part No. ST-1273, in the intakemanifold crossover.

5. Observe the reading on the pressure gauge.

INTAKE AIR RESTRICTION

6. Measure the inlet air restriction. Install the vacuum gauge,Part No. ST-434, or a manometer in the intake air piping.

� The gauge adapter must be installed at a 90 degree angleto the air flow in a straight section of pipe at a minimum ofone pipe diameter before the turbocharger.

EXHAUST RESTRICTION

7. Measure the exhaust air restriction. Install the pressuregauge, Part No. ST-1273, or a manometer in the exhaust airpiping.

� The gauge adapter must be installed near the turbochargerin a straight section of pipe at the turbine outlet.

12-29 1


ENGINE BLOWBY

� Excessive blowby indicates an air compressor, a turbo-charger, or an engine malfunction, allowing combustiongases or air to enter the crankcase and build a pressurehigher than normal.

This procedure describes how to measure crankcase pressureand how to determine the component that is malfunctioning.

Use one of the three blowby tools and a water manometer, PartNo. ST-1111-3. Maximum gauge capacity is 1270 mm-H2O (50in-H2O).

The engine blowby tools are similar in design. The difference between the tools is in the size of the orifice.Blowby Tool Part No. 382256: 0.302” orifice

8. Use a length of hose (1) to attach the blowby tool to one ofthe crankcase breathers.

9. Plug all of the other breathers.

10. Attach a manometer to the location shown (2).

11. Operate the engine at rated rpm and full load (wide openthrottle) until a steady reading is obtained.

12. Compare the blowby readings to previous readings on theengine. If previous readings for the engine are not avail-able, compare the blowby reading to new engine specifica-tions.

� A sudden increase in blowby indicates a problem. A gradualincrease over a period of time is normal (due to wear ofinternal engine components).

Blowby Limits(using 0.302 inch diameter orifice at rated load and speed)

Engine HP (RPM Rating) New/Rebuilt Used Engine Limit

All ratings305 mm H2O(12 in H2O)

762 mm H2O(30 in H2O)

12-30 1


13. If the blowby is higher than normal, check the crankcasebreathers and breather tubes to see if they are plugged.

14. Check the engine oil level. If the level is too high it cancause a higher than normal crankcase pressure.

15. Isolate the air compressor to determine if it is malfunctioningand causing the high blowby pressure.

16. Relieve the air pressure on the first air tank in the systemafter the air compressor (wet tank).

17. Disconnect the air inlet and outlet connections. Plug theintake manifold or air piping where the inlet connection wasremoved.

18. Operate the engine at rated speed and full load (wide openthrottle) until a steady blowby reading is obtained.

19. Compare the blowby readings to the previous value. If theblowby is now acceptable, replace the air compressor.

12-31 1


A sudden increase in blowby or a high reading that is not steadyindicates that there is internal damage in the engine.

LUBRICATING OIL PRESSURE

20. Use a pressure gauge, Part No. 3375275, to measure lubri-cating oil pressure.

21. Install the pressure gauge to the main oil rifle (1) or air filterhead (2).

138 kPa (20 psi)207 kPa (30 psi)

COOLANT PRESSURE

22. Measure the coolant pressure at the water manifold (1).

241 kPa (35 psi)

LUBRICATING OIL TEMPERATURE

23. Drain oil and remove plug from oil pan. Install mastergauge. Fill pan with oil and operate engine. Compare tem-perature of original and master gauge.

� If defect is found, replace defective part.

12-32 1


AIR COMPRESSOR

All air compressors must be operating during the engine run-in.During the performance check, all air compressors must be inthe unload or non-operating mode.

24. Connect a source of compressed air capable of producing665 kPa (95 psi) to the air compressor unloader (1). This airline must contain a valve between the source and theunloader

� The compressed air load in the accompanying illustrationmust be attached to the air compressor outlet (2).

25. Use an air tank (2). Install an air regulator (3) capable ofmaintaining 345 to 517 kPa (50 to 75 psi) air pressure atboth minimum and maximum engine rpm.

26. Install a steel tube or high temperature hose (1).

235°C (500°F)

27. Connect the tube or hose (1) to the air compressor outlet.

STARTING MOTOR

Always connect the negative (-) cable first to avoid arc-ing that can ignite explosive battery gases.

28. Inspect the voltage rating on the starting motor beforeinstalling the electrical wiring.

29. Install the electrical wiring to the starting motor and batter-ies, if used.

� If another method of starting the engine is used, follow themanufacturer’s instructions to make the necessary connections.

12-33 1


12ENGINE RUN-IN INSTRUCTIONS

TEST LOAD

The run-in test must be performed with the engine operating at torque peak rpm. Operate a generator set engineat rated rpm.

Example: The test load for a 475 up engine rated at 2,000 rpm with a 15 percent torque rise is (300 ft-lb)

� This chart assumes the dynamometer constant is 5,252. If the dynamometer constant is not 5,252, use the fol-lowing formula to determine the correct test load:

Correct test load = (Dynamometer constant) x (Test load) \ 5,252.

Example: The dynamometer constant for testing the engine in the above example is 4,000.

Correct test load = (4,000 x 300) \ 5,252 = (228 ft-lb)

� This chart assumes engine run-in on a chassis dynamometer.

Do not crank the starting motor for more than 30 sec-onds. Excessive heat will damage the starter.

1. START the engine. If the engine does not begin operatingafter 30 seconds, allow two minutes for the starting motor tocool.

If the oil pressure is not within specifications, STOP theengine immediately. Both low and high oil pressure willcause engine damage.

Main oil rifle pressure at idle:

Minimum: 138 kPa (20 psi)

Maximum: 483 kPa (70 psi)

Rated RPM Rated Horsepower Torque Rise Test Load

2100210021002100

1050950850760

ALLALLALLALL

1157 N•m (854 ft-lb)1047 N•m (772 ft-lb)937 N•m (691 ft-lb)838 N•m (618 ft-lb)

12-34 1


2. Operate the engine at the IDLE position. Check for leaks.

Do not operate the engine at IDLE for longer than spec-ified. Excessive carbon formation will cause enginedamage.

3. Adjust the engine rpm to 1,200 rpm. Adjust the dynamome-ter load to the test load as previously determined. Operatethe engine at this setting until the coolant temperature indi-cates 70°C (160°F).

4. Check for leaks. Fix all leaks.

5. Check all of the gauges and record the readings.

Do not proceed to the next step until the blowby becomes sta-ble within specifications.

6. Adjust the engine rpm to the torque peak rpm. Adjust thedynamometer load to equal two times the test load. Operatethe engine for two minutes.

7. Check all the gauges and record the readings.


8. Maintain the engine rpm at torque peak rpm. Increase thedynamometer load to equal three times the test load.

9. Operate the engine at this load for 2 minutes.



12-35 1


11. Move the throttle lever to the FULL OPEN position. Increasethe load until the engine rpm is at torque peak rpm.

12. Operate the engine at this setting for 10 minutes or until theblowby becomes stable within the specifications.


14. Decrease the dynamometer load until the engine rpmincreases to the rated rpm.

15. Operate the engine at this load for 5 minutes.


17. Decrease the dynamometer load completely.

Do not turn the engine OFF immediately. The enginemust be allowed to cool.

18. Move the throttle lever to the LOW IDLE position. Operatethe engine at this setting for 3 to 5 minutes. This will allowthe turbocharger and the other engine components to cool.

Do not operate the engine at IDLE longer than speci-fied. Excessive carbon formation can cause enginedamage.

19. Turn the engine OFF.

12-36 1

TESTING AND ADJUSTING TESTING AND ADJUSTING TOOL LIST

12TESTING AND ADJUSTING TOOL LIST

No. Testing and Measuring Item Tool Description Part Number

1 Engine SpeedHand Tachometer 3823782

Digital Optical Tachometer 3377462

2 Battery Specific Gravity Specific Gravity Tester Commercially Available

3 Freezing Temperature of Coolant Fleetguard Coolant Test Kit CC2602

4

Water Temperature

Digital Thermometer 3822666Oil Temperature

Air Temperature

5 Exhaust Temperature Contact Pyrometer 3376336

6

Lubrication Oil Pressure

Pressure-Vacuum Meter 3824645Fuel Pressure

Intake Manifold Pressure

7

Exhaust Pressure

Slack Tube Manometer ST1111-30Blow-by Pressure

Intake Restriction

8 Compression Pressure Compression Gauge Commercially Available

9 Valve Clearance Feeler Gauges Commercially Available

10 Exhaust Gas Color Smoke Meter Commercially Available

11 Water and Fuel Content in Oil Engine Oil Testing Commercially Available

12 Fuel Injection Pressure and Pattern Nozzle Tester 3376946

13 Coolant quality, Molybdate and Nitrite Fleetguard Coolant Test Kit CC2602

14 Cooling Pressure Valve Function, Leakage Radiator Cap Tester Commercially Available

15 Radiator Wind Speed Anemometer Commercially Available

16 Engine Barring Barring Device 3201740

17 Electrical Circuit Testing Multimeter 3377161

18 Fuel Injection TimingProximity Sensor and Lights Bosch # 0 986 612 174

Fuel Pump Locking Pin Part of Pump Assembly

19 Performance Options Insite Service Tool 3886188

20 Alternator Belt Tension Tension Gauge ST1293

21 Fan Belt Tension Tension Gauge Burroughs BT-33-72B

12-37 1

TESTING AND ADJUSTING TESTING AND ADJUSTING TOOL LIST

12

� The values given in the Testing and Adjusting data are NOT for adjustment of the output.Do not use these values as a guide to change the setting of the fuel injection pump.

Engine model 12V140Z-1

Applicable machine model 330M WA900 WA800

Classifi-cation Item Condition, etc. Unit

Standardvalue

Permissiblevalue

Standardvalue

Permissiblevalue

Standardvalue

Permissiblevalue

Per

form

anc

e Engine speed(adjustable)

High idling speedrpm

2100 - 2200 2100 - 2200 2100 - 2200 2100 - 2200 2100 - 2200 2100 - 2200

Low idling speed 600 - 700 600 - 700 650 - 700 650 - 700 650 - 700 650 - 700

Necessary starting speed0°C

rpmMin. 110 – Min. 110 – Min. 110 –

–20°C (with starting aid) Min. 100 – Min. 100 – Min. 100 –

Inta

ke a

nd e

xhau

st s

yste

m

Intake resistance At all speed mmH2O Max. 380 635 Max. 380 635 Max. 380 635

Intake pressure At rated output mmHg 1321 – 1170 – 1016 –

Exhaust pressure(Turbine inlet pressure)

At rated output mmHg – – – – – –

Exhaust temperature(Turbine inlet temp.)

All speed(intake air temp.: 25°C)

°C Max. 750 750 Max. 750 750 – –

Exhaust gas color

Quick acceleration(Low idling to High idling)

Boschscale

Max. 5.0 7.0 Max. 5.0 7.0 5.0 7.0

At rated output Max. 0.6 1.0 – – – –

At high idling Max. 0.6 1.0 Max. 1.0 1.5 1.0 1.5

Valve clearance(when engine is hotor cold)

Intake valvemm

0.43 – 0.43 – 0.43 –

Exhaust valve 0.80 – 0.80 – 0.80 –

Eng

ine

body

Compression pressure(SAE30 oil)

Oil temperature: 40 – 60°C(Engine speed: 160-200rpm)

MPa(kg/cm2)

Min. 3.1(Min. 32)

2.2(22)

Min. 3.1(Min. 32)

2.2(22)

Min. 3.1(Min. 32)

2.2(22)

Blowby pressure(SAE30 oil)

At rated outputWater temperature: Min. 70°C

mmH2O 305 635 305 635 305 635

Lub

rica

tion

syst

em Oil pressure

(Oil temperature:Min. 107°C (225°F))

At rated outputSAE30 oil

MPa(kg/cm2)

0.3 – 0.44(3.0 – 4.5)

0.21(2.1)

0.25 – 0.39(2.5 – 4.0)

0.18(1.8)

– –

SAE10W oil 0.25 – 0.39(2.5 – 4.0)

0.18(1.8)

0.20 – 0.34(2.0 – 3.5)

0.13(1.3)

– –

At low idlingSAE30 oil Min. 0.1(Min. 1.0)

0.07(0.7)

Min. 0.1(Min. 1.0)

0.07(0.7)

– –

SAE10W oil Min. 0.1(Min. 1.0)

0.07(0.7)

Min. 0.1(Min. 1.0)

0.07(0.7)

– –

Oil temperature All speed (oil in oil pan) °C 80 – 110 120 80 – 110 120 80 – 110 120

Oil consumption ratioAt continuous rated output(Ratio of fuel consumption)

% Max. 0.5 1.0 Max. 0.5 1.0 – –

Fu

el s

yste

m

Fuel injection pressure Nozzle testerMPa(psi)

30

–

30

–

30

–

4350 4350 4350

Fuel injection timing B.T.D.C. degree 6.5 6.5 ± 0.5 6.5 6.5 ± 0.5 6.5 6.5 ± 0.5

C

oolin

g sy

stem

Radiator pressure valveOpening pressure(Differential pressure)

MPa(kg/cm2)

0.1 ± 0.015(1.0 ± 0.15)

0.1 ± 0.015(1.0 ± 0.15)

0.07 ± 0.01(0.70 ± 0.1)

0.07 ± 0.01(0.70 ± 0.1)

– –

Fan speed At rated engine speed rpm 1000 ± 30 – 1000 ± 30 – 1000 ± 30 –

Fan belt tension mm Autotension Autotension Autotension

+1.0- 0

+1.0- 0

+1.0- 0

+200- 0

+200- 0

+200- 0

12-38 1

TESTING AND ADJUSTING COOLING SYSTEM

COOLING SYSTEM

CHECKING FAN BELT TENSION

330M

1. Install belt tension gauge (Burroughs # BT-33-72B)

• New belt tension: 2660 N (600 lb)• Used belt tension: 2220 N (500 lbF)• Range: 1780 N (400 lbF)

2. If tension is below specifications, loosen nuts (1) and (2).Tighten nut 2 until tension is correct.

Lock nut: 81 N•m (60 ft-lb)

WA800/WA900

Use same procedure for retension. New belt requires movinglock nut (1) to end of rod and moving second idler to contactbelt. Tighten second idler and repeat new belt tensioning proce-dure.

ALTERNATOR BELT

CHECKING BELT TENSION

Push belt (4) at mid-point between alternator and alternatordrive pulley with a force of approximately 58.8 N (1.3 lbf) andmeasure the distance the belt moves.

12-39 1

TESTING AND ADJUSTING ALTERNATOR BELT

ADJUSTING BELT TENSION

Turn the lockout adjustment bolt (1) in the direction to extendthe belt (3). Adjust the belt to specifications. Tighten the lockbolt (2) and the locknut.

Locknut: 55 N•m (40 ft-lb)

DRIVE BELT TENSION

� This chart does not apply to automatic belt tensioners.� A belt is considered used if it has been in service for ten minutes or longer.� If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.

SAE Belt Size Belt Tension Gauge Part No. Belt Tension New Belt Tension Range Used*Click-type Burroughs N lbf N lbf

0.380 in0.440 in

1/2 in11/16 in3/4 in7/8 in4 rib5 rib6 rib8 rib10 rib12 rib

12 rib K section

3822524382252438225243822524382252438225243822524382252438225253822525382252538225253822525

ST-1138ST-1138ST-1138ST-1138ST-1138ST-1138ST-1293ST-1293382313838231383823138

620620620620620620620670710890111013301330

140140140140140140140150160200250300300

270 to 490270 to 490270 to 490270 to 490270 to 490270 to 490270 to 490270 to 530290 to 580360 to 710440 to 890

530 to 1070890 to 1070

60 to 11060 to 11060 to 11060 to 11060 to 11060 to 11060 to 11060 to 12065 to 13080 to 160100 to 200120 to 240200 to 240

12-40 1

13 DISASSEMBLY AND ASSEMBLY

DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3WASHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3SETTING ENGINE STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3GENERAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3

Engine cooling water and engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3Muffler assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4Intake connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5Turbocharger assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5Intake manifold, aftercooler assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6Exhaust manifold assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7Air compressor assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8Fuel pump drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9Water pump assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11Oil cooler assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12Rocker lever cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12Rocker lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13Cylinder head assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14Cam follower assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14Thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15Accessory drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15Damper, crankshaft pulley assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16Oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16Main relief valve, suction tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16Front support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17Gear case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-19

WASHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23WASHING CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23WASHING CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-25WASHING CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-25

MEASURING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26MEASURING CURVATURE OF CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26MEASURING OUTSIDE DIAMETER OF JOURNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26MEASURING OUT-OF-ROUNDNESS OF JOURNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26MEASURING SURFACE ROUGHNESS OF OUTSIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-27DIAMETER OF JOURNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-27MEASURING DEPTH OF CYLINDER LINER COUNTERBORE . . . . . . . . . . . . . . . . . . . . . . . . . 13-27MEASURING MAIN BEARING BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-28MEASURING CURVATURE OF CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-28MEASURING OUTSIDE DIAMETER OF JOURNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-28MEASURING HEIGHT OF CAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-29

13-1 1

DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS

13-2 1

MEASURING PISTON RING GROOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-29Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-29

MEASURING PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-29MEASURING OUTSIDE DIAMETER OF PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-30MEASURING LENGTH OF CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-30MEASURING INSIDE DIAMETER AT SMALL END OF CONNECTING ROD . . . . . . . . . . . . . . 13-31MEASURING INSIDE DIAMETER AT BIG END OF CONNECTING ROD . . . . . . . . . . . . . . . . . 13-31MEASURING CURVATURE, TWISTING OF CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . 13-31STANDARD PRESSURE FOR PARTS PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 13-32

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-33TIGHTENING BOLTS BY PLASTIC RANGE TURNING ANGLE METHOD . . . . . . . . . . . . . . . . 13-33SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-34PREPARATORY WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-34GENERAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-35

Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-35Gear Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-47Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-53Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-57Front support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-58Main relief valve, suction pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-58Oil pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-58Damper, crankshaft pulley assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-58Accessory drive assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-59Thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-60Cam follower assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-60Cylinder head assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-60Rocker lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-63Rocker lever cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-64Oil cooler assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-65Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-67Water pump assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-67Fuel pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-68Air compressor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-70Fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-71Exhaust manifold assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-71Intake manifold, aftercooler assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-72Turbocharger assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-73Intake connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-74Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-74General assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-75

DISASSEMBLY AND ASSEMBLY DISASSEMBLY

12DISASSEMBLY

SPECIAL TOOLS

WASHING• Before disassembling the engine, check all parts for any

cracks or damage, then clean the whole engine carefullywith steam so that the disassembly work can be carried outswiftly.A) Before washing, remove starting motor assembly (1),

alternator assembly (2), and electric wiring.B) Cover all the openings of the engine with tape.C) Using a washing machine, clean engine.

� Carefully wash all mating surfaces where mud tends to col-lect

SETTING ENGINE STAND• Prepare a stable engine stand that will prevent the engine

from falling over, then set the engine assembly on the standand secure it in position.

Engine assembly: Approx. 3,200 kg (7,056 lb)

(The weight differs according to the machine mounting theengine.)

GENERAL DISASSEMBLY

Engine cooling water and engine oil

1. Drain engine cooling water and engine oil.

Engine oil: Approx. 147 L (39 gal) (The amount of oil differs according to the engine model.)

Government agencies have determined that used engine oil is toxic and carcinogenic. Avoid inhalation,ingestion, and prolonged contact with used engine oil.

No. Part Number Part Description

A 3375960 Valve Spring Compressor

B 3823137 Piston Ring Expander

C 3376015 Liner Puller3375629

D 3823495 Protrusion Gauge

E 3825190 Fuel Injector Puller

13-3 1


2. Filter

• Engine equipped with filtersA) Using filter wrench, remove corrosion resistor (1), oil fil-

ter (2), and fuel filter (3).B) Remove bypass filterC) Remove mounting brackets and filter head.

Muffler assembly

1. Disconnect komaclone tube (4), then remove mufflerassembly (5) and muffler bracket.

Fan

1. Using nylon sling, sling fan, then remove mounting bolts.

2. Remove fan (1).

Fan: 75 kg (165 lb)(The weight differs according to the machine model.)

3. Fan belt

The fan belt idler is under tension. Do NOT place yourhands between the idler and the belt or the fan hub.Personal injury can result.

A) Loosen locknuts (1) and (2). B) Slowly remove nut (1) until the spring tension is relieved

and remove the belt.

13-4 1


4. Fan pulley assembly

A) Using nylon sling, sling fan pulley assembly, andremove mounting bolts.

B) Remove fan pulley assembly (2)

Fan pulley assembly: 85 kg (187 lb)

Intake connector

1. Remove intake connectors. Loosen V-band clamp, slide O-ring connector into crossover.

2. Remove capscrews and air crossover

Turbocharger assembly

1. Disconnect turbocharger oil supply tube (1) and drain tube(2).

2. Remove turbocharger assembly (3).

13-5 1


Intake manifold, aftercooler assembly

1. Left bank

A) Remove tubes for aftercooler.B) Remove heater relay wiring.C) Disconnect air supply to air compressor.

