Manual Book

SERVICE MANUAL
199269-20170
September 2010
Pub. No. 99269-20170
FOREWORD
This service manual describes the maintenance and adjustment procedures, and specifi-
cations for the Mitsubishi marine engine.
To maintain the performance of the engine for many years and to ensure safe operation,
it is important to use the engine correctly and conduct scheduled inspection and mainte-
nance, and it may also be necessary to take appropriate measures which involve in disas-
sembly, inspection, repair and assembly work of the engine and engine parts.
Read through this manual carefully and understand the work procedures fully before dis-
assembling, inspecting, repairing or assembling the engine.
The contents of this manual are based on the engine model produced at the time of publi-
cation.Please note that the contents of this manual may change due to improvements made
thereafter.
Cautions on emissions requirements
This engine is compliant with the EU's emissions requirements Stage III A.
Inspection and maintenance work should be performed in accordance with this service
manual and the separate operation manual to maintain the emission performance.
I
FOREWORD
HOW TO USE THIS MANUAL

This service manual consists of several chapters, which will give you quick references to specifications, maintenance standards,
adjustment and service procedures including practices to disassemble, inspect, repair and assemble the Mitsubishi marine
engines.
A short summary describing the contents of each chapter is given in the CHAPTER INDEX page, and there is also a detailed
table of contents at the beginning of each chapter.
Regarding the procedures for operation and scheduled maintenance of the engine, refer to the Operation and Maintenance Man-
ual. For information on the engine components and ordering of service parts, refer to the Parts Catalogue. Structure and func-
tion of the engine are described in the relevant training manuals.
If you have an inquiry, please check the engine model and serial number, and contact our service department.
Description format
(1) Index numbers allotted to parts in exploded views are not only a call-out of part names listed in the text but also an indica-
tion of the sequence of disassembly.
(2) Inspections to be conducted during disassembly process are indicated in boxes in the relevant exploded views.
(3) Maintenance standards required for inspection and repair works are indicated in the appropriate positions in the text. They
are also collectively indicated in the Chapter 2.
(4) The tightening torque with engine oil applied on the thread, is specified [Wet].Unless otherwise specified, the tightening
torque is of dry condition.
(5) In this manual, important safety or other cautionary instructions are emphasized with the following head marks.
Indicates an immediately hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
Indicates a potentially hazardous situation which, if not avoided, may result in property
damage.
Note Emphasizes important matter, or indicates information useful for operation or maintenance
of the engine.
II
FOREWORD
Terms used in this manual

Nominal value
means the basic nominal size of a part to be measured.
Standard value
means the quantitative requirement for dimension of a part, clearance between parts and performance.The values are rounded
off for the inspection job, and do not necessarily conform to the design values.
Limit value
means the limit value, which the measured value reaches, the part needs repair or replacement with a new one.
Abbreviations and Standards

BTDC : Before Top Dead Center
ATDC : After Top Dead Center
BBDC : Before Bottom Dead Center
ABDC : After Bottom Dead Center
TIR : Total Indicator Reading
API : American Petroleum Institute
ASTM : American Society for Testing and Materials
JIS : Japanese Industrial Standards
LLC : Long Life Coolant
MIL : Military Specifications and Standards (U.S.A.)
MSDS : Material Safety Data Sheet
SAE : Society of Automotive Engineers (U.S.A.)
P/N : Part Number
Unit of Measurement
Measurements are based on the International System of Units (SI), and their converted metric values are indicated in { } and
U.S. customary values are in [ ].For metric conversion, the following rates are used.
Pressure :1 MPa = 10.197 kgf/cm2
Torque :1 N·m = 0.10197 kgf·m
Force :1 N = 0.10197 kgf
Output power :1 kW = 1.341 HP = 1.3596 PS
Pressure (mercury column) :1 kPa = 0.7 cmHg
Pressure (water column) :1 kPa = 10.197 cmH2O (cmAq)
Rotation speed:1 min-1 = 1 rpm
III
FOREWORD
Safety Cautions
Fire and Explosion Precautions
Keep Flames Away Pay Attention to Fuel, Oil and Exhaust Gas
Do not use flames near the engine (in Leak
the engine room).The flame is dan- If any fuel, oil or exhaust gas leakage is found, imme-
gerous to ignite combustibles and diately take corrective measures to stop it.Such leak-
cause a fire.Wipe off spilled fuel, oil ages, if left uncorrected, can cause fuel or engine oil to
and LLC immediately and thor- reach hot engine surfaces or hot exhaust gas to con-
oughly.Spilled fuel, oil and LLC may ignite and cause a tact flammable material, may results in a fire, personal
fire.Store the fuel and engine oil in a well ventilated injury and damage to the equipment.
area. Make sure that the fuel and engine oil container
Use Explosion-Proof Light
caps are tightly fastened.
When inspecting fuel, engine oil, coolant, battery elec-
Keep Engine Surrounding Area Tidy and trolyte, etc., use an explosion-proof light.If the lighting
Clean is not an explosion-proof type, it may ignite and cause
Do not place combustible or explosive material, such an explosion.
as fuel, engine oil, LLC or explosive powder near the Prevent Electrical Wires From Short Circuit
engine.Such substances can cause a fire or explo- Avoid inspecting or servicing the electrical system with
sion.Thoroughly remove dust, dirt and other foreign the battery cable connected to the battery. Otherwise,
material collected on the engine and the area around a fire could result from short circuit.Be sure to discon-
the engine.Such material can cause a fire or the nect the battery cable from the negative (-) terminal
engine to overheat.In particular, clean the top surface before starting work.A loose terminal and a damaged
of the battery thoroughly.Dust can cause a short-cir- cable or wire may result in a short circuit and a
cuit.Always place the engine at a position at least 1 m fire.Inspect, and if any defect is found, repair or
[3.28 ft.] apart from buildings and other equipment to replace it before starting work.
prevent a possible fire caused by engine heat.
Keep Fire Extinguishers and First-Aid Kit
Do Not Open Side Covers Until Engine
Handy
Cools Keep fire extinguishers handy, and
Do not try to open the side cover of crankcase before become familiar with their
the engine cools down. Wait at least 10 minutes after usage.Keep a first-aid kit at the desig-
stopping the engine.Opening the cover when the nated place to be ready for use in an
engine is hot allows fresh air to flow into the crank- emergency.Make counteract proce-
case, which can cause oil mist to ignite and explode. dures against a fire or an accident. Provide the contact
person and means of communication in case of emer-
gency.
IV
FOREWORD
Stay Away From Rotating and Moving Parts
Install Protective Covers Over Rotating Lockout and Tagout

Parts After Inspection and Maintenance Be sure to lockout and tagout before starting inspec-
Work tion and maintenance. Lockout and tagout are effec-

tive methods of cutting off machines and equipment
Check the covers over engine rotating
from energy sources. To accomplish the lockout/
parts for correct installation.Repair
tagout, remove the starter switch key, set the battery
any damaged or loosed covers.Never
switch to OFF position and attach a DO NOT RUN or
remove the protective covers over
equivalent caution tag to the starter switch. The starter
rotating parts during operation. When
switch key must be kept by the person who performs
the engine is coupled to a radiator or other equipment,
inspection and maintenance work.
install protective covers over the exposed connecting
belt and coupling. Be Sure to Stop the Engine Before Inspec-
Check Work Area for Safety Before Starting tion and Maintenance
Before starting the engine, make sure that no one is Be sure to stop the engine before proceeding to
near the engine and that tools are not left on or near inspection and maintenance work.Never try to make
the engine. Verbally notify persons within the immedi- adjustments on the engine parts while the engine is
ate area when starting the engine.When the starter running.Rotating parts such as belt can reel in your
device is tagged with the warning sign saying DO NOT body and cause serious injuries.
RUN, never start the engine. Always Put Back Engine Turning Tool After
Stay Away From Moving Parts While Engine Use
Operates Be sure to remove the turning tool used for inspection
Keep away from the rotating parts and maintenance work.Make sure to pull back the
during operation.Do not leave any turning gear to the engine running position before
objects that may get caught in rotating starting the engine.If the engine is started with a turn-
parts.If clothes or a tool gets caught in ing tool inserted or turning condition, it can not only
rotating parts, serious injury will result. cause a damage to the engine, but also lead to a per-
sonal injury.
V
FOREWORD
Be Careful of Exhaust Gas Poison- Be Careful of Falling

ing
Lift Engine Carefully
Be careful of Ventilation to Operate Engine Use slings or wire ropes strong
If the engine is installed in an enough to lift the load considering the
enclosed area, and the exhaust gas is engine weight.To lift the engine, hitch
ducted outside, make sure that duct the proper slings to the lifting hangers
joints are free from gas leak.Exhaust prepared on the engine.To lift the
gas from the engine contains harmful engine, keep the engine in a well-bal-
components such as carbon monoxide.Operating the anced position, thinking carefully of the engine center
engine in an ill-ventilated area can cause gas poison- of gravity.
ing. The hangers prepared on the engine are designed for
lifting the weight of engine only.In the case where the
Be Careful of Hearing Loss
generator, marine gear, and others are installed to the
engine, consideration that the additional weight will not
Wear Ear Plugs
affect the hangers of the engine.
Always wear ear plugs when entering
Keep the angle formed by slings attached to hangers
the machine room (engine
within 60°.If the angle exceeds this limit, excessive
room).Combustion sound and
load may be applied to the hangers and damage the
mechanical noise of engine can cause
hangers.If the wire rope contacts the engine directly,
hearing loss.
place a cloth or other soft pad to avoid damage to the
engine and sling.
Do not Climb Onto the Engine

Do not climb onto the engine, nor step on any engine
parts on the engine sides.To work on parts located
high on the engine, use a ladder, footing, and others to
prevent from slipping and falling.Climbing onto the
engine may result in engine part damage and your
injury by falling down.
Always Prepare a Stable Footing

When working on the upper part of
the engine and other hard-to-reach
places, use a stable footing.Standing
on an old footstool or parts box may
result in personal injury.Do not put
any unnecessary objects on a footing.
VI
FOREWORD
Be Careful When Handling Fuel, Be Careful of Burns

Engine Oil or LLC
Do Not Touch the Engine During or Immedi-
Use Specified Fuel, Engine Oil and Long- ately After Operation
Life Coolant (LLC) Only Do not touch any parts of the engine
Use the fuel, oil and LLC specified in this manual only, during or immediately after opera-
and handle them carefully.Use of any other fuel, oil or tion.You can get burned.Before start-
LLC, or improper handling may cause various engine ing the maintenance and inspection
defects and malfunctions.Get the MSDS issued by the work, check the water temperature meter to make sure
fuel, oil and LLC suppliers, and follow the directions in that the engine is cooled down.
the MSDS for proper handling. Be Careful to Open and Close the Radiator
Handle LLC Carefully Cap
When handling LLC, wear rubber gloves and a protec- Never open the radiator cap while the engine is run-
tive face mask.If LLC or cooling water containing LLC ning or immediately after the engine stops.Stop the
comes into contact with your skin or eyes, or if it is engine and give a sufficient time to allow the coolant to
swallowed, you would suffer from inflammation, irrita- cool down before opening the cap.When opening the
tion or poisoning.If LLC is accidentally swallowed, radiator cap, slowly open the cap so as to release
induce vomiting immediately and seek medical atten- internal pressure.To prevent hot steam scalds, wear
tion.If LLC enter your eyes, flush them immediately thick rubber gloves or cover the cap with a cloth.When
with plenty of water and seek medical attention.If LLC closing the radiator cap, tightly close the cap.Do not
contact your skin or clothing, wash it away immedi- open the radiator cap during engine running or imme-
ately with plenty of water.Keep flames away from diately after engine stop. Otherwise hot steam and
LLC.LLC can catch flames and cause a fire.Drained coolant gush out and can cause burns.
coolant containing LLC is a hazardous material. Do Refill Coolant Only After the Coolant Tem-
not discard it in an unauthorized procedure.Practice
perature Dropped
the applicable law and regulations when discard
Do not refill coolant immediately after the engine
drained coolant.
stops. Wait until the coolant temperature lowers suffi-
Proper Discarding of Waste Oil, LLC and ciently to avoid risk of burns.
Coolant Do not Remove Heat Shields
Do not discard waste engine oil, LLC and coolant in an
The exhaust system, which becomes extremely hot
unauthorized procedure.Such a way of disposal is
while the engine is operating, is provided with various
strictly prohibited by laws and regulations.Discard
heat shields.Never remove the heat shields.If any of
waste oil, LLC, coolant and other environmentally haz-
these heat shields were inevitably removed for the
ardous waste in accordance with the applicable laws
inspection and maintenance, be sure to install them
and regulations.
after the work.
Be Careful of Burns When Changing Oil

Wear gloves when draining oil or changing oil filters.If
your skin contacts hot oil or hot parts, you get burn
injury.
VII
FOREWORD
Battery When Abnormality Occurs
Be Careful with Battery Do Not Add Cooling Water Immediately

Never use flames or generate After a Sudden Stop Due to Overheating
sparks near the battery.The bat- If the engine stops suddenly due to overheating, or
tery gives off highly flammable you suddenly stop the engine by any reason, do not
hydrogen gas and oxygen gas.Any add cooling water immediately.If water is added imme-
flame or spark near a battery may diately, parts such as cylinder heads can be damaged
cause an explosion.
due to the sudden drop of temperature.Add cooling
Do not use the battery if its fluid level is below the
water slowly after the engine becomes cool.
lower limit line.Long use of the battery may result in
an explosion. Be Careful to Restart After Abnormal Stop
Do not short the battery terminals with a tool or other If the engine stops abnormally, do not restart the
metal object. engine immediately.If the engine stops giving an emer-
When disconnecting battery cables, always remove gency alert, inspect the engine and correct the cause
first from negative (-) terminal first.When reconnect- of the defect before restarting.If the engine is kept
ing the cables, always connect first to the positive operating in such a condition, it can result in serious
(+) terminal. engine failure.
Charge the battery in a well-ventilated area, with all
Immediately Stop the Engine When Engine
battery plugs removed.
Make sure the cable clamps are securely fastened to Oil Pressure Drops
the battery terminals.A loose terminal can cause If the engine oil pressure drops significantly, stop the
sparks that may result in an explosion. engine immediately, and inspect the lubrication sys-
Before servicing electrical components or conducting tem to find the cause.Continuous engine operation
electric welding, set the battery switch to the [Open/ with low oil pressure may cause bearings and other
OFF] position or disconnect the cable from the nega- parts to seize.
tive (-) battery terminal to cut off the electrical cur-
Stop the Engine Immediately When the Belt
rent.
Electrolyte (battery fluid) contains dilute sulfuric
Break
acid.Careless handling of the battery may lead to the If the belt breaks, stop the engine immediately.Contin-
loss of sight and/or skin burns.Also, do not swallow uous engine operation with the broken belt can cause
battery fluid. the engine to overheat. Steam of boiled cooling water
Wear protective goggles and rubber gloves when may gush out from the reserve tank or radiator, and
working with the battery (such as adding water or results in burns.
charging).
If battery electrolyte is spilled onto the skin or cloth-
ing, immediately wash it away with lots of water. Use
soap to clean thoroughly.
Battery fluid can make you blind if splash into your
eyes.Immediately flush it away with plenty of clean
water, and seek immediate medical attention.
If battery fluid is accidentally swallowed, gargle with
plenty of water, then drink lots of water, and seek
immediate medical attention.
VIII
FOREWORD
Other Cautions
Do Not Tamper Never Break the Seals

