14 MAINTENANCE STANDARD 170-3 SERIES NTAKE AND EXHAUST SYSTEM Turbocharger. ENGINE BODY Cylinder head Valve, valve guide .... Crosshead and crosshead guide ‘Tappet and push rod Rocker arm. Cylinder block... Cylinder liner Crankshaft Timing gear Piston, Piston ring, Piston pin .. Connecting rod... LUBRICATION SYSTEM il pump, Gil cooler. COOLING SYSTEM Water pump.. Thermostat. 14-1MAINTENANCE STANDARD TURBOCHARGER KTRIV0L ‘TURBOCHARGER 170-8 SERIESMAINTENANCE STANDARD TURBOCHARGER Unit: mm No. ‘Cheek item Criteria Remedy + [ene pty Standard size Repair int Replace parts (Gy in al cretion) 008-013, 018 tit Radalplay _ Rertace pas 2 | lay inradat rection) 026-048 080 rosect ‘tanard Telorance Repair nit outside ameter ot oumal ie —~ 3. [bearing inside diameter of Sha Hole ‘Shat Hole center housing 0050 0021 5 050 0 2age 25.08 inside ameter of joumnal ~.0s2 0.009 Dearing, outside damster of 7 16.95 v0 [Deana ou coos 200s Curvature of wheel shat Repair init 0.010 (otal tition of iefeaton ooh replace Tolerance Repair Standard size mi 5. | Thickness of thrust bearing wath Groove Wet Groove “008 ‘0.02 6 38 °. 434 Bot r “008 008 Turbine end 23 245 238 og | Thickness of 10 204 coal "? — Jetoner ona 2 ae m8 185 208 Replace parts Cleerance between blower 7_ | Gterance betwoen Ctoarance iit (in) 0.20 ated 170-3 SERIES 14-3MAINTENANCE STANDARD CYLINDER HEAD CYLINDER HEAD * Nos. @ ~ © in the drawing indicate the order for tightening the cylinder head mounting bolts. sxE01826 — No. ‘Check item Criteria Remedy ema, «foment oneness woe a a Reagent = Sun eatvase a 2 | Protrusion of nozzle ‘Sequence Target Ne{igen} Range Nm(kgm)} Rownna rmoctome | gang, |S | 888 [RAR rin 9 eemeremt yy | “Bie | autsee [sete [sro soztonman_| gece (emia, mee (LMP) Bolts No. ® and @ 98 (10) 93 - 103 {9.5 ~ 10.5) Tightening torque of injector ‘1st Step. 2943) 25-34 (2.5-35} acre + Ee cro ue - centcuets | acu rete or Sone | tien 5 | Tihtoning torque of rocker ‘Target Nmkgm ange Nem(kgrn) arm housing mounting bolt 86 (8.75) 78-98 (8.0~9.5} «6 | antening torque ot eyinder 10(1) o-11 09-1. 14-4 170-3 SERIESMAINTENANCE STANDARD VALVE, VALVE GUIDE svrots27 VALVE, VALVE GUIDE nit mm — No. Check item Criteria Remedy ‘Standard Repairint | Rapace 1 | sinking ot vate valve orvave Inakeforhaust vane 2 4 feeat Seandardsiee | Towrance | _ Repairimt a I meanest ae tp talons a2 - a7 | fepace Etiaustvale | 33 = 2a ‘Standard Tolerance 2. | Amie ot vamo sat intake vale 3° aS Shaws vave = wie ‘Standardize Tolerance Repair iit tee sae ve 3.088 ‘190 4 [vatw atom 2 exaust vane Bose 11.80 “eter oplaco Inside damotr of valve 2.001 guce 2 ore 1210 3 [Proiuson of vave guido 2 208 = Persstotoad Free ln instatediongtn | intaed oad Nik) Valve epring an te) Niko} * we wa earassjosoues) | 600(620) - Perpendicular ovale — Peres Repalr mt: 1703 SERIES 145MAINTENANCE STANDARD CROSSHEAD AND CROSSHEAD GUIDE CROSSHEAD AND CROSSHEAD GUIDE 9xE01528 Unit mm No. Cheek item