D) Remove engine harness mount clamps.E) Remove sensor connections.

2. Right bank

A) Remove tubes for aftercoolerB) Remove wiring of electrical intake air heater.C) Remove sensors.D) Remove engine harness clamps and engine harness

with mounting panel.

E) Sling intake manifold and aftercooler assembly (11),andremove mounting bolts.

� To prevent the electrical intake air heater from falling off,install a guide bar in the mounting bolt hole of the intakemanifold below.

F) Remove intake manifold and aftercooler assembly.

Intake manifold, aftercooler assembly: 50 kg (110 lb)

13-6 1


3. Aftercooler core

A) Remove connector (12).B) Remove cover (13).C) Remove aftercooler core (14).

Exhaust manifold assemblyRemove exhaust manifold assembly (1).

Exhaust manifold assembly: 30 kg (66 lb)

Fuel Injector

1. Fuel injection spill pipe

A) Remove fuel injection pressure lines (1).B) Remove drain tube (2).

� Install a protective cover to prevent any dirt or dust from get-ting into the discharge port of the injection pump or the inletport of the nozzle connector.

2. Fuel injection pump assembly

� Rotate the crankshaft to the engine timing specificationbefore removing the right bank fuel pump.

� Install a protective cover to prevent any dirt or dust from get-ting into the discharge port of the injection pump or the inletport of the nozzle connector. Clean the debris from aroundthe inline fuel injection pump.

A) Remove electrical connections (1) and fuel lines (2).B) Remove all of the oil lines (3).

13-7 1


� If the fuel pump is to be reused, remove the timing lock pinand install in the locked position, as shown, to preserve thepump timing.

C) Remove the four capscrews (1), washers and nuts hold-ing the pump to the drive housing.

D) Remove the injection pump bracket mounting bolts (2).

� The right bank fuel pump bracket has six mounting bolts.The left bank fuel pump bracket has three mounting bolts.

E) Disengage the pump driveshaft gear from the splinecoupling.

F) Remove the pump from the drive housing.

Air compressor assembly

1. Remove air inlet, air outlet, water inlet, and water outlet con-nections.

13-8 1


The component weighs more than 23 kg (50 lb). Toavoid personal injury, use a hoist or get assistance to liftthe component.

2. Remove the air compressor support mounting capscrews(5).

3. Remove the capscrews (6) from the air compressor mount-ing bracket.

4. Remove the air compressor. Remove the splined coupling(1).

5. Remove and discard the gasket.

Fuel pump drive assembly

1. Remove the fuel pump drive gear cover plate on the frontgear cover.

2. Loosen (2 to 3 turns) the large nut securing the two-piecedrive gear to the drive shaft.

3. Remove the two opposing capscrews securing the fuelpump drive gear to the hub.

4. Fabricate two jackscrews (M12x1.5) using capscrews, PartNo. 01011-31265. Remove 25 mm of thread form the end ofeach capscrew to form a 6 mm diameter. The remaining 25mm of thread will be used to install the jackscrews.

A) Install the two jackscrews.B) Tighten the jackscrews through the gear and hub until

making contact with the thrust plate.

13-9 1


C) Tighten each capscrew with 1/4 turn until the two-piecegear assembly pops off the drive shaft taper.

� Check to make sure the drive gear assembly will be sup-ported by the gear train. If NOT, use a wire to prevent it fromdropping into the oil pan.

D) Remove the jackscrews.E) Remove the nut and washer.

5. Remove the four capscrews securing the flange mounthousing assembly to the rear gear cover.

6. Remove two capscrews from support bracket.

7. Remove the housing assembly.

8. Fuel pump drive disassembly

A) Remove retaining nut (1). (Use modified spline couplingto hold shaft at spline (2).)

B) Remove shaft toward pump mount.C) Remove spline retaining nut (3) (Use modified coupling

to hold shaft)

D) Use puller to remove spline coupling (2)E) Drive bushing (4) from housing (5).

13-10 1


F) Fuel pump drive case assembly

i) Remove drive spline.ii) Pull out drive shaft (3) towards portion A.iii) Left bank: Short

Right bank: Longiv) Remove oil seal (4).v) Pull bushings (5) out from drive case (6).

Water pump assembly

1. Remove the water bypass connection and water transfertube.

2. Remove the four water pump mounting capscrews.

� Two of the mounting capscrews are installed from the frontof the water pump and two from the back.

3. Remove the water pump assembly and gasket. Discard thegasket.

Breather

1. Remove alternator bracket (1).

� The alternator bracket is on the right bank only.2. Remove clamp, then remove tube (2).

3. Remove breather (3).

13-11 1


Oil cooler assembly

1. Remove front oil cooler assembly (1).

2. Remove manifolds (2) and (3).

3. Remove rear oil cooler assembly(4).

4. Oil filter, oil level gauge

A) Remove bracket, then oil filler (1).B) Remove oil level gauge guide (2).

� Loosen the nut at the root of the level guide, then removethe guide.

Rocker lever cover

1. Remove rocker lever cover (1).

2. Remove turbocharger oil supply tube (2) and drain tube (3).

3. Remove air vent tube (4).

4. Remove fuel drain line.

Remove fuel supply connection before removing injec-tor to prevent damage to the rocker lever housing.

13-12 1


5. Nozzle holder, connection

A) Loosen locknut, and remove connection (1).B) Remove holder (2).

C) Using tool E, remove nozzle holder (3).

� Mark each nozzle holder with the cylinder number, keep it ina safe place, and be careful not to damage the tip.

� Check that the gasket is fitted to the tip of the nozzle holder.

Rocker lever

1. Remove rocker lever (1)

� To prevent pressure on the push rod when installing, loosenthe locknut and turn the adjustment screw back 2 to 3 turnsbefore removing the rocker lever assembly.

2. Push rod

Remove push rod (2).

3. Crosshead

Remove crosshead (3).

4. Rocker lever housing

Remove rocker lever housing

13-13 1


Cylinder head assembly

1. Remove mounting bolts (1), then remove cylinder headassembly (2).

2. Remove gasket (3) of each cylinder head.

3. Cylinder head disassembly

A) Using spring pusher A, compress valve spring, thenremove cotter (4).

B) Remove upper seat (5), outer spring (6), and innerspring (7).

C) Remove seals.

D) Remove lower seat (8).E) Raise cylinder head, and remove valve (9).

� Use tags to mark the assembly portion of the valves of eachcylinder.

Cam follower assembly

1. Remove cover (1).

2. Remove mounting bolts (2), then remove cam followerassembly (3).

� The mounting bolt of the cam follower is a special bolt, sokeep it in a safe place and be careful not to lose it.

13-14 1


Thermostat housing

1. Remove connector tube (1).

2. Screw eyebolts (Thread dia. – 10 mm, Pitch – 1.5 mm)[0.3937 in, P – 0.0591 in] into thermostat case (2), slingthermostat case assembly (2), (3), then remove it.

3. Disconnect thermostat case (2) and thermostat housing.

4. Remove thermostat (4) from thermostat case.

5. Remove seal (5).

Accessory drive assembly

1. Remove pulley (1).

2. Remove drive assembly (2).

3. Accessory drive disassembly

A) Pull out hub (3), and remove thrust plate (4).B) Remove shaft (5), thrust plate (6), and gear (7) as one

unit.C) Remove gear (7) from shaft (5).D) Pull out oil seal (9) and bushings (10) form housing (8).

13-15 1


Damper, crankshaft pulley assembly

1. Sling damper and crankshaft pulley assembly (1), andremove mounting bolts.

2. Remove damper and crankshaft pulley assembly.

Damper, crankshaft pulley assembly: 56 kg (123 lb)

Do not use an impact wrench to loosen bolts, to preventpossible damage to threads.

Oil pan

1. Raise cylinder block assembly, and set stand under flywheelhousing and front support.

2. Support oil pan with transmission jack, and remove mount-ing bolts, then remove oil pan (1).

Oil pan: 45 kg (99lb)

Government agencies have determined that usedengine oil is toxic and carcinogenic. Avoid inhalation,ingestion, and prolonged contact with used engine oil.

Main relief valve, suction tube

1. Remove main relief valve (2).

2. Remove bracket (3), then remove suction tube (4).

Front support

Raise cylinder block assembly and remove front support (1).

Sensors

Remove rpm (1) and timing (2) sensors.

13-16 1


Flywheel

1. Using eyebolts (3), (Thread dia. – 12 mm, Pitch – 1.75 mm)[0.4724 in, P – 0.0689 in] sling flywheel (2), then removemounting bolts (1), and screw in forcing screws (4), (Threaddia. – 12 mm, Pitch – 1.75 mm) [0.4724 in, P – 0.0689 in] toremove flywheel (2).

Flywheel: 136 kg (300 lb)

Do not use an impact wrench to loosen bolts, to preventpossible damage to threads.

2. Flywheel housing, rear seal

A) Remove 2 – 3 mounting bolts, then install guide bolts.B) Sling flywheel housing (1), then remove remaining

mounting bolts, and remove flywheel housing (1).� Support the housing by hand when removing it to prevent it

from falling over.

Flywheel housing: 102 kg (225 lb)

C) Remove rear seal.

Gear case

1. Using eyebolts (1) (Thread dia. – 10 mm, Pitch – 1.5 mm)[0.3937 in, P – 0.0591 in], sling gear case cover (1), thenremove mounting bolts, install guide bolts, and remove gearcase cover (1).

Gear case cover: 72 kg (159 lb)

2. Remove front seal.

3. Idler gear (large)

Remove mounting bolts, then remove plate (1) and idler gear(large) (2).

13-17 1


4. Oil pump assembly

Remove oil pump assembly (1).

5. Idler gear (small)

Remove mounting bolts, then remove plate (1) and idler gear(small) (2).

6. Camshaft assembly

Remove bolt from hole in cam gear, then pull out camshaftassembly (1).

� When removing the camshaft, rotate it while pulling it out toprevent damage to the cam bushing.

7. Timing gear case

A) Using eyebolts (A) (Thread dia. – 10 mm, Pitch – 1.5mm) [0.3937 in, P – 0.0591 in], sling gear case, thenremove mounting bolts.

B) Install guide bolts, and remove gear case (1).

Timing gear case: 65 kg (143 lb)

13-18 1


Cylinder Block

1. Piston cooling nozzle

Remove mounting bolts, then remove each piston cooling noz-zle (1).� Before removing the piston and connecting rod assembly,

remove the piston cooling nozzle.� Rotate 90° so that it does not contact the piston when it is

removed.

2. Piston and connecting rod assembly

A) Using dial gauge (1), measure connecting rod sideclearance to act as a guide when assembling.

� Check the stamped number on the connecting rod cap.(The cap number and cylinder number must match. Thenumber is stamped on the cam side.)

� If there is no stamped mark, mark the cylinder No. with anelectric pen before removing. Do not stamp a mark.

B) Rotate the crankshaft so that the piston to be removedis at bottom dead center.

C) Loosen connecting rod bolt (1) 5 – 6 turns.

If an impact wrench is used to loosen the bolts, there isdanger of damage to the thread, so loosen the boltswith a hand tool.

D) Tap head of connecting rod bolt with a plastic hammer,then disassemble connecting rod cap and connectingrod.

E) Remove carbon from top wall of liner with fine sandpa-per.

F) Rotate crankshaft, and align with top dead center, thenremove connecting rod cap (2).

G) Push in piston and connecting rod from oil pan end withpush bar (1), and support piston (3) at cylinder headend while removing it.

� Be careful not to damage the inside surface of the liner withthe corner of the connecting rod when removing it.

13-19 1


H) Remove other piston and connecting rods in the sameway.

� Keep in a safe place and be careful not to damage the pis-ton sliding surface and the bearing.

� Assemble the connecting rod and cap temporarily and keeptogether with the bearing to prevent mistakes when reas-sembling.

I) Disassemble the piston and connecting rod assembly.

i) Remove snap ring (4).ii) Support connecting rod (5) with hand, then pull out

piston pin (6), and disassemble piston (7) and con-necting rod.

iii) If the piston pin is stiff and cannot be removed, heatit in hot water (100°C [212°F], 5 min.) before remov-ing it.

iv) Remove snap ring on the opposite side.

v) Using piston ring tool B, remove piston ring (8).vi) Remove oil ring expander (9).

� Keep the piston, connecting rod, connecting rod bearing,piston ring, and piston pin in sets for each cylinder.

3. Crankshaft

A) Before removing the crankshaft, use dial gauge (1) tomeasure end play of crankshaft, and use it as a guidewhen assembling.

13-20 1


B) Remove mounting bolts (2) of main cap (1).C) Insert bolt in hole of main cap, and move the main cap

from side to side to remove it.

� Lower thrust bearing (3) is installed to the No. 7 main cap,so after removing it, mark the assembly position.

D) Using wire, lift off crankshaft (4).

� When raising the crankshaft, be careful not to hit it againstthe cylinder block and damage it. After removal, keep it in asafe place.

Crankshaft: 210 kg (463 lb)

E) Remove upper thrust bearing (5).F) Remove upper bearing (6).

� Use tags or a felt pen to mark the assembly position of themain cap, main bearing, and thrust bearing, then keep themin sets for each cap in a safe place.

13-21 1


4. Cylinder liner

A) Before removing cylinder liner, use tool D and dial indi-cator (1) to measure protrusion of cylinder liner.

� When measuring the protrusion of liner, tighten the liner witha plate to prevent the liner from floating up on the O-ring.

Plate mounting bolt: 7 – 10 kgm (51 – 72 ft-lb)

B) Using liner puller C, pull out cylinder liner (1).

13-22 1

DISASSEMBLY AND ASSEMBLY WASHING

12WASHING

Wear protective eyewear to prevent fluid from possiblecontact with the eyes.

• When washing, divide the parts into small parts and largeparts, and wash the small parts in a bath like the one shownon the right.

• Before washing disassembled parts, remove the gasket car-bon with a wire brush.

• After washing, dry the washing fluid off completely withcompressed air.

• Make sure that no cleaning fluid remains in the bolt holes.Bolts may not be properly tightened if fluid is present.

WASHING CYLINDER BLOCK

1. Before washing the cylinder block, remove the plugs of theoil line in the cylinder block.

� Timing case end: 7 places� Flywheel end: 5 places

2. Clean with a stiff wire brush to prevent any metal particlesfrom remaining in the oil line.

3. Use sandpaper to polish the O-ring contact surface smoothat the bottom of the liner bore and to remove the burrs andflashes from the liner bore.

4. Clean the oil line thoroughly with the jet cleaner nozzle ofthe cleaning machine.

5. Dry off the cleaning fluid completely with compressed air.

� Make sure that no cleaning fluid remains in the bolt holes.Bolts may not be properly tightened if fluid is present.

13-23 1


126. Press fit plug with push tool.

Outer circumference of plug: Thread tightener (LT-2)

� If the plug is bent when it is pushed in, it will cause leakageof water, so be careful to insert it straight.

Unit: mm

Inside diameter of plug

ø30[1.1811 in]

ø40[1.5748 in]

øD

29.5 0–0.1 39.4 0

–0.1

[1.1614 0 –0.0039 in] [1.15512 0

–0.0039 in]

ød

26.5 0–0.1 36.4 0

–0.1

[1.0433 0–0.0039 in] [1.4331 0

–0.0039 in]

H6.4 ± 0.1

[0.252 ± 0.0039 in]8.9 ± 0.1

[0.3504 ± 0.0039 in]

t1.0

[0.0394 in]1.0

[0.0394 in]

13-24 1


12WASHING CRANKSHAFT

• If the engine is disassembled, wash the crankshaft beforeinspecting.

1. Clean the crankshaft with a steam cleaner, then use a wirebrush like the one shown in the diagram on the right to cleanall the oil holes.

2. After washing, dry the cleaning fluid off thoroughly with com-pressed air.

3. Use a small magnet to completely to completely remove allthe metal particles from the oil holes.

WASHING CONNECTING ROD

1. Clean the connecting rod with a steam cleaner, then use a wire brush to clean the oil holes.

2. If the inside surface of the hole at the big end of the connecting rod is black, but the problem is small and thedimensions are still within the specified value, the connecting rod can be used as it is.If the black portion is to be removed, use sandpaper (#800 – #1000) and polish lightly.

� Polish lightly so that the original honing grain is not removed.If the polishing removes the honing grain, and the wave on the inside surface exceeds the limit, the connectingrod must not be used again.

3. Blow with air and use a cloth to remove all the dirt inside the big end of the connecting rod.

13-25 1

DISASSEMBLY AND ASSEMBLY MEASURING PARTS

12MEASURING PARTS

• Before reassembling disassembled parts, check visually that there are no cracks, damage, or abnormal wear.• Inspect for reuse.• If no abnormalities are found during the visual inspection, use an accurate measuring device to measure the

specified position precisely.• Action and judgement on whether the parts can be reused shall be in accordance with the maintenance stan-

dard.

MEASURING CURVATURE OF CRANK-SHAFT1. Support the center of both ends of the crankshaft with

lathes, put the indicator of the dial gauge perpendicularly incontact with the journal at the center, and set it to 0.

� If no lathe is available, support the No. 1 and No. 7 journalsin a V block.

2. Rotate the crankshaft one turn, and measure the differencebetween the maximum reading and minimum reading of thedial gauge.

� Do not measure with both ends of the crankshaft supportedon V blocks. This method produces an error because of theeccentric wear of the journal.

MEASURING OUTSIDE DIAMETER OF JOURNAL

Using a micrometer, measure the outside diameter of the mainjournal and pin journal in the X and Y directions.

MEASURING OUT-OF-ROUNDNESS OF JOURNAL

Measure the outside diameter of the journal in the X and Ydirections and calculate the difference.

13-26 1


12MEASURING SURFACE ROUGHNESS OF OUTSIDE DIAMETER OF JOURNAL

Check the surface roughness using the surface roughness standard piece shown in the diagram below.

� When measuring the surface roughness, compare the surface roughness of the journal with the standardpiece.

� If there are any scratches or dents in the surface of the crankshaft journal, correct the surface roughness. How-ever, if the outside diameter of the journal is close to the standard value and there is no margin for correction(the scratches and dents cannot be removed by correcting the surface roughness), correct by grinding.

MEASURING DEPTH OF CYLINDER LINER COUNTERBORE

1. Set the depth gauge (2) on gauge block (1), then set thegauge indicator to 0.

2. Set the gauge block parallel with the top surface of the cylin-der block, and measure the depth of the counterbore.When doing this, slide the measurement portion and mea-sure at several places.

� Clean the counterbore and top surface of the cylinder blockbefore measuring.

Part No.

Standard piece 790-101-8110

13-27 1


MEASURING MAIN BEARING BORE

1. Install the main bearing cap to the cylinder block, andtighten to the specified torque.

2. Using a dial bore gauge to inside micrometer, measure themain bearing bore.

� When measuring the main bearing bore, measure in twodirections (X and Y).

MEASURING CURVATURE OF CAMSHAFT

1. Support the center of both ends of the camshaft with lathes,put the indicator of the dial gauge perpendicularly in contactwith the journal at the center, and set it to 0.

2. Rotate the camshaft one turn, and measure the differencebetween the maximum reading and minimum reading of thedial gauge.

MEASURING OUTSIDE DIAMETER OF JOURNAL

Using a micrometer, measure the outside diameter of the cam-shaft journal.

13-28 1


MEASURING HEIGHT OF CAM

Using a micrometer, measure cam height H for the intake andexhaust.

MEASURING PISTON RING GROOVE

Special tools

1. Measuring keystone ring groove

Push piston ring wear gauge A lightly into the ring grooves ofthe top ring and second ring, and measure the wear of the ringgroove.

� If the shoulder of the wear gauge contacts the piston,replace the piston.

� Carry out the measurements at 8 places around the circum-ference.

2. Measuring straight ring groove

Assemble the piston ring to the cylinder liner, push the pistonring into the area of the cylinder where there is least wear, then measure the piston ring end gap with a feelergauge.

� Insert the piston ring so that it is at right angles to the sliding portion of the liner.

MEASURING PISTON RING END GAP

Assemble the piston ring to the cylinder liner, push the pistonring into the area of the cylinder where there is least wear, thenmeasure the piston ring end gap with a feeler gauge.

� Insert the piston ring so that it is at right angles to the slidingportion of the liner.

No. Part No. Part Name Q’ty

A 795-901-1130 Wear gauge 1

13-29 1


12MEASURING OUTSIDE DIAMETER OF PIS-TON

Use a micrometer to measure the dimension L at the piston skirt(45 mm from bottom, at right angles from pin hole).

MEASURING LENGTH OF CONNECTING ROD

1. Tighten the mounting bolts of the connecting rod cap to thespecified torque.

� Check that the number at the rod and cap ends of the con-necting rod are the same.

� Do not assemble the connecting rod bearing.

2. Assemble a new piston ring pin in the hole at the small endof the connecting rod.

� Coat the piston with grease (G2-LI) before installing.

3. Support both ends of the piston pin on V blocks, and sup-port both ends of the connecting rod on square blocks

4. Measure the distance A between the big end and small endwith a height gauge.

5. Measure the inside diameter of the big end and small end.

� Calculate the value for the length B of the connecting rod asfollows.