If tampered, the warranty is totally void even in the To ensure the proper engine operation, the fuel control
warranty period.Tampering with the engine can not link is provided with seals that protect the fuel injection
only damage the engine but also may lead to personal volume and rotation speed settings against tamper-
injury. ing.If the seal is tampered, no guarantee will be pro-
vided. If the seal is tampered, the defects shown below
Perform All Specified Pre-operation Inspec-
can occur.
tions and Scheduled Inspections
Rapid wear of moving and rotating parts
Conduct the daily inspection and scheduled inspec-
Engine troubles such as seizure and damage of
tion/maintenance as described in this manual.
engine parts
Failure to conduct the specified inspections may cause
Sudden increase of fuel and lubricating oil consump-
various engine problems, damage to parts, and a seri- tion
ous accident. Deterioration of engine performance due to improper
Wear Proper Work Clothing and Protective balance between fuel injection volume and governor
control, or a serious accident due to overrunning of
Gears
the engine
Wear a hard hat, face shield, safety shoes, dust mask,
gloves and other protective gears as needed.When Inspect the Engine After Operation
using compressed air, wear safety goggles, a hard After the engine operation, inspect each part of engine
hat, gloves and other necessary protective gear.Works once again.If any defect is found, correct immediately.
without wearing proper protective gears may result in Break-in the Engine
serious injury. To break-in a new engine or overhauled engine, oper-
ate the engine at a speed lower than the rated speed
in a light load condition during the first 50 hours of
operation.Operating a new engine or overhauled
engine in a severe condition during the break-in period
shortens the service life of the engine.
IX
FOREWORD
Warm-up the Engine Before Use Use Care to Protect Engine From Water
After starting the engine, run the engine at a low idling Use care to protect engine from water such as rain
speed for 5 to 10 minutes for warming-up. Start the entering through the air inlet or exhaust openings.Do
work after this operation is completed.Warm-up opera- not wash the engine while it is running.Cleaning fluid
tion circulates lubricant in the engine, and works for or water can be sucked into the engine.Starting the
the longer service life and economical operation.Do engine with water inside the combustion chambers
not continue the warm-up operation for a longer time can cause the water hammering, and may result in
than necessary.Long warm-up operation causes car- engine inner parts damage and serious accident.
bon deposits in the cylinders, and may lead to incom- Air cleaner or
plete combustion. pre-cleaner is to be properly maintained.
Do Not Operate the Engine in an Over- With foreign material in the intake air, excessive wear
loaded Condition of the engine can result.Worn parts produce many
If the engine shows an overloaded condition such as problems such as increase of oil consumption,
black exhaust smoke, reduce the load immediately to decrease of output and starting difficulties.For effec-
an appropriate load condition.Overloading causes not tive removal of dust from intake air, maintain the air
only high fuel consumption but also excessive carbon cleaner/pre-cleaner according to the following instruc-
deposits inside the engine. Carbon deposits cause tions.
various problems and will shorten the service life of the Never perform maintenance of the air cleaner or pre-
engine. cleaner during operation.Foreign material enters the
turbocharger and may result in a serious failure.
Cool Down the Engine Before Stop
When removing the air cleaner or pre-cleaner, be
Cool down the engine at low idling for five to six min-
careful to prevent dust and foreign material collected
utes before stopping it.Stopping the engine immedi- on the cleaner from entering the engine.After remov-
ately after high-load operation will cause local heat up ing the air cleaner or pre-cleaner, immediately cover
of engine parts and shorten the service life of the the opening (inlet port of engine or turbocharger
engine.During the cooling operation, check the engine silencer) with plastic sheet or similar means to pre-
for abnormalities. vent foreign materials from entering the engine.
An air cleaner with a dust indicator gives an alarm
Do Not Continue Low Load Operation
when it is clogged. Conduct maintenance when the
Low load continuous operation (less than 30%) must
alarm is given.
be limited within one hour.Long warm-up operation
causes carbon deposits in the cylinders, and may lead
to incomplete combustion.Also, after low load opera-
tion for approx one hour, run the engine at a 30% or
higher load for five minutes or more.
X
FOREWORD
Observe Safety Rules at Work Site Cautions for Engine Transportation

Observe the safety rules established at the workplace To road-transport the engine, consider the engine
when operating and maintaining the engine.Do not weight, width and height, and obey applicable laws
operate the engine if you are in bad health. Consult and regulations such as road traffic laws, vehicle road
your supervisor about your condition.Operation of the acts and vehicle restriction ordinances.
engine with decreased attention may cause improper Be Careful of Engine Room Ventilation
operation and results in an accident.When working in Always keep the engine room well-ventilated.Insuffi-
a team of two or more people, use specified hand sig- cient intake air amount of the engine can cause an
nals to communicate among workers. increase in the engine temperature, and could result in
Use Proper Tools for Maintenance Work a decrease in the output power and poor perfor-
Always keep in mind to select most appropriate tools mance.It is highly recommended to calculate the
for the work and use them correctly.If a tool is dam- required amount of air supply to the engine and install
aged, replace with new tool. an adequate ventilation system before installing the
engine.
Do Not Operate Starter for a Long Time
Do not use the starter for more than 10 seconds at a Do Not Touch High Pressure Fuel Jet
time. If the engine does not start, wait for at least 1 Do not touch fuel jet leaked or sprayed from the high
minute before starting again.Continuous operation of pressure injection pipe.Fuel in the fuel injection pipe
the starter to start a stubborn engine may lead to a flat has a high pressure and if the fuel impinges your skin,
battery or starter burning out. it goes through the skin and can cause serious injury.
Do Not Turn Off the Battery Switch During

Operation
Do Not Turn Off the Battery Switch During Operation.
If the battery switch is turned OFF when the engine is
running, not only various meters will stop working but
also the diodes and transistors in the starter can be
damaged.
XI
FOREWORD
Warning Labels
Maintenance of Warning Labels

Make sure all warning/caution labels are legible.
Clean or replace the warning or caution label when the description or illustration is not clear to read.
For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvent, gasoline or other
chemicals to prevent the label from fading and peering.
Replace a damaged or missing label with a new one.
If any engine part stuck with a warning label is replaced with a new one, attach a new identical warning label to the
new part.
To get new warning labels, contact our approved dealer.
Warning labels
XII
FOREWORD
Points on Disassembling and As- Points on Assembling

Wash all engine parts, except such parts as oil seals, O-
sembling
This service manual contains the recommended practices to rings and rubber seats, in cleaning oil and dry them with
service the engine.The manual also contains dedicated spe- compressed air.
Use correct tools and instruments.
cial tools made for the work, and the basic safety cautions to
Use only high-quality lubricating oil and grease of the
obey when working.Note that this manual does not cover all
appropriate type.Be sure to apply oil, grease or adhesive
potential hazards that could occur during maintenance,
to specified surfaces.
inspection and service works of the engine.
Use a torque wrench to tighten parts correctly when their
When working on the engine, follow the related instructions
tightening torques are specified.Refer to "Tightening
in this manual and also be careful of the following:
torque table."
Points on Disassembling Replace Gaskets, packings and O-rings with new
Use correct tools and instruments.Or serious damage or ones.Apply adhesive as required.Do not apply adhesive
accident may result. too much.
Do not use jack bolts having sharp edge, as they may cause Use protective gloves when you touch overheated or fro-
damage to the surface. zen parts.Touching the part with a bear hand can cause
Use a footing and workbench to place disassembled parts if burns.
necessary, and obey the disassembling procedures
described in this manual.Do not place the parts on the
floor directly. Place them on a workbench or the like.
Place the engine parts in the order of removal to prevent
from missing.Place the parts in the serial order for reas-
sembling.
When reusing the engine parts, unless there are special rea-
sons, install them to their original positions.
Pay attention to assembling marks. Put your marks on the
parts, if necessary, to ensure correct assembling.
Carefully check each part for defects during disassembling
or cleaning. Do not miss symptoms which can not be
found after disassembling or cleaning.
Pay attention to the safety, especially for the balancing of
disassembled parts and carrying of heavy parts.(Get help,
and use jacks, chain blocks and guide bolts as necessary.)
Use protective gloves when you touch overheated or fro-
zen parts.Touching the part with a bear hand can cause
burns.
XIII
GENERAL CONTENTS
Chapter 1 GENERAL
1. External View
2. Outline of Systems
3. Contents of Plate and Label
4. Specifications
Chapter 2 SERVICE DATA

1. Maintenance Service Data
2. Tightening Torque Table
Chapter 3 SERVICE TOOLS

1. Special Tools
Chapter 4 OVERHAUL INSTRUCTIONS

1. Determining Overhaul Timing
2. Compression Pressure - Measure
Chapter 5 DISASSEMBLY OF BASIC ENGINE

1. Cylinder Heads and Valve Mechanisms - Disassemble and Inspect
2. Rear Mechanism - Disassemble and Inspect
3. Front Mechanism - Disassemble and Inspect
4. Cylinder Liner, Piston and Connecting Rod - Disassemble and Inspect
5. Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect
Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

1. Cylinder Head and Valve Mechanism - Inspect and Repair
2. Rear Mechanism - Inspect and Repair
3. Front Mechanism - Inspect and Repair
4. Piston and Connecting Rod - Inspect and Repair
5. Crankcase and Crankshaft - Inspect and Repair
Chapter 7 ASSEMBLY OF BASIC ENGINE

1. Crankshaft and Main Bearing - Install
2. Cylinder Liner, Piston and Connecting Rod - Assemble
3. Front Mechanism - Assemble
4. Rear Mechanism - Assemble
5. Cylinder Head and Valve Mechanism - Assemble
Chapter 8 FUEL SYSTEM
1. Fuel System - Remove and Inspect
2. Fuel System - Disassemble, Inspect and Assemble
3. Fuel System - Install
Chapter 9 LUBRICATION SYSTEM

1. Lubrication System - Remove and Inspect
2. Lubrication System - Disassemble, Inspect and Assemble
3. Lubrication System - Install
Chapter 10 COOLING SYSTEM

1. Cooling System - Remove and Inspect
2. Cooling System - Disassemble, Inspect and Assemble
3. Cooling System - Install
Chapter 11 INLET AND EXHAUST SYSTEMS

1. Inlet and Exhaust Systems - Remove and Inspect
2. Inlet and Exhaust Systems - Disassemble, Inspect and Assemble
3. Inlet and Exhaust Systems - Install
Chapter 12 AIR START SYSTEM

1. Air Start System - Remove and Inspect
2. Air Start System - Disassemble, Inspect and Assemble
3. Air Start System - Install
Chapter 13 ADJUSTMENT AND OPERATION

1. Engine - Adjust
2. Break-in Operation
3. Engine-Test and Adjustment
Chapter 1 GENERAL
1. External View ........................................................................................................... 1-3
2. Outline of Systems ................................................................................................ 1-15
2.1 Outline of Fuel System ........................................................................................................... 1-15
2.2 Outline of Lubrication System................................................................................................. 1-15
2.3 Outline of Cooling System ...................................................................................................... 1-16
2.4 Outline of Inlet and Exhaust System....................................................................................... 1-18
3. Contents of Plate and Label ................................................................................. 1-19
3.1 Name Plate ............................................................................................................................. 1-19
3.2 Caution Plate .......................................................................................................................... 1-19
3.3 Emissions Certification Label.................................................................................................. 1-19
4. Specifications ........................................................................................................ 1-20
1-1
Chapter 1 GENERAL
Chapter 1 GENERAL
1. External View
S12A2-PTA
Thermostat
Thermostat
Front hanger
Alternator
Water pump
Tension Pulley
Damper
Note: Configuration may differ depending

on the customization and specifications.
Engine Front View
Exhaust gas outlet S12A2-PTA
Rear hanger
Direction of rotation
Flywheel
Note: Configuration may differ depending Oil pan

Engine Rear View
1-3
Chapter 1 GENERAL
S12A2-PTA
Turbocharger
Cooling Fuel injection pump

water outlet
Air cooler Governor oil filter
Fuel filter Stop lever
Front Rear
Cooling Governor
water inlet
Fuel feed pump
Water drain cock
Oil filler Starter
Breather
Oil level gauge
Stop solenoid Fuel return port
Fuel inlet
on the customization and specifications. Fuel filter(wire mesh type)
Left Side View
S12A2-PTA
Air cooler
Oil cooler
Fuel injection pump
Rear Front
Fuel feed pump

Bypass oil filter
Starter Oil filter
Water drain cock

on the customization and specifications. Fuel filter
Right Side View
1-4
Chapter 1 GENERAL
S12A2-PTA2
Front hanger
Thermostat
Thermostat
Tension Pulley
Alternator
Water pump
Damper
Note: Configuration may differ depending on the customization and specifications.

Engine Front View
Exhaust gas outlet S12A2-PTA2
Rear hanger
Flywheel

Engine Rear View
1-5
Chapter 1 GENERAL
Silencer
S12A2-PTA2
Turbocharger
Cooling Fuel injection pump

water outlet
Air cooler
Front Rear
Actuator
Cooling
water inlet
Fuel feed pump
Water drain cock
Oil filler
Starter
Breather
Oil level gauge Fuel return port
Note: Configuration may differ depending Stop solenoid Fuel filter(wire mesh type)
on the customization and specifications. Fuel inlet
Left Side View
S12A2-PTA2
Air cooler
Oil cooler
Fuel injection pump
Rear Front
Fuel feed pump
Bypass oil filter
Starter Oil filter
Water drain cock

Right Side View
1-6
Chapter 1 GENERAL
S12A2-Y1PTA2
Front hanger
Thermostat
Thermostat
Water pump side

Fan side tension pulley
tension pulley
Alternator
Water pump
Damper

Engine Front View
Exhaust gas outlet S12A2-Y1PTA2
Rear hanger
Flywheel

Engine Rear View
1-7
Chapter 1 GENERAL
Air cooler Fuel filter S12A2-Y1PTA2
Cooling water outlet
Fan Fuel injection pump
Stop lever
Front Rear
Actuator
Cooling Fuel feed pump
water inlet
Water drain cock

Oil filler
Starter
Breather
Stop solenoid
Note: Configuration may differ depending Fuel filter(wire mesh type)
Left Side View
S12A2-Y1PTA2
Turbocharger
Air cooler Oil cooler
Fuel injection pump
Rear Front
Fuel feed pump
Bypass oil filter
Starter
Oil filter
Water drain cock
Right Side View
1-8
Chapter 1 GENERAL
S12A2-PTK
Thermostat
Thermostat
Front hanger
Air cooler cooling water outlet
Alternator
Water pump
Damper
Tension Pulley

Engine Front View
Exhaust gas outlet

S12A2-PTK
Rear hanger
Air cooler cooling water inlet
Flywheel
Note: Configuration may differ depending on Oil pan

the customization and specifications.
Engine Rear View
1-9
Chapter 1 GENERAL
S12A2-PTK
Turbocharger
Engine cooling
water outlet Fuel injection pump
Air cooler
Front Rear
Actuator
Engine cooling
water inlet Fuel feed pump
Water drain cock
Oil filler
Starter
Breather
Oil level gauge
Note: Configuration may differ depending Stop solenoid Fuel return port
on the customization and specifications. Fuel inlet Fuel filter(wire mesh type)
Left Side View
S12A2-PTK
Air cooler
Oil cooler
Fuel injection pump
Rear Front
Fuel feed pump

Bypass oil filter
Starter Oil filter
Water drain cock

Right Side View
1-10
Chapter 1 GENERAL
S12A2-PTAW
Thermostat
Thermostat
Front hanger
Alternator
Water pump
Damper Tension Pulley

Engine Front View
Exhaust gas outlet S12A2-PTAW
Rear hanger
Flywheel

Engine Rear View
1-11
Chapter 1 GENERAL
Engine cooling water outlet Air cooler Fuel filter S12A2-PTAW

Air cooler
cooling water outlet
Fuel injection pump

Fan
Stop lever
Front Rear
Actuator
Engine cooling
water inlet Fuel feed pump
Water drain cock

Oil filler
Starter
Breather
Note: Configuration may differ depending Stop solenoid
Fuel filter(wire mesh type)
Left Side View
Turbocharger Air cooler S12A2-PTAW
Air cooler
cooling water inlet
Oil cooler
Fuel injection pump
Rear Front
Fuel feed pump
Bypass oil filter
Starter
Oil filter
Water drain cock

Right Side View
1-12
Chapter 1 GENERAL
S12A2-Y2PTAW
Thermostat Thermostat
Alternator
Air cooler water pump Water pump
Tension Pulley
Tension Pulley
Damper
Engine Front View
Exhaust gas outlet S12A2-PTAW
Flywheel

Engine Rear View
1-13
Chapter 1 GENERAL
Fuel filter S12A2-Y2PTAW
Air cooler Fuel injection pump
Stop lever
Front Rear
Actuator
Engine cooling Fuel feed pump
water inlet
Water drain cock
Oil filler Starter
Breather
Oil level gauge
Fuel return port
Stop solenoid
Note: Configuration may differ depending Fuel filter(wire mesh type)
Left Side View
Engine cooling S12A2-Y2PTAW

Turbocharger
water outlet Air cooler cooling
water outlet
Air cooler
Oil cooler
Fuel injection pump

Bypass oil filter
Rear Front
Fuel feed pump

Air cooler cooling
water inlet
Starter
Oil filter
Water drain cock
Fuel filter
Right Side View
1-14
Chapter 1 GENERAL
2. Outline of Systems
2.1 Outline of Fuel System
Fuel injection nozzle