Criteria Remedy ‘Standard sia “Tolerance Repair imi 1 | Depth ef eosahoad tem a 78 128 ~ 2 |i ameter sates 8 2 va Outsiie ameter of cross o08e ead guide 1% ese 13.00 > | clearance between cose Standard dearance ‘Glearance tt head guide and crosshead ‘oon oor? = Aust 4 | Provution of rshesa Standard size Tolerance ude 7% 3025 Replace tntake vaivo Exhaust vake 5 | Valve clearance (at old) ox 062 Tightening torque of erase. ” 6 | panening tr 59 6 Nim (6.0: 06 kam} Tighe 14-6 170-3 SERIESMAINTENANCE STANDARD ‘TAPPET AND PUSH ROD TAPPET AND PUSH ROD INTAKE VALVE, EXHAUST VALVE sxevsse Unt am No. ‘Check item Criteria, Remedy Sind se oo ecarie 1 | osteo ot am ob ce ‘ors 2 2 38 % te gator cam aa 2 lower lover 2 ° 3 nace dane oar or ‘oer or 267 01 253 a | Outside diameter of cam fol 2s 40.075, 250 Replace Deeroter pn tase ; Ouse ameter team 7. 4 flower roller 50 40.75 5 [iter of push op ba 1898 3, ~ vse dart ot pak vo 0 | isce 13678 3 14-8 170-3 SERIESMAINTENANCE STANDARD TAPPET AND PUSH ROD INJECTOR sxeorsne Unt mn No. Check item Criteria Remedy Sandee Twennece epar t 1 | tee mote tam tok fowar at . oe 25 9.083 2s iio amor fam ok acet 2 | lower lover 2 o 25 sie maar of am or weir 3 fewerroter ar soi 272 Outise damotor of cam ek p vase me |Renece fewer rll Tats Outside of am tok “0.25 4 [lower rotor 50 ° 500 T ° 5 [ameter ot push od i bat mae Se - inlde damier of push vod ° | mas son - 170-8 SERIES 14-9MAINTENANCE STANDARD ROCKER ARM ROCKER ARM INTAKE VALVE, EXHAUST VALVE oxen nt mm No, Check item Criteria, Remedy Cancardae Tene ose dancer | roeone Peace am 450 woes shat Te dane eoarame me a0 apace 7 | bushing +0024 ‘rocker arm Sid caraee iarano tk Repace tarnc etn oct kota scat an cota arm pou -oatar oe itera vee Send Tonos 2: | va dearance at co) Tako vavo ose aut 002 Exhaust vab ace Foeang wave a nant Tarot (aR ange Wan 2 |orroora aucment rpten Soon sie) Sa 7768~79) 14-10 170-3 SERIESMAINTENANCE STANDARD ROCKER ARM, INJECTOR snE01832 Unit: mm, No. Check item Criteria Remedy ‘Standard size ‘Tolerance ‘Outside diameter of rocker Reiace arm shaft 0.0150 rocker arm 45.0 tees shaft Inside diameter of rocker arm 450 40.097 Replace * [bushing 30.001 rocker arm ‘Standard clearance Clearance limit Replace (Clearance between rocker rocker arm arm shalt and rocker arm 0.088 — 0.125 a6 sat orrockor | Rapteinasor of okt Targot (Nexfkgen}) Range (Nm{kgm}) ah rocker arm ten sorow 226 (23) 206 - 246 {21 - 25) 170-3 SERIES 14-11MAINTENANCE STANDARD CYLINDER BLOCK CYLINDER BLOCK SxE01538 14-12 170-3 SERIESMAINTENANCE STANDARD CYLINDER BLOCK Ui mm No. Check item Criteria Remedy Tolerance Standard | Gleerance Standard size +, | iearance benveen eytnder Detbicck | ODainer | Sewrance | tint | Replace Hiner bog ane nor 3 = oreyinder 1904 Bo 21 | o05-o:6 ine Gameierofman bear | __ Standard size Tolerance Repair imi ing mouning role [igi atte sparen) 148 0.028 ~ torque “aot Replace a, | There ofmaln bosing 40 2.088 - inside