Connecting rod dimension B

A

� If the value exceeds the permitted value, replace the connecting rod.

ID of big end + ID of small end

2-------------------------------------------------------------------------------- +–

13-30 1


MEASURING INSIDE DIAMETER AT SMALL END OF CONNECTING ROD

Use an inside micrometer to measure the dimension at positions(a) and (b) in the X and Y directions.

� If the value exceeds the permitted value, replace the bush-ing.

MEASURING INSIDE DIAMETER AT BIG END OF CONNECTING ROD

Use an inside micrometer to measure the dimension at positions(c) and (d) in the X, Y, and Z directions.

� If the value exceeds the permitted value, or if there arescratches on the inside diameter at the large end, replacethe connecting rod.

� Do not re-use any connecting rod if there has been seizureof the bearing.

MEASURING CURVATURE, TWISTING OF CONNECTING ROD

1. Method for measuring curvature

A) Tighten the mounting bolts of the connecting rod to thespecified torque.

� Do not assemble the connecting rod bearing.

B) Assemble a new piston pin in the hole at the small endof the connecting rod, place V blocks on a flat surface,then set both ends of the piston pin on the V block.

� Coat the piston pin with grease (G2-LI) before installing.

C) Stand the connecting rod perpendicularly, and supportboth sides of the big end with square blocks.

D) Set the indicator of height gauge (1) at the front of the hole at the big end, set it in contact with the bottom,then set the gauge to 0.

E) Move the height gauge to the opposite side by a distance equal to the width of the big end, and read themeasurement of the gauge.

13-31 1


2. Method for measuring twisting

A) From the condition described above, remove the squareblocks, lay the connecting rod down, and support thebig end on the tip of a conical jack.

B) Measure the big end in the same way as when measur-ing the curvature.

� Calculate the value for the curvature and twisting as follows.

Curvature, twisting

STANDARD PRESSURE FOR PARTS PRESSURE TESTING

• Cylinder head: 3 – 3.5 kg/cm2 (42.6 – 49.8 psi)

• Oil cooler element: 16 kg/cm2 (227.5 psi)

• Between oil cooler and cover: 2 kg/cm2 (28.4 psi)

• Aftercooler: 4 kg/cm2 (56.9 psi)

Dimension ADimension B-------------------------------- Actual measured value×–

13-32 1

DISASSEMBLY AND ASSEMBLY ASSEMBLY

12ASSEMBLY

TIGHTENING BOLTS BY PLASTIC RANGE TURNING ANGLE METHOD

• The important bolts on the 12V140Z-1 series engine use theplastic range turning angle method for tightening.This method uses special bolts, and by tightening the boltsto the load where the bolt starts to deform permanently(plastic range), it is possible to get an accurate, high tighten-ing force.(Of the methods used for tightening bolts, the method usingchecking of torque is the most common, but because of theinfluence of friction factors, it is difficult to control the tight-ening force accurately.)

• The tightening method using the plastic range turning angle method uses the initial tightening torque and theturning angle to tighten the bolts.

• Bolts tightened with the plastic range turning angle method on the 12V140Z-1 series engine.• Cylinder head mounting bolts• Main cap mounting bolts• Connecting rod cap mounting bolts

� With the plastic range turning angle method, there is a permanent deformation remaining after tightening.Therefore, there is a limit to the number of times that the bolt can be used, so please observe the following.

• After tightening, make one punch mark. If any bolt has more than 5 punch marks, do not use it again; replaceit with a new bolt.

• When tightening to an angle greater than the specified angle, loosen completely before tightening again. (Inthis case, make two punch marks.)

• The target for the tightening angle should be the standard value ± tolerance.

13-33 1


12SPECIAL TOOLS

• Wash all parts clean, and check that there are no dents, scratches, or casting defects. Check also that all oil orwater passages are clear before assembling

.

PREPARATORY WORK

Before inserting the cylinder liner, take the following action withthe cylinder block.

1. Remove the rust and scale from surfaces (A) and (B) withsandpaper until the machining surface appears.

2. Polish portions (R) and (r) with #200 sandpaper so that theR surface is smooth.

3. Polish potions (B), (R), and (r) with #200 sandpaper so thatthey become smooth. If the corner of the R portion is sharpor there are burrs, polish with a scraper or sandpaper. Besure to finish this surface particularly smoothly so that isdoes not scratch the O-ring.

4. If surface (R) is pitted and rough, and cannot be corrected,replace the cylinder block.

5. If surface (A) and portions (R) and (r) are pitted and rough,finish them smoothly.

6. Inspect the counterbore, and remove any burrs or flashes.If there are any metal particles or dirt on surface (C), the liner will not fit properly in close contact, and this maycause problems such as leakage of water or protrusion of liner.

� If there is any drooping, corrosion, or pitting left in the counterbore, carry out additional machining.

No. Part Number Part Description

A 3375960 Valve Spring Compressor

B 3823137 Piston Ring Expander

D 3823495 Protrusion Gauge

E ST1229 Liner Driver

F 3822736 Piston Ring Compressor

G 790-331-1110 Wrench (Angle/Torque)

H 795-602-2200 Seal Installer (front)

795-602-2300 Seal Installer (rear)

13-34 1


12GENERAL ASSEMBLY

Cylinder block

1. Cylinder liner

� Replace the liner O-ring and clevis seal with new parts immediately before assembling the liner.

A) Installing liner O-ring and clevis seali) Check the cylinder liner O-ring groove and outside circumference of the liner to confirm that there is no

rust or pitting.� If the surface is rough and pitted, it may cause leakage of water, so replace the liner.

ii) Coat the liner O-ring and clevis seal with soapywater.

� Oil causes the clevis seal and O-ring to swell and deterio-rate, so do not leave them soaking in oil. If oil is used, coatwith a small amount of clean engine oil (SAE30) with abrush immediately before assembly.

iii) Assemble the liner O-ring and clevis seal to theliner as shown in the diagram on the right.

B) After installing the liner O-ring, check for twisting. If anytwisting is found, use a smooth bar (approx. ø 10) [ø0.3937 in] to remove the twisting.

� To prevent the clevis seal from twisting when it is installed,press it around the whole circumference so that it fits intothe seal groove.

� Assemble the clevis seal with the chamfered side facingdown.

13-35 1


C) Inserting cylinder liner.

i) Using a cloth, wipe off all the dirt and oil from thecontact surface of the liner lip and the cylinder blockcounterbore.

ii) Coat the mating surface (a) of the cylinder blockand cylinder liner counterbore with silicon-basedgasket sealant (LG-6).

� Width of gasket sealant: ø1.5 – 2.0 mm (0.0590 – 0.0787 in)

� Make an overlap of 6 ± 6 mm (0 – 0.4724 in) at the begin-ning and end when coating with gasket sealant LG-6.

13-36 1


D) When machining the bottom contact surface of thecounterbore liner lip and using a shim.i) Coat the bottom of the shim thinly with gasket seal-

ant LG-6, then assemble the shim.ii) Next, coat with gasket sealant LG-6 in the same

way as when not using a shim.

E) Coat the liner O-ring, clevis seal, and cylinder blockcontact surface with a small amount of engine oil (SAE#30) immediately before press fitting the liner.

� Coat the contact surface of the cylinder block uniformlyaround the whole circumference by hand.

� There are two different types of pistons and cylinder liners.Small piston Part No. 6212-31-2151 must be used withsmall liner Part No. 6211-21-2230. Large piston Part No.6212-31-2161 must be used with large cylinder liner PartNo. 6211-21-2240.

F) Set the “T” mark on the top surface of the liner facingthe front, then insert cylinder liner (1) into the cylinderblock, taking care not to damage the O-ring.

G) Use your weight and push the liner in with both hands.� If the liner does not go in smoothly when you apply your

weight, there is danger that the O-ring may be damaged, socheck the cylinder block for burrs or flashes.

H) Using a liner driver E, press fit cylinder liner (1) into thecylinder block.

I) Using the following procedure, squeeze out the gasketsealant coated on the counterbore.

i) Tighten the cylinder head temporarily with a usedhead gasket.

� Bolt (7) may be tightened partially.

13-37 1


ii) Remove the cylinder head, and wipe off gasketsealant that comes out from between the cylinderliner and cylinder block.

� If the gasket sealant sticks to the head gasket grommet, thegrommet will be deformed. This will cause water leakage,so be sure to wipe off all excess gasket sealant.

J) After press fitting the cylinder liner, use tool D to mea-sure the protrusion of the cylinder liner.

� When measuring the protrusion of the cylinder liner, holdthe cylinder liner down with plate (1) to prevent the cylinderliner from being forced up by the elasticity of the O-ring dur-ing measurement.Measurement positions: (a), (b), (c), (d) (4 places)

Plate mounting bolt: 69 – 98 N•m (51 – 72 ft-lb)� Protrusion of cylinder liner: 0.080 – 0.185 mm (0.0031 –

0.0073 in)� If it is not within the standard value, take the action given in

the MAINTENANCE STANDARD.

2. Crankshaft

A) Align the protrusion of upper main bearing (6) with thenotch in the cylinder block, then assemble in the cylin-der block.

� Upper bearing: With oil hole� The bearing for No. 4 is wider than the other bearings, so be

careful not to mistake it when assembling.� Width a of bearing

No. 4 bearing: 52 mm (2.0 in)Other bearings: 48 mm (1.9 in)

� Check that there is no dirt at the rear face of the bearingbefore tightening.

� Do not coat the rear face of the bearing with oil.

B) Knock in roll pin so that protrusion from end face ofblock is 2.7 – 3.4 mm (0.11 – 0.13), then install upperthrust bearing (5).

� Install the thrust bearing with the side with the groove on thecrankshaft side.

13-38 1


C) Coat inside surface of upper main bearing with engineoil (SAE#30).

� Check for the following before assembling the crankshaft.• Abnormality in the front, rear side threaded portion

(The bolt must go in smoothly when turned by hand.)• Scratches or dents on the pin or main journal portion.• Dirt stuck to the inside of the oil hole.

D) Raise crankshaft (4), and assemble to the mountingposition, taking care not to hit the cylinder block.

E) Align the protrusion of lower bearing (5) with the notchin the main cap, and install.

� Check that there is no dirt at the rear face of the bearingbefore tightening. Coat the inside surface of the bearingwith engine oil (SAE#30).

� Do not coat the rear face of the bearing with oil.

13-39 1


� Lower bearing: No oil hole� The bearing for No. 4 is wider than the other bearings, so be

careful not to mistake it when assembling.� Width a of bearing

No. 4 bearing: 52 mm (2.0 in)Other bearings: 48mm (1.9 in)

F) For No. 7 cap, knock in the roll pin so that the protrusionfrom the end face of the cap is 2.7 – 3.4 mm, then installlower thrust bearing (3) on both sides.

� Install the thrust bearing with the side with the groove on thecrankshaft side.G) Coat the journal surface of the crankshaft with engine

oil (SAE#30), check that the stamped number on eachmain cap (2) matches the number on the cylinder block,then install the main caps.

� Assemble the main cap with the cast part number facing thefront of the engine.

H) Coat the washer and the mounting bolt thread of themain cap with engine oil (SAE#30), then screw in thebolts in turn to insert the main cap completely.

� Do not use an impact wrench to tighten the bolts. This maydamage the threads. Always tighten with a hand tool.I) When tightening, start from the center main cap and

work in order to the outside. Tighten the bolts to thespecified tightening torque using the following steps.

i) Tighten main cap mounting bolts in three steps, asfollows:

• Tighten both bolts to first torque value.

271 – 299 N•m (199 – 220 ft-lb)

• Tighten both bolts to second torque value.

559 – 579 N•m (413 – 426 ft-lb)

• Reference marks on the bolt and cap; then turn the bolt anadditional 90°.

13-40 1


ii) After tightening, make one punch mark on the bolthead. If the bolt head has five punch marks, do notreuse it. Replace the bolt with a new bolt.

J) After tightening bolts, rotate crankshaft, and check thatit rotates smoothly.

� Starting torque of shaft: Max. 147 N•m (108.5 ft-lb)

K) Measure end play of crankshaft with dial gauge (1). � End play: 0.140 – 0.32 mm (0.0056 – 0.0125in)� Lever the center portion of the counterweight and measure

the end play.� If it is within the standard value, take the action given in the

maintenance standard.

3. Piston, connecting rod assembly

A) Assemble piston and connecting rod.i) Fit oil ring expander (9) in oil ring groove.ii) Using piston ring tool B, assemble oil ring, second

ring, and top ring in order.

� Assemble each piston ring as shown in the diagram.� Set each ring with the stamped mark facing up, then assem-

ble to the piston.� When assembling the oil ring, first take out the expander

and fit it to the piston, then assemble the oil ring. Whendoing this, check that the expander is fitted completely intothe ring groove.

� The end gap of the expander coil must be at 180° to the endgap of the oil ring.

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B) Install snap ring (10) on one side.

There are two different connecting rods. The left bankuses connecting rod, Part No. 6215-31-3200 (small pis-ton) ONLY. The right bank uses connecting rod, PartNo. 6215-31-3100 (large piston) ONLY. Using the wrongpart will cause engine failure.

C) Set piston (7) and connecting rod (5) in position. Alignthe casting mark [EX ‹— F] on the piston with the cham-fered side of the hole at the big end of the connectingrod when assembling.

D) Coat the piston pin boss and the inside of the connect-ing rod bushing with engine oil (SAE#30), face the con-necting rod in the position described above, then insertpiston pin (6).

E) Install snap ring (4) on the opposite side.� Rotate the left and right snap rings to check that the snap

rings are completely fitted into the ring groove.� Check that the connecting rod moves smoothly.

F) Align the protrusion of connecting rod upper bearing(11) with the notch in the connecting rod, then install

� Check that there is no dirt at the rear face of the bearingbefore assembling.

� Do not coat the rear face of the bearing with oil.� Check that the hole in the bearing at the big end and the

bushing at the small end of the connecting rod are alignedwith the oil hole in the connecting rod.

� Before assembling the connecting rod, check that there isno dirt stuck inside the connecting rod oil hole.

G) Align the protrusion of connecting rod lower bearing(12) with the notch in the connecting rod cap, theninstall.

� Check that there is no dirt at the rear face of the bearingbefore assembling. When assembling, do not coat the rearface with engine oil.

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H) Coat cylinder liner with engine oil (SAE#30).� Coat the whole circumference uniformly with engine oil by

hand.

I) Rotate the crankshaft and set pin journal of cylinder forinsertion at top dead center

� There are two different types of pistons and cylinder liners.Small piston Part No. 6212-31-2151 must be used withsmall liner Part No. 6211-21-2230. Large piston Part No.6212-31-2161 must be used with large cylinder liner PartNo. 6211-21-2240.

J) Check number of piston and connecting rod assembly,and insert in cylinder at position shown in the diagramon the right.

� Set the cylinder block so that the cylinder faces the side inorder to prevent the piston and connecting rod assemblyfrom entering the cylinder suddenly when it is inserted.

K) Original engine assembly has large piston and liner on one bank. The small piston and liner are on theother bank.

� Piston assembly position

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12 L) Align end gap of each piston ring in the position shown in the diagram below

M) Coat piston ring uniformly with engine oil (SAE#30).

N) Tighten piston ring with piston ring holder F, then pushin piston head with wooden bar.

O) Using connecting rod pulling tool shown in the diagramon the right, pull connecting rod, and fit it in close con-tact with pin journal.

� Check that the connecting rod bearing is correctly in posi-tion.

� To make a connecting rod pulling tool, weld a bar to an oldconnecting rod bolt.

P) Coat crankshaft pin journal with engine oil (SAE#30).

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Q) Rotate crankshaft 180° while pulling connecting rod.

R) Coat connecting rod lower bearing (12) with engine oil(SAE #30), check cap number, then align with dowelpin, and install connecting rod cap (2).

� When coating with engine oil, spread the oil with a fingerover the whole part.

� When assembling a new connecting rod, mark the cylindernumber with an electric pen. (Do not make a stampedmark) Do not change combination of connecting rod andcap under any circumstances.

S) Coat thread and washer of connecting rod bolt withengine oil (SAE #30).

T) Tighten connecting rod bolts (1) in turn until connectingrod cap is in tight contact.

If an impact wrench is used to tighten the bolts, there isdanger of damage to the thread, so tighten the boltswith a hand tool.

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U) Rotate crankshaft 180°, and insert piston and connect-ing rod assembly of other bank using procedure inSteps H) – T).

� Tighten the connecting rod bolts as follows.� If impact wrench is used to tighten bolts quickly, there is

danger of damage to thread, so tighten the bolts with handtool.

1st step:Tighten to 69 – 78 N•m (51 – 57 ft-lb) in ordershown in diagram.

2nd step:Tighten again to 69 – 78 N•m (51 – 57 ft-lb) in order shown in diagram.

3rd step:

Using wrench G, turn 90 °to tighten.

� When not using wrench G, tighten as follows.

• Tighten bolts.

69 – 78 N•m (51 – 57 ft-lb)

• Place reference marks on bolt and cap, then tighten the boltan additional 90°.

• After tightening, make one punch mark on the bolt head. Ifthe bolt head has five punch marks, so not reuse it.Replace the bolt with a new bolt.

• After assembling the connecting rod, check that the crank-shaft rotates smoothly.

V) Using dial gauge (1), measure side clearance on con-necting rod.

� Standard for side clearance:0.3 – 0.454 mm (0.0119 – 0.0178 in)

� If the connecting rod does not move, remove the connectingrod cap and check that there is no mistake in assembly, andthat there are no burrs, or dirt caught anywhere.

+30° 0

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4. Piston cooling nozzle

A) Install cooling nozzle (1).

Mounting bolts:34 – 74 N•m (26 – 54 ft-lb)

� Before installing, check for cracks in the nozzle, and checkthat there is no clogging inside the nozzle.

• Face the tip of the nozzle to the side with the mounting holeat the top, insert into the piston, taking care that it does nothit the piston, then turn 90° to install.

• Before installing, check for cracks in the nozzle, andcheck that there is no clogging inside the nozzle.

B) Rotate crankshaft slowly and check that there is nointerference between piston cooling nozzle and piston,crankshaft.

Gear Case

1. Timing gear case

Fit gasket and install timing gear case (1).� Coat the gasket thinly in several places with gasket sealant

and stick it in position to prevent it from coming off.

Exercise caution when inserting the camshaft, to pre-vent injury to fingers.

2. Camshaft assembly

A) Coat cam bushing with engine oil (SAE#30).B) Install camshaft assembly (1), then align with mounting

hole of thrust plate, and tighten nylock bolts.� Replace the nylock bolts with new parts.

• Tighten nylock bolts.

Nylock Bolts:54 – 122 N•m (40 – 90 ft-lb)

� When inserting the cam shaft, rotate it while inserting it inorder to prevent damage to the cam bushing.

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3. Idler gear (small)

A) Align match mark “D” of cam gear and idler gear (2),and install idler gear.

B) Fit plate (1) and tighten mounting bolts.

4. Oil pump assembly

Fit O-ring, set oil pump assembly (1) in mounting position, thentighten mounting bolts.

Mounting Bolts:34 – 74 N•m (26 – 54 ft-lb)

5. Idler gear (large) (right bank)

A) Align match mark of gear and install idler gear (large).i) Align mark “D” of cam gear (1) and idler gear

(small) (2).ii) Align mark “A” of idler gear (small) (2) and sub-idler

gear (3).iii) Align mark “R” of idler gear (larger) (3) and crank-

shaft gear (5).

B) Fit plate (6) and tighten mounting bolts.� Set plate (6) with the OUT mark facing the outside, then

assemble.� Check that match marks “D”, “A”, and “R” at four

places are aligned.

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6. Idler gear (large) (left bank)

A) Align match of gear and install idler gear (large).i) Align mark “C” of cam gear (1) and sub-idler gear

(2).ii) Align mark “L” of idler gear (large) (2) and crank-

shaft gear (4).

B) Fit plate (5) and tighten mounting bolts.� Set plate (5) with the OUT mark facing the outside, then

assemble.� Check that match marks “C” and “L” at three places are

aligned.

� After assembling each gear, check the timing mark of thegear again.

7. Measuring backlash of gear

A) Fit gear (1) to rear compressor and install temporarily.

B) Install water pump assembly (2) temporarily.

• Measure the backlash and end play of each gear with a dialgauge.

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12• Standard value for backlash of each gear

• Standard value for end play of each gear

8. Front oil seal, sleeve

Take the following action according to the wear of the crankshaftseal contact surface.

A) If crankshaft is new, or if there is no wear of surface incontact with seal oil.

� Measure dimension of portion (b) of front cover and checkfor a bolt hole in the end face of the cover. Then use thetable below and press fit the oil seal to press-fitting depth a.