Fuel leak-off pipe
Fuel injection pump
To right side of engine
Fuel filter From right side of engine
From fuel tank To fuel tank

Outline of Fuel System
2.2 Outline of Lubrication System
Woodward PSG type governor
Turbocharger
Rocker shaft
Camshaft Piston
Main gallery Piston cooling nozzle
Timing gear
Oil cooler
Fuel Injection Pump

Bypass oil filter
Governor
Water pump
Governor oil filter
Oil filter
Crankshaft
Oil strainer Safety valve Oil pump
Outline of Lubrication System
1-15
Chapter 1 GENERAL
TOHO SEISAKUSHO SG4017 type actuator spec

Turbocharger Woodward PROACT type governor spec
Camshaft
Rocker shaft
Piston
Main gallery
Piston cooling nozzle
Oil cooler
Timing gear
Fuel Injection Pump

Bypass oil filter
Crankshaft
Water pump
Oil pump
Oil filter
Safety valve
Oil strainer
Outline of Lubrication System
2.3 Outline of Cooling System
PTA,PTA2 spec Radiator cooling

Air cooler(right)
Oil cooler
Thermostat
Water jacket
Radiator
Water outlet pipe
Water bypass pipe

Water pump Air cooler(left)
Outline of Cooling System
1-16
Chapter 1 GENERAL
PTK, PTAW specExternal cooling type

Air cooler(right)
Oil cooler
Thermostat Water jacket
Engine
Air cooler
Engine Air cooler
cooling water inlet
Water outlet pipe

Water bypass pipe
Engine
cooling water inlet
Water pump Air cooler(left)
Y2PTAW spec Two way pump system external cooling
Air cooler water pump Air cooler cooling water inlet

Air cooler
(right)
Thermostat Air cooler Oil cooler
cooling water
outlet
Engine Water jacket

cooling water
outlet
Engine
cooling water
Water outlet pipe
outlet
Jacket
Thermostat water pump
Air cooler(left)
Engine cooling water inlet
1-17
Chapter 1 GENERAL
MTK, MPTK spec with fresh water cooling system or seawater cooling system
Water pump
Air cooler Oil cooler Air cooler(right)
cooling water
inlet
Thermostat
Heat Water jacket
exchanger
Air cooler Water outlet pipe

cooling water
outlet Expansion
tank
Air cooler(left)
Water bypass pipe

Water pump
2.4 Outline of Inlet and Exhaust System
Exhaust gas outlet

Inlet
Turbocharger Turbocharger
Exhaust
From air cleaner From air cleaner
Air cooler Air cooler
Cylinder
Outline of Inlet and Exhaust System
1-18
Chapter 1 GENERAL
3. Contents of Plate and Label

3.1 Name Plate
The name plate is attached on the lateral side of the engine,
and shows the following information: Right
Engine serial number
Manufactured date 1 2 3 4 5 6
Total displacement
Front Rear
Engine output
Rated speed 7 8 9 10 11 12
Left
Cylinder No.
Name Plate
3.2 Caution Plate
The caution plate is attached to the top face of the rocker
VALVE CLEARANCE(COLD)
cover of No. 1 cylinder and shows the following informa- INLET 0.4 mm EXHAUST 0.5 mm
tion: FIRING ORDER

1-12-5-8-3-10-6-7-2-11-4-9
Valve clearance FUEL INJECTION TIMING °BTDC
CON-ROD RANK
Firing order
Fuel injection timing 1 2 3 4 5 6
Connecting rod weight rank
7 8 9 10 11 12
Caution Plate
3.3 Emissions Certification Label
The emission certification label that shows compliance with
emission requirements is attached to the engine.
1-19
Chapter 1 GENERAL
4. Specifications
Engine model S12A2
Type Water cooled, four stroke cycle diesel, turbo charged
No. of cylinders - Arrangement 12-V
Combustion system Direct injection system
Valve mechanism Overhead
Cylinder bore × stroke 150 × 160 mm [5.905 × 6.299 in.]
Total displacement 33.93 L [2070.534 cu. in.]
Firing order 1-12-5-8-3-10-6-7-2-11-4-9
Direction of rotation Counterclockwise as viewed from flywheel side
Engine oil Class CF or CH-4 (API service classification)
Specification table
The mark "Y" in the table represents the installed equipment of each engine type.
Note:(a) This table shows the general information. The installation of equipment differs in accordance with the customization
and specifications.
(b) The specification and part number may be changed with the design progress without prior notice.
Y2PTAW-2
C2MPTK
Y1PTA
Equipment name Specification name
PTA-S
MPTK
PTAW
MPTA
PTA2
MTK
PTK
PTA
Overlap 110°
Camshaft (Right 32605-40101) Y Y Y Y Y Y Y Y Y Y Y
(Left 32605-40201)
32507-62400 Y Y Y Y Y Y Y Y Y Y
Cylinder liner
32607-03400 Y
Shallow type
Y Y Y Y Y Y Y
(32613-40101)
Deep type (170L
[44.91 U.S.gal]) Y Y Y
32613-63100
Oil pan
Deep type (170L
[44.91 U.S.gal]) Y
(32613-03700)
Deep type
Y Y Y Y
45113-93701
Compression ratio
14.0
Without Almite treat- Y Y Y Y Y
ment
(32517-91201)
Compression ratio
14.0
Y Y Y
With Almite treatment
(32517-91101)
Piston
Compression ratio
15.3
Without Almite treat- Y Y Y Y Y
ment
(32617-00701)
Compression ratio
15.3
Y
With Almite treatment
(32617-00600)
32620-40193 Y Y Y Y Y Y Y Y Y
Crankshaft
32620-01892 Y Y
1-20
Chapter 1 GENERAL
Y2PTAW-2
C2MPTK
Y1PTA
PTA-S
PTAW
MPTK
MPTA
PTA2
MTK
PTK
PTA
V-belt
Y Y Y Y Y Y Y Y Y Y Y
32620-00300
V-belt
Crankshaft pulley Y
32620-10500
Ribbed belt
Y
32620-01100
Standard
Y Y Y Y Y Y Y
(32621-00052)
Flywheel
FCD
Y Y Y Y
(32621-00080)
Single damper Y Y Y Y Y Y Y Y Y Y Y
Damper
Double damper Y
(32625-54101) Y Y Y Y
(45685-60600) Y Y Y Y Y
(32625-04301) Y
(45120-90300) Y Y Y
Front pulley
(32625-04801) Y Y
(32625-05901) Y
(45125-97300) Y
(32620-00700) Y Y
Screw adjust type
Y Y Y
(32561-76050)
Screw adjust type
Y Y Y Y
(32561-64010)
Screw adjust type
Y Y
(32561-79010)
Screw adjust type
Y Y
(32561-54010)
Fuel Shim adjust type
Y Y Y Y
injection nozzle (35A61-11030)
Shim adjust type
Y Y
(32661-11070)
Shim adjust type
Y
(32661-11060)
Shim adjust type
Y Y
(32661-01050)
Shim adjust type
Y
(32661-01090)
Diesel oil
Y Y Y Y Y Y
(32562-61010)
Diesel oil
Y Y Y Y
(32562-60010)
Fuel filter Diesel oil, change
over type Y Y Y Y
(37562-70800)
Wire element type
Y Y Y Y Y Y Y Y Y
(04122-39001)
1-21
Chapter 1 GENERAL
Y2PTAW-2
C2MPTK
Y1PTA
PTA-S
PTAW
MPTK
MPTA
PTA2
MTK
PTK
PTA
Woodward make
Y Y Y Y Y
PSG type governor
TOHO SEI-
SAKUSHO Co., LTD. Y Y Y Y Y
Governor
SG4017 type actuator
Woodward make
PROACT type actua- Y Y Y
tor
RUN ON
Y Y Y Y Y
(04400-08801)
RUN ON
Stop solenoid Y Y
(04400-28800)
RUN OFF
Y Y Y Y Y Y
(04400-02000)
TD13M-54VRC-40 Y
TD13M-42B-40 Y Y Y
TD13M-48F-40 Y
TD10L-42F-34 Y Y Y
TD10L-42F-43 Y Y Y Y
TD10L-45VRC-28 Y
Turbocharger TD10L-45VRC-43 Y Y
TD10L-45VRC-34 Y Y Y
TD10L2-45VRC-34 Y Y Y
TD10L2-45VRC-28 Y
TD10L2-45VRC-34
Y
PTA2
TD10L2-48VRC-34
Y
PTA2
Fresh water cooling
(Right 32630-46021) Y Y Y Y Y Y Y
(Left 32630-45021)
External cooling
(Right 32630-11021) Y
Air cooler (Left 32630-12021)
PTA2
(Right 32630-37020) Y Y
(Left 32630-37030)
Sea water cooling
Y Y
(32655-00021)
D1250,PUSH
Fan Y Y Y Y Y Y Y
46648-03400
Expansion tank
Y
(45146-98200)
Heat exchanger
Heat exchanger Y
(46805-22001)
Heat exchanger
Y
(45152-90001)
Land use starter
Y Y Y Y Y Y Y
(32666-10300)×2
Starter
Marine starter
Y Y Y Y
(32666-10400)×2
1-22
Chapter 1 GENERAL
Y2PTAW-2
C2MPTK
Y1PTA
PTA-S
PTAW
MPTK
MPTA
PTA2
MTK
PTK
PTA
30A
Y Y Y
(04343-38000)
30A
Y Y Y Y
(34468-21100)
24A
Alternator Y Y
(04344-05001)
35A
Y Y Y Y Y
(04343-35500)
50A
Y
(34368-02400)
1-23
1. Maintenance Service Data ...................................................................................... 2-3
1.1 Maintenance Service Data of Engine General.......................................................................... 2-3
1.2 Maintenance Service Data of Basic Engine.............................................................................. 2-4
1.3 Maintenance Service Data of Fuel System............................................................................... 2-9
1.4 Maintenance Service Data of Lubrication System .................................................................. 2-13
1.5 Maintenance Service Data of Cooling System ....................................................................... 2-13
1.6 Maintenance Service Data of Electrical System ..................................................................... 2-17
1.7 Air Start System...................................................................................................................... 2-20
2. Tightening Torque Table....................................................................................... 2-21
2.1 Tightening Torque Spec for Basic Engine .............................................................................. 2-21
2.2 Tightening Torque Spec for Fuel System ............................................................................... 2-22
2.3 Tightening Torque Spec for Lubrication System..................................................................... 2-22
2.4 Tightening Torque Spec for Cooling System .......................................................................... 2-22
2.5 Tightening Torque Spec for Inlet and Exhaust System .......................................................... 2-22
2.6 Tightening Torque Spec for Electrical System........................................................................ 2-23
2.7 Tightening Torque Spec for Air Start System ......................................................................... 2-23
2.8 Tightening Torque for Standard Bolts..................................................................................... 2-24
2.9 Tightening Torque for Standard Eyebolts ............................................................................... 2-25
2.10 Tightening Torque for Standard Union Nuts ........................................................................... 2-25
2.11 Tightening Torque for Fuel Injection Pipe............................................................................... 2-25
2-1
1. Maintenance Service Data

1.1 Maintenance Service Data of Engine General
Item Nominal value Standard value Limit value Remarks
2.35 MPa 1.86 Mpa
Cranking
Compression pressure {24 kgf/cm2} {300 kgf/cm2}
(120 to 200 min-1)
[419 psi] [4267 psi]
0.49 to 0.64 MPa 0.29 Mpa
(at rated) {300 kgf/cm2} {300 kgf/cm2}
[4267 psi] [4267 psi] At oil temperature range
Engine oil pressure from 90 to 100°C [194 to
0.20 to 0.29 MPa 0.15 Mpa 212°F]
When idling {300 kgf/cm2} {300 kgf/cm2}
[4267 psi] [4267 psi]
Open BTDC 55°
Inlet
Close ABDC 65° At normal valve clearance
Open BBDC 65° (0 mm)
Exhaust
Close ATDC 55°
Valve timing
Open BTDC 11°
Inlet
Close ABDC 21° ±2° Valve clearance
Open BBDC 21° (crank angle) 2 mm [0.08 in.]
Exhaust
Close BTDC 11°
Valve clearance Inlet 0.4 mm [0.016 in.]

(when cold) Exhaust 0.5 mm [0.019 in.]
Check the caution plate on
Fuel injection timing
No. 1 rocker cover.
2-3
1.2 Maintenance Service Data of Basic Engine

Unit: mm [in.]
Nominal
Item Standard value Limit value Remarks
value
32.055 to 32.080 32.100
Rocker bushing inside diameter ø32 [1.26]
[1.2620 to 1.2630] [1.2638]
Rockers
31.975 to 31.991 31.950
Rocker shaft outside diameter ø32 [1.26]
[1.2589 to 1.2595] [1.2579]
9.940 to 9.960 9.910
Inlet ø10 [0.39]
[0.3913 to 0.3921] [0.3902]
Valve stem outside diameter
9.910 to 9.930 9.880
Exhaust ø10 [0.39]
[0.3902 to 0.3909] [0.3890]
10.000 to 10.015 10.060 Same for both inlet and
Valve guide inside diameter ø10 [0.39]
[0.3937 to 0.3943] [0.3961] exhaust valves.
Valve Clearance
Between the Adjusting screw side 2.5 [0.0984]
Bottom Face
of Valve
Bridge and
the Top Face Non adjusting side 1.5 [0.0591]
of Valve
Rotator
Valve seat angle 30°
- 0.1 to 0.1
Valve sinkage 0 0.5 [0.0197]
[-0.0039 to 0.0039]
2.08 1.98 to 2.18
Inlet 2.5 [0.0984] Seat width
[0.0819] [0.0780 to 0.0858]
Seat width
1.85 1.75 to 1.95
Exhaust 2.3 [0.0906]
[0.0728] [0.0689 to 0.0768]
2.9 2.7 to 3.1 Valve
Inlet Valve Valve margin
[0.114] [0.1063 to 0.1220] 2.0 [0.098] seat angle sinkage
Valve margin
3.0 2.8 to 3.2 after refacing
Exhaust
[0.118] [0.1102 to 0.1260]
58.000 to 58.030
Inlet 58.09 [2.2870]
Inside diameter of valve seat [2.2835 to 2.2846]
counterbore 54.000 to 54.030
Valve seat Exhaust 54.09 [2.1295]
[2.1260 to 2.1272]
and valve
58.100 to 58.130
Standard Single red line
[2.2874 to 2.2886]
58.130 to 58.160
Inlet 0.03 [0.0012] Double red lines
[2.2886 to 2.2898]
58.160 to 58.190
0.06 [0.0024] Triple red lines
Outside of [2.2898 to 2.2909]
valve seat 54.100 to 54.130 Double blue lines
Standard
[2.1299 to 2.1311]
54.130 to 54.160 Triple blue lines
Exhaust 0.03 [0.0012]
[2.1311 to 2.1323]
54.160 to 54.190 Four blue lines
0.06 [0.0024]
[2.1323 to 2.1335]
0.070 to 0.130
Valve seat interference
[0.0028 to 0.0051]
Free length 67.5 [2.6575] 66.2 [2.6063]
A
A=1.5° or less B=2.3 [0.087] B
Squareness B=1.46 or less over entire
Lf
Valve spring Lf=67.5 [2.6575] length
60.0 [2.36]/259 to 286