Gameer of main bear 30.127 na 0 soo76 14020 ‘Clearance between main Standard dearanse Clearance int beating and crankshaft jour al 0.076-0.182 02 4, |Iteroroncebetwaen cap and ‘Standard interference Interference tn evn sock (0.090-0740 0.05 Standard ize Tolerance Repair init Inside diameter of camshaft Correct or busting “o.084 replace ‘ 105 $2484 105.10 cioarance rom camshat Standard clearance Clearance im jours (01053-01168 02 «| Btonon ot ytnder nea Tolerance Repair tit mounting eurface 009) oo Sequence Target nom) Range Nikomn) Tightening torque for main «| eomrog ep meray bot Tat Step 204 8) a7 20 275-905), [Eesti beer) a amet fare 3rd Stop “Tiphening 80° cca 170-3 SERIES 14-13MAINTENANCE STANDARD CYLINDER LINER CYLINDER LINER A. Cylinder liner portion B. Cylinder block portion at RK sxcorens ne No. ‘Check item Criteria Remedy , Tape 1 jon of liner wssible range: 0.07 fer liner Proton of other Diterence among yinders Max. 05 ence Sandra se Towance ‘apa Inside daretr of pnd ts wat : 1 3 roa arene at a0 ovinaniy ean [0s Sua dtr of yn Sundardaze 7 nor 4. [Canteen 1088 tse 194.16 itera fide nr rater Stonars ierternce 0088-0195 {Gout ore over bat) Pepaeor er nr Ouse amet of incor Sancta Tama nw [Esme bre pat) 8 ease 206078 ‘ eerence betwen ner Interne 028 Sowrance 0008 (Counter trepat) Oise amet of nar Scand Tamrac rer (O-ring part) 19040 190.24- 190.29 5 taranceeatwona andr fer and beck Stunt terres 0.05 0.18 (O-ring part) «5. |Unevenness of counter bore ‘Tolerance Repair iit Repair by [depth = 0.08 grinding 14-14 170-3 SERIESMAINTENANCE STANDARD (CRANKSHAFT CRANKSHAFT 14-16 170-3 SERIESMAINTENANCE STANDARD CRANK SHAFT uit mm No. ‘heck item Criteria Remedy Size ‘Standardize | Tolerance Repal jit ‘tna 0 va981 asus 1878 10.86 1 [utsise sanetero main Prt ° sous 13280 Doon 10a o7sus 702s ‘2838 Caneel unser 1000s ‘2900 ross [Serer standare 108.0 vo781 ozs us 10778 vores 2 [Susie camer escane | p20 8 10780 Dees tora 07608 1o728 10738 1.00008 ‘e700 ‘0501 Sanders repaint 2 | every oral Wain ural Mex oto ais Pe paral Max 010 ais Tlernce Pepa tt 4 | enopiy ona-0ae oo epee standard ice Tolerance Pepa it 5. | Tretoss oman bering tone “aase “0 20 390 uisae dometor aver 6 [oe 1 soan9 - Teiearce pepe it 7 | Curvature of crankshaft ena (annacan ees) e J 0.09 0.08 ‘Sequence: ‘Target Nm{kgm) ‘Range Nm(kgm)_ 188 78 54=09(68-95) 18. | Mahtening torque of crank ° lla “Totten Feeney ening bot ‘nd Sep aes) 220-268 @9-27 ‘va sep eri05) 18-87 6967) 170-3 SERIES 14-17MAINTENANCE STANDARD CAMSHAFT CAMSHAFT 4 3 2 1 sxeuisas nk nm No. ‘Check item Criteria Remedy Sindarace "elo Repara oi08i + Joamnagee | tee 0.800 0308) woz |eparor vo. ome ees 90:00 saaeee 80 2 |oxtsio dame tat 108 po 1438 ~ Foplace 9 |stats 5 oo 320 Sanda co karan it enlace 4 |camshat onda pay 0.05-0.20 0.40 ‘thrust plato 5 [Rentcfeanera epi 020 by ato) aece 14-18 170-3 SERIESMAINTENANCE STANDARD GEAR TRAIN GEAR TRAIN FRONT SIDE SxE01837 14-20 