Position Judgement positionStandard

mm in

A • A Right idler gear (small)and right sub-idler gear

0.130 – 0.390 0.0052 – 0.0153

B1 • B1RIght sub-idler gear and rightinjection pump gear

0.051 – 0.469 0.0021 – 0.0184

B1 • B1Left sub-idler gearand left injection pump gear

0.051 – 0.469 0.0021 – 0.0184

C • C Left sub-idler gearand left cam gear

0.129 – 0.391 0.0051 – 0.0153

D • D Right idler gear (small)and right cam gear

0.129 – 0.391 0.0051 – 0.0153

E • E Right idler gear (large)and water pump drive gear

0.052 – 0.481 0.0021 – 0.0189

F • F Right idler gear (large)and oil pump gear

0.137 – 0.421 0.0054 – 0.0165

G • G Left injection pump gear andcompressor gear

0.106 – 0.381 0.0042 – 0.0150

H • H Right cam gear and accessorydrive gear

0.085 – 0.492 0.0034 – 0.0193

L • L Crankshaft gear and right idlergear (large)

0.141 – 0.425 0.0056 – 0.0167

R • R Crankshaft gear and right idlergear (large)

0.141 – 0.425 0.0056 – 0.0167

Posi-tion

Part Name Standard

mm in

1 Idler gear (large) 0.07 – 0.18 0.0027 – 0.0070

2 Idler gear (small) 0.07 – 0.18 0.0027 – 0.0070

3 Injection pump drive gear 0.07 – 0.20 0.0028 – 0.0078

4 Oil pump drive gear 0.03 – 0.088 0.0012 – 0.0034

5 Accessory drive gear 0.1 – 0.4 0.004 – 0.0157

6 Crankshaft gear 0.14 – 0.32 0.0056 – 0.0125

7 Camshaft gear 0.10 – 0.25 0.004 – 0.098

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B) If there is wear of oil seal contact on the surface ofcrankshaft, and it is possible to correct by movingmounting position of oil seal.

� Push in a new oil seal and install it at a point where the lip ofthe oil seal does not reach the wear groove on the crank-shaft.

� Use plastic sleeve supplied with seal to guide seal overnose of crankshaft.

C) If crankshaft has already been corrected in Step B).� Install sleeve to crankshaft, then install oversize oil seal.

D) Install sleeve as follows.i) Remove all rust from sleeve press-fitting portion of

crankshaft (range of 60 mm from tip).ii) Coat whole of inside surface of sleeve with gasket

sealant (LG-7).

Dimension of portion b1

Bolt hole 6 – 12 x 1.75

Press-fittingdepth a for oil

seal

109 mm No 13 – 14 mm

114 mm Yes 18 – 19 mm

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iii) Using a plastic hammer, tap end face of sleevearound circumference and install sleeve (1) parallelto crankshaft.

� The sleeve is symmetrical, so it can be installed in eitherdirection.

iv) Using tool H1, press fit sleeve (1) to specified posi-tion.

� Tighten the bolts uniformly.� After press fitting the sleeve, wipe off the gasket sealant that

has been squeezed out. (If the gasket sealant that has beensqueezed out gets on the seal lip, it will cause oil leakage.)

E) Using tool H1, install front oil seal (2).� Tighten the mounting bolts uniformly.� The press-fitting depth for the oil seal differs according to

the condition of the crankshaft.Select one of the following three types.

i) When crankshaft is new, or there is no wear on sealcontact surface, insert spacer (1) of 1.8 – 2.8 mmbetween installer and oil seal, then install.

ii) When changing mounting position of oil seal toinstall, install oil seal with installer H1.

iii) When using sleeve on crankshaft, fit one washerbetween the installer and crankshaft and install.

� Before assembling the oil seal, clean the outside circumfer-ence of the crankshaft, then coat the whole circumferencewith engine oil (SAE#30).

iv) Use plastic sleeve supplied with seal to guide sealover the nose of the crankshaft.

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9. Gear case cover

Using eyebolts (A),(Thread dia. – 10 mm, Pitch – 1.5 mm) [0.3937 in, P – 0.0591 in]sling then fit gasket and install gear case cover.

Flywheel

1. Rear oil seal, sleeve

Take the following action according to the wear of the crankshaftseal contact surface.

A) If crankshaft is new, or if there is no wear of surface incontact with seal oil.i) Install at the standard dimension from the end face

of the crankshaft.ii) Use plastic sleeve supplied with seal to guide seal

over the nose of the crankshaft.

B) If there is wear of oil seal contact surface of crankshaft,and it is possible to correct by moving mounting positionof oil seal.

� Push in a new oil seal and install it at a point where the lip ofthe oil seal does not reach the wear groove on the crank-shaft.

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C) If crankshaft has already been corrected in Step B).� Install sleeve to crankshaft, then install oversize oil seal.

D) Install sleeve as follows.i) Remove all rust from sleeve press-fitting portion of

crankshaft (range of 60 mm from tip).ii) Coat whole of inside surface of sleeve with gasket

sealant (LG-7).

iii) Using a plastic hammer, tap end face of sleevearound circumference and install sleeve (1) parallelto crankshaft.

� The sleeve is symmetrical, so it can be installed in eitherdirection.

iv) Using tool H2, press fit sleeve (1) to specified posi-tion.

� Tighten the bolts uniformly.� After press fitting the sleeve, wipe off the gasket sealant that

has been squeezed out. (If the gasket sealant that has beensqueezed out gets on the seal lip, it will cause oil leakage.)

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E) Rear oil sealUsing tool H2, install rear oil seal (2).

� Tighten the mounting bolts uniformly.

� The press-fitting depth for the oil seal differs according tothe condition of the crankshaft. Select one of the followingthree types.

i) When crankshaft is new or there is no wear on sealcontact surface, insert two washers betweeninstaller and crankshaft.

ii) When changing mounting position of oil seal toinstall, do not use any washer between the installerand crankshaft.

iii) When using sleeve on crankshaft, fit two washers inthe same way as in Step i).

F) After installing flywheel housing, using dial gauge (1) tomeasure face runout and radial runout.

• SAE No. 00: Max. 0.30 mm (0.012 in)• SAE No. 0: Max. 0.25 mm (0.010 in)

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2. Flywheel

A) Using guide bolt, install flywheel (1).B) Align dowel hole in crankshaft with dowel hole in fly-

wheel. This will establish timing position of flywheel.

Coat the thread and washer of the bolt with engine oil(SAE #30).

C) Tighten bolts in turn until flywheel is in tight contact.

If an impact wrench is used to loosen the bolts, there isdanger of damage to the thread, so loosen the boltswith a hand tool.

D) Secure flywheel with housing (1).

� One capscrew has a large shoulder to prevent movement.Install capscrew next to timing hole.

� Tighten the mounting bolts as follows.

Flywheel mounting bolt

StepTarget Range

kgm ft-lb kgm ft-lb

1st 10 72 8 – 12 58 – 86

2nd 30 217 28 – 32 203 – 231

3rd 55 398 53 – 57 384 – 412

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E) Using dial gauge (1), measure face runout and radialrunout.

• Face runout: Max. 0.30 mm (0.0118 in)• Radial runout: Max. 0.30 mm (0.0118 in)

� For speed and timing sensor installation information, refer tosection 12.

3. Flywheel housing

Fit gasket, raise flywheel housing (2), then install and tightenbolts (1).

� Tighten the flywheel housing mounting bolts in the ordershown in the diagram using the following procedure.

Flywheel housing mounting bolt

Sensor

Install RPM (1) and timing (2) sensors.

Step Procedure

1st Tighten to 345 ± 49 N•m (255 ft-lb)

2nd Loosen completely.

3rd Tighten to 411 ± 20 N•m (303 ft-lb)

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12

Front supportFill oil groove of front support (1) with grease and install.� Amount of grease: Approx. 20 cc (1.2 cu.in)

Groove of front mount: Coat with G2-LI

� Lower the cylinder block assembly on the stable stand.

Main relief valve, suction pipe

1. Fit gasket and install main relief valve (2).

2. After fitting O-ring, fit suction pipe (4), install bracket (3), andsecure in position.

Oil pan

1. Stick gasket to oil pan.

2. Support oil pan (1) with transmission jack, set in mountingposition, then tighten bolts.

Damper, crankshaft pulley assembly

1. Raise crankshaft pulley and damper assembly (1), thenalign dowel pin of crankshaft and install.

Coat the thread and washer of the bolts with engine oil(SAE #30).

2. Tighten bolts in turn until damper and crankshaft pulley arein tight contact.

If an impact wrench is used to loosen the bolts, there isdanger of damage to the threads, so loosen the boltswith a hand tool

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A) Tighten crankshaft pulley mounting bolts as follows:

i) Tighten bolts to first torque value.

54 – 93 N•m (40 – 68 ft-lb)

ii) Tighten bolts to second torque value.

225 – 264 N•m (167 – 195 ft-lb)

iii) Tighten bolts to third torque value.

725 – 764 N•m (536 – 564 ft-lb)

iv) Tighten damper mounting bolt.

97 – 117 N•m (73 – 86 ft-lb)

Accessory drive assembly

1. Assemble accessory drive.

A) Press fit bushings (10) and oil seal (9) to housing (8).� Press fit the bushing 2 mm (0.0787 in) below the end face.

Inside surface of bushing: Engine oil (SAE #30)

� Press fit the oil seal 1.5 mm (0.0591 in) below the end face.

Lip of seal: Grease (G2-LI)� Fill 50 – 80% of the space at the lip.

B) Press fit gear (7) to shaft (5).C) Assemble thrust plate (6) to shaft and gear assembly, then insert from rear of housing.D) Assemble thrust plate (4) to shaft, and press fit hub (3).

� Be careful not to damage the seal lip.2. Fit O-ring and install drive assembly (2).

3. Install pulley (1).

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Thermostat housing

1. Press fit seal (5) to thermostat case (2).

2. Make sure that the seal is not at an angle when press fitting.

3. Assemble thermostat (4) in thermostat case.

4. Fit gasket, then install thermostat case (2) to thermostathousing (3), and tighten mounting bolts.

5. Screw eyebolts (Thread dia. – 10 mm, Pitch – 1.5 mm)[0.3937 in, P – 0.0591 in] into thermostat case, and sling.

6. Fit gasket and install thermostat case assembly (2), (3) tocylinder block.

7. Fit gasket and install connector tube (1).

Cam follower assembly

1. Install cam follower assembly (3), then tighten mountingbolts (2) and secure in position.

44 – 58 N•m (33 – 43 ft-lb)

2. Fit gasket and install cover (1).

34 – 44 N•m (26 – 32 ft-lb)� Fit the seal washers to 4 bolts under the cover and tighten.

Cylinder head assembly

1. Assemble cylinder head

A) Coat valve stem and inside surface of valve guide withengine oil (SAE #30), and assemble valve (9).

B) Raise cylinder head, and assemble lower seat (8).� Check part number of valve for proper location.

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C) Install a stem seal to valve (5). Knock in until bottomsurface a of the jig contacts lower seat (795-130-1720).

� Assemble and install valve springs with closed coils down.D) Fit inner spring (7) and outer spring (6), and assemble

upper seat (5).E) Using spring pusher A, compress valve spring, then

assemble valve cotter (4).

� Tap the valve stem with a plastic hammer, and check thatthe cotter is fitted securely in the valve stem groove.

2. Check that there is no dirt or dust inside cylinder and mount-ing surface of cylinder head, and set cylinder head gasket(3) in position.

� When installing the gasket, check that the grommet hasbeen fitted and has not come out of position.

� The grommets in the head gasket may become deformedby swelling, so do not coat them with gasket sealant.

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3. Install cylinder head assembly (2), and tighten mountingbolts (1).

Coat under the bolt head with SAE 140 and coat thebolt thread with SAE 30 lubricant.

� Tighten cylinder head mounting bolts 1-6 as follows:• Tighten bolts to first torque value.

137 – 157 N•m (102 – 115 ft-lb)

• Tighten bolts to second torque value.

210 – 220 N•m (156 – 162 ft-lb)

• Tighten bolts an additional 90°±30°.

� Tighten bolt 7.

59 – 73 N•m (44 – 54 ft-lb)

� After tightening, make one punch mark on the bolt head.� If the bolt head has five punch marks, do not reuse it.

Replace it with a new bolt.

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Rocker lever

1. Rocker lever housing

Fit gasket and install rocker lever housing (2).Tighten mounting bolts.

44 – 50 N•m (33 – 43 ft-lb)

2. Crosshead

A) Install crosshead (3).� Adjust the crosshead as follows.

i) Loosen locknut, and turn back adjustment screw.ii) Hold top surface of crosshead lightly, and screw in

adjustment screw.iii) After adjustment screw contacts valve stem, screw

in a further 20°.iv) Tighten locknut to hold in position.

53 – 65 N•m (39 – 47ft-lb)

3. Push rod

Install push rod (2).� Check that the push rod is fitted in the cam follower.

4. Rocker lever

Assemble rocker cover.

A) Using push tool, align oil hole of bushing, and knock inrocker lever (2).

B) Assemble adjustment screw (3) and locknut (4) torocker lever.

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C) Coat rocker shaft with engine oil (SAE #30), set sidewith plug facing exhaust rocker lever, then insert rockershaft.

� Exhaust end rocker lever: Long� Intake end rocker lever: Short

D) Install rocker lever (1)� Install with the wide end face of the rocker lever shaft facing

down.� Check that the ball of the adjustment screw is fitted securely

into the socket of the push rod, then tighten the mountingbolts.

93 – 103 N•m (68 – 75 ft-lb)

Rocker lever cover

1. Nozzle holder, connection

� Check that there is no dirt or dust inside the nozzle holdersleeve.A) Fit O-ring (7) and coat with engine oil (SAE #30).

� Check that there are no scratches on the O-ring.

B) Install gasket (6) to nozzle holder.

C) Align with mounting hole of connection of nozzle holder(5), and insert nozzle holder.

� Align the match mark, and make sure that the inlet connec-tor tap hole (nozzle holder end) and inlet connector insertionhole (rocker housing end) do not move out of position.

D) Insert connection (2) in rocker arm housing, and tightentemporarily.

E) Fit holder (4), then fit spherical washer to mounting bolt(3), and tighten.

� Set one holder on top of the head of the rocker housingmounting bolt, and tighten it.

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12 F) Tighten connection (2), then tighten locknut (1).

Mounting bolt: 63 – 73 N•m (44 – 54 ft-lb)

Connection: 34 – 40 N•m (26 – 29 ft-lb)

Locknut: 34 – 44 N•m (26 – 32 ft-lb)

� No. 1 injector is equipped with timing control. Lead wire must NOT be pinched.

2. Adjusting valve clearance

Adjust valve clearance.For details, see TESTING AND ADJUSTING, Adjusting valve clearance.

3. Head cover, turbocharger lubrication tube

A) Fit gasket and install air vent tube (4).

B) Fit gasket and install turbocharger drain tube (3), theninstall oil supply tube (2).

C) Fit gasket and install head cover (1).

D) Install fuel drain tubing

Mounting bolt: 5 N•m (48 in-lb)

Fuel drain mounting banjo capscrew:9 N•m (80 in-lb)

Oil cooler assembly

1. Oil level gauge, oil filler

A) Install oil level gauge guide (2).� Fit the O-ring and tighten the nut at the root of the level

gauge guide to secure it in position.

50 N•m (38 ft-lb)

B) Fit O-ring and install oil filler (1), then secure withbracket.

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2. Oil cooler installation

A) Install oil coolers

B) Tighten capscrews

Capscrews:66 N•m (49 ft-lb)

C) Install the o-rings into the back of the oil transfer con-nection.

D) Install the oil transfer connection and capscrews ontothe cylinder block. Tighten the capscrews


E) Install the lubricating oil bypass valve with gasket.Tighten the capscrews.


F) Install the O-rings on the aluminum oil transfer connec-tion.

G) Install the connection to the cylinder block and the otheroil transfer connection.Tighten the capscrews.


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Breather

1. Breather with O-ring groove

A) Fit O-ring and install breather (3).B) Fit tube (2), then tighten with clamp.C) Install alternator bracket (1).

� The alternator bracket is installed to the right bank only.

2. Breather with no O-ring groove.

A) Install breather (3).

Breather mounting surface: Gasket sealant (LG-7)

Breather:25 – 29 N•m (18.0 – 21.5 ft-lb)B) Install tube (2), and secure with clamp.C) Install alternator bracket (1).

Water pump assembly

1. Lubricate the O-ring with soapy water and install on thewater pump.

2. Install the water pump into the gear case.

� Make sure that the threaded plug has been installed into thewater pump.

3. Install the four mounting capscrews.


� Two of the capscrews install from the back side.


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5. Use vegetable oil and lubricate the O-ring on the bypasstube.

6. Install the bypass tube.

7. Install the bypass connection gasket.



9. Install water connection from water pump to block.

Water connection:40 N•m (30 ft-lb)

10. Install water filter head and new O-rings.

Filter head:40 N•m (30 ft-lb)

Fuel pump drive

1. Fuel pump drive assembly

A) Assemble bushings (4) into housing (5) with press andmandrel.

B) Align oil hole in bushing with oil hole in housing.

C) Coat bushings with engine oil.

D) Lubricate shaft (7) and thrust washer (4).

E) Insert shaft through housing (5) with thrust washer (4),washer (6), spline (2), and retaining nut (3).

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F) Install thrust washer (5), washer (6), and retaining nut(8) on end of shaft.

G) Use fabricated tool to secure spline coupling (2) whiletorquing retaining nut (3) and retaining nut (8).

Nut (3): 406.7 N•m (300 ft-lb)Nut (8): 542.3 N•m (400 ft-lb)

H) Install injection pump drive case.

I) Install new O-rings on front of housing.

J) Install upper support capscrews and four flange mountcapscrews.

K) Install ECM mount on both sides (1).

2. Injection pump drive gear

A) Install assembled hub and gear (1) and (2) on tapershaft.

B) Hand tighten large nut (3) and (4). Do not torque untilpump timing is set.

Hub to gear capscrews:114 N•m (84 ft-lb)

13-69 1


Air compressor assembly

1. Install the gasket and the cover plate (support bracket) onthe compressor. Do not tighten the six capscrews. Thesupport must be adjusted.

� Do not install the splined coupling or the mounting gasket.

2. Install the compressor on the rear of the front gear cover.

3. Install the four capscrews (6). Do not tighten. The com-pressor must be turned to align the support bracket.

The support MUST be flat against the block. Rotate thecompressor until the support is aligned properly againstthe block. If the support is NOT flat, the compressor willfail.

4. Tighten the four capscrews (6).

60 N•m (45 ft-lb)

� The bracket must remain flat against the block. Tighten thesupport capscrews (7) that are accessible.

45 N•m (35 ft-lb)

5. Remove the four capscrews (6). Remove the compressor.

6. Tighten the two remaining support to compressor cap-screws.

45 N•m (35 ft-lb)

13-70 1


7. Install the splined coupling (1), the gasket, and the com-pressor.

The support MUST be flat against the block. Rotate thecompressor until the support is aligned properly againstthe block. If the support is NOT flat, the compressorand/or accessory will fail.

8. Install the four capscrews (6) and two capscrews (5).

Capscrew (6): 60 N•m (45 ft-lb)Capscrew (5): 45 N•m (35 ft-lb)

9. Install the lubricating oil inlet line to the air compressor.

10. Install the air inlet and outlet connections to the air compres-sor. Tighten the clamps.

Clamp: 6 N•m (50 in-lb)

11. Install water inlet and outlet tubes.

Fuel injection pumpFor details on fuel injection pump installation and timing, refer to section 12.

Exhaust manifold assembly

1. Fit gasket and install exhaust manifold assembly (1).

44 – 54 N•m (33 – 40 ft-lb)

� Fit a spacer to the bolt before tightening.

2. Tighten the mounting bolts in the order shown in the dia-gram.

13-71 1


Coat the thread of the bolt and the bottom of the bolthead with anti-friction compound (LM-P) before tightening.

Intake manifold, aftercooler assembly

1. Install aftercooler core as follows.

A) Fit gasket and install aftercooler core (14).� Install with the welded aftercooler core at the top.

B) Fit gasket and install cover (13).C) Fit gaskets and install connectors (12).D) Tighten high pressure fuel line clamps.

2. Fit gaskets to both ends of electrical intake air heater andinstall aftercooler and intake manifold assembly (11).

� To prevent the electrical intake air heater from falling out, fita guide bar into the bottom mounting bolt hole of the intakemanifold when installing.

Mounting bolt: 59 – 73 N•m (44 – 54 ft-lb)

� Tighten the mounting bolts in the order shown in the dia-gram.A) Install electronic control modulesB) Install wiring harness and manifold sensors.C) Install harness support clamps and connectors.

13-72 1


3. Right bank

A) Install electrical intake air heater wiring (10).B) Fit O-ring and install tube (8).

4. Left bank

A) Install clamp (1) of fuel injection tubes and secure injec-tion tubes.

B) Install heater relay wiring (5).C) Install tube (3) for aftercooler.D) Install tubes (1) and (2) for air compressor.E) Install harness supports, ground connections, and con-

nect sensors.

Turbocharger assembly

1. Install turbocharger assembly (3).

Mounting bolt: 44 – 54 N•m (32.6 – 39.7 ft-lb)� When installing the turbocharger mounting bolts, install

each connection, then align the center and tighten fully.

2. Fit gasket and connect turbocharger drain tube (2).

3. Connect turbocharger oil supply tubes (1).

13-73 1


Intake connector

Fit gaskets and O-rings at each end, then install intake connec-tor (1).� Rotate offset connector for alignment

Fan

1. Fan pulley assembly

Using a nylon sling, sling fan pulley assembly (2), set in mount-ing position, then tighten mounting bolts.� Check that the fan pulley rotates smoothly.