Installed length/load (mm [in.]/N {kgf} [lbf]) {26.41 to 29.16}
[58.22 to 64.29]
Push rod Runout 0.50 [0.0197] or less TIR
2-4
Unit: mm [in.]
Nominal
value
Distortion of bottom surface 0.03 [0.0012] or less 0.07 [0.0028]
Cylinder
head 134.9 to 135.1
Height (reference)
[5.3110 to 5.3189]
150.000 to 150.040 150.140
Inside diameter ø150 [5.9]
[5.9055 to 5.9071] [5.9110]
Roundness 0.02 [0.0008] or less
Cylindricity 0.02 [0.0008] or less
0.10 to 0.19
Flange protrusion
Cylinder [0.0039 to 0.0075]
liner
15.15 to 15.19
P/N:32607-03400
Flange thick- [0.5965 to 0.5980]
ness 12.15 to 12.19
P/N:32507-62400
[0.4783 to 0.4799]
0.16 to 0.24
Top ridge height
[0.0063 to 0.0094]
P/N: At the height from lower
32517-91101("91101" stamp) end of piston at 95.8 mm
Outside 149.71 to 149.75 149.68
32617-00701("00701" stamp) ø150 [5.9] [3.77 in.]
diameter [5.8941 to 5.8957] [5.8929]
32517-91201("91201" stamp) with right angles to the
32617-00600("00600" stamp) piston pin.
P/N:
In one 32517-91101("91101" stamp) Within ±15 g [0.53 oz]
engine 32617-00701("00701" stamp)
Piston
Weight dif- P/N:
ference 32517-91201("91201" stamp) Within 20 g [0.71 oz]
32617-00600("00600" stamp)
58.002 to 58.012 58.040
Piston pin bore inside diameter ø58 [2.28]
[2.2835 to 2.2839] [2.2850]
0.229 to 0.839
Protrusion
[0.0090 to 0.0330]
Cylinder
1.8 1.77 to 1.83
head Thickness when tightened
[0.0709] [0.0697 to 0.0720]
gasket
Piston 0.26 to 0.32 MPa
cooling Valve opening pressure {2.7 to 3.3 kgf/cm2}
nozzle [38 to 47 psi]
Piston and
1.191 to 2.031
cylinder Top clearance
[0.0469 to 0.0800]
head
0.6 to 0.8
No. 1 compression 2.0 [0.079]
[0.024 to 0.032]
Piston 0.5 to 0.7
End gap No. 2 compression 2.0 [0.079]
ring [0.020 to 0.028]
0.5 to 0.7
Oil 2.0 [0.079]
[0.020 to 0.028]
Piston 57.987 to 58.000 57.970
Outside diameter ø58 [2.28]
pin [2.2829 to 2.2835] [2.2823]
2-5
Unit: mm [in.]
Nominal
value
58.020 to 58.040 58.070
Inside diameter of connecting rod bushing ø58 [2.28]
[2.2842 to 2.2850] [2.2862]
0.05/100 [0.0020/3.94]
Bend and twist
or less
0.6 to 0.9
End play 1.0 [0.039]
[0.024 to 0.035]
Minimum:
Connecting
109.950
rod
110.000 to 110.022 [4.3287]
Inside diameter of big end bore ø110 [4.33]
[4.3307 to 4.3316] Maximum:
110.050
[4.3327]
Roundness for inside diameter of big end bore 0.100 [0.0039]
53.7 to 53.8
Big end side (width)
[2.114 to 2.118]
3.000 2.987 to 3.000
Standard 2.950 [0.1161]
[0.1181] [0.1176 to 0.1181]
3.125 3.112 to 3.125
0.25 [0.0098] 3.075 [0.1211]
[0.1230] [0.1225 to 0.1230]
Connecting
Thickness at 3.250 3.237 to 3.250
rod 0.50 [0.0197] 3.200 [0.1260]
center [0.1280] [0.1274 to 0.1280]
bearing Under size
3.375 3.362 to 3.375
0.75 [0.0295] 3.325 [0.1309]
[0.1329] [0.1324 to 0.1329]
3.500 3.487 to 3.500
1.00 [0.0394] 3.450 [0.1358]
[0.1378] [0.1373 to 0.1378]
Face runout (reference) 0.285 [0.0112] or less
Flywheel
Radial runout (reference) 0.127 [0.0050] or less
Face runout (reference) 0.5 [0.0197] or less
Damper
Radial runout (reference) 0.5 [0.0197] or less
0.11 to 0.25
Backlash between crank gear and idler gear 0.50 [0.0197]
[0.0043 to 0.0098]
Backlash between fuel injection pump gear and 0.12 to 0.18
0.50 [0.0197]
camshaft gear [0.0047 to 0.0071]
Backlash between idler gear and fuel injection 0.12 to 0.18
0.50 [0.0197]
pump gear [0.0047 to 0.0071]
Rear mecha- Backlash between oil pump gear and crankshaft 0.12 to 0.18
0.50 [0.0197]
nism gear [0.0047 to 0.0071]
50.000 to 50.025 50.060
Idler bushing inside diameter ø50 [1.97]
[1.9685 to 1.9695] [1.9709]
49.950 to 49.975 49.900
Idler shaft outside diameter ø50 [1.97]
[1.9665 to 1.9675] [1.9646]
0.2 to 0.4
Idler gear end play 0.6 [0.0236]
[0.0079 to 0.0157]
Cam lift 7.71 to 7.76
6.79 [0.2673]
(major axis - minor axis) [0.3035 to 0.3055]
Runout 0.05 [0.0020] or less 0.08 [0.0031] TIR
63.920 to 63.940 63.870
No. 1 journal ø64 [2.5]
[2.5165 to 2.5173] [2.5146]
Journal diameter
67.920 to 67.940 67.870
Cam No. 2-7 journal ø68 [2.6]
[2.6740 to 2.6748] [2.6720]
shaft
64.000 to 64.030 64.090
Camshaft bushing inside No. 1 journal ø64 [2.5]
[2.5197 to 2.5209] [2.5232]
diameter
(as installed in crankcase) 68.000 to 68.030 68.090
No. 2-7 journal ø68 [2.6]
[2.6772 to 2.6783] [2.6807]
0.20 to 0.30
End play 0.40 [0.0157]
[0.0079 to 0.0118]
2-6
Unit: mm [in.]
Nominal
value
103.900 to 103.920 103.860
Standard
[4.0905 to 4.0913] [4.0890]
103.650 to 103.670 103.610
0.25 [0.0098]
[4.0807 to 4.0815] [4.0791]
Crankpin
103.400 to 103.420 103.360
outside 0.50 [0.0197] ø104 [4.1]
[4.0709 to 4.0716] [4.0693]
diameter Under size
103.150 to 103.170 103.110
0.75 [0.0295]
[4.0610 to 4.0618] [4.0594]
102.900 to 102.920 102.860
1.00 [0.0394]
[4.0512 to 4.0520] [4.0496]
129.880 to 129.900 129.840
Standard
[5.1134 to 5.1142] [5.1118]
129.630 to 129.650 129.590
0.25 [0.0098]
[5.1035 to 5.1043] [5.1020]
Crankshaft
main journal 129.380 to 129.400 129.340
0.50 [0.0197] ø130 [5.1]
outside [5.0937 to 5.0945] [5.0921]
diameter Under size
129.130 to 129.150 129.090
0.75 [0.0295]
[5.0838 to 5.0846] [5.0823]
Crankshaft
128.880 to 128.900 128.840
1.00 [0.0394]
[5.0740 to 5.0748] [5.0724]
Deviation of 0.01
0.03
Parallelism of journal and crankpin [0.0004] or less over
[0.0012]
entire pin length
Diameter difference 0.03
Circularity of journal and crankpin
0.01 [0.0004] or less [0.0012]
Diameter difference 0.03
Cylindricity of journal and crankpin
0.01 [0.0004] or less [0.0012]
6.8 to 7.0
Fillet radius of pin R7 [0.28]
[0.2677 to 0.2756]
6.8 to 7.0
Fillet radius of journals R7 [0.28]
[0.2677 to 0.2756]
Hardness of journals and crankpins Hv > 620
Finishing surface roughness Ra 0.2 μm [0.008 µin.]
Angular deviation between pins ±0.3°
108 108.20 to 108.30
Crankpin width
[4.2520] [4.2598 to 4.2638]
58.00 to 58.03
Standard
[2.2835 to 2.2846]
58.25 to 58.28
0.25 [0.0098]
[2.2933 to 2.2945]
58.50 to 58.53
0.50 [0.0197]
[2.3031 to 2.3043]
Rearmost
58.75 to 58.78
crank jour- 0.75 [0.0295] 58 [2.2835]
[2.3130 to 2.3142]
nal width Over size
Crankshaft 59.00 to 59.03
1.00 [0.0394]
[2.3228 to 2.3240]
59.25 to 59.28
1.25 [0.0492]
[2.3327 to 2.3339]
59.50 to 59.53
1.50 [0.0591]
[2.3425 to 2.3437]
Runout 0.04 [0.0016] or less 0.10 [0.0039] TIR
End play 0.200 to 0.395
0.500 [0.0197]
(width between webs and thrust bearings) [0.0079 to 0.0156]
2-7
Unit: mm [in.]
Nominal
value
3.500 3.482 to 3.500
Standard 3.450 [0.1358]
[0.1378] [0.1371 to 0.1378]
3.625 3.607 to 3.625
0.25 [0.0098] 3.575 [0.1407]
[0.1427] [0.1420 to 0.1427]
Main bear- Thickness at 3.750 3.732 to 3.750
0.50 [0.0197] 3.700 [0.1457]
ing center [0.1476] [0.1469 to 0.1476]
Under size
3.875 3.857 to 3.875
0.75 [0.0295] 3.825 [0.1506]
[0.1526] [0.1519 to 0.1526]
4.000 3.982 to 4.000
1.00 [0.0394] 3.950 [0.1555]
[0.1575] [0.1568 to 0.1575]
5.00 4.83 to 4.90
Standard 4.76 [0.1874]
[0.1969] [0.1902 to 0.1929]
5.25 5.08 to 5.15
0.25 [0.0098] 5.01 [0.1972]
[0.2067] [0.2000 to 0.2028]
Thrust plate Thickness
5.50 5.33 to 5.40
Over size 0.50 [0.0197] 5.26 [0.2071]
[0.2165] [0.2098 to 0.2126]
5.75 5.58 to 5.65
0.75 [0.0295] 5.51 [0.2169]
[0.2264] [0.2197 to 0.2224]
Distortion of top surface 0.1 [0.004] or less 0.20 [0.0079]
137.000 to 137.025 137.045
Inside diameter of main bearing bore ø137 [5.4]
[5.3937 to 5.3947] [5.3955]
12.00 to 12.05
Depth of P/N:32608-00200
Crankcase [0.4724 to 0.4744]
counterbore
in crankcase 15.00 to 15.05
P/N:32608-00300
[0.5906 to 0.5925]
Height from journal center to top face 468.95 to 469.05
(reference value) [18.4626 to 18.4665]
2-8
1.3 Maintenance Service Data of Fuel System

Unit: mm [in.]
Limit
Item Nominal value Standard value Remarks
value
P/N:
32561-54010("C" mark)
21.6 MPa 22.1- 22.6 MPa
32561-57090("E" mark)
{220 kgf/cm²} {225 to 230 kgf/cm²}
32561-64010("A" mark)
[3129 psi] [3200 to 3271 psi]
32561-76050("-" mark)
Fuel injection 32561-79010("B" mark)
starting pres-
sure P/N:
32661-01050("P" mark)
29.4 MPa 29.9 to 30.7 MPa
32661-01090("N" mark)
{300 kgf/cm²} {304 to 313 kgf/cm²}
32661-11060("2M" mark)
[4267 psi] [4324 to 4452 psi]
32661-11070("J" mark)
35A61-11030("J" mark)
P/N:
32561-57090("E" mark) 155°
32561-79010("B" mark)
P/N:
32561-54010("C" mark) 157°
32561-64010("A" mark)
Orifice cone
angle P/N:
32561-76050("-" mark)
32661-01050("P" mark)
Fuel injection 32661-01090("N" mark) 158°
nozzle 32661-11060("2M" mark)
32661-11070("J" mark)
32A61-11030("J" mark)
P/N:
0.23 [0.0091]
32661-01050("P" mark)
P/N:
32561-57090("E" mark) 0.24 [0.0094]
32661-01090("N" mark)
P/N:
0.25 [0.0098]
32661-11060("2M" mark)
Orifice diame- P/N:
ter 32561-79010("B" mark)
0.26 [0.0102]
32661-11070("J" mark)
35A61-11030("J" mark)
P/N:
32561-54010("C" mark) 0.27 [0.0106]
32561-64010("A" mark)
P/N:
0.28 [0.0110]
32561-76050("-" mark)
Number of orifices 8
2-9
Unit: mm [in.]
Limit
value
71.988 to 72.018
ø72 [2.83]
Case bearing [2.8342 to 2.8353]
inside diameter of counterbore 89.985 to 90.020
ø90 [3.54]
[3.5427 to 3.5441]
Out- 71.987 to 72.000

Small ø72 [2.83]
side [2.8341 to 2.8346]
diame- 89.985 to 90.000
S3S spec Large ø90 [3.54]
Injection pump ter [3.5427 to 3.5433]
(Drive case
drive shaft
P/N: 34.988 to 35.000
bearing Small ø35 [1.38]
32525-10300) Inside [1.3775 to 1.3780]
diame-
ter 39.988 to 40.000
Large ø40 [1.57]
[1.5743 to 1.5748]
35.002 to 35.013
ø35 [1.38]
Outside diameter of drive shaft [1.3780 to 1.3785]
bearing fit 40.002 to 40.013
Fuel injection ø40 [1.57]
[1.5749 to 1.5753]
pump accessory
drive 79.988 to 80.018
ø80 [3.15]
Inside diameter of case bearing [3.1491 to 3.1503]
housing 99.987 to 100.022
ø100 [3.94]
[3.9365 to 3.9379]
Out- 79.987 to 80.000

Small ø80 [3.15]
side [3.1491 to 3.1496]
diame- 99.985 to 100.000
S7S spec Large ø100 [3.94]
Injection pump ter [3.9364 to 3.9370]
(Drive case
drive shaft
P/N: 39.988 to 40.000
32625-09100) Inside [1.5743 to 1.5748]
diame-
ter 44.988 to 45.000
Large ø45 [1.77]
[1.7712 to 1.7717]
40.002 to 40.013
ø40 [1.57]
ø45 [1.77]
[1.7717 to 1.7722]
2-10
Unit: mm [in.]
Limit
value
46.989 to 47.014
ø47 [1.85]
[1.8500 to 1.8509]
Inside diameter of case bearing 79.988 to 80.018
ø80 [3.15]
housing [3.1491 to 3.1503]
89.987 to 90.022
ø90 [3.54]
[3.5428 to 3.5442]
46.989 to 47.014
ø47 [1.85]
[1.8500 to 1.8509]
Inside diameter of case cover bear- 61.988 to 62.018
ø62 [2.44]
ing housing [2.4405 to 2.4416]
71.988 to 72.018
ø72 [2.83]
[2.8342 to 2.8353]
46.890 to 47.000
Small ø47 [1.85]
[1.8461 to 1.8504]
Out-
side 79.987 to 80.000
Middle ø80 [3.15]
diame- [3.1491 to 3.1496]
ter
89.985 to 90.000
Large ø90 [3.54]
Drive case [3.5427 to 3.5433]
bearing 19.990 to 20.000
S3S spec Small ø20 [0.79]
(Drive case [0.7870 to 0.7874]
Governor drive Inside
P/N: 39.988 to 40.000
32625-15100) diame- Middle ø40 [1.57]
[1.5743 to 1.5748]
ter
39.988 to 40.000
Large ø40 [1.57]
[1.5743 to 1.5748]
46.890 to 47.000
Small ø47 [1.85]
[1.8461 to 1.8504]
Out-
side 61.987 to 62.000
Middle ø62 [2.44]
diame- [2.4404 to 2.4409]
ter
71.987 to 72.000
Drive case Large ø72 [2.83]
[2.8341 to 2.8346]
cover
bearing 19.990 to 20.000
Small ø20 [0.79]
[0.7870 to 0.7874]
Inside
29.990 to 30.000
diame- Middle ø30 [1.18]
[1.1807 to 1.1811]
ter
34.988 to 35.000
Large ø35 [1.38]
[1.3775 to 1.3780]
35.002 to 35.013
ø35 [1.38]
ø40 [1.57]
[1.5749 to 1.5753]
2-11
Unit: mm [in.]
Limit
value
46.989 to 47.014
ø47 [1.85]
[1.8500 to 1.8509]
Inside diameter of case bearing 79.988 to 80.018
ø80 [3.15]
housing [3.1491 to 3.1503]
99.987 to 100.022
ø100 [3.94]
[3.9365 to 3.9379]
46.989 to 47.014
ø47 [1.85]
[1.8500 to 1.8509]
Inside diameter of case cover bear- 61.988 to 62.018
ø62 [2.44]
ing housing [2.4405 to 2.4416]
79.988 to 80.018
ø80 [3.15]
[3.1491 to 3.1503]
46.890 to 47.000
Small ø47 [1.85]
[1.8461 to 1.8504]
Out-
side 79.987 to 80.000
Middle ø80 [3.15]
diame- [3.1491 to 3.1496]
ter
99.985 to 100.000
Drive Large ø100 [3.94]
[3.9364 to 3.9370]
Case
S7S spec 19.990 to 20.000
(Drive [0.7870 to 0.7874]
Case Inside
P/N: 39.988 to 40.000
32625-09200) [1.5743 to 1.5748]
Governor drive ter
44.988 to 45.000
Large ø45 [1.77]
[1.7712 to 1.7717]
46.890 to 47.000
Small ø47 [1.85]
[1.8461 to 1.8504]
Out-
side 61.987 to 62.000
Middle ø62 [2.44]
diame- [2.4404 to 2.4409]
ter
Drive 79.987 to 80.000
Large ø80 [3.15]
Case [3.1491 to 3.1496]
Cover 19.990 to 20.000
[0.7870 to 0.7874]
Inside
29.990 to 30.000
[1.1807 to 1.1811]
ter
39.988 to 40.000
Large ø40 [1.57]
[1.5743 to 1.5748]
40.002 to 40.013
ø40 [1.57]
ø45 [1.77]
[1.7717 to 1.7722]
Backlash between drive gear and idler gear 0.12 to 0.18 0.50
backlash [0.0047 to 0.0071] [0.0197]
0.12 to 0.18 0.50
Backlash between idler gear and driven gear
[0.0047 to 0.0071] [0.0197]
2-12
1.4 Maintenance Service Data of Lubrication System