170-3 SERIES.MAINTENANCE STANDARD GEAR TRAIN Ut mm No. Check item Criteria Remedy Teleance Standard ane ‘Standard | ceorance it 1 | Clearance between idler gear ‘Shatt Holo noe (large) bushing and shatt Replace woos} sa008 ae | sat | 9065 | 5005 o08e | 0.25 [evening “earance between klorgner woo | v0.08 ~ 2 | (medium) bushing and shat | 478 +0.001 +0.039 0.025 ~ 0.082 0.25 > | earance rer gas are) Sincere Searance Geararce ina won fnaxtr dreten ee 008-017 oa el Glaranca oer goa oorng 4 | (medium) in axial direction 0.05 ~ 0.17 one Stepped erence of potion surtaco beween Qander ' Conector 5 block and gear train case Repair Hint: 0.15 replace Posten Nessurement pace Sencar | _Repaiimat ‘rankanat gear and ier gear 7 7 a | Gans ore-o2es | 0s Ceankshet gear andi gear y 7 5 | canara ons-0a00 ~ | sactash of eaen gore ide gar oan) and el pump replace | ieee ans-oaeo| 05 ‘der ger (argo) and water pump = b | ‘aeraear orei—oase | 0s - aor gor dro) ando¥ pane ave | ora oaaa | 08 | sear 170-8 SERIES 14-21MAINTENANCE STANDARD. TIMING GEAR TIMING GEAR REAR SIDE SxEDI638 14-22 170-3 SERIESMAINTENANCE STANDARD TIMING GEAR une No.] Check tem Criteria Remedy Taleance Sanwa Standard siz0 ctarance 4, | Clearance between idler gear ‘Shaft Hole clearance Replace Sting aa nig 2 paar [+008 Tocer— coas| 025 «| eerance otter geartnasia Standard Gerace laanes ew Repu erection 0.08-0.18 0s bearing Feakon | __Weasuremnt pace Gerais | pana ‘rants gear andor goar S = | Backlash of each gear A (large) 0.185 ~ 0.412 06 Replace . 3 | Canktbat gearandider ses: To 145-0980} a 1703 SERIES 14-23MAINTENANCE STANDARD. PISTON, PISTON RING, PISTON PIN PISTON, PISTON RING, PISTON PIN FCD PISTON TYPE SxED(83¢ Unit mm No. ‘Check iter Criteria Remedy [Ouiside dametr of piston Standard size “Tolerance palit 1 |/-8t3.0 mm from botom of 770 er (eee a) Teron ie are Toerance ‘Cloarance ‘mit Standard stzo Linkegroove | Link thickness |(Gearance 2. [Piston ring groove Tepring | Keystone | Chock with piston loop wear ]gauge or check clearance a5 2ndving | Keystone _| om new ring 7008 007 iting 400 7998 we os |, Standard dearance Clearance init “op rng 050-085 8. | Gap in pton ring at ena. er wsstond gee ‘and ng 070-085 18 Ong (050-070 ido cam , Standard cearance Giearance iit 1 dlameter of piston pin 4 nate pene 8 $0084) 40088 & |outoise dameterot pon pin Poee 14-24 170-3 SERIESMAINTENANCE STANDARD CONNECTING ROD CONNECTING ROD g | SSS sxeorsae Unt mm No.| Check item Criteria Remedy Trance % Replace Clearance between comect | Stndardste }—————-———_}_ ESSN | clearance tm | i hinge 1 |ingred bushing and iton sipped 2s 8 en “aaa | soos Sonmfnished ee 900] 49048 | ooe0-o07s | ont Standard ee “oerance | ede metro connect ingrocbig ond 4 10.088 ° Glsrance between nee Standard cearance Gearanco ume «| ameter of connecting rod Senden centtat c0ss-0s82 ose Sie ‘Standard zo | Tooranco | __ Repair tit Sx "3500 aa Replace 4. | omentng erent 025 U8 aes am Fides Comey onus ano] 3 388 0750S are are 10008 000 aa 5 ik of bend 0.10 5, [Panter ttt meting epi apa nt of st: 0.28 © [Connecting rod weigh 1020: 0.00 kg Frgttening torque of connect Order Target value mica) [Range Walkam) 7 [Bete te 196 20) 195-206 (18-21) _ | Tighten a 2nd rs oe 170-3 SERIES. 