2. Fan belt

For details on fan belt installation, refer to section 12.

3. Fan

Using a nylon sling, sling fan (1), set in mounting position, thentighten mounting bolts.

13-74 1


12General assembly

1. Filter

A) Install bypass filter (4).

B) Install fuel filter (3), oil filter (2), and corrosion resistor(1).

� Install each filter as follows.• Coat seal portion and thread portion of filter cartridge thinly

with engine oil (SAE #30).• Tighten until packing surface contacts seal surface of filter

holder, then tighten further by hand as follows:Bypass filter: 3/4 – 1 turn Oil filter: 3/4 – 1 turnFuel filter: 1/2 – 3/4 turnCorrosion resistor: 2/3 turn

2. Alternator assembly

A) Install alternator assembly (4), tighten lock bolt (2) andadjustment bolt (1) temporarily, then install belt (3).

B) Set so that locknut of adjustment bolt (1) faces in direc-tion of extension of belt (3), then adjust so that deflec-tion is approx. 15 mm when belt (3) is pressed at mid-point with a force of approx. 6kg. After adjusting,tighten lock bolt (2) and locknut of adjustment bolt.

3. Starting motor assembly

Fit gasket and install starting motor (1)

13-75 1


12

13-76 1

14-1

14 MAINTENANCE STANDARD

INTAKE AND EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

ENGINE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3VALVE, VALVE SPRING AND VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4ROCKER ARM AND SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6CROSSHEAD AND GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8CYLINDER LINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-10CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13CAM FOLLOWER AND PUSH ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-14TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15PISTON, PISTON RING AND PISTON PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19FLYWHEEL AND FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-21

LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-22OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-22MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-24OIL COOLER BY-PASS VALVE, REGULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-25

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-26WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-26THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-27

MAINTENANCE STANDARD INTAKE AND EXHAUST SYSTEM

14-2

INTAKE AND EXHAUST SYSTEMTURBOCHARGER

Unit: mm [in]No Check item Criteria Remedy

1 End play (Play in axial direction) Standard Repair limit Replacethrust parts0.03 [0.001] 0.10 [0.004]

2 Radial play (Play in radial direction) at compressorwheel

0.15 [0.006] 0.46 [0.018] Replacebearingparts3 Radial play (Play in radial direction) at turbine wheel 0.20 [0.008] 0.53 [0.021]

4 Tightening torque of blower impeller locknut 41 N•m [362 in-lb] Tighten

5 Tightening torque of turbocharger mounting bolt 61 N•m [540 in-lb]

6 Tightening torque of V band locknut 8 N•m [70 in-lb]

MAINTENANCE STANDARD ENGINE BODY

14-3

ENGINE BODYCYLINDER HEADTightening order of cylinder head mounting bolts


1 Distortion of cylinder head mounting surface

Standard Repair limit Repair by grinding or replace

0 - 0.06 [0 - 0.023] 0.09 [0.0035]

2 Protrusion of nozzle Standard: 4.65 – 5.65 [0.183 – 0.222] Replace nozzle or cylinder head

3 Tightening torque of cylin-der head mounting bolt (Coat the thread areas and bearing surface with molybdenum disulfide)

Bolt no. Order Target Range Tighten bolts in accor-dance with bolt No.

¨ ? ±

1st step0 15 kgm[108.5 ft.lb]

4 -16 kgm[101.3 - 115.7

ft.lb]

2nd step 22 kgm[159.1 ft.lb]

21.5 - 22.5 kgm[155.5 - 162.7

ft.lb]

3rd step Retighten with 90°

90° – 120°

ð- 7 kgm

[50.6 ft.lb]6 – 7.5 kgm[43.4 – 54.2

ft.lb]

4 Tightening torque of nozzle holder mounting bolt

Target Range Retighten

6.8 kgm [49.2 ft.lb] 6 – 7.5 kgm [43.4 – 54.2 ft.lb]

5 Tightening torque of fuel inlet connector

3.8 kgm [27.5 ft.lb] 3.5 – 4.1 kgm [25.4 – 29.6 ft.lb]

6 Tightening torque of con-nector pipe locknut

4.0 kgm [28.9 ft.lb] 3.5 – 4.5 kgm [25.4 – 32.5 ft.lb]

7 Tightening torque of cylin-der head cover mounting bolt

0.5 kgm [3.6 ft.lb] 0.4 – 0.6 kgm [2.9 – 4.3 ft.lb]


14-4

VALVE, VALVE SPRING AND VALVE GUIDE


14-5

Unit mm[in]

H The intake valve cannot be reground. It must be replaced with a new part.H If the exhaust valve has been used for more than 10,000 hours, replace with a new part.

No Check item Criteria Remedy

1 Amount of valve sinking Valve Standard size Tolerance Repair limit Replace valve or valve seat

Intake valve 0 ± 0.10[± 0.0039]

0.70[0.0275]

Exhaust valve 0 ± 0.10[± 0.0039]

0.70[0.0275]

2 Thickness of valve lip Valve Standard size Repair limits Replace valveIntake valve 2.4 [0.094] 1.9 [0.075]

Exhaust valve 2.15 [0.085] 1.6 [0.063]

3 Valve seat angle H Valve Standard size Repair limits Repair or replace valve and valve seat

Intake valve 60° ±0°15´

Exhaust valve 45° ±0°15´

4 Outside diameter of valve stem

Intake valve 10 [0.394] -0.045[-0.0017]-0.060[-0.0023]

Replace valve

Exhaust valve 10 [0.394] -0.074[-0.0029]-0.089[-0.0035]

Inside diameter of valve guide

Before inserting 10 [0.394] +0.011[+0.0004]-0.011[-0.0004]

Replace valve guide

After inserting 10 [0.394] +0.011[+0.0004]-0.011[-0.0004]

Clearance between valve guide and valve stem

Valve Standard clearance Clearance limit Replace valve or valve guide

Intake valve 0.034-0.071[0.0013-0.0027]

0.22[0.0086]

Exhaust valve 0.063-0.100[0.0025-0.0039]

0.24[0.0094]

Bend of valve stem Repair limit: 0.02 [0.0007] (total indicated runout for 100 [3.937] Replacevalve

5 Protrusion of valve guide Standard size Tolerance Repair

23 [0.906] ± 0.2 [± 0.0078]

6 Valve spring Valve spring

Standard size Repair limit Replacevalve springFree

lengthInstalled length

Installed load

Free length

Installed load

Outer (Large)

81.7 [3.22]

51.0 [2.01]

43.3±2.2 kg

[95.45±9.7 lb]

38.7 kg[85.3 lb]

Inner (Small)

72.0 [2.84]

46.0 [1.81]

22.0±1.5 kg

[48.5±6.6lb]

19.7 kg[43.4 lb]

Squarence of valve spring Repair limit: 2° (for both ends)


14-6

ROCKER ARM AND SHAFT

Unit: mm [in]No. Check item Criteria Remedy

1 Outside diameter of rocker arm shaft

Standard size Tolerance Replace rocker arm shaft

32.0 [1.26] ± 0.0065 [± 0.0002]

Inside diameter of rocker arm bushing

32.0 [1.26] + 0.087 [+0.0034]+ 0.035 [+0.0013]

Replace rocker arm

Clearance between rocker arm shaft and rocker arm bushing

Standard clearance Clearance limit Replace rocker arm or rocker arm shaft

0.0285 – 0.0935[0.0012 – 0.0036]

0.13 [0.0051]

2 Valve clearance (When engine cold)

Valve Standard size Tolerance Adjust

Intake 0.43 [0.0169] ± 0.02 [0.0007]

Exhaust 0.80 [0.0315] ± 0.02 [0.0007]

3 Tightening torque of rocker arm adjustment screw locknut

Target Range Tighten

6 kgm [43.4 ft.lb] 5.4 – 6.6 kgm [39.1 – 47.7 ft.lb]


14-7

CROSSHEAD AND GUIDE


1 Depth of crosshead stem Standard size Tolerance Repair limit Replace

6.2 [0.244] +0.3 [+0.0118]0 [0]

6.71 [0.264]

2 Inside diameter of cross-head

11 [0.433] +0.06 [+0.0023]+0.02 [+0.0007]

11.17 [0.440]

Outside diameter of cross-head guide

11 [0.433] +0.11 [+0.0043]0 [0]

10.95 [0.431]

3 Protrusion of crosshead guide

49.0 [1.929] ± 0.25 [± 0.0098] - Repair

4 Tightening torque of cross-head locknut

6 ± 0.6 kgm [43.4 ± 4.3 ft-lb] Tighten


14-8

CYLINDER BLOCK


14-9

Unit: mm [in]

H The main cap bolt can be tightened a maximum of 12 times. Make a punch mark on the bolt head each time itis tightened.

No. Check item Criteria Remedy

1 Distortion of cylinder head mounting surface

Standard size Repair limit Repair by grinding or replace

0 – 0.09 [0 – 0.0035] 0.135 [0.0053]

2 Inside diameter of main bearing hole

Standard size Tolerance Replace or repair main bearing cap

157 [6.18] + 0.025 [+ 0.001]– 0.010 [– 0.0004]

Surface roughness of main bearing mount hole

Within 10 S Correct

Out-of-roundness of mount hole

Service limit: 0.005 [0.0002]

Thickness of main bearing

No.4only

4.5 [0.177] – 0.050 [– 0.0019]– 0.060 [– 0.0023]

Replace main bear-ingExcept

No.44.5 [0.177] – 0.065 [– 0.0026]

– 0.075 [– 0.0030]

3 Inside diame-ter of main bearing

Journal Standard size Tolerance Repair limit

No.4only

148 [5.827] + 0.175 [+ 0.0068]+ 0.130 [+ 0.0051]

148.23 [5.835]

ExceptNo.4

148 [5.827] + 0.145 [+ 0.0057]+ 0.100 [+ 0.0039]

148.20 [5.834]

4 Inside diameter of cam-shaft bushing hole

69 [2.717] + 0.025 [+ 0.0009] 0 [0]

– Repair or replace cyl-inder block

5 Inside diameter of cam-shaft bushing

65 [2.559] + 0.040 [+ 0.0016]0 [0]

65.15 [2.565] Replace camshaft bushing

6 Tightening torque of main bearing cap bolt (Coat thread area with engine oil)

Order Target Range Retighten

1st step 29 kgm [209.8 ft.lb] 27.5 – 30.5 kgm[198.9 – 220.6 ft.lb]

2nd step 58 kgm [419.5 ft.lb] 57.0 – 59.0 kgm[412.3 – 426.7 ft.lb]

3rd step Retighten with 90° 90 – 120°

– Tightening torque of oil pan mounting bolt

Target Range

6.7 kgm [48.5 ft.lb] 6 – 7.5 kgm [43.4 – 54.2 ft.lb]

– Difference of face between cylinder block and front cover

Repair limit: 0.14 [0.0055] Replace by reassem-bling


14-10

CYLINDER LINER


1 Protrusion of cylinder liner Permissible range: 0.08 – 0.185 [.0031 – .0073] Repair cylin-der liner or repair or replace cyl-inder block

2 Inside diameter of cylinder liner

Rank Standard size Tolerance Repair limit Replace cyl-inder liner(Only L is supplied)

S 140 [5.512] +0.020 [+0.0008]

0 [ 0 ]

140.12 [5.516]

L 140 [5.512] +0.040 [+0.0015]

+0.021 [+0.0008]

140.14 [5.517]

3 Outside diameter of cylin-der liner (Counter bore)

Standard size Tolerance

170.2 [6.692] 0 [ 0 ]–0.10 [–0.0039]

Clearance between cylin-der liner and block (Counter bore)

Standard: 0 – 0.163 [0 – 0.0064] Replace cyl-inder liner or cylinder block

4 Outside diameter of cylin-der liner (Counter bore bottom)

Standard size Tolerance Replace cyl-inder liner161.2 [6.346] +0.090 [+0.0035]

+0.050 [+0.0019]

Interference between cylin-der liner and block (Counter bore bottom)

Standard interference Interference limit Repair cylin-der liner or repair or replace cyl-inder block

0.02 – 0.12 [0.0008 – 0.0047] 0.02 – 0.12 [0.0008 – 0.0047]

5 Outside diameter of cylin-der liner (O-ring part)

Standard size Tolerance Replace cyl-inder liner158 [6.22] –0.024 [–0.0009]

–0.049 [–0.0019]

Clearance between cylin-der liner and block (O-ring part)

0.024 – 0.094 [0.001 – 0.0037] Replace cyl-inder liner or cylinder block


14-11

CRANKSHAFT


1 End play Standard size Repair limit Repair by using over size thrust bearing or replace

0.140 – 0.315[0.0056 – 0.0124]

0.50 [0.0196]

2 Outside diameter of main journal

Standard size Tolerance Repair limit Repair by using over size bearing or replace

STD 148.00 [5.827] 0–0.020

[0][–0.0008]

147.98 [5.825]

0.25 U.S. [0.0098]

147.75 [5.817] 147.73 [5.816]

0.50 U.S. [0.0197]

147.50 [5.807] 147.48 [5.787]

0.75 U.S. [0.0295]

147.25 [5.797] 147.23 [5.796]

1.00 U.S. [0.0394]

147.00 [5.787] 146.98 [5.786]

Roundness of main journal Repair limit

0 – 0.010 [0– 0.0003]

Clearance of main journal

Journal Standard clearance Clearance limit Correct by using under size bearing or replace main bear-ing

No. 4 only 0.130 – 0.195 [0.0051 – 0.0076]

0.25 [0.0099]

Except No.4

0.100 – 0.165 [0.004 – 0.0064] 0.22 [0.0087]

Surface roughness of main journal

0.8 S (Surface roughness at R portion: 3.2 S) Correct sur-face rough-ness of crankshaft journal


14-12

Judgement standards for judging if crankshaft can be used again

If it is impossible to measure all the items in the MAINTENANCE STANDARD (including roughness), use the fol-lowing conditions to judge if the crankshaft can be used again.

1. If more than 60% of the overlay of the pin bearing has been lost after about 4000 hours of operation due to the entry of dust, the crankshaft journal surface has probably become rough, so grind again or replace.

2. On engines where the oil filter may have be-come clogged because of deterioration of the oil or entry of water into the oil pan, there are probably scratches or increased roughness on the journal surface caused by dirt, so grind again or replace.

3. If the main journal or pin journal has seized, the crankshaft hardness will have been lost because of the high temperature and the strength may have dropped, so do not use such parts again. (There is danger that the crankshaft may break.)

3 Outside diameter of crank pin journal

Standard size Tolerance Repair limit Repair by using over size bearing or replace

STD 100.00 [3.937] 0–0.020

[0][–0.0008]

99.88 [3.932]

0.25 U.S. [0.0098]

99.75 [3.927] 99.63 [3.922]

0.50 U.S. [0.0197]

99.50 [3.917] 99.38 [3.913]

0.75 U.S. [0.0295]

99.25 [3.907] 99.13 [3.903]

1.00 U.S. [0.0394]

99.00 [3.897] 98.88 [3.893]

Roundness of crank pin journal

Repair limit

0 – 0.010 [0 – 0.0003]

Clearance of crank pin journal

Standard clearance Clearance limit Replace connecting rod bearing

0.046 – 0.116 [0.0019 – 0.0045]

0.17 [0.0067]

Surface roughness of crankshaft pin journal

0.8 S (Surface roughness at R portion: 3.2 S) Correct sur-face rough-ness of crankshaft journal

4 Straightness of all main journal

Standard size Repair limit Replace

within 0 – 0.09 [0 – 0.0035] 0.09 [0.0035]

Straightness of two main journal

within 0 – 0.05 [0 – 0.0019] 0.05 [0.0019]

5 Crank pulley mounting bolt Target Range Tighten bolts in accor-dance with bolt No.

1st step 7.5 kgm [54.2 ft.lb]

5.5 – 9.5 kgm [39.8 – 68.7 ft.lb]

2nd step 25.0 kgm [180.8 ft.lb]

23.0 – 27.0 kgm [166.4 – 195.2 ft.lb]

3rd step 76.0 kgm [549.7 ft.lb]

74.0 – 78.0 kgm [535.3 – 564.1 ft.lb]

6 Tightening torque of vibra-tion damper mounting bolts

11 ± 1.0 kgm [79.6 ± 7.2 ft.lb]


14-13

CAMSHAFT


1 End play Standard size Repair limit Replace thrust plate0.1 – 0.25 [0.0039 – 0.0098] 0.36 [0.0142]

2 Outside diameter of cam-shaft journal

Standard size Tolerance Replace camshaft65 [2.559] –0.016 [–0.0006]

–0.036 [–0.0014]

Clearance of camshaft journal

Standard clearance Clearance limit Replace camshaft bushing

0.016 – 0.096 [0.0007 – 0.0037]

0.15 [0.0059]

3 Bend of camshaft Repair limit: 0.04 [0.0016] (Total indicated runout) Replace camshaft4 Cam height Cam Standard size Tolerance Repair limit

Intake 55.48 [2.184] ± 0.1 [± 0.0039]

55.08 [2.168]

Exhaust 55.75 [2.195] ± 0.1 [± 0.0039]

55.35 [2.179]


14-14

CAM FOLLOWER AND PUSH ROD


1 Outside diameter of cam follower shaft

Standard size Tolerance Repair limit Replace

22 [0.866] –0.021 [–0.0008]–0.034 [–0.0013]

21.92 [0.864]

Inside diameter of cam fol-lower shaft

22 [0.866] +0.021 [+0.0008]0 [ 0 ]

22.07 [0.870]

2 Outside diameter of cam roller

31.7 [1.248] +0.05 [+0.0019]+0.02 [+0.0007]

31.5 [1.240]

3 Inside diameter of cam roller

12.7 [0.500] +0.038 [+0.0015]+0.013 [+0.0005]

12.78 [0.503]

Outside diameter of cam roller pin

12.63 [0.497] ± 0.006 [± 0.0002] 12.56 [0.494]

4 Radius of push rod ball end Standard size Tolerance

12.7 [0.500] 0 [ 0 ]–0.20 [–0.0078]

5 Radius of push rod socket end

13.4 [0.528] 0 [ 0 ]–0.20 [–0.0078]

6 Bend of push rod Repair limit: 0.3 [0.0118] (Total indicated runout)

7 Tightening torque of cam follower mounting bolt

4.5 – 6.0 kgm [32.6 – 43.3 ft.lb] Tighten


14-15

TIMING GEAR


14-16


–Backlash of each gear (* : Between spur gears)

Measuring point

Gears Standard size Repair limit

Replace

aCrankshaft gear and R-main

idler gear (Large)0.141-0.425

[0.0056-0.0167]0.6 [0.0236]

bR-main idler gear (Small) and

R-sub idler gear0.130-0.390

[0.0052-0.0153]0.6 [0.0236]

*bR-main idler gear (Small) and

R-sub idler gear0.125-0.363

[0.0049-0.0143]0.6 [0.0236]

cR-main idler gear (Small) and

R-camshaft gear0.129-0.391

[0.0051-0.0153]0.6 [0.0236]

*cR-main idler gear (Small) and

R-camshaft gear0.125-0.363

[0.0049-0.0143]0.6 [0.0236]

dR-camshaft gear and acces-

sory drive gear0.085-0.492

[0.0034-0.0193]0.6 [0.0236]

*dR-camshaft gear and acces-

sory drive gear0.138-0.354

[0.0054-0.0139]0.6 [0.0236]

eR-main idler gear (Small) and R-injection pump drive gear

0.051-0.469[0.0021-0.0184]

0.6 [0.0236]

*eR-main idler gear (Small) and R-injection pump drive gear

0.125-0.363[0.0049-0.0143]

0.6 [0.0236]

fR-main idler gear (Small) and

water pump drive gear0.052-0.481

[0.0021-0.0189]0.6 [0.0236]

gR-main idler gear (Small) and

oil pump drive gear0.137-0.421

[0.0054-0.0165]0.6 [0.0236]

hCrankshaft gear and L-main

idler gear (Large)0.141-0.425

[0.0056-0.0167]0.6 [0.0236]

iL-main idler gear (Small) and

L-camshaft gear0.129-0.391

[0.0051-0.0153]0.6 [0.0236]

*iL-main idler gear (Small) and

L-camshaft gear0.125-0.363

[0.0049-0.0143]0.6 [0.0236]

jL-main idler gear (Small) and L-injection pump drive gear

0.051-0.469[0.0021-0.0184]

0.6 [0.0236]

*jL-main idler gear (Small) and L-injection pump drive gear

0.125-0.363[0.0049-0.0143]

0.6 [0.0236]

kL-injection pump drive gear

and air compressor drive gear0.106-0.381

[0.0042-0.015]0.6 [0.0236]

*kL-injection pump drive gear

and air compressor drive gear0.138-0.354

[0.0054-0.0139]0.6 [0.0236]

1Clearance between main idler gear bushing and shaft (R and L bank)

Standard size

Tolerance Standardclearance

Clearancelimit

Replace bushing

Shaft Bushing

56 [2.205]-0.016 [-0.0006]-0.029 [-0.0011]