Unit: mm [in.]
Item Nominal value Standard value Limit value Remarks
0.100 to 0.200 0.400
Drive gear and driven gear backlash
[0.0039 to 0.0079] [0.0157]
Backlash between oil pump gear and 0.12 to 0.18
crankshaft gear [0.0047 to 0.0071]
Top clearance between gear teeth and 0.150 to 0.230 0.350
case [0.0059 to 0.0091] [0.0138]
Side clearance 0.130 to 0.200 0.250

P/N:32635-20010
between gear [0.0051 to 0.0079] [0.0098]
width and case 0.130 to 0.300 0.350
depth P/N:32635-10020
[0.0051 to 0.0118] [0.0138]
33.944 to 33.960 33.920
Drive shaft outside diameter
Oil pump [1.3364 to 1.3370] [1.3354]
33.944 to 33.960 33.920
Driven shaft outside diameter ø34 [1.34]
[1.3364 to 1.3370] [1.3354]
34.000 to 34.025 34.055
Bushing inside diameter
[1.3386 to 1.3396] [1.3407]
1.42 MPa
Safety valve opening pressure {14.5 kgf/cm²}
[206 psi]
Safety valve spring installed length/load 97/833.6 N
{85 kgf}
[187.4 lbf]
Free length of safety valve spring 120 [4.7244]
0.55 MPa
Valve opening pressure {5.6 kgf/cm²}
Relief valve [80 psi]
Spring free length 147 [5.7874]
0.165 ± 0.015 MPa
Turn on start pressure (differential pres-
Oil filter alarm {1.68 ± 0.15 kgf/cm²}
sure)
[24±2 psi]
0.44 ± 0.05 MPa
Bypass valve Valve opening pressure {4.49 ± 0.51 kgf/cm²}
[64± 7 psi]
2-13
1.5 Maintenance Service Data of Cooling System

Unit: mm [in.]
Nominal Limit
Item Standard value Remarks
value value
Inside diameter of pulley 79.961 to 79.991
ø80 [3.15]
bearing fit [3.1481 to 3.1492]
Outside 79.987 to 80.000
ø80 [3.15]
diameter [3.1491 to 3.1496]
P/N:32645-92020 Bearing
Inside 34.988 to 35.000
ø35 [1.38]
diameter [1.3775 to 1.3780]
Bracket bearing 34.984 to 35.000
ø35 [1.38]
Outside diameter to fit [1.3773 to 1.3780]
Pulley bearing
51.970 to 51.995
inside diameter of counter- ø52 [2.05]
[2.0461 to 2.0470]
bore
Outside 51.987 to 52.000
Water ø52 [2.05]
P/N:32653-05010 diameter [2.0467 to 2.0472]
pump Bearing
Inside 19.988 to 20.000
ø20 [0.79]
diameter [0.7869 to 0.7874]
Outside diameter of bracket 19.987 to 20.000
Tension ø20 [0.79]
pulley
Inside diameter of pulley 89.972 to 89.994
ø90 [3.54]
Outside 89.985 to 90.000
ø90 [3.54]
diameter [3.5427 to 3.5433]
P/N:32645-18401 Bearing
Inside 39.988 to 40.000
ø40 [1.57]
diameter [1.5743 to 1.5748]
Bracket bearing 39.984 to 40.000
ø40 [1.57]
Outside diameter to fit [1.5742 to 1.5748]
Inside diameter of pulley ø120 119.972 to 119.994
bearing fit [4.72] [4.7233 to 4.7242]
Outside ø120 119.985 to 120.000
diameter [4.72] [4.7238 to 4.7244]
Fan Bearing
Inside 44.988 to 45.000
ø45 [1.77]
diameter [1.7712 to 1.7717]
Outside diameter of bracket 44.984 to 45.000
ø45 [1.77]
Valve opening tempera-
69 to 73°C
Primary ture stamp: 71°C
[156 to 163°F]
Valve opening temperature [160°F]
Thermo-
stat Second- 72 to 76°C
ary [162 to 169°F]
Temperature at which valve lift becomes 10 [0.433] or more 85°C [185°F]
2-14
Unit: mm [in.]
Nominal Limit
value value
ø62 61.988 to 62.018
[2.44] [2.4405 to 2.4416]
Inside diameter of case bearing housing
71.988 to 72.018
ø72 [2.83]
[2.8342 to 2.8353]
Outside 71.987 to 72.000
ø72 [2.83]
diameter [2.8341 to 2.8346]
Large
Inside 29.988 to 30.000
ø30 [1.18]
diameter [1.1806 to 1.1811]
Bearing
Outside ø62 61.987 to 62.000
diameter [2.44] [2.4404 to 2.4409]
Small
Inside 29.988 to 30.000
ø30 [1.18]
diameter [1.1806 to 1.1811]
30.002 to 30.011
Outside diameter of shaft fit to bearing ø30 [1.18]
[1.1812 to 1.1815]
Water
0.6 to 1.4
pump Impeller front clearance
[0.024 to 0.055]
Impeller back clearance 1.0 [0.04]
ø62 61.988 to 62.018
Pump case
[2.44] [2.4405 to 2.4416]
Inside diameter of bearing fit
67.961 to 67.991
Bearing cover ø68 [2.6]
[2.6756 to 2.6768]
67.987 to 68.000
[2.6766 to 2.6772]
Bearing
27.990 to 28.000
[1.1020 to 1.1024]
ø28 28.002 to 28.015
Outside diameter of shaft fit to bearing
[1.10] [1.1024 to 1.1030]
0.5 to 1.1
Impeller front clearance 0.8 [0.032]
[0.020 to 0.043]
71.985 to 72.004
Inside diameter of case bearing housing ø72 [2.83]
[2.8340 to 2.8348]
71.983 to 72.004
Sea water [2.8340 to 2.8348]
Bearing
pump 29.987 to 30.003
[1.1806 to 1.1812]
30.002 to 30.015
Outside diameter of shaft fit to bearing ø30 [1.18]
[1.1812 to 1.1817]
2-15
Unit: mm [in.]
Nominal Limit
value value
ø110 109.987 to 110.022
[4.33] [4.3302 to 4.3316]
ø120 119.987 to 120.022
[4.72] [4.7239 to 4.7253]
Outside ø120 119.985 to 120.000
diameter [4.72] [4.7238 to 4.7244]
Large
Inside 44.988 to 45.000
ø45 [1.77]
Ribbed diameter [1.7712 to 1.7717]
Bearing
belt Outside ø110 109.985 to 110.000
diameter [4.33] [4.3301 to 4.3307]
Small
Inside 49.988 to 50.000
ø50 [1.97]
diameter [1.9680 to 1.9685]
50.002 to 50.013
ø50 [1.97]
[1.9686 to 1.9690]
45.002 to 45.013
ø45 [1.77]
Fan [1.7717 to 1.7722]
drive ø100 99.987 to 100.022
[3.94] [3.9365 to 3.9379]
ø110 109.987 to 110.022
[4.33] [4.3302 to 4.3316]
Outside ø110 109.985 to 110.000
diameter [4.33] [4.3301 to 4.3307]
Large
Inside 39.988 to 40.000
ø40 [1.57]
diameter [1.5743 to 1.5748]
V-belt Bearing
Outside ø100 99.985 to 100.000
diameter [3.94] [3.9364 to 3.9370]
Small
Inside 44.988 to 45.000
ø45 [1.77]
diameter [1.7712 to 1.7717]
45.002 to 45.013
ø45 [1.77]
[1.7717 to 1.7722]
40.002 to 40.013
ø40 [1.57]
[1.5749 to 1.5753]
2-16
1.6 Maintenance Service Data of Electrical System

Unit: mm [in.]
Item Nominal Limit
Standard value Remarks
value value
18.90 to 18.94
Front shaft outside diameter ø19 [0.75]
[0.7441 to 0.7457]
19.000 to 19.033
Front bearing inside diameter ø19 [0.75]
[0.7480 to 0.7493]
19.000 to 19.033
Pinion bearing inside diameter ø19 [0.75]
[0.7480 to 0.7493]
30.002 to 30.011
Rear shaft outside diameter ø30 [1.18]
[1.1812 to 1.1815]
Pinion shaft
Center bracket 55.1
ø55 [2.17]
Inside diameter of bearing fit [2.1693]
Outside 54.987 to 55.000
ø55 [2.17]
diameter [2.1648 to 2.1654]
Rear shaft bearing
Inside 29.990 to 30.000
ø30 [1.18]
diameter [1.1807 to 1.1811]
0.2 to 0.8
End play Adjust with
[0.0079 to 0.0315]
the adjust
0.25 washer
Clearance between pinion shaft and bearing
[0.0098]
22 to 23
Brush length 13 [0.51]
P/N: [0.87 to 0.91]
32666-10300 44.1 N 40.2 N
Single wire With brush
Brush spring load {4.5 kgf} {4.1 kgf}
Starter type installed
[9.9 lbf] [9.0 lbf]
P/N:
32666-10400 20.002 to 20.011
Front shaft outside diameter ø20 [0.79]
2-wire type [0.7875 to 0.7878]
47.1
Front bearing fit diameter ø47 [1.85]
[1.854]
Outside 46.989 to 47.000
ø47 [1.85]
diameter [1.8500 to 1.8504]
Front shaft bearing
Inside 19.990 to 20.000
ø20 [0.79]
diameter [0.7870 to 0.7874]
10.001 to 10.007
Rear shaft outside diameter ø10 [0.39]
[0.3937 to 0.3940]
Armature 30.1
Rear bearing fit diameter ø30 [1.18]
[1.185]
Outside 29.991 to 30.000
ø30 [1.18]
diameter [1.1807 to 1.1811]
Rear shaft bearing
Inside 9.992 to 10.000
ø10 [0.39]
diameter [0.3934 to 0.3937]
Shaft runout 0.05 [0.0020] TIR
Single wire type 0.15 to 0.75
(body grounding) [0.0059 to 0.0295] Adjust with
End play the adjust
0.2 to 0.7 washer
2-wire type
[0.008 to 0.028]
2-17
Unit: mm [in.]
Item Nominal Limit
value value
Outside diameter ø43 [1.69] 42 [1.65]
0.1
Runout 0.06 [0.0024] TIR
Commutator [0.004]
0.7 to 0.9 0.2
Undercut depth
[0.028 to 0.035] [0.008]
(reference at
Coil At pull starting 0.066 [0.0026]
20°C [68 ºF] )
Resistance
Magnetic switch (Ω) (reference at
P/N: Hold condition 1.07 [0.0421]
20°C [68 ºF] )
32666-10300
Single wire Contactor deflection 1.35 to 2.05 0.6
Starter type
100MΩor higher
P/N:
Commutator to (Room tempera- 0.02MΩ
32666-10400 Armature
earth ture and humidity or more
2-wire type
at 500 V megger)
100MΩor higher
Insulating M terminal lead to (Room tempera- 0.02MΩ
Yoke assy
resistance earth ture and humidity or more
at 500 V megger)
100MΩor higher
positive brush box (Room tempera- 0.02MΩ
Brush holder
to holder ring ture and humidity or more
at 500 V megger)
30 A or more
2500
Output cur- Rotating (when cold)
Initial rent speed 35 A or more
exciting (at 27 V) (min-1) 5000 (when engine is
P/N:
type hot)
04343-35500
(brush-
less) Regulator adjusting voltage
28.5 ± 0.5 V
(Alternator 5000 min-1, load 5A or less)
Field coil resistance (20 °C [68 °F]) 7.3 to 8.5 Ω
26 A or more
2500 (when engine is
Output cur- Rotating hot)
rent speed
(at 27 V) (min-1) 30 A or more
hot)
Alternator Regulator adjusting voltage

Self excit- (Alternator 5000 min-1, load 5A or less) 28.5 ± 0.5 V
P/N: ing type
04343-38000 (with 32.8 to 33.2 32.4
Outside diameter of rotor slip ring 33 [1.30]
brush) [1.291 to 1.307] [1.276]
The part
21.5
Height of brushes 8.0 [0.32] shows a limit
[0.847]
line.
3.7N
3.1 to 4.3 N 1.8 N
{0.38kgf}
Pressure of brush springs {0.32 to 0.44 kgf} {0.18 kgf}
[83.78
[0.71 to 0.97 lbf] [0.40 psi]
lbf]
Output cur- Rotating 70A or higher
Self excit- rent speed 5000 (when engine is
P/N: ing type (at 28 V) (min-1) hot)
04344-05001 (with
brush) Regulator adjusting voltage
28.5±0.5 V
2-18
Unit: mm [in.]
Item Nominal Limit
value value
24 A or more
hot)
Initial Output cur- Rotating 38 A or more

exciting rent speed 2500 (when engine is
P/N: (at 27 V) (min-1) hot)
type
34368-02400
(brush- 45 A or more
less) 5000 (when engine is
hot)
Regulator adjusting voltage
28.5±0.5 V
13 A or higher
hot)
Alternator Output cur- Rotating 22 A or higher
Initial rent speed 2500 (when engine is
P/N: exciting (at 27 V) (min-1) hot)
34468-21100 type (with
brush) 30 A or more
hot)
Regulator adjusting voltage
28.5±0.5 V
When the cen-
ter of the belt
is pushed with
10 to 15 a force of
Belt tension (cogged type)
[0.39 to 0.59] approx 98 to
147 N {10 to
15 kgf} [22 to
33 lbf]
2-19
1.6.1 Belt tension