14-25MAINTENANCE STANDARD. OL PUMP. OIL PUMP OIL PUMP, RERIEF VALVE SxED66t 14-26 170-3 SERIESMAINTENANCE STANDARD: OIL PUMP Un en No. Check item Criteria Remedy Tse coaranee | Stnaze | ~aoay Tam] SERIE. |oeance nt slaarance of pump gear | Body depth nce 1 {oe wns ¢ waaay | 00m Sa 0.030 40.040 0.097 _| 9040-0087 | ace gear "ein Standard ze " « Sandard | cerance it 2. | Clearance of pump gear in Gear!D Body OD »arance radia " 0.15 0.04 0.18. cue | 38 2 65, | ons-o2s Terence Standard Sze ‘Standard | cesranco mit 4 | Interference of dive shaft and ‘Shatt Hole fearance cover seaso | 0040 | o0oo- | oor | _tacee Oe 7 tetrenoe of avn gear n waes0 | sone | o0u-] enc woos | *0 0 Tolerance standard 0 iandrd | crane int 5 Gieerance between rive shaft ‘Shaft Hole nce td aen gear using waco | sonar | one 8 ++0.070 40.122 ‘0.077 | 0.092 0.077 ++0.090 40.129 0012 ~ Replace ° 8 yoo [sae 12, | aore-o0se [patie 7 esas} vo.7s | 000- Tom ® 70.088 40.146 0.035 _| 0040- 0.085 Trance Standard size imodoroncs | = «| eterenc pump gearand an [rae te oak . 10.108 a oos8 08 | erteroce obo analogy | py 70.050 cou | using joes m0 To | naerence of panp ive 2 0100 | saan | oazs- | soar and aver hak eam | Torr 88 1 [Rating re fram 2 568.4 (2.1640.5 kam} rien Seid soe Tepar Vetted Indaod oad inte oad roe a F re ace 12 | Mala ret va eping reovnat [Naa | Posies 85 Feo iengn | led ed ag Z = [ireaeaa | = [taten preseare ofman orecior xg | Aguation p ‘Standard: 283649 KPa (.020.5 kg/em?) episce Spring 1708 SERIES 14-27MAINTENANCE STANDARD. OIL COOLER Ol COOLER SxEO 1642 Unit mm No. Check item Criteria Remedy Thermostat fal open it | Nin. & mr [boak vavo ino bath at 100° for 4— 5 minutos to check) 1 Replaco [Check that valve closes fly when ot tmperature of 100°C at fay open i lowered Crenincoang of memos | as Soke non bainiors~ Siunfeete check 14-28 170-3 SERIESMAINTENANCE STANDARD WATER PUMP WATER PUMP sxE01543 Ut: mim No. Check item, Criteria Remedy “Tolerance standard size Seana 1 | intortorenoe between front Shaft Hole shaft and bearing 0.011 ° 25 00K ooo 0.002 - 0.021 Interference between roar ‘0.017 © 2 | shaft and bearing 35 40.002 2010 0.002 0.021 ference betwee 0.018 0.028 Replace ‘ rear * 3 | shaft and impal bie 40.008 0.050 0.002 ~ 0.0881 Standard clearance ‘Clearance fit «4, | Stesrance between impetier and connection 026-068 - 170-3 SERIES 14-29MAINTENANCE STANDARD THERMOSTAT THERMOSTAT oxeoines ‘ t Unt om ‘Check item L Criteria Remedy Faemosia a opniit | in Or anc valve ater bath a 00° for 45 auto hea 1 Replace ; Chee hat ate cose fay when water poate of °C a uy pens ered [sraeriens est | EET Sen ae aca ree 14-30 170-3 SERIES