+0.055 [+0.0021]

0 [ 0 ]

0.016 - 0.084[0.0006 - 0.0032]

0.20[0.0078]

2Clearance between sub idler gear bushing and shaft

56 [2.205]-0.016 [-0.0006]-0.029 [-0.0011]

+0.055 [+0.0021]

0 [ 0 ]

0.016 - 0.084[0.0006 - 0.0032]

0.20[0.0078]

3End play of main idler gear

Standard size Repair limit

Replace thrust bearing

0.07 – 0.18 [0.0028 – 0.0071] 0.4 [0.0157]

4 End play of sub ider gear 0.06 – 0.14 [0.0024 – 0.0055] 0.4 [0.0157]

5End play of injection pump drive gear

0.09 – 0.51 [0.003 – 0.020] 0.63 [0.024]

6End play of oil pump drive gear

0.03 – 0.088 [0.0012 – 0.0034] 0.4 [0.0157]

7End play of accessory drive gear

0.10 – 0.40 [0.004 – 0.0157] 0.4 [0.0157]


14-17

PISTON, PISTON RING AND PISTON PIN


14-18


1 Outside diameter of piston (at right angles to boss)

Rank Standard size Tolerance Repair limit Replace pis-ton (only S is supplied)

S 140 [5.512] –0.070 [–0.0027]–0.085 [–0.0033]

139.85 [5.510]

L 140 [5.512] –0.070 [–0.0027]–0.085 [–0.0033]

139.85 [5.510]

2-4 Clearance at piston ring end gap

No. Measurement location

Standard clear-ance

Clearance limit Replace pis-ton ring

2 Top ring 0.42-0.57[0.0166-0.0224]

1.0 [0.0394]

3 Second ring 0.42-0.57[0.0166-0.0224]

1.0 [0.0394]

4 Oil ring 0.37-0.52[0.0146-0.0204]

1.0 [0.0394]

Clearance between piston ring groove and piston ring

No. Measure-ment

location

Standard size

Tolerance Stan-dard clear-ance

Clear-ance limit

Replace pis-ton ring or piston

Ring Piston

2 Top ring

2.4[0.0945]

–0.015[-0.0005]–0.035

[–0.0013]

Judge with groove wear gauge

3 2nd ring

2.4[0.0949]

–0.010[–0.0003]

–0.035[–0.0013]

Judge with groove wear gauge

4 Oil ring 4[0.157]

–0.010[–0.0004]

–0.030[–0.0012]

+0.030[+0.0012]

+0.010[+0.0004]

0.02-0.06[0.0008-0.0024]

0.14[0.0055]

5 Clearance between piston and piston pin

Standard size

Tolerance Standard clear-ance

Clear-ancelimit

Replace pis-ton ring or piston pin

Shaft Hole

52[2.047]

0 [0 ]–0.006

[–0.0023]

+0.045 [+0.0017]+0.035 [+0.0013]

0.035-0.051[0.0014-0.0020]

0.10[0.0039]

- Piston portion B Carbon deposit (Thickness: 1mm [0.0394] or more) Replace pis-ton (if thick-ness is less than 1 mm [0.0394], it is possible to clean off car-bon at A and B and use again


14-19

CONNECTING ROD


14-20

Unit: mm [in]

H The connecting rod bolt can be tightened a maximum of 5 times. Make a punch mark on the bolt head eachtime it is tightened.


1 Inside diameter of connect-ing rod small end bushing

Standard size Tolerance Repair limit Replace bushing (supplied as semi-fin-ished prod-uct)

52 [2.047] +0.049 [+0.0019]+0.030 [+0.0011]

52.09 [2.051]

Clearance between con-necting rod small end bushing and piston pin

Standard clearance Clearance limit Replace bushing or piston pin

0.030 – 0.055 [0.0012 – 0.0021]

0.11 [0.0043]

2 Inside diameter of mount-ing hole of connecting rod small end bushing

Standard size Tolerance Replace connecting rod (not per-mitted to correct)

57.4 [2.260] +0.030 [+0.0011]0 [ 0 ]

3 Inside diameter of connect-ing rod big end bearing (crankshaft pin journal)

Standard size Tolerance Repair limit Replace bearing100 [3.937] +0.096 [+0.0037]

+0.046 [+0.0018]100.15 [3.946]

4 Inside diameter of connect-ing rod big end hole (no bearing, X, Y, Z directions)

106 [4.173] +0.026 [+0.0010]–0.004 [–0.0002]

— Replace connecting rod (not per-mitted to correct)

Tighten connecting rod cap to specified torque, then measure

5 Thickness of connecting rod bearing

3.0 [0.118] –0.025 [–0.0009]–0.035 [–0.0013]

— Replace bearing

6 Parallelism, twisting of connecting rod

Standard Repair limit

Replace connecting rod bushing or connect-ing rod

Parallel-ism

0-0.10[0- 0.0039]

0.15[0.0059]

Twisting 0-0.25[0- 0.0098]

0.30[0.0118]

7 Tightening torque for con-necting rod cap mounting bolt (coat nut seat face at bolt head with engine oil)

Procedure Target Range Tighten in order shown in diagram

1st 7.5 kgm [54.2 ft.lb] 7 – 8 kgm[50.7 – 57.8 ft.lb]

2nd Tighten 90° 90° + 300

8 Inside diame-ter of connect-ing rod big end

Rough-ness

3.2 S Replace

Wave 0.004 [0.00015] (Whole width)


14-21

FLYWHEEL AND FLYWHEEL HOUSING


1 Face runout of flywheel housing

Repair limit: 0.25 [0.0098] Repair

2 Radial runout of flywheel housing

Repair limit: 0.25 [0.0098]

3 Face runout of flywheel Repair limit: 0.30 [0.0118]

4 Radial runout of flywheel Repair limit: 0.13 [0.0051]

5 Tightening torque of fly-wheel housing mounting bolts (Coat thread areas and bearing surface with engine oil)

Order Target Range Tighten bolts in accor-dance with bolt No.

1st step 35 kgm [253 ft.lb] 30 – 40[217 – 289 ft.lb]

2nd step 42 kgm [304 ft.lb] 40 – 44[289 – 318 ft.lb]

6 Tightening torque of fly-wheel mounting bolts (Coat thread areas and bearing surface with engine oil)

Order Target Range

1st step 10 kgm [72 ft.lb] 8 – 12[58 – 86 ft.lb]

2nd step 30 kgm [217 ft.lb] 28 – 32[203 – 231 ft.lb]

3rd step 55 kgm [398 ft.lb] 53 – 57[384 – 412 ft.lb]

MAINTENANCE STANDARD LUBRICATION SYSTEM

14-22

LUBRICATION SYSTEMOIL PUMP


1 Axial clearance of pump gear

Standard size

Tolerance Standard clearance

Clearance limit

ReplacegearGear

thicknessHousing width

54[2.128]

0 [ 0 ]-0.030

[-0.0012]

+0.067 [+0.0026]

+0.040 [+0.0015]

0.040-0.097[0.0016-0.0038]

0.040-0.097[0.0016-0.0038]

2 Radial clearance of pump gear

Standard size


Clearance limitGear O.D. Housing

I.D.

54.99[2.167]

-0.15[-0.0059]

-0.21[-0.0082]

+0.06 [+0.0023]

0 [ 0 ]

0.15-0.27[0.0059-0.0106]

0.15-0.27[0.0059-0.0106]

3 Interference between driven shaft and pump cover

Standard size

Tolerance Standard interference

Interference limit

Replace

Shaft Hole

18[0.709]

+0.090 [+0.0035]

+0.070 [+0.0027]

+0.040 [+0.0015]

+0.022 [+0.0008]

0.030-0.068[0.0012-0.0027]

–

4 Interference between driven shaft and driven gear bushing

21[0.827]

+0.090 [+0.0035]

+0.070 [+0.0027]

+0.035 [+0.0013]

0 [ 0 ]

0.030-0.090[0.0012-0.0035]

–


14-23

5 Clearance between driven shaft and driven gear bushing

Standard size


Clearance limit

ReplacebushingShaft Hole

18[0.709]

+0.090 [+0.0035]

+0.070 [+0.0027]

+0.147 [+0.0057]

+0.122 [+0.0048]

0.032-0.077[0.0013-0.0030]

0.032-0.077[0.0013-0.0030]

6 Clearance between driven shaft and body

18[0.709]

+0.090 [+0.0035]

+0.070 [+0.0027]

+0.129 [+0.005]+0.102 [+0.004]

0.012-0.059[0.0005-0.0023]

0.012-0.059[0.0005-0.0023]

7 Clearance between drive shaft and pump body bush-ing

18[0.709]

+0.106 [+0.0041]

+0.088 [+0.0034]

+0.173 [+0.0068]

+0.146 [+0.0057]

0.040-0.085[0.0016-0.0033]

0.040-0.085[0.0016-0.0033]

8 Interference between drive gear and drive shaft

Standard size

Tolerance Standard interference

Interference limit

Replace

Shaft Hole

18[0.709]

+0.106 [+0.0041]

+0.088 [+0.0034]

+0.063 [+0.0024]

+0.028 [+0.0011]

0.025-0.078[0.001-0.003]

–

9 Interference between drive shaft bushing and pump cover

21[0.827]

+0.090 [+0.0035]

+0.065 [+0.0025]

+0.021 [+0.0008]

0 [ 0 ]

0.044-0.090[0.0017-0.0035]

–

10 Interference between drive shaft and oil pump drive gear

18[0.709]

+0.106 [+0.0041]

+0.088 [+0.0034]

+0.065 [+0.0025]

+0.047 [+0.0018]

0.023-0.059[0.0009-0.0023]

–

11 Tightening torque of pump cover mounting bolt

3.15 ± 0.35 kgm [20.3 – 25.3 ft.lb]



14-24

MAIN RELIEF VALVE


1 Clearance between main relief valve and body

Standardsize


Replace valve or body

Valve O.D. Body I.D.

28 [1.1024] –0.020 [–0.0008]–0.053 [–0.0021]

+0.033 [+0.0012]0 [ 0 ]

0.020 – 0.086[0.0008 – 0.0033]

2 Main relief valve spring Standard size Repair limit Replace springFree length Installed

lengthInstalled load Installed load

72.4 [2.8504]

60.5 [2.3819] 40 kg [88.1 lb] 36 kg [79.2 lb]

3 Main relief valve set pressure 8.5 ± 0.5 kg/cm2 [113.8 – 127.9 psi] Adjust or replace spring


14-25

OIL COOLER BY-PASS VALVE, REGULATOR VALVE


1 Clearance between regula-tor valve and body

Standard size Tolerance Standard clearance



22 [0.8661] –0.020 [–0.0008]–0.041 [–0.0017]

+0.033 [+0.0012]0 [ 0 ]

0.020-0.074[0.0008-0.0029]

2 Regulator valve spring Standard size Repair limit Replace springFree length Installed


111.5 [4.3898] 75 [2.9528] 13.87 kg [30.6 lb]

24.4 kg [53.8 lb]

3 Regulator valve set pres-sure

4.1 ± 0.5 kg/cm2 [51.2 – 65.4 psi] Adjust or replace spring

4 Clearance between oil cooler by-pass valve and body

Standardsize




28 [1.1024] –0.020 [–0.0008]–0.053 [–0.0021]

+0.033 [+0.0012]0 [ 0 ]

0.020-0.086[0.0008-0.0033]

5 Oil cooler by-pass valve spring

Standard size Repair limit Replace springFree length Installed


125.8 [4.921] 89.8 [3.5381] 19 kg [41.9 lb] –

6 Oil cooler by-pass valve set pressure

4.0 ± 0.2 kg/cm2 [56.9 ± 2.8 psi] Adjust or replace spring

MAINTENANCE STANDARD COOLING SYSTEM

14-26

COOLING SYSTEMWATER PUMP


1 Interference between impeller and shaft

Standard size Tolerance Standard interference

Replace. Usually, replace impeller (there is almost no change in outside diameter of shaft)

Shaft Hole

19.0 [0.748] +0.018 [+0.0007]

+0.006 [+0.0002]

–0.025 [-0.001]–0.050 [-0.002]

0.031-0.068[0.0012-0.0027]

2 Interference between drive gear and shaft

30 [1.181] +0.021 [+0.0008]

+0.008 [+0.0003]

–0.012 [–0.005]–0.039 [–0.015]

0.020-0.060[0.0008-0.0024]

Replace (usually, replace gear)

3 Clearance between impel-ler and body

Standard clearance: 0.25 – 1.02 (Including end play)(0.0099 – 0.0401)

Replace

4 Abrasion of seal ring in water seal

4a. seal ring

Surface roughness: Max. 0.8 S

4b. water seal

Surface roughness: Max. 1.2 S

MAINTENANCE STANDARD COOLING SYSTEM

14-27

THERMOSTAT


1 Lift of thermostat valve Min. 10 mm [0.394] (Check after immersion in a hot water bath of 90°C [194°F] for 4 or 5 minutes.)

2 Opening and closing of valve in thermostat

Valve must be closed fully when immersed in a hot water bath (71°C) [159.8°F] for 4 or 5 minutes after being immersed in a hot water bath (90°) [194°F] to fully open the valve.

15 REPAIR AND REPLACEMENT OF PARTS

TABLE OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3

CYLINDER AND MOUNTING FACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6REPLACING VALVE SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7PRESSURE TEST OF CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11REPLACING VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12REPLACING CROSSHEAD GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12GRINDING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13

CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14METHOD OF CHECKING INSIDE DIAMETER OF MAIN BEARING MOUNTING HOLE USING ALIGNMENT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17CORRECTING CYLINDER BLOCK TOP SURFACE, COUNTERBORE . . . . . . . . . . . . . . . . . . . 15-18REPLACING MAIN BEARING CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-25REPLACING CAM BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-27

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-29CORRECTING SURFACE ROUGHNESS OF CRANKSHAFT JOURNAL PORTION . . . . . . . . . 15-31GRINDING CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-35CORRECTING FRONT SEAL CONTACT SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-42CORRECTING REAR SEAL CONTACT SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-44

CONNECTING ROD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-46REPLACING CONNECTING ROD SMALL END BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-48REPLACING CRANKSHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-49REPLACING CAMSHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-50REPLACING FLYWHEEL RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-50

15-1 2

REPAIR AND REPLACEMENT OF PARTS TABLE OF SPECIAL TOOLS

TABLE OF SPECIAL TOOLS

Operation Tool description Part Number

Replacing valve seat

Puller adapter, Intake valve 3377396

Puller adapter, Exhaust valve 3376617

Valve seat grinder, 110 volt ST685A

Valve seat grinder, 220 volt ST685C

Replacing valve guide Valve guide puller 3824919

Valve guide installer 3824918

Replacing cross head guideCross head guide puller ST1134

Cross head guide installer 3824920

Grinding valve Tool kit Commercially available

Fuel injector removal Fuel injector puller 3825190

Checking ID of main bearing bores Alignment bar Commercially available

Machining counterbore Tool kit Commercially available

Measure liner protrusion Protrusion gauge 3823495

Replacing cam bushing Tool kit Commercially available

Correcting surface roughness of crank journal Standard piece 790-101-8110

Measure crankshaft thrust Indicator gauge 3823495

Connecting rod bend/twist Gauge mandrel kit 3825185

Mount front sealSleeve installer 795-502-2220

Seal installer 795-502-2210

Mount rear sealSleeve installer 795-502-2120

Seal installer 795-502-2110

Replacing connecting rod small end bushing Use ReCon rod

Replacing crankshaft gearBearing puller 790-101-2800

Push puller 790-101-2300

Install cup plugCup plug driver, 30 mm 3376796

Cup plug driver, 40 mm 3824895

Engine revolution Barring device 3201740

15-2 2

REPAIR AND REPLACEMENT OF PARTS CYLINDER HEAD

CYLINDER HEAD

1. Cylinder head2. Cross head guide3. Valve guide4. O-ring5. Push rod tube6. Valve seat (intake side)7. Valve seat (exhaust side)

15-3 2


Unit: mmSymbol Inspection item Judgement standards Remedy

A Cracks, leakage from cylinder head

� Check for cracks (external color check)� Check for water leakage with air pressure test

(3.0 � 3.5 kg/cm2, 30 sec.)� Water pressure test (3.5 � 4.0 kg/cm2, 10 minutes)

Correct by welding or replace

B Distortion of top, bottom surface of cylinder head Grind to correct

Tolerance Repair limit

0 � 0.06 0.09

C Protrusion of injectionnozzle Permissible range: 4.65 � 5.65

DDamage to valve contact surface of valve seat, loosening of valve seat

� Pitting of valve contact surface� Check contact of valve contact surface� Airtightness test� Tap cylinder head and check for looseness

Do not grind intake valve.Correct valve contact surfaceof valve seat or replace valve seat

E Sinking of valve (both intake and exhaust)

Replace valve or valve seat

Standard value Repair limit

0 ± 0.1 0.7

F Thickness of valve head

� Thickness of valve head

Replace

Standard value Repair limit

Intake value 2.4Exhaust value 2.15

1.91.6

� Angle of valve seat contact surfaceIntake valve: 30°Exhaust valve: 45°

�

15-4 2



G

� Check if head has become concave� Check for cracks or pitting of valve seat contact surface� Airtightness test� Check for play in cotter pin when new cotter pin is

inserted in cotter groove.� Check for uneven wear or curvature of valve stem

Replace

� Check for hollow in tip of valve stem Correct

H Outside diameter of valve stem

� Outside diameter

Replace

Valve Standard size Standard value Repair limit

Intake valve 10 9.940 � 9.955 �

Exhaust valve 10 9.911 � 9.926 �

E Sinking of valve (both intake and exhaust)

Replace

Value Standard size Standard value Repair limit

Intake valve 10 9.989 � 10.011 �

Exhaust valve 10 9.989 � 10.011 �

J Protrusion of valve guide Permissible range: 23 ± 0.2

K Outside diameter of cross head guide

Standard size Standard value Repair limit

11 11.000 � 11.011 10.95

L Protrusion of cross head guide Permissible range: 49 ± 0.25 Correct

15-5 2


CYLINDER AND MOUNTING FACE

1. GrindingA. Remove valve seat. For details, see "REPLACING VALVE SEAT" on page 15-7.

B. Grind cylinder head to remove deformation or rust. Donot exceed repair limit of cylinder head height "a". Stamp[R] on left side of cylinder head.� Standard dimension for height of cylinder head "a":

105 ± 0.05 mm� Repair limit after grinding: 0.10 � 0.15 mm� Surface roughness of grinding surface: Within 6S� Flatness (deformation): Within 0.05 mm� Grinding limit: 0.3 mm� Difference in head height per unit: Within 0.15 mm

C. Press fit one size larger over size valve seat. For details,see "REPLACING VALVE SEAT" on page 15-7.

2. Checking after completion of grinding� Check that sinking of valve is within standard value. Carry out adjustment and modification if necessary.

� Sinking of valve: Standard: 0 ± 0.1 mm

WARNING! Wear protective eye wear to prevent fluid from possible contact with the eyes.

15-6 2


REPLACING VALVE SEAT

1. Removal of seatA. When removing with a valve seat puller

1) Install grindstone (5) to grinder (1).2) Align the groove of sleeve (3) with holder (2), and

insert.� Adjust the position of the grinder with set screw

(4).3) Adjust the position of the grinder so that the center of

grindstone (5) is at the center of valve seat (1), thentighten the set screw to fix the grinder in place.

4) Rotate the grindstone and move it slowly until itcontacts valve seat (1).

5) Press the grindstone lightly against the inside face ofthe valve seat and make a groove around the wholecircumference of the inside face of the valve seat.� Depth of groove: Approx. 1 mm

6) Push the three claws (6a) of puller head (6) of tool Ainwards by hand, and fit into valve seat (1).

7) Tighten screw (8) to push the three claws into thegroove on the inside face of the valve seat.� When the claws are completely in contact with

the groove, stop tightening.8) Insert bridge (9) on the outside of the puller head, set

plates (10) and (11) on top of the bridge and tightennut (12) to pull out the valve seat.

WARNING! Wear protective eye wear to prevent fluid from possible contact with the eyes.

15-7 2


B. When welding a bar to the valve seat to remove1) Weld bar (2) (length: 0.1 � 0.5 mm shorter that inside

diameter of valve seat, diameter: approx. 10 mm) toinside of valve seat (1).� Be careful not to deposit any of the welding metal

on the head itself.2) When the temperature of the weld has dropped to

around room temperature, insert a used valve (3) inthe opposite direction, and hit the face of the valvewith a small hammer to remove the valve seat.� Be careful not to hit too hard, as any excessive

shock may cause the weld to break off.

2. Press fitting valve seatA. When not grinding and correcting press-fitting surface of

valve seat1) Using tools B1 and B2, or tools B1 and B3, press fit

standard valve seat (1) with a press.� Do not use a hammer to press fit.� Press-fitting force for valve seat;

Intake side: Approx. 1.5 tonExhaust side: Approx. 1.5 ton

2) Check the insertion depth a of valve seat from thebottom surface of cylinder head.� Insertion depth a of valve seat;

Intake side: 2.2 mmExhaust side: 2.4 mm

3. Over size machining of mounting hole for valve seat insert.A. Using tools C1 and C2, grind the hole to one level larger

over size.� Machine within an over size range of 1.0 mm

(0.0394 in). If it is more than 1.0 mm (0.0394 in),replace the cylinder head.