Unit N {kgf} [lbf]
Belt straight distance (mm) [in.]
Number
Item 300 [11.81] or more than 300 to 400 more than 400 to 500 more than 500 to 600 more than 600
of ribs
below [11.81 to 15.75] [15.75 to 19.69] [16.69 to 23.62] [23.62]
3 74 {7.55} [16.64] 49 {5.00} [11.02] 37 {3.77} [8.32] 29 {2.96} [6.52] 25 {2.55} [5.62]
4 88 {8.97} [19.78] 59 {6.02} [13.26] 44 {4.49} [9.89] 35 {3.57} [7.87] 29 {2.96} [6.52]
5 103 {10.50} [23.16] 69 {7.04} [15.51] 51 {5.20} [11.47] 41 {4.18} [9.22] 34 {3.47} [7.64]
6 118 {12.03} [26.53] 79 {8.06} [17.76] 59 {6.02} [13.26] 47 {4.79} [10.57] 39 {3.98} [8.77]
When a new 7 132 {13.46} [29.67] 88 {8.97} [19.78] 66 {6.73} [14.84] 53 {5.40} [11.91] 44 {4.49} [9.89]
belt is installed: 8 147 {14.99} [33.05] 98 {9.99} [22.03] 74 {7.55} [16.64] 59 {6.02} [13.26] 49 {5.00} [11.02]
9 162 {16.52} [36.42] 108 {11.01} [24.28] 81 {8.26} [18.21] 65 {6.63} [14.61] 54 {5.51} [12.14]
10 176 {17.95} [39.57] 118 {12.03} [26.53] 88 {8.97} [19.78] 71 {7.24} [15.96] 59 {6.02} [13.26]
11 191 {19.48} [42.94] 127 {12.95} [28.55] 96 {9.79} [21.58] 76 {7.75} [17.09] 64 {6.53} [14.39]
12 206 {21.01} [46.31] 137 {13.97} [30.80] 103 {10.50} [23.16] 82 {8.36} [18.43] 69 {7.04} [15.51]
3 51 {5.20} [11.47] 34 {3.47} [7.64] 26 {2.65} [5.85] 21 {2.14} [4.72] 17 {1.73} [3.82]
4 62 {6.32} [13.94] 41 {4.18} [9.22] 31 {3.16} [6.97] 25 {2.55} [5.62] 21 {2.14} [4.72]
5 72 {7.34} [16.19] 48 {4.89} [10.79] 36 {3.67} [8.09] 29 {2.96} [6.52] 24 {2.45} [5.40]
6 82 {8.36} [18.43] 55 {5.61} [12.36] 41 {4.18} [9.22] 33 {3.37} [7.42] 27 {2.75} [6.07]
When re- 7 93 {9.48} [20.91] 62 {6.32} [13.94] 46 {4.69} [10.34] 37 {3.77} [8.32] 31 {3.16} [6.97]
adjusted: 8 103 {10.50} [23.16] 69 {7.04} [15.51] 51 {5.20} [11.47] 41 {4.18} [9.22] 34 {3.47} [7.64]
9 113 {11.52} [25.40] 75 {7.65} [16.86] 57 {5.81} [12.81] 45 {4.59} [10.12] 38 {3.87} [8.54]
10 123 {12.54} [27.65] 82 {8.36} [18.43] 62 {6.32} [13.94] 49 {5.00} [11.02] 41 {4.18} [9.22]
11 134 {13.66} [30.12] 89 {9.08} [20.01] 67 {6.83} [15.06] 54 {5.51} [12.14] 45 {4.59} [10.12]
12 144 {14.68} [32.37] 96 {9.79} [21.58] 72 {7.34} [16.19] 58 {5.91} [13.04] 48 {4.89} [10.79]
The force when the middle of belt straight line is pushed and deflected by 15 mm [0.5906 in.]
1.7 Air Start System

Unit: mm [in.]
Nominal Limit
value value
12.973 to 12.984
Starter valve outside diameter ø13 [0.51]
[0.5107 to 0.5112]
13.000 to 13.018
Starter valve inside diameter ø13 [0.51]
[0.5118 to 0.5125]
Starter valve
Clearance between valve and valve 0.016 to 0.045 0.100
guide [0.0006 to 0.0018] [0.0039]
28
Valve spring free length 30 [1.18]
[1.10]
21.8 to 21.9 21.5
Distributer valve height 22 [0.87]
[0.858 to 0.862] [0.847]
19.959 to 19.980
Distributer shaft outside diameter ø20 [0.79]
[0.7858 to 0.7866]
Distributer valve
20.000 to 20.021
Bushing inside diameter ø20 [0.79]
[0.7874 to 0.7882]
0.020 to 0.062 0.150
Clearance between shaft and bushing
[0.0008 to 0.0024] [0.0059]
2-20
2. Tightening Torque Table

2.1 Tightening Torque Spec for Basic Engine
Dia x Pitch Tightening torque

Description Remarks
(M-thread) N·m kgf·m lbf·ft
Cylinder head bolt 20 × 2.5 Note (a) [Wet]
Rocker cover 12 x 1.25 15 ± 2 1.5 ± 0.2 10.9 ± 1.5
Rocker shaft bracket 12 x 1.75 49 ± 2.5 5 ± 0.25 36 ± 1.81
Rocker arm (lock nut) 12 x 1.25 64 ± 6.4 6.5 ± 0.65 47 ± 4.70
Bridge (lock nut) 10 x 1.25 55 ± 5.5 5.6 ± 0.56 40.5 ± 4.05
Camshaft gear 30 x 1.5 294 ± 15 30 ± 1.5 217 ± 10.9 Left-hand thread
Main bearing cap 24 × 3.0 588 ± 29 60 ± 3.0 434 ± 22 [Wet], Note (b)
Main bearing cap (side bolt) 16 × 2.0 147 ± 7.4 15 ± 0.75 109 ± 5.42 [Wet], Note (b)
Piston cooling nozzle 12 x 1.75 34 ± 1.7 3.5 ± 0.17 25.3 ± 1.23 Note (c)
12 x 1.75 98 ± 4.9 10 ± 0.5 72 ± 3.6
Timing gear case
16 x 1.5 255 ± 12.8 26 ± 1.3 188 ± 9.4
Rear plate 12 x 1.25 98 ± 4.9 10 ± 0.5 72 ± 3.6
Front mounting bracket 20 x 1.5 392 ± 20 40 ± 2.0 289 ± 14
Rear mounting bracket 18 × 2.5 245 ± 12 25 ± 1.3 180 ± 9.4
Connecting rod cap 18 x 1.5 Note (e) [Wet]
Balance weight 16 x 1.5 196 ± 10 20 ± 1.0 145 ± 7.2
Flywheel 22 x 1.5 539 ± 27 55 ± 2.8 397 ± 20.3 [Wet]
Damper 22 x 1.5 539 ± 27 55 ± 2.8 397 ± 20.3
Idler shaft 12 x 1.75 54 ± 2.7 5.5 ± 0.28 39.8 ± 2.03
Idler gear thrust plate 10 x 1.25 39 ± 3.9 4.0 ± 0.4 28 ± 2.9
Fuel injection pump gear 30 x 1.5 294 ± 15 30 ± 1.5 217 ± 10.9
Oil pump gear 27 × 1.5 294 ± 15 30 ± 1.5 217 ± 10.9
Note:(a) Tighten cylinder head bolts as shown in the table below.
Torque method (2-time tightening Angle method (2-time tightening

Parts name
method) method)
118 ± 5.9 N·m {12 ± 0.6 kgf·m}
Cylinder head bolt (short) [87± 4.3 lbf·ft] →
392 ± 20 N·m Type 1:75 ± 3° Type 2:110± 3°
{40 ± 2.0 kgf·m}
[289.1± 14.75 lbf·ft] 196 ± 9.8 N·m {20 ±1.0 kgf·m}
Cylinder head bolt (long) [144 ±7.2 lbf·ft] →
Type 1: 75 ± 3° Type 2:110± 3°
For tightening procedure, refer to "Cylinder Head Bolt - Tighten" of "ASSEMBLY OF BASIC ENGINE".
(b) For tightening of main bearing cap bolts and main bearing cap side bolts, follow the specified sequence. Snug tighten
the all bolts to the half of specified torque, and after the snug tightening of all the bolts is completed, then finally tighten
them to the specified torque.
For tightening procedure, refer to "Main bearing cap - Install" of "ASSEMBLY OF BASIC ENGINE."
(c) Tighten piston cooling nozzle check valves to the specified torque.Do not over-tighten. If the tightening torque exceeds
the specified torque, it could cause the check valve to malfunction, which may result in piston seizure.
(d) When [Wet] is indicated, apply engine oil to the threads and bolt seat surface.
(e) Connecting rod cap bolts should be tightened as shown below.
Torque method (2-time tightening method) Angle method (2-time tightening method)
343 ± 17 N·m {35 ± 1.8 kgf·m} [253 ± 12 lbf·ft] Snug torque 147 ± 7.4 N•m {15 ± 0.75 kgf•m} [147 ± 7.4 lbf•ft]→45 ± 3°
(f) Parts (bolts/nuts) indicated by 2-time tightening method are to be tightened as follows: tighten to the specified torque,
and loosen, then retighten to the specified torque.
2-21
2.2 Tightening Torque Spec for Fuel System

Description Remarks
Coupling shaft 12 x 1.75 88 ± 5 9 ± 0.5 65 ± 3.6
Bosch S3S pump with bolt P.C.D.
10 x 1.5 61.5 ± 2.5 6.25 ± 0.25 45.21 ± 1.81
ø85
Laminated plate Bosch S3S pump with bolt P.C.D.
12 x 1.75 88 ± 5 9 ± 0.5 65 ± 3.6
ø100, S7S pump
12 x 1.25 88 ± 5 9 ± 0.5 65 ± 3.6 MHI PS pump
Pump mounting
Fuel injection 10 x 1.5 58 ± 2.9 5.9 ± 0.3 42.7 ± 2.2
bolt
pump
Bracket 10 x 1.5 58 ± 5.8 5.9 ± 0.59 42.7 ± 4.27 10.9 bolt
Stay (pump back Dedicated bolt with width across
14 × 1.5 34 ± 3.4 3.5 ± 0.35 25.3 ± 2.53
face) flats 19
Stay
(Installing crank- 10 x 1.5 58 ± 5.8 5.9 ± 0.59 42.7 ± 4.27 10.9 bolt
case)
Stay (connect) 12 x 1.25 108 ± 11 11 ± 1.1 80 ± 8.0 10.9 bolt
Fuel rack control lever 8 x 1.25 25 ± 2.5 2.5 ± 0.25 18.1 ± 1.81 2-time tightening method
Fuel filter air vent plug 8 x 1.25 9±1 0.9 ± 0.1 6.5 ± 0.7
Nozzle tip retaining nut 19 × 1.0 68.5 ± 9.5 7±1 51 ± 7
Nozzle inlet connector 14 × 1.5 74 ± 5 7.5 ± 0.5 54.3 ± 3.6
Nozzle holder cap nut 14 x 1.0 44 ± 5 4.5 ± 0.5 32.6 ± 3.6
Nozzle holder eye bolt 10 × 1.0 17.5 ± 2.5 1.75 ± 0.25 12.66 ± 1.81
Nozzle gland (nut) 12 x 1.25 59 ± 2.9 6 ± 0.3 43 ± 2.2
S7S feed pump inlet 14 × 1.5 27 ± 2 2.75 ± 2.5 19.89 ± 18.1
2.3 Tightening Torque Spec for Lubrication System

Description Remarks
Oil pan 10 x 1.5 39 ± 3.9 4 ± 0.4 19 ± 2.9
2.4 Tightening Torque Spec for Cooling System

Description Remarks
Pump impeller 22 x 1.5 196 ± 29.6 20 ± 3.0 145 ± 22
Water pump
Pump shaft pulley (nut) 24 × 1.5 260 ± 12 26 ± 1.2 188 ± 8.7
Pump cam 10 x 1.25 15 ± 1.5 1.5 ± 0.1 10.9 ± 0.7
Sea water
Pump cover 10 x 1.25 7.5 ± 0.5 0.75 ± 0.05 5.42 ± 0.36
pump
Pump shaft pulley (nut) 33 × 3.5 196 ± 10 20 ± 1 145 ± 7
Fan drive Drive pulley (nut) 30 x 1.5 441 ± 22 45 ± 2.3 325 ± 16.6 Apply Locktite 262
Water outlet pipe 10 x 1.25 54 ± 5 5.5 ± 0.5 39.8 ± 3.6
2.5 Tightening Torque Spec for Inlet and Exhaust System

Description Remarks
Exhaust manifold mounting bolt 10 x 1.5 64 ± 5 6.5 ± 0.5 47.0 ± 3.6
Exhaust manifold coupling (nut) 6 x 1.0 9 ± 0.45 0.9 ± 0.04 6.5 ± 0.29
2-22
2.6 Tightening Torque Spec for Electrical System

Description Remarks
Starter - Install 12 x 1.25 59 ± 5.9 6 ± 0.6 43 ± 4.3
Magnetic switch
6 x 1.0 4.5 ± 0.6 0.46 ± 0.06 3.33 ± 0.43
assembly
Lever assembly 8 x 1.25 10.9 ± 1.3 1.1 ± 0.14 8.0 ± 1.01
Front bracket 6 x 1.0 5.85 ± 0.75 0.6 ± 0.07 4.3 ± 0.51
P/N:
Safety switch 6 x 1.0 4.2 ± 0.3 0.43 ± 0.03 3.11 ± 0.22
32666-10300
Single wire Center bracket 8 x 1.25 14 ± 1.7 1.4 ± 0.17 10.1 ± 1.23 Hexagon socket bolt
Starter type
Brush holder 5 × 0.8 3.2 ± 0.4 0.33 ± 0.04 2.39 ± 0.29
P/N:
32666-10400 Through bolt 6 x 1.0 8.7 ± 1.1 0.9 ± 0.11 6.5 ± 0.80
2-wire type Single
wire 10 x 1.25 22.6 ± 2.9 2.3 ± 0.3 16.6 ± 2.2
B terminal type
nut
2-wire
10 x 1.25 17.7 ± 1.9 1.8 ± 0.19 13.0 ± 1.37
type
E terminal nut 10 x 1.25 22.6 ± 2.9 2.3 ± 0.3 16.6 ± 2.2 2- wire type only
Pulley nut 20 x 1.5 147 ± 15 14.99 ± 1.53 108.42 ± 11.07
Retainer tightening
5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.7
screw
Through bolt 6 x 1.0 5.4 ± 1.5 0.55 ± 0.15 3.98 ± 1.08
Regulator assembly
5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.7
tightening screw
Rectifier assembly
5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.7
tightening screw
P/N:
04343-35500 B terminal nut 5 × 0.8 6.9 ± 0.9 0.7 ± 0.09 5.1 ± 0.65
E terminal nut 5 × 0.8 6.9 ± 0.9 0.7 ± 0.09 5.1 ± 0.65
Coil assembly
5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.7
tightening screw
Alternator Screw connecting

field coil and regula- 5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.7
tor
Connector assembly
6 x 1.0 5.4 ± 1.5 0.55 ± 0.15 3.98 ± 1.08
tightening bolt
Pulley nut 20 x 1.5 147 ± 29 14.99 ± 2.95 108.42 ± 21.34
Retainer tightening
5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.7
screw
Through bolt 5 × 0.8 4.4 ± 1 0.45 ± 0.1 3.25 ± 0.7
P/N:
04343-38000 Regulator assembly 5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.7
tightening screw
Rectifier assembly
5 × 0.8 3.9 ± 1 0.4 ± 0.1 2.9 ± 0.7
tightening screw
B terminal nut 5 × 0.8 6.9 ± 1.9 0.7 ± 0.19 5.1 ± 1.37
2.7 Tightening Torque Spec for Air Start System

Description Remarks
Starter valve nut 8 x 1.25 19 ± 0.95 1.94 ± 0.09 14.03 ± 0.65
Starter valve cap nut 30 x 1.5 147 ± 7.35 15 ± 0.75 109 ± 5.42
2-23
2.8 Tightening Torque for Standard Bolts

Thread size Width across Strength classification
Threads Dia. x Pitch flats
(M-thread) (mm) [in.] 7T 10.9
7 10
N·m kgf·m lbf·ft N·m kgf·m lbf·ft
8 x 1.25 12 [0.47] 17 1.7 12.3 30 3.1 22.4
10 x 1.25 14 [0.55] 33 3.4 24.6 60 6.1 44.1
Metric automobile 12 x 1.25 17 [0.67] 60 6.1 44.1 108 11.0 79.6
screw thread 14 × 1.5 22 [0.87] 97 9.9 71.6 176 17.9 129.5
16 x 1.5 24 [0.94] 145 14.8 107.1 262 26.7 193.1
18 x 1.5 27 [1.06] 210 21.4 154.8 378 38.5 278.5
20 x 1.5 30 [1.18] 291 29.7 214.8 524 53.4 386.2
22 x 1.5 32 [1.26] 385 39.3 284.3 694 70.8 512.1
24 × 1.5 36 [1.42] 487 49.7 359.5 878 89.5 647.4
27 × 1.5 41 [1.61] 738 75.3 544.7 1328 135.5 980.1
N·m kgf·m lbf·ft N·m kgf·m lbf·ft

10 x 1.5 14 [0.55] 32 3.3 23.9 58 5.9 42.67
12 x 1.75 17 [0.67] 57 5.8 42.0 102 10.4 75.2
Metric course screw
14 × 2 22 [0.87] 93 9.5 68.7 167 17.0 123.0
thread
16 × 2 24 [0.94] 139 14.2 102.7 251 25.6 185.2
18 × 2.5 27 [1.06] 194 19.8 143.2 350 35.7 258.2
20 × 2.5 30 [1.18] 272 27.7 200.4 489 49.9 361.0
22 × 2.5 32 [1.26] 363 37.0 267.6 653 66.6 482.0
24 × 3 36 [1.42] 468 47.7 345.0 843 86.0 622.0
27 × 3 41 [1.61] 686 70.0 506.3 1236 126.0 911.4
Note:(a) The tightening torque listed in this table is for standard bolts and nuts.
(b) The numerical values in the table are the values when spring washers are used.
(c) The table shows the standard values with a maximum tolerance value of ±10%.
(d) Use the tightening torque in this table unless otherwise specified.
(e) Do not apply oil to threaded portions.(Dry)
2-24
2.9 Tightening Torque for Standard Eyebolts

Strength classification
Thread size
Width across flats
Dia. × Pitch 4T
(mm) [in.]
(M-thread)
N·m kgf·m lbf·ft
8 × 1.25 12 [0.47] 8±1 0.8 ± 0.1 5.90 ± 0.73
10 × 1.25 14 [0.55] 15 ± 2 1.5 ± 0.2 11.06 ± 1.47
12 × 1.25 17 [0.67] 25 ± 3 2.5 ± 0.3 18.44 ± 2.21
14 × 1.5 19 [0.75] 34 ± 4 3.5 ± 0.4 25.08 ± 2.95
16 × 1.5 22 [0.87] 44 ± 5 4.5 ± 0.5 32.45 ± 3.68
18 × 1.5 24 [0.94] 74 ± 5 7.5 ± 0.5 54.58 ± 3.68
20 × 1.5 27 [1.06] 98 ± 10 10.0 ± 1.0 72.28 ± 7.37
24 × 1.5 32 [1.26] 147 ± 15 15.0 ± 1.5 108.42 ± 11.06
27 × 1.5 41 [1.61] 226 ± 20 23.0 ± 2.0 166.69 ± 14.75
(Dry)
2.10 Tightening Torque for Standard Union Nuts

Cap nut thread size
Width across flats
Nominal Dia. × Pitch N·m kgf·m lbf·ft
(mm) [in.]
(M-thread)
63 14 × 1.5 19 [0.75] 39 4 28.76
80 16 × 1.5 22 [0.87] 49 5 36.14
100 20 × 1.5 27 [1.06] 78 8 57.53
120 22 × 1.5 30 [1.18] 98 10 72.28
150 27 × 1.5 32 [1.26] 157 16 115.80
180 30 × 1.5 36 [1.42] 196 20 144.56
200 30 × 1.5 36 [1.42] 196 20 144.56
220 33 × 1.5 41 [1.61] 245 25 180.70
254 36 × 1.5 41 [1.61] 294 30 216.84
(Maximum tolerance value: ±10%, dry condition)
2.11 Tightening Torque for Fuel Injection Pipe

Cap nut thread size
N·m kgf·m lbf·ft
Dia. x Pitch
12 x 1.5 39 ± 5 4 ± 0.5 28.8 ± 3.68
14 × 1.5 49 ± 5 5 ± 0.5 36.1 ± 3.68
18 x 1.5 59 ± 10 6 ± 1.0 43.5 ± 7.37
(Dry)
2-25
1. Special Tools............................................................................................................ 3-3
3-1
1. Special Tools
Maintenance
Tool name Part No. Illustration Usage
item
Basic engine Rocker bushing puller 32591-02600 Rocker Bushing - Replace
Bushing inside/outside diam : ø32× 36
mm [1.26 × 1.42 in.]
Idler bushing puller 32591-02500 Idler Bushing - Replace

Bushing inside diam : ø50 X 55 mm
[1.97 X 2.17 in.]
Eye bolt 45815-32201 Piston - lift
M8 × 1.25
Eye bolt 45815-32301 Piston - lift
M10 × 1.5
Eye bolt 05930-00200 Gear case - lift
M12 × 1.25
Eye nut 08014-00003 Cylinder head assembly - install/

remove
M12 × 1.25
Front seal 32691-00042 Front oil seal - install

installer assembly
Rear seal installer assembly 32591-07012 Rear oil seal - install
3-3
Maintenance
item
Basic engine Nozzle remover 36291-00900 Fuel injection nozzle - remove
M18×1.5 mm
Valve spring 33591-04500 Valve spring - install/remove

pusher
Valve guide remover 36291-04200 Valve guide - remove

Applicable valve guide inside/outside
diam:
ø10 X 18 mm [0.39 X 0.71 in.]
ø17.5 × L60
ø9.85 × L45
Guide and 32591-10300 Valve guide and stem seal -

seal installer Install
Guide height: 27.5 mm [1.08 in.]
Stem seal height: 30.3 mm [1.19 in.]
Socket 32591-02800 Camshaft connector installation/

removal
Adapter 32591-04300 Main bearing cap -

M10 × 1.25 mm Remove
M18 × 1.5 mm
Ring expander 37191-03200 Piston ring - install/remove

Applicable diam: o101.6 to 177.8 mm
[4.00 to 7.00 in.]
Cylinder liner remover 32591-14100 Cylinder Liner - Remove

Applicable cylinder liner inner diam:
ø150 mm [5.91 in.]
Installer 32591-01800 Cylinder Liner - Install
3-4
Maintenance
item
Basic engine Projection 37598-09201 Depth of counterbore in crankcase -
plate measure
L230 × W50 × T15 mm
[L9.06 × W1.97 × T0.59 in.]
Connecting rod 32591-18010 Connecting Rod Bushing -Install and

bushing installer Remove
Valve lapper Suction cup Valve lapping

diam:
ø35 mm
[1.38 in.]
30091-07500
Suction cup
diam:
ø40 mm
[1.57 in.]
30091-08800
Valve seat cutter Shaft Valve Seat - Reface
37591-06400 Width across flats: 32 mm [1.26 in.]
Applicable seat inside/outside diame-
ø10 mm ter: ø45 to 66 [1.77 to 2.60 in.]
W1 1/8 -18
Cutter
37591-06430
W1 1/8 -18
θ＝30°
Socket wrench 32591-01100 Cylinder head bolt - Install and
Remove
Inlet valve seat caulking 35A91-05010 Inlet valve seat installation

tool
Exhaust valve 35A91-05020 Exhaust valve seat - Press-in

seat caulking tool
3-5
Maintenance
item
Basic engine Valve seat puller 32591-04200 Valve seat - remove
Piston installer 37191-07100 Piston- Install

Applicable piston diam: ø89 to 178
mm [3.50 to 7.01 in.]
Crankcase 32591-04050 Depth of counterbore in crankcase -

grinder Reface
Connecting rod gauge 0.5 mm Connecting rod - Assembly

[0.019 in.]
32691-01500
0.6 mm
[0.024 in.]
32691-01600
Fuel Nozzle tester 04239-00050 Fuel injection nozzle opening pressure

system - measure
Lubrication Oil pump bush 32691-02700 Oil Pump Bushing - Replace

system Puller Bushing inside/outside diam : ø34× 37
mm [1.34×1.46 in.]
Cooling Oil seal installer 32591-03200 Water pump oil seal - Press-in
system
Thread cover 37191-06600 Water pump Shaft - Press-in
Bearing installer 32591-03600 Water pump bearing - Press-in
3-6
Maintenance
item
Cooling Oil seal 32591-03100 Water pump, fan drive oil seal - Press-
system installer in
Unit seal 37191-06300 Water pump unit seal - Install

installer
Water pump wrench 32691-01200 Water pump

Oil drain pipe removal/installation
Bearing installer 32691-04200 Fan drive bearing - Press-in
Bearing installer 32691-04300 Fan drive bearing - Press-in
Fan pulley adapter 32691-07100 Fan Pulley - Lock
Air start system Starter valve adapter 32591-01200 Starter Valve - Remove
Inspection and Compression gauge 33A91-01700 Compression Pressure - Measure

measurement Measurement range: 0 to 7 MPa
{0 to 71 kgf/cm2} [0 to 1015 psi]
Gauge adapter 36291-02200 Compression Pressure - Measure

U5/8-18
3-7
Maintenance
item
Inspection and Belt gauge 32591-09100 Belt tension - measure
measurement 20
25
30
15
10
5
3-8
1. Determining Overhaul Timing ................................................................................ 4-3
2. Compression Pressure - Measure.......................................................................... 4-4
4-1
1. Determining Overhaul Timing

In most cases, the engine should be overhauled when the compression pressure of the engine decrease. An increase in engine oil
consumption and blow-by gas should be considered when evaluating the engine condition.
Such symptoms as the output decrease, fuel consumption increase, oil pressure decrease, engine starting difficulty and noise
increase should be considered to evaluate overhaul timing, although these symptoms are often affected by various causes, and
are not always effective to consider overhaul timing.
Decreased compression pressure shows a variety of symptoms and engine conditions, thus making it difficult to accurately
determine when the engine needs an overhaul.
The following shows typical symptoms:
(1) Output power decrease
(2) Fuel consumption increase
(3) Engine oil consumption increase
(4) Combustion gas leak increase by cylinder liner and piston ring wear, and as a result, blow-by gas increase through the
breather. (Visually check the blow-by amount.)
(5) Gas leak increase due to poor seating of inlet and exhaust valves
(6) Difficult starting
(7) Noise increase from engine parts
(8) Abnormal exhaust color after engine warm-up
The engine shows these symptoms in various combinations.
Some of these symptoms are directly caused by worn engine parts, while others are not.
Symptoms of items (2) and (6) are affected by improper fuel injection volume and timing of the fuel injection pump, worn
plunger, faulty nozzles and also faulty conditions of electrical devices such as battery and starter.
The most valid reason to overhaul an engine is the compression pressure decrease due to worn cylinder liner and piston ring, as
described in item (4). And once this symptom is shown, it is reasonable to take other symptoms into consideration for making
the final decision.
4-3
2. Compression Pressure - Measure

Compression gauge
P/N:33A91-01700
(a) Be sure to measure the compression pressure of
Gauge adapter
all cylinders. It is not a clever way to measure P/N:36291-02200
the compression pressure of only two or three
cylinders, and assume the compression pres-
sure of all other cylinders. Cylinders are all inde-
pendent.
(b) Also be sure to check the engine speed when
measuring the compression pressure, as the
compression pressure varies depending on the Compression Pressure - Measure
engine speed.
(c) It is important to measure the compression pres-
sure at regular intervals, and know the change of
the pressure.
(1) Remove the injection nozzle from the cylinder head
where the compression pressure is to be measured.
(2) Attach the compression gauge adapter to the fuel injec-
tion nozzle hole and connect the compression gauge.
(3) Place the fuel injection pump rack at the no-injection
position (rack "0" position), and crank the engine with
the starter.
Read the engine speed and compression pressure while
the engine is running at a stable speed.
Note: Ensure the battery being fully charged when cranking
the engine with the starter.
If the battery voltage is low, the proper compression
pressure can not be measured because of a low crank-
ing speed.
(4) If the measured value exceeds the limit, overhaul the
engine.
Basic
Item Standard value Limit value
Rotation speed
Compres- 2.35 MPa 1.86 MPa
sion pres- {24 kgf/cm2} or {300 kgf/cm2} 120 to 200 min-1
sure more [4267 psi]
4-4
1. Cylinder Heads and Valve Mechanisms - Disassemble and Inspect .................. 5-3
1.1 Fuel Pipe - Remove .................................................................................................................. 5-4
1.2 Nozzle Assembly - Remove...................................................................................................... 5-4
1.3 Valve Clearance - Inspect......................................................................................................... 5-4
1.4 Fuel Injection Timing - Inspect.................................................................................................. 5-5
1.5 Rocker Shaft Assembly - Remove............................................................................................ 5-5
1.6 Clearance Between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect... 5-5
1.7 Valve Bridge - Remove............................................................................................................. 5-6
1.8 Cylinder Head Assembly - Remove.......................................................................................... 5-6
1.9 Valve Sinkage - Measure.......................................................................................................... 5-6
1.10 Valve and Valve Spring - Remove............................................................................................ 5-7
1.11 Nozzle Gland Stud Bolt and Bridge Guide - Remove ............................................................... 5-7
1.12 Fuel Connector - Remove......................................................................................................... 5-7
2. Rear Mechanism - Disassemble and Inspect ........................................................ 5-8
2.1 Flywheel Face and Radial Runout - Measure........................................................................... 5-9
2.2 Flywheel - Remove ................................................................................................................... 5-9
2.3 Timing Gear Case - Remove .................................................................................................... 5-9
2.4 Timing Gear Backlash - Measure ........................................................................................... 5-10
2.5 Idler Gear End Play - Measure ............................................................................................... 5-10
2.6 Camshaft End Play - Measure................................................................................................ 5-10
2.7 Idler Gear - Remove ............................................................................................................... 5-11
2.8 Fuel Injection Pump Gear - Remove ...................................................................................... 5-11
2.9 Governor Drive and Fuel Injection Pump Accessory Drive - Remove .................................... 5-11
2.10 Camshaft Gear - Remove....................................................................................................... 5-12
2.11 Camshaft - Remove................................................................................................................ 5-12
2.12 Idler Shaft - Remove............................................................................................................... 5-12
2.13 Rear Plate - Remove .............................................................................................................. 5-13
3. Front Mechanism - Disassemble and Inspect..................................................... 5-14
3.1 Fan, Fan Bracket Assembly and Belt - Remove..................................................................... 5-15
3.2 Damper Face and Radial Runout - Measure .......................................................................... 5-15
3.3 Front Pulley, Damper and Crankshaft Pulley - Remove ......................................................... 5-15
3.4 Front Cover - Remove ............................................................................................................ 5-16
4. Cylinder Liner, Piston and Connecting Rod - Disassemble and Inspect ......... 5-17
4.1 Piston Protrusion - Measure ................................................................................................... 5-18
4.2 Connecting Rod End Play - Measure ..................................................................................... 5-18
4.3 Hard Carbon Deposits on the Upper Part of Cylinder Liner - Remove ................................... 5-18
4.4 Connecting Rod Cap - Remove.............................................................................................. 5-18
4.5 Piston - Remove ..................................................................................................................... 5-19
4.6 Piston Ring - Remove............................................................................................................. 5-20
4.7 Piston Pin and Piston - Remove ............................................................................................. 5-21
4.8 Cylinder Liner Inside Diameter - Measure .............................................................................. 5-21
4.9 Cylinder Liner Flange Protrusion - Measure ........................................................................... 5-21
4.10 Cylinder Liner - Remove ......................................................................................................... 5-21
5. Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect............. 5-22
5.1 Crankcase - Turn Over (Upend) ............................................................................................. 5-23
5.2 Crankshaft End Play - Measure.............................................................................................. 5-23
5.3 Piston Cooling Nozzle - Remove ............................................................................................ 5-23
5.4 Main Bearing Cap - Remove .................................................................................................. 5-23
5.5 Crankshaft - Remove.............................................................................................................. 5-24
5-1
1. Cylinder Heads and Valve Mechanisms - Disassemble and Inspect

Understanding of the current engine condition before disassembling is very important to know the cause of trouble and do the
efficient work.
Depending on the maintenance work or purpose, it is desirable to inspect some of the following items before proceeding with
any job.
Valve Clearance - Inspect
Fuel Injection Timing - Inspect
Clearance Between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect
Valve Sinkage - Measure
10
Replace
9 3
1
Replace
Crack, oil leak, 2
settling
13 8 4
5 6
Replace Replace
12 Replace
7
Wear 11 Wear, oil hole 17

clogging Replace
14 Wear
Wear at both 18
15
Flaw ends, bend
19
Wear, oil hole clogging
20 16
21
Settling, crack
22 25 Crack, carbon deposit,
flaw, scale deposit
Corrosion
Cam contact face and outer
23 Contact, wear
peripheral contact face wear
Crack, flaw, settling,

Stem/face portion wear, corrosion, rubber portion crack
flaw, carbon deposit
24
Replace
Cylinder Heads and Valve Mechanisms - Disassemble and Inspect

Disassembling Sequence
1 Rocker cover 9 Rocker bracket bolt 17 Cylinder head bolt (short)
2 Fuel injection pipe 10 Cylinder head bolt (long) 18 Cylinder head (Approx. 29 kg [64 lb])
3 Fuel leak-off pipe 11 Rocker arm 19 Valve cotter
4 Washer, nut 12 Rocker shaft 20 Valve rotator
5 Nozzle gland 13 Rocker shaft bracket 21 Valve spring
6 Fuel injection nozzle 14 Bridge cap 22 Stem seal
7 Gasket 15 Valve bridge 23 Valve
8 Adjusting screw 16 Push rod 24 Cylinder head gasket
25 Tappet
5-3
1.1 Fuel Pipe - Remove