15-8 2


� Method of machining valve seat and mounting hole Unit: mm

� Roughness of inside surface: Within 6.3S� Roughness at bottom of mounting hole: Within 12.5 S� Concentricity with valve guide inside surface: Within 0.03 mm (0.0012 in) (TIR)

Valve seat size Valve

Valve seat Valve seat mounting holed1 c1 d2 d3 c2

S.T.D.Intake 55.0 +0.100

+0.090 8.8 0�0.1 55.0 +0.019

0 58.00 ± 0.2 11 0�0.1

Exhaust 52.0 +0.080+0.070 8.6 0

�0.1 52.0 +0.019 0 55.00 ± 0.2 11 0

�0.1

0.25 O.S.Intake 55.25 +0.100

+0.090 8.8 0�0.1 55.25 +0.019

0 58.25 ± 0.2 11 0�0.1

Exhaust 52.25 +0.080+0.070 8.6 0

�0.1 52.25 +0.019 0 55.25 ± 0.2 11 0

�0.1

0.50 O.S.Intake 55.5 +0.100

+0.090 8.92 0�0.1 55.5 +0.019

0 58.50 ± 0.2 11.12 0�0.1

Exhaust 52.5 +0.080+0.070 8.72 0

�0.1 52.5 +0.019 0 55.50 ± 0.2 11.12 0

�0.1

0.75 O.S.Intake 55.75 +0.100

+0.090 9.05 0�0.1 55.75 +0.019

0 58.75 ± 0.2 11.25 0�0.1

Exhaust 52.75 +0.080+0.070 8.85 0

�0.1 52.75 +0.019 0 55.75 ± 0.2 11.25 0

�0.1

1.00 O.S.Intake 56.0 +0.100

+0.090 9.18 0�0.1 56.0 +0.019

0 59.00 ± 0.2 11.38 0�0.1

Exhaust 53.0 +0.080+0.070 8.98 0

�0.1 53.0 +0.019 0 56.00 ± 0.2 11.38 0

�0.1

15-9 2


4. Finishing valve seat contact surface A. Using tools C1, C3, and C4, finish surface of the valve

contact surface of valve seat to dimensions shown indiagram on the right.� When selecting tool C5 to insert into the valve guide,

choose one that gives no clearance.

B. Rub the valve seat contact surface with compound.

C. Concentricity of valve guide and valve seat:Within 0.05 mm (TIR)

D. Width of finished surface of valve seat at exhaust side,and width of contact with valve.

5. Final inspectionA. Coat valve seat contact surface of the new valve thinly

with red lead (minimum), insert it in the valve guide, pushlightly against valve seat surface, and rotate 10°. Checkvalve seat contact surface, and confirm that the contact isuniform without any breaks.

or

Exhaust Intake

Part No.

6210-11-1320 (S.T.D.)6210-19-1320 (0.25 O.S.)6210-18-1320 (0.50 O.S.)6210-17-1320 (0.75 O.S.)6210-16-1320 (1.00 O.S.)

6210-11-1321 (S.T.D.)6210-19-1321 (0.25 O.S.)6210-18-1321 (0.50 O.S.)6210-17-1321 (0.75 O.S.)6210-16-1321 (1.00 O.S.)

Width of finished surface e: 47.1 f: 1.5 e: 45.7 f: 2.5

Width of contact with valve (when using master valve) g: 1.5 ± 0.2 g: 2.5 ± 0.2

15-10 2


B. Make marks with a pencil on valve seat contact surfaceof the new valve as shown in diagram on the right, insertit in the valve guide, push lightly against valve seatsurface, and rotate 10°. Check that pencil marks havebeen erased uniformly around the whole circumference.

PRESSURE TEST OF CYLINDER HEAD� When corrections have been made around the cylinder head,

test pressure as follows.

1. Water pressure testA. Assemble tool E and tool F, and connect the hose to

flange (1). B. Apply water pressure at 3.5 � 4.0 kg/cm2 (50 � 57 psi) for

approx. 10 minutes. Check that there is no leakage fromaround cylinder head.� When carrying out this test, heat the whole cylinder

head and carry out test with hot water 82 � 93°C (180- 200oF).

2. Air pressure testA. Connect the air compressor hose to flange (1).B. Put cylinder head in a container of water, apply air pressure 3.0 � 3.5 kg/cm2 (43 � 50 psi) for approx. 30

seconds. Check that there is no air leakage into the water.� If the above test shows any cracks around the plate plugs of the cylinder head, replace cylinder head.

15-11 2


REPLACING VALVE GUIDE1. Removal of valve guide

� Using tool G1, remove the valve guide.

2. Press fitting valve guideA. Press fit the valve guide until tip of tool G2 contacts the

cylinder head.B. Measure protrusion of the valve guide and check that it is

within standard range.� Protrusion of valve guide

Tolerance: 23 ± 0.2 mm (0.9 ± 0.007 in)

REPLACING CROSSHEAD GUIDE1. Removal of cross head guide

� Using tool H1, remove the cross head guide.

A. As shown in the diagram grip cross head guide with collet(5) of puller.

B. Tighten collet with bolt (1), and lock sleeve (2).C. Turn nut (3), and pull out cross head guide.D. Remove any burrs or flashes from the cross head guide

mount.

2. Press fitting cross head guideA. Using tool H2, insert the cross head guide into cylinder head, and use a copper bar or plastic hammer to

press fit until protrusion is within the permitted tolerance.� Protrusion of cross head guide

Tolerance: 49 ± 0.25 mm (1.9 ± 0.01 in)

15-12 2


GRINDING VALVE

1. Grinding valve seat contact surface� Using tool I (valve refacer), grind the valve seat contact

surface.� Valve seat contact surface angle (α)

Intake valve: 60° ± 0°15� (DO NOT GRIND)Exhaust valve: 45° ± 0°15�

2. Checking after grinding� Check thickness of the valve head, amount of sinking of

the valve, and contact of the valve seat contact surface,and confirm that it is within the standard value.� Repair limit for thickness a of valve head

Intake valve: Min. 1.9 mm (standard dimension:2.15 mm)Exhaust valve: Min. 1.6 mm (standard dimension:2.15 mm)

� Sinking of valveStandard: 0 ± 0.1 mmRepair limit: 0.7 mm

� Use dial gauge (1) to measure face run out (TIR) ofvalve seat contact surface.Intake valve: 0.045 mmExhaust valve: 0.030 mm

� Use one of the following methods to check contact ofthe valve seat contact surface.

� Coat the valve seat contact surface of ground valve thinlywith red lead (minimum), insert it into valve guide, pushlightly against the valve seat, and rotate 10°. Check thevalve seat contact surface, and confirm that contact isuniform without any breaks.

� Make marks with a pencil on valve seat contact surfaceof the ground valve as shown in diagram, insert it into thevalve guide, push lightly against valve seat, and rotate10°. Check that pencil marks have been erased uniformlyaround the entire circumference.

WARNING! Wear protective eye wear when grinding to prevent injury to eyes from grinding material.

15-13 2

REPAIR AND REPLACEMENT OF PARTS CYLINDER BLOCK

CYLINDER BLOCK

1. Cylinder liner2. Clevis seal3. Cylinder liner O-ring4. Cylinder block5. Main bearing cap bolt6. Main bearing cap

(No. 1, 2, 3, 5, 6 are common)7. Camshaft bushing

15-14 2


Unit: mm

Symbol Inspection item Judgement standards Remedy

A Cracks Check for cracks (external collar check)Cylinder head bolt hole portion, etc. Replace

B Correction of contact atpacking portion Replace

C Clearance from cylinderliner

Replacecylinderliner orcylinderblock

D Inside diameter ofcamshaft bushing

Replacebushing

E Protrusion of liner

Replacecylinderliner orcorrectcylinderblock

FDepth of counterboreand corrosion of bottomsurface

Repair bymachining,add shim

GDistortion, wear ofcylinder head mountingsurface

Repair bymachining

15-15 2


H

Inside diameter of mainbearing mounting hole� Tighten main bearing

cap bolt to specifiedtorque

� Measure main bearingcap mating surfacewithin up-and-downrange of 10°

Replace

I Fitting of main bearing capand cylinder block

JInside diameter of counter-bore, outside diameter ofcylinder liner flange

Replacecylinderliner

Correctcylinderblocksleeve


15-16 2


METHOD OF CHECKING INSIDE DIAMETER OF MAIN BEARING MOUNTING HOLE USING ALIGNMENT BAR

� When checking inside diameter of the main bearing mounting hole using an alignment bar, do as follows.

Unit: mm

1. Set cylinder block on a stand with main bearing cap mount at the top.2. Coat inside surface of main bearing hole of the cylinder block with engine oil.3. Remove main bearing cap.4. Set tool J (alignment bar) in main bearing hole of the cylinder block.5. Install the main bearing cap, then tighten mounting bolts to specified torque.6. Check that tool J moves smoothly.

Tool J (alignment bar) Standard dimension

Diameter 157�0.014�0.039

Roundness 0.005

Straightness 0.010

Length Min. 1300

15-17 2


CORRECTING CYLINDER BLOCK TOP SURFACE, COUNTERBOREFlow for correction procedure

� When removing, installing, disassembling, or assembling the engine, see "DISASSEMBLY AND ASSEMBLY"section for details.

� If judgement for Item 9 is NO, go to (A). If the answer is NO again, go on to (B).

15-18 2


15-19 2


Grinding� If there is strain or corrosion of top surface of the cylinder block, grind the top surface.� If there are blackened portions on the cylinder liner contact surface of the counterbore (particularly in front-to-

rear direction), or there is speckled wear, and these portions extend over more than half of the contact surface,or if grinding has been carried out on the top surface, correct the counterpower.

1. Grinding top surface of cylinder blockA. Measure wear and strain of top surface of the cylinder

block, and if it is over the repair limit, grind top surface ofthe cylinder block within the repair limit for height "d" ofthe cylinder block.� Guideline for grinding to surface of cylinder block

� When wear and corrosion on top surface ofcylinder block are the same shape as mark leftby the head gasket

� When wear amount "a" is more than 0.15 mm

Table 1 Unit: mm

When grinding with grindstone (reference)� Grindstone speed: 1650 � 1950 m/min� Table speed: 15 � 30 m/min� Amount of grinding for one pass: 0.025 mm� Cross feed for one pass: 1 � 2 mm� Grindstone: A461V� Grinding fluid: Water soluble grinding fluid

2. Grinding counterbore� After grinding top surface of the cylinder block, measure

depth of the counterbore. If necessary, correct thecounterbore depth "f" within the repair limit.

� Guideline for correcting counterbore

� If it is not within standard dimension.� If there are blackened portions on cylinder liner contact

surface of counterbore (particularly in front-to-reardirection), or there is speckled wear, and these portionsextend over more than half of the contact surface.


Standarddimension

Repairlimit

Flatness of cylinder block (for one cylinder) 0.05 0.10

Height of cylinder block "d" 471.5 ± 0.04 471.0

Roughness of top surface ofcylinder block Within 12.5 S

15-20 2


� After correcting, if the counterbore depth is within 14.05 �15.525 mm, combine with shims and adjust so that linerprotrusion is 0.07 � 0.15 mm.

Table 2 Unit: mm

� For the machining amount for counterbore depth "f", decidean amount that will bring protrusion "e" of cylinder liner withinthe standard value.

� When grinding within repair limit in cases where counterboredepth "f" exceeds standard dimension, set machiningamount so that one shim can be used for each cylinder asshown in the table below.

Table 3Adjustment shims for counterbore depth Unit: mm

Standarddimension

Repairlimit

counterbore depth f 11 +0.05 12.52 S

Cylinder liner protrusion e --- 0.080 - 0.185

Roughness of counterbore Within 12.5 S

Machined shape In accordance with diagram on right (detail diagram for portion b)

Part No. T t Weight (kg) Remarks

6210-29-2260 1.50 0.025 0.023

6210-29-2250 0.08 0.025 0.012

6210-29-2240 0.50 0.025 0.008

6210-29-2230 0.26 0.025 0.004

6210-29-2220 0.20 0.020 0.003

6210-29-2210 0.16 0.016 0.002

15-21 2


Use tool K when grinding the counterbore.

3. Checking and distinguishing after grinding andcorrecting� After grinding and correcting, check for scratches on the

flat surface around the water and oil holes in the cylinderblock top surface.

� Remove all burrs and flashes completely.� After grinding the top surface, if cylinder block height "d"

exceeds the standard dimension, but it within repair limit(471.0 � 471.4 mm), always use an over size headgasket.

Table 4 Unit: mm

� To distinguish, the letters [OS] are stamped on theplate.

� After correcting, stamp top surface of cylinder block (rearof left bank) according to the nature of correction asshown in table below.

Table 5

(Size of letters: 5 - 10 mm)

Head gasket Part No. Plate thickness

S.T.D. 6210-11-1812 2.0

Over size 6210-19-1813 2.4

Over size head gasket Shim Stamp

Parts

use

d fo

r co

rrect

ion

� � Not needed

X � OS

� X SH

X X WS

15-22 2


4. Procedure for coating cylinder block top surface deckwith gasket sealant� When pulling out the cylinder liner and press fitting it

again, coat cylinder block top surface deck (cylinder linerflange contact surface of the cylinder block) with gasketsealant (LG-6) as follows.

� Use the same procedure when using a shim for thedeck.

A. Use a cloth to wipe off all dirt and oil from cylinder blocktop surface deck and cylinder liner flange contactsurface.

B. Coat position marked in the diagram with LG-6.� Diameter of line of gasket sealant: 2 � 3 mm� Overlap of beginning and end of sealant: 6 ± 6 mm

� When using shims for deck� After coating bottom of the shim thinly with

LG-6, install it to left portion of the cylinderblock.

� Next, coat with LG-6 in same way as whennot using shims.

C. Press fit liner into the cylinder block. When doing this, coat the cylinder block contact surfaceof seal and O-ring with a small amount of engine oil(SAE30) immediately before press fitting the liner.� Do not coat with engine oil until immediately before

press fitting the cylinder liner.

D. After setting the cylinder liner into the cylinder block,assemble a used head gasket and temporarily tighten thecylinder head. When doing this, tighten in the tighteningorder shown in diagram on the right.

137 - 157 Nm (101 � 115 lbf ft)

15-23 2


E. Loosen cylinder head mounting bolts, remove cylinderhead, then wipe off excess gasket sealant that has comeout from the counterbore.� The gasket sealant that comes out may cause

deformation of head gasket grommet, so alwayscarry out Steps 4) and 5) without fail.

� After carrying out Steps 4) and 5), use a new headgasket to install the cylinder head.

5. Standard for rebuilding cylinder liner O-ring portion ofcylinder block� If the bushing of cylinder liner O-ring of the cylinder block

has been corrected, make the finishing dimensions asfollows.� Concentricity of (6) in relation to standard (A):

Max. 0.05 mm

Table 6 Unit: mmNo. Finishing dimensions

(1) ø 167 see "REPLACING MAIN BEARING CAP"on page 15-25.

(2) ø 161.45 ± 0.25

(3) ø 160.67 ± 0.064

(4) 176 ± 0.25

(5) 184.94 ± 0.18

(6) ø 158 +0.040 0

(7) ø 159.03 (Gauge diameter)

15-24 2


REPLACING MAIN BEARING CAP� When replacing the main bearing cap, machine semi-finished product to the following dimensions, then install.

Correction parts

1. Machining inside diameter of main bearing capA. Remove the cylinder liner.

B. Install replacement main bearing cap to the cylinder block, and tighten to specified torque.

� Align cylinder block and main bearing cap notch.

C. Set a cylinder block mounting jig on table of a horizontalboring machine, fit cylinder liner mounting hole of thecylinder block to standard line on the jig, and install thecylinder block.

D. Of the main bearing caps to be used again, take one withlongest pitch and put a dial gauge in contact with insidediameter at two places to align center of the boringmachine arbor.

Part Number Part Name

6215-29-1210 Main bearing caps other than No. 4, 7

6215-29-1230 Main bearing cap No. 4

6215-29-1250 Main bearing cap No. 7

Main bearing cap mounting bolt:Coat seat face of threaded potion with engine oil.

Main bearing cap mounting bolt:

Order Target Range

1st step 2.9 kgf m (21 lbf ft) 2.8 - 3.1 kgf m (20 - 23 lbf ft)

2nd step 5.9 kgf m (43 lbf ft) 5.8 - 6.0 kgf m (42 - 44 lbf ft)

3rd step Tighten 90° further 90°+30° 0

15-25 2


E. Check machined inside diameter of bearing cap (1) andgrind a little at a time.� Grind until the bit touches inside surface of cylinder

block (2).� Inside diameter of cap main bearing cap

1) Machining dimensionTolerance: 157 +0.025

0 mm2) Inside diameter of cap when main bearing cap is

tightened to specified torque after machiningTolerance: 157 +0.025

-0.010 mm(Up-down range of 10° at mating surface of main bearing cap)

� Finishing roughness: Within 10 S� Do not grind inside face of cylinder block.

2. Machining width of main bearing cap(Only when machining No. 7 main bearing cap)A. Insert cast iron bushing (1), then pass arbor (2) through.B. Install facing bit (3) to arbor.C. Grind cap (4) until bit touches cylinder block face.D. Grind opposite side in the same way.

� Roughness of thrust bearing mounting surface:Within 12.5 S

� Do not grind cylinder block� Width of main bearing cap

Tolerance: 52 0-0.030 mm


15-26 2


REPLACING CAM BUSHING� When replacing the cam bushing, first remove blind plug at

rear of cylinder block.

1. Removal of No. 1, 7 bushingsA. As shown in diagram, assemble push tool L2, collar L3,

and push bar L1 of push tool L, then hit the push bar toknock bushing (2) out from cylinder block (1).

2. Removal of No. 2, 6 bushingsA. Assemble push bar L1, push tool L2, collar L3, and guide

L4 of push tool L, then hit the push bar to knock bushing(3) out from cylinder block (1).

3. Removal of No. 3, 4, 5 bushingsA. Assemble push bar L1, push tool L2, collar L3, and guide

L4 of push tool L, then hit the push bar to knock bushing(4) out from cylinder block(1).

B. After removing bushing, remove any burrs or dirt, andclean mounting hole of the bushing.

15-27 2


4. Press fitting No. 3, 4, 5 bushingsA. Assemble bushing (4) to tool L, and press fit the bushing

until oil hole of cylinder block (1) matches oil hole of thebushing.

5. Press fitting No. 2, 6 bushingsA. Assemble bushing (3) to tool L, and press fit the bushing


6. Press fitting No. 1, 7 bushingsA. Assemble bushing (2) to tool L, and press fit the bushing


7. Measuring after press fitting bushingA. Using inside gauge (1), measure inside diameter of

bushing.B. Check clearance between bushing and shaft, and if the

clearance is not within specified range, or shaft does notmove smoothly, correct inside diameter of bushing with areamer.� When inside diameter of bushing has been corrected

with a reamer, clean all metal particles from the oilhole and oil groove.� Inside diameter of cam bushing:

ø 65 0+0.06 mm

� Clearance of camshaft journal:0.016 � 0.096 mm

15-28 2

REPAIR AND REPLACEMENT OF PARTS CRANKSHAFT

CRANKSHAFT

1. Crankshaft.2. Main bearing (upper)

(common except for No. 4).3. Main bearing (lower)

(common except for No. 4).4. Thrust bearing

(Top x 1, bottom x 2, all common).Unit: mm


A. Cracks Use a magnetic flaw detector to check for cracks Replace

B. DamageCheck for damage to journal portion:

Scratches, Seizure, Discoloration

If damage is slight, correct with an oil-stone or correct by lapping. Replace if there is seizure.

Damage to threaded hole at front and rear end of crankshaftCorrect

C. Clogging of oil hole Check for clogging of oil hole

D. End play of crankshaft

Standard value Repair limit Replace thrustbearing orcorrect withover size

0.140 � 0.320 0.50

15-29 2



E. Thickness of thrustbearing

Size Standard size Tolerance Repair limit

Replace thrust bearing or correct crankshaft with over size

STD 4.000

�0.07�0.12

3.79

0.25 OS 4.125 3.92

0.50 OS 4.250 4.04

0.75 OS 4.375 4.17

1.00 OS 4.500 4.29

F. Outside diameter of crankshaft pin journal


Correct withunder size or replace

STD 100.00

0�0.020

99.88

0.25 US 99.75 99.63

0.50 US 99.50 99.38

0.75 US 99.25 99.13

1.00 US 99.00 98.88

G. Roundness ofcrankshaft pin journal


0 � 0.010 0.010

H. Clearance of crankshaftpin journal 0.046 � 0.116 0.260

Correct with under size or replaceconnecting rodbearing

I. Outside diameter of main journal


Correct withunder size or replace

STD 148.00

0�0.020

147.98

0.25 US 147.75 147.73

0.50 US 147.50 147.48

0.75 US 147.25 147.23

1.00 US 147.00 146.98

J. Roundness of mainjournal


0 � 0.010 0.010

K. Clearance of mainjournal

No. 4 only 0.130 � 0.195 0.250 Correct withunder size or replace mainbearing

Other than No. 4 0.100 � 0.165 0.220

L.Curvature of crankshaft(total run out ofindicator)


Replace

Total coaxially ofmain journal Within 0.09 0.09

Coaxially of neighboring jour-

nalsWithin 0.05 0.05

15-30 2


CORRECTING SURFACE ROUGHNESS OF CRANKSHAFT JOURNAL PORTIONIf roughness of crankshaft journal portion does not fulfill standard,and there are scratches or dents on outside diameter which it ispossible to correct, then correct the surface roughness

A. Cleaning and blowing with airBefore polishing, brush oil holes and blow with air.

B. Correcting surface roughness of journal portion.

1. When correcting with special polishing machineUse a special polishing machine as shown in diagram on theright.

A. Set rotating speed for polishing machine at 40 � 50 rpm.When correcting, use sandpaper (belt type), and movesandpaper once up and down entire journal width foreach journal.� Use #320 sandpaper (belt type).� Move sandpaper smoothly and do not stop at any

point.� Do not use honing oil.

B. Next, replace with #500 sandpaper, coat journal surface with honing oil, and move handle of machine tothe left and right by amount of play to give fine movement. Use this movement to move once up and downentire width of the journal.� Move sandpaper smoothly and do not stop at any point

C. Using tool M (standard gauge), check surface roughness.� When measuring surface roughness, compare

surface roughness of journal portion with tool M(standard piece). Standard value for surfaceroughness (pin journal, main journal):

Journal portion: Max. 0.8 SR portion: Max. 3.2 S

D. Check surface roughness, and if it is not within standard,polish again once up and down the width of journal with#500 sandpaper.� Check that there are no scratches or dents in journal portion or fillet portion.

If there are any scratches or dents, polish again and follow procedure from Step 1).

15-31 2


2. When a special polishing machine is not available, use apolishing jig such as shown in diagram to right.A. Use a crankshaft grinding machine and rotate crankshaft

to polish.� Sandpaper: #800� Machining oil: Honing oil (or diesel oil)� Work speed: 40 rpm

B. Move polishing jig the amount of play of journal width(approx. 5 mm), and move up and down journal in axialdirection to carry out polishing.� Polishing time for one journal is approx. 6 minutes.

After completing honing of one journal, replacesandpaper with new.

� When honing the pin journal, carry out work with pinjournal at rotation center.

3. Assembly of polishing jig and method of useA. Assemble polishing jig for pin journal and main journal as

shown in diagram to the right.

B. Cut out a piece of #800 sandpaper with shape shown indiagram to the right.

C. Take 2 pieces of sandpaper, align with slit of jig plate (1),then insert and fix in position with tape.

D. Fit journal in jig plate (1), and fix ends of jig lever (2) witha rubber band.

15-32 2


Polishing jigMake a polishing jig according to diagram below.

Polishing jig (for pin journal)Plate (1) [2 are used for each jig]

Lever (2) [2 are used for each jig]

15-33 2


Polishing jig (for main journal)Plate (1) [2 are used for each jig]

Lever (2) [2 are used for each jig]

15-34 2


GRINDING CRANKSHAFT

� When grinding crankshaft to correct wear, light seizure ordamage, grind to any of the following under size dimensions.Under size: 0.25, 0.50, 0.75, 1.00 mm

� If there is curvature or uneven wear of the crankshaft, it ispreferable to replace crankshaft and not repair it. (A highlevel of skill is required.)

� Be particularly careful when finishing the fillet portion R, shoulder r, and R around the hole.

Finishing dimension for fillet: Unit: mm

Finishing dimensions for oil holes in main journal and pin journalare as shown in diagram to the right.

Main journal portion


Finishing dimension

Surfaceroughness

Pin journalR1 4+0.4

0 3.2 S

r1 5 ± 0.5 12.5 S

Main journalR2 3.5 0

�0.5 3.2 S

r2 6 ± 0.5 12.5 S

15-35 2


Pin journal portion

� Surface roughness for outside diameter of the pin journal and main journal shall be 0.8 S or less.

� Necessary equipment and jigs for grinding1. Magnet flaw detector2. Shore hardness gauge3. Etching kit4. Crankshaft mill5. Crankshaft polisher6. Roughness gauge7. Fillet R measurement ball gauge

1. Inspecting before grinding

A. Visual inspection Check for cracks, damage, discoloration caused by seizure, and wear, and judge if it ispossible to correct by grinding.

B. Inspecting hardness of journal surfaceStandard value: 63 � 69 HsIf it is below repair limit, discard the part.

15-36 2


2. Inspection during grinding and after grinding

A. Inspecting fillet R.� Check that fillet R is connected smoothly to shoulder

of the journal.� Use a fillet R measurement ball gauge to check that

R dimension is between the dimension for minimumvalue gauge and the dimension for maximum valuegauge

Unit: mm

B. Checking for traces of seizure using etching� After grinding, carry out an etching test to confirm that there is no grinding seizure.� If any traces of seizure are found, grind approx. 0.02 mm and correct again to the next under size

dimension.� After inspection, neutralize and wash inspection surface, then coat with rust prevention oil.

C. Magnetic flaw detection� Carry out a magnetic flaw detection of the corrected

crankshaft before use and check that there are nocracks.

� Be particularly careful to check journal fillet portionentering watch danger zone of the crankshaft.

� After carrying out magnetic flaw detection, alwayscarry out demagnetization.

C. Measuring curvature (measuring alignment)� Measure the curvature of crankshaft after grinding and check that it is within standard value.� Check curvature (alignment) at the following four places:

1) Total length of alignmentTolerance: Max. 0.09 mm

2) Neighboring alignmentTolerance: Max. 0.05 mm

3) Tip alignmentTolerance: Max. 0.03 mm

4) Rear end alignmentTolerance: Max. 0.03 mm

Fillet R Min. radius Max. radius

Main journal 4.0 4.4

Pin journal 3.0 3.5

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3. Grinding main journal� Grind each main journal to same under size dimension. � When grinding, leave a tolerance of 0.007 � 0.008 mm

for finishing.� Mark under size dimension on the ground crankshaft as

shown in the diagram to prevent any mistake in the sizewhen assembling the bearing.

Main journal under size dimension Unit: mm

Roundness, cylindricity (TIR), surface roughness of main journal.

Tolerance: Max. 0.010 mmRepair limit: 0.010 mmSurface roughness: Max. 0.8 µm

4. Grinding thrust surface� There is no particular need to grind front and rear thrust

surface to same under size dimension.� Mark under size dimension on ground crankshaft as

shown in diagram to prevent any mistake in the sizewhen assembling thrust bearing.

� If thrust surface has been ground, check that end play ofcrankshaft is within the permitted range.(For details, see overall assembly in "DISASSEMBLYAND ASSEMBLY" section.)


Size Standard size Tolerance

S.T.D.0.25 US0.50 US0.75 US1.00 US

100.00099.75099.50099.25099.000

0�0.020

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Thrust surface over size dimension Unit: mm

Squareness of thrust surface (TIR)Tolerance: 0.02 mmRepair limit: 0.02 mm

5. Grinding pin journal� Grind each pin journal to same under size dimension.� When grinding, leave a tolerance of 0.007 � 0.008 mm

for finishing.� Mark under size dimension on ground crankshaft as

shown in diagram to prevent any mistake in size whenassembling bearing.

Pin journal under size dimension Unit: mm

Roundness, cylindricity (TIR), surface roughness of main journal.Tolerance: Max. 0.010 mmRepair limit: 0.010 mmSurface roughness: Max. 0.8 µm

Rear thrust surface

STD. 0.25 O.S. 0.50 O.S.

Frontthrustsurface

STD.Standard size 59 0

+0.050 59.25 0+0.050 59.5 0

+0.050

Repair limit 59.060 59.310 59.560

0.25O.S.

Standard size 59.25 0+0.050 59.5 0

+0.050 59.75 0+0.050

Repair limit 59.310 59.560 59.810

0.50O.S.

Standard size 59.50 0+0.050 59.75 0

+0.050 60 0+0.050

Repair limit 59.560 59.810 60.050


Size Standard size Tolerance

S.T.D.0.25 US0.50 US0.75 US1.00 US

100.00099.75099.50099.25099.000

0�0.020

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6. Grinding main journal width and pin journal width� When correcting wear surface of main journal and pin

journal, correct using minimum amount of grinding.� Crankshaft pin journal width

� When grinding one side onlyStandard: 92 0

+0.054 mm

� Squareness (TIR) of thrust surfaceRepair limit: 0.02 mm

7. Correcting grindstone� Carry out dressing for grindstone for each journal� Adjust grindstone correction device and correct grindstone to a dimension matching arc of the fillet.� When checking and correcting grindstone edge, grind a wooden test piece and check with a ball gauge.

8. Prevention of grinding seizure� Use plunge grind method when grinding.� Use whole width of grindstone

� Avoid grinding boss surface as far as possible.� Direct an ample supply of cooling oil� When crankshaft speed is 40 rpm, make standard grinding speed at circumference of grindstone

2000 m/min.

9. Finishing surfaceSee section on "Surface Roughness".� Surface roughness standard (pin journal, main journal)

Journal face: Max. 0.8 SThrust surface: Max. 1.6 STip taper portion, pin, journal boss portion, fillet portion: Max. 3.2S

� Allowance for polish finishing: 0.007 � 0.008 mm

10. Action after grinding� Check again that each dimension is as specified.� Wash each part thoroughly and coat it with rust prevention oil.� When storing for a long period, support at three points or fit a lifting tool and stand upright.

11. Balancing (reference)As far as possible, do not carry out repairs that will affect balance of the crankshaft.� Service limit for imbalance: 10 g�cm� Limitations for accurate reading of balance

Crankshaft curvature: 0.05 mm (TIR)Crankshaft rotation speed: Max. 325 rpm

� To correct balance, make a drill hole in the counterweight or carry our grinding.Direction of drill hole: Radial directionHole diameter: Max. 13 mmHole depth: Max. 50 mmNo. of holes: Max. total of 6 for one counterweightCenter of hole: Align with center of counterweight (deviation shall not exceed 0.5 mm)Distance between holes: Min. 5 mm

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12. Procedure for measuring curvature of crankshaft andoutside diameter of journalA. Support center of both ends of crankshaft with lathes. Put

probe of a dial gauge perpendicularly in contact with thecenter journal (No. 4) and set dial to 0 at the peak. Thenrotate one turn and read minimum and maximum values.� If no lathes are available, support No. 1 and No. 7

journals on a V block.

B. Measure outside diameter of the main journal andoutside diameter of the pin journal with a micrometeror air micrometer.

� Locations for measuring journalPin journal: X and Y directions, 5 placesMain journal: X and Y directions, 3 places

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CORRECTING FRONT SEAL CONTACT SURFACE

Correction parts

� If there is wear or damage to the front seal contact surface ofcrankshaft (1), use correction oil seal (2) and sleeve (3) tocorrect.

� Remove crankshaft pulley and damper.� Remove front seal (2).

� Be careful not to damage surface of the crankshaft.

1. Press fitting sleeveA. Use sandpaper to remove any dust or mud from the

sleeve press-fitting portion of crankshaft (1), then cleanthe part.� 60 mm range (hatched portion) from end face of the

crankshaft.

B. Coat the whole inside of the sleeve thinly with sealant(LG-7).

C. Using a plastic hammer or wooden hammer, tap edge ofsleeve (3) around the circumference to install sleeve (3)uniformly to end face of crankshaft (1).

� Do not use a metal hammer. If a metal hammer isused, burrs or flashes will be made at end face of thesleeve, and this will damage the lip surface of oilseal.

� The sleeve is symmetrical, so it can be installed ineither direction.

D. Using sleeve press-fitting tool N1, press fit until inside ofthe press-fitting tool is in contact with end face of thecrankshaft.

� Tighten mounting bolts in turn to press fit. (Do not hitwith a hammer to press fit.)

� Press fit sleeve to a position 5 mm from front face ofthe crankshaft.

E. After press fitting the sleeve, wipe off all sealant that issqueezed out.

� If sealant sticks to lip of the oil seal, it will cause leakageof oil.

Komatsu Part No. Part Name

6215-29-4320 Sleeve, front seal assembly

6215-29-4340 Sleeve

6215-29-4330 Front seal

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� If a sleeve is already being used

F. Using a puller, remove sleeve (3).

� If no puller is available, make a cut in the sleeve with a cutter, hit with a chisel to release force holdingthe sleeve, then remove sleeve.

G. After removing the old sleeve, clean surface of crankshaft and polish with emery cloth.The remaining procedure is same as for Steps A thru E above.

2. Press fitting front seal

A. Use plastic sleeve to install seal over end of crankshaft

B. Using sleeve press-fitting tool N2, press fit until the inside of press-fitting tool is in contact with end face ofthe crankshaft.

� Tighten mounting bolts in turn to press fit. (Do not hit with a hammer to press fit.)� Press fit front seal to a position 13 mm from front face of the crankshaft.

C. Install damper and crankshaft pulley.

15-43 2


CORRECTING REAR SEAL CONTACT SURFACE

Correction parts

� If there is wear or damage to rear seal contact surface ofcrankshaft (1), use correction oil seal (2) and sleeve (3) tocorrect.

� Remove flywheel.� Remove rear seal (2).

� Be careful not to damage surface of crankshaft.

1. Press fitting sleeveA. Use sandpaper to remove any dust or mud from sleeve

press-fitting portion of crankshaft (1), then clean the part.� 60 mm range (hatched portion) from end face of the

crankshaft.

B. Coat entire inside of sleeve thinly with sealant (LG-7).

C. Using a plastic hammer or wooden hammer, tap edge ofsleeve (3) around circumference to install sleeve (3)uniformly to the end face of crankshaft (1).

� Do not use a metal hammer. If a metal hammer isused, burrs or flashes will be made at end face of thesleeve, and this will damage lip surface of the oilseal.

� The sleeve is symmetrical, so it can be installed ineither direction.

D. Using sleeve press-fitting tool O1, press fit until inside ofthe press-fitting tool is in contact with end face of thecrankshaft.

� Tighten mounting bolts in turn to press fit.(Do not hit with a hammer to press fit.)

� Press fit sleeve to a position 14 mm from front face ofthe crankshaft.

E. After press fitting the sleeve, wipe off all sealant that issqueezed out.

� If sealant sticks to lip of the oil seal, it will cause leakageof oil.

Komatsu Part No. Part Name

6215-29-4220 Sleeve, rear seal assembly

6215-29-4240 Sleeve

6215-29-4230 Rear seal

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� If a sleeve is already being used

F. Using a puller, remove sleeve (3).

� If no puller is available, make a cut in the sleeve with a cutter, hit with a chisel to release force holdingthe sleeve, then remove sleeve.

G. After removing the old sleeve, clean surface of crankshaft and polish with emery cloth.The remaining procedure is same as for Steps A thru E above.

2. Press fitting rear seal

A. Use plastic sleeve to install seal over end of crankshaft

B. Using sleeve press-fitting tool O2, press fit until inside of the press-fitting tool is in contact with end face ofthe crankshaft.

� Tighten the mounting bolts in turn to press fit. (Do not hit with a hammer to press fit.)� Press fit front seal to a position 21 mm from front face of the crankshaft.

C. Install flywheel.

15-45 2

REPAIR AND REPLACEMENT OF PARTS CONNECTING ROD

CONNECTING ROD1. Connecting rod bolt2. Washer3. Cap4. Dowel pin5. Bearing (lower)6. Bearing (upper)7. Rod8. Bushing

Unit: mm


A Cracks Check for cracks with a color check or magnetic flaw detector

ReplaceB Curvature, twisting

CClearance betweenconnecting rod bushingand piston pin

Standard size


Clearance limit

Replace bushing,roughness ofinside surface of bushing:Max. 3.2 S

Shaft Hole

52 0�0.006

+0.049+0.030

0.030 �0.055 0.11

DInside diameter of holeat big end ofconnecting rod

� Inside diameter of hole at big end

� Without bearing� Roughness of inside surface of

hole at big end: Max. 3.2 S

� Clearance from crankshaft pinjournal (with bearing)

� Localized wear of big endinternal circumference:Max. 0.004 (whole width)

Standard size Tolerance

Replace

106 +0.026+0.006

Standard clearance

Clearance limit

0.046 � 0.116 0.26

Even if each part is withinrepair limit, if it is abovethe clearance limit, replacethe part (bearing etc.)

E Thickness of bearing


Replace

STD. 3.000

�0.025�0.035

2.91

0.125 US 3.125 3.04

0.250 US 3.250 3.16

0.375 US 3.375 3.29

0.500 US 3.500 3.40

15-46 2


� It is impossible to measure all items in this judgement standard (in particular, the localized wear of big internalcircumference) after machining and rebuilding the connecting rod, do not carry out any rebuilding. The reasonfor this is that it is impossible to confirm the precision after machining and rebuilding the hole at connecting rodbig end.

� When deciding on whether to reuse or discard the connecting rod, if honing grain can be observed on holesurface at big end, measurement of big end hole surface toughness and wave is unnecessary.

FScratches on insidesurface of bearing,seizure

Check for scratches or seizure

Replace bearing(replace connecting rodalso)

GDistance between holesat big end and smallend

Standard size ToleranceReplace

305 0 � 0.05

H

Scratches at I shapeportion of connectingrod

Check for scratches in horizontaldirection in area A

Check for grinder grain in horizontaldirection in area A

Replace

Dents

Replace if thereare any dents,regardless ofsize.

I Fretting of matingsurface of cap

Check for fretting of mating surfaceRoughness of mating surface: Max. 6.3 SBack contact of mating surface: Min. 70%

Replace iffingernail catchesin fretting

J Scuffing of bolt surface

Scuffing of cap bolt seat surface Correct withoilstone

Scuffing of bolt seat surface Replace bolt

Scuffing of washer surface Replace washer

K Deformation of dowelpin

Check for deformation of dowel pinCheck for deformation of dowel pin hole Replace

L Damage to bolt Check for cracks, damage to bolt threadCheck for curvature of bolt Replace bolt


15-47 2


REPLACING CONNECTING ROD SMALL END BUSHING1. Removal of connecting rod bushing

A. Set connecting rod on tool P3.

B. Using tools P1 and P4, remove connecting rod bushingwith a press.� After removing bushing, remove any burrs or dirt,

and clean mounting hole of the bushing.

2. Press fitting connecting rod bushing

A. Set the connecting rod on tool P3.

B. Assemble connecting rod bushing to tool P1, then settool P2 and secure with tool P4 so that it does not move.� Align connecting rod bushing oil hole and connecting

rod oil hole.

C. Push tool P1 with a press and press fit connecting rod bearing.� Bushing is a semi-finished product, and inside diameter is small, so piston pin will not fit.� After press fitting the bushing, machine inside diameter of bushing with a reamer or honing machine in

accordance with the MAINTENANCE STANDARD.� After machining, remove all metal particles from the oil hole and oil groove.� Surface roughness of inside diameter after machining bushing: Within 3.2 S

15-48 2


REPLACING CRANKSHAFT GEAR1. Removal of gear

� Make a scratch in surface at root of teeth with a grinder,then assemble tools Q1 and Q2 and turn nut (1) toremove gear.� If gear cannot be removed in this way, make a

scratch in surface at root of teeth with a grinder, thenheat gear with a gas burner and knock gear out witha copper rod.

� Be careful not to damage crankshaft.

2. Press fitting gear

A. Check gear mounting surface, key groove, and flangesurface, and if there are any scratches, correct them withan oilstone.

B. Knock a new key into key groove of the shaft.

C. Heat gear for specified time at the specified shrink-fitting temperature.� Gear shrink-fitting temperature: 200°C

Heating time: Min. 30 minutes

D. Put timing mark of gear on outside, then use a hitting tool to press fit until the side face of gear is in closecontact with crankshaft flange.� Knock in quickly before gear becomes cool.

15-49 2


REPLACING CAMSHAFT GEAR

1. Removal of gear

Set camshaft assembly on press stand, then push camshaft toremove gear.


A. Check gear mounting surface, key groove, and flangesurface, and if there are any scratches, correct them withan oilstone.

B. Knock a new key into groove of the shaft.

C. Assemble the thrust plate.

D. Heat gear for the specified time at specified shrink-fitting temperature.� Gear shrink-fitting temperature: 200 � 240°C (392 - 464oF)


E. Put timing mark of gear on the outside, then use a hitting tool to press fit until side face of gear is in closecontact with the camshaft flange.� Knock in quickly before gear becomes cool.

REPLACING FLYWHEEL RING GEAR

1. Removal of gear� Make a scratch in surface at root of the gear teeth with a grinder, then split with a chisel to remove.


A. Check gear mounting surface, and if there are any scratches, correct them with an oilstone.

B. Heat gear for specified time at the specified shrink-fitting temperature.� Gear shrink-fitting temperature: Max. 200°C


C. Set chamfered face of gear facing the flywheel, and press fit until side face of gear is in close contact withthe flywheel.

WARNING! Use care when placing camshaft assembly to prevent injury to fingers.


15-50 2

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