(1) Remove the clamp, and remove the fuel injection pipe.
Eye bolt Fuel injection pipe
(2) Remove the eyebolt of fuel injection nozzle, and
Sealing Clamp
remove the fuel leak-off pipe.
washers
While doing so, remove the sealing washers and keep
them together to avoid the risk of losing.
Fuel leak-off pipe

Fuel Pipe - Remove
1.2 Nozzle Assembly - Remove
Nozzle remover
P/N:36291-00900 Bar
When removing the nozzle assembly with nozzle
Weight
remover, be careful not to get caught your fingers Gasket
between the nozzle remover weight, bar and plate.
Before removing the nozzle assembly, clean the noz-

zle assembly to prevent foreign material from getting
into the cylinder head.Keep the nozzle and the fuel
pipe together, and handle the nozzle with care to Nozzle Assembly - Remove
avoid damage to the nozzle tip.
(1) Remove the nozzle gland.
(2) Remove the nozzle holder with nozzle remover.
(3) Remove the gasket remained inside the cylinder head.
1.3 Valve Clearance - Inspect

Inspect the valve clearance, and know the current condition.
For the inspection procedure, refer to "Valve Clearance -
Valve clearance
Inspect and Adjust" of "ASSEMBLY OF BASIC
ENGINE."
Valve Clearance - Inspect
5-4
1.4 Fuel Injection Timing - Inspect

Inspect the fuel injection timing, and know the current con-
88 ± 5 N·m
dition. {9 ± 0.5 kgf·m}
[65 ± 3.7 lbf·ft]
For the inspection procedures, refer to "Fuel Injection Tim-
ing - Check and Adjust" of "ASSEMBLY OF BASIC
ENGINE."
Pointer
Fuel injection pump
coupling (punch) mark
Fuel Injection Timing - Inspect
1.5 Rocker Shaft Assembly - Remove
(1) Loosen the adjusting screw of rocker arm.
Rocker bracket bolt
(2) Remove the rocker bracket bolt. Loosen
(3) Remove the cylinder head bolt (long), which is also fix-
ing the rocker bracket. Adjusting screw
(4) Remove the rocker shaft assembly from the cylinder
head.
Note: Keep the removed rocker shaft assembly and bolts as a
set.
Cylinder head bolt
(long) Lock nut
Rocker Shaft Assembly - Remove
(5) Remove the push rod.
Lock nut Rocker shaft
(6) Disassemble the rocker shaft assembly.
Rocker arm
Note: Do not remove the rocker bushing unless it is defective
or its inside diameter exceeds the limit.
Washer
Rocker shaft
bracket
Snap ring Adjusting screw
Push rod
Rocker Shaft Assembly - Disassemble
1.6 Clearance Between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect
Inspect the clearance between the bottom face of valve
Hold down the top
bridge and the top face of valve rotator, and know the cur-
Bridge cap of bridge by hand. Clearance between
rent condition. Valve bridge valve bridge bottom
face and valve
For the inspection procedure, refer to "Clearance Between rotator top face
Bottom Face of Valve Bridge and Top Face of Valve Rota- Valve rotator
tor - Measure" of "ASSEMBLY OF BASIC ENGINE."
Clearance Between Bottom Face of Valve Bridge and

Top Face of Valve Rotator - Inspect
5-5
1.7 Valve Bridge - Remove

Remove the valve bridge and bridge cap.
Note: Be careful not to drop the bridge cap into the cylinder Screw
head. Bridge cap
Valve Bridge - Remove

1.8 Cylinder Head Assembly - Remove
When removing the cylinder head gasket, be careful Eye nut

P/N:08014-00003
not to damage the cylinder head or crankcase surface (M12 × 1.25 mm)
with a screwdriver or the like.
(1) Remove the cylinder head bolt.
(2) Lift the cylinder head up using the sling.
Note: Dowel pins are used to retain the cylinder head in a po-
sition. Therefore, pull the cylinder head vertical to the
mounting surface to remove.
(3) Remove the cylinder head gasket. Cylinder Head Assembly - Remove
1.9 Valve Sinkage - Measure

Measure the valve sinkage, and know the current condition.
For the measurement procedure, refer to "Valve Sinkage -
Measure" of "ASSEMBLY OF BASIC ENGINE."
5-6
1.10 Valve and Valve Spring - Remove

Using a valve spring pusher, compress the valve spring
evenly and remove the valve cotters. Valve spring pusher
Note: If valves are reusable, mark each valve seat and the P/N : 33591-04500
mating valve to identify their original positions. Do not
change the combination of the valve seat and the valve
when reassembling.
Valve Spring - Compress
Valve cotter
Valve rotator
Valve spring
Stem seal
Valve and Valve Spring - Remove

1.11 Nozzle Gland Stud Bolt and Bridge Guide - Remove
Do not remove the nozzle gland stud bolt and the bridge
guide from the cylinder head, unless they are defective.
Bridge guide
If they are removed, see "Nozzle Gland Stud Bolt and
Bridge Guide - Inspect and Replace" of "INSPECTION
AND REPAIR OF BASIC ENGINE." Nozzle gland
stud bolt
Nozzle Gland Stud Bolt and Bridge Guide -

Remove
1.12 Fuel Connector - Remove
Do not remove the fuel injection connector, fuel leak-off
connector from the cylinder head unless they are found to be
defective. Fuel leak-off
connector
Fuel injection
connector
Fuel Connector - Remove
5-7
2. Rear Mechanism - Disassemble and Inspect

efficient work.
any job.
Flywheel Face and Radial Runout - Measure
Timing Gear Backlash - Measure
Idler Gear and Camshaft End Play - Measure
Replace: Gasket, O-ring
Flaw, wear, 12 9
key groove defect
Flaw, wear
11
Oil hole clogging
Flaking, wear,
key way deformation and wear
9 9
14 Groove crack, wear

Electronic Oil pressure
governor spec governor spec 13 7 6
10 5
8 Wear, flaw,
deterioration
Non- Non-
Crack, dowel hole defect Hour meter spec attachment spec attachment spec
1
4
2
3
Crack, dowel hole defect,

Non- Non-
Tachometer spec attachment spec attachment spec Wear, flaw, deterioration flaw on gear, abnormal wear
Rear Mechanism - Disassemble and Inspect

1 Pick up (electronic governor spec) 9 Accessory drive (electronic governor spec)
2 Flywheel (Approx. 83 kg [183 lb]) Governor drive (Oil pressure governor spec)
3 Timing gear case (Approx. 43 kg [95 lb]) (Refer to the chapter "FUEL SYSTEM" for disassembly, in-
4 Oil seal spection and assembly.)
5 Oil seal slinger 10 Camshaft gear
6 Thrust plate 11 Thrust plate
7 Idler gear 12 Camshaft (Approx. 25 kg [55 lb.])
8 Fuel injection pump gear 13 Idler shaft
14 Rear plate (Approx. 21 kg [46 lb])
5-8
2.1 Flywheel Face and Radial Runout - Measure

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

2.2 Flywheel - Remove
Sling
(a) Be careful not to drop or bump the flywheel.It can,

not only cause damage to parts, but also lead to
personnel injury.
(b) Be careful not to cut your hands with the ring gear
when pulling-out the flywheel.
Flywheel
Be sure to remove the pickups before removing the
Jack bolt (M12 × 1.75 mm)
flywheel. Flywheel - Remove
(1) Hitch a sling to the flywheel to prevent it from falling.
(2) Screw two jack bolts evenly into the jack bolt holes,
and remove the flywheel.
2.3 Timing Gear Case - Remove

Eyebolt
P/N:05930-00200
Be careful not to drop or bump the timing gear case.It (M12 × 1.25 mm )
can, not only cause damage to parts, but also lead to
personnel injury.
(1) Hitch a sling to the timing gear case to prevent it from
falling.
(2) Lift the timing gear case to disengage the dowel pins,
and remove the timing gear case. Timing gear case
(3) Remove the oil seal from the timing gear case. Oil seal
Note: Do not reuse the removed oil seal. Timing Gear Case - Remove
5-9
2.4 Timing Gear Backlash - Measure

Measure the timing gear backlash, and know the current
condition.
For the measurement procedure, refer to "Timing Gear
Backlash - Measure" of "ASSEMBLY OF BASIC Camshaft gear
ENGINE."
Fuel injection
pump gear
Idler gear
2.5 Idler Gear End Play - Measure
Measure the idler gear end play, and know the current con-
dition.
For the measurement procedure, refer to "Idler Gear End
Play - Measure" of "ASSEMBLY OF BASIC ENGINE."
Idler gear
Idler Gear End Play - Measure
2.6 Camshaft End Play - Measure
Measure the camshaft end play, and know the current condi-
tion.
For the measurement procedure, refer to "Camshaft End
Camshaft gear
Camshaft End Play - Measure
5-10
2.7 Idler Gear - Remove
The camshaft gear mounting nuts are left-hand

Socket
threaded. Be sure to turn them clockwise to loosen P/N : 32591-02800
them.
If the idler gear is removed first, the nut that fixes the cam-
shaft gear cannot be loosened because the camshaft gear
rotates. Thus, loosen the camshaft gear mounting nut before Camshaft gear
nut [Left-handed
removing the idler gear. screw]
(1) Remove the oil seal slinger from the crankshaft. Thrust plate Idler gear
(2) Using a socket, loosen the camshaft gear mounting nut Idler Gear - Remove
(left-hand thread).
(3) Remove the thrust plate.
(4) Remove idler gears.
2.8 Fuel Injection Pump Gear - Remove
Using a puller, remove the fuel injection pump gear.
Threaded holes
(M10 × 1.25 mm)
Fuel injection pump gear

Puller
Fuel Injection Pump Gear - Remove
2.9 Governor Drive and Fuel Injection Pump Accessory Drive - Remove
Remove the governor drive (oil pressure governor spec) and
fuel injection pump accessory drive from the rear plate. Accessory drive
(Refer to the chapter "FUEL SYSTEM" for disassembly,

inspection and assembly.)
Electronic
governor spec Governor drive
Oil pressure
governor spec
Governor Drive and Fuel Injection Pump and
Accessory Drive - Remove
5-11
2.10 Camshaft Gear - Remove

(1) Remove the nut (left-hand thread).
(2) Remove the camshaft gear with the puller using the
threads in the gear. Threaded holes
(M10 × 1.25 mm)
Camshaft gear Puller

Camshaft Gear - Remove
2.11 Camshaft - Remove
Remove the camshaft by lifting from Crankcase top Thrust plate

face, paying attention not to damage the Crankcase
and camshaft.
(1) Remove the thrust plate.
(2) Lift the camshaft with a sling fitted to the top of the
crankcase and remove the camshaft to the rear of the
engine. Camshaft
Camshaft - Remove (1)
Sling
Camshaft bush
Cam
Camshaft
Crankcase
Camshaft - Remove (2)
2.12 Idler Shaft - Remove
Screw two jack bolts evenly into the jack bolt holes, and
Jack bolt (M10 × 1.25 mm)
remove the idler shaft.
Idler Shaft - Remove
5-12
2.13 Rear Plate - Remove

Remove the rear plate from the crankcase.
Dowel pin
Rear Plate - Remove
5-13
3. Front Mechanism - Disassemble and Inspect

efficient work.
any job.
Damper Face and Radial Runout - Measure
Fan attachment spec Oil pipe

1
3
2
4 Replace
Replace
Belt groove wear
With pulley (ribbed belt) Double installation spec
6
5 10 (Slinger portion)
4 10 (Seal lip portion) 9 Crack, dowel hole defect

8
With pulley (V-belt)
4 7
Crack, oil leak
Front oil seal assembly in the form of a cassette combing an seal lip and slinger.
With cranking pulley Front oil seal should be replaced whenever the front cover is removed.
Front Mechanism - Disassemble and Inspect
1 Fan (Approx. 41 kg [90 lb]) (with fan spec) 6 Spacer (double damper spec)
2 Fan bracket assembly (with fan spec) 7 Damper (Approx. 56 kg [123 lb.])
3 Belt (with fan spec) 8 Crankshaft pulley
4 Front pulley 9 Front cover
5 Damper (Approx. 56 kg [123 lb]) (double damper spec) 10 Oil seal (cassette type)
Note:(a) The shape of fan differs in accordance with the customization and specification.
(b) The consisting parts of the damper differ in accordance with the customization and specification.
5-14
3.1 Fan, Fan Bracket Assembly and Belt - Remove

(With fan spec)
Remove the fan, fan bracket assembly and belt.
3.2 Damper Face and Radial Runout - Measure

Measure the face and radial runout of the damper, and know
the current condition.
For the measurement procedure, refer to "Damper Face and
Radial Runout - Measure" of "ASSEMBLY OF BASIC
ENGINE."
Face runout
Radial runout
3.3 Front Pulley, Damper and Crankshaft Pulley - Remove
Raise using a rope, etc.

Be careful not to drop or bump the pulley and damper.
It can, not only cause damage to parts, but also lead Jack bolt
(M12 × 1.75 mm)
to personnel injury.
(1) Install the guide bolt to damper mounting thread on the
crankshaft.
(2) Hitch a rope or the like to the groove of front pulley to
support. Screw two jack bolts evenly into the jack bolt
holes, and remove the pulley. Guide bolt Front pulley
Front Pulley - Remove
(3) While supporting the damper with a sling, screw two
jack bolts evenly into the jack bolt holes, and remove
Double installation
the damper. spec Guide bolt
Spacer Jack bolt

(M12 × 1.25 mm)
Damper - Remove
and remove the crankshaft pulley from the crankshaft.
Jack bolt
(M12 × 1.25 mm)
Crankshaft pulley
Crankshaft Pulley - Remove

5-15
3.4 Front Cover - Remove
When removing the oil seal (slinger portion), be careful Pointer
not to damage the crankshaft.If the crankshaft has a

flaw, oil will leak from its flaw even if new oil seal is Bolt
installed.
and remove the front cover from the crankcase, Front cover
(2) Remove the oil seal (seal lip portion) from the front Oil seal Jack bolt
cover. (M10 × 1.5 mm)
(3) Remove the oil seal (slinger portion) from the crank- Front Cover - Remove
shaft by tapping lightly or prying it.
5-16
4. Cylinder Liner, Piston and Connecting Rod - Disassemble and Inspect

efficient work.
any job.
Piston Protrusion - Measure
Connecting Rod End Play - Measure
Cylinder Liner Inside Diameter - Measure
Cylinder Liner Flange Protrusion - Measure
Wear, flaw
Inner face scratches/wear,
outer peripheral O-ring Outer peripheral surface scratch, 5
groove rust/cavitation crack, flaw, carbon deposit 6
7
Replace.
Deformation, wear 12 9
8
10
Inner face wear,

flaw, discoloration
11
Crack, oil hole clogging
4
3
Inner and outer
peripheral
surface flaw, 2
seizure, peeling
Serrated portion
wear, crack 1
Flaw
Cylinder Liner, Piston and Connecting Rod - Disassemble and Inspect

1 Connecting rod cap bolt 7 Oil ring
2 Connecting rod cap 8 Snap ring
3 Lower connecting rod bearing 9 Piston pin
4 Upper connecting rod bearing 10 Piston
5 No. 1 compression ring 11 Connecting rod
6 No. 2 compression ring 12 Cylinder liner (Approx 16 kg [35 lb])
5-17
4.1 Piston Protrusion - Measure

Measure the piston protrusion, and know the current condi-
tion.
For the measurement procedure, refer to "Piston Protrusion Piston protrusion
- Measure" of "ASSEMBLY OF BASIC ENGINE."
Piston Protrusion - Measure

4.2 Connecting Rod End Play - Measure
Measure the connecting rod end play, and know the current
condition. Connecting rod
For the measurement procedure, refer to "Connecting Rod
End Play - Measure" of "ASSEMBLY OF BASIC
ENGINE."
Connecting rod end play

4.3 Hard Carbon Deposits on the Upper Part of Cylinder Liner - Remove
Be sure to remove hard carbon deposits from the Hard carbon

upper part of the cylinder liner before pulling-out the
piston.Hard carbon deposits, if not removed, cause
damage to the piston and piston rings.
Remove hard carbon deposits from the upper part of cylin-
Cylinder liner
der liner with carbon remover (scraper, sandpaper, etc.)
Note: Be careful not to damage the inner surface of the cyl-
inder liner.
Hard Carbon Deposits on the Upper Part of Cylinder
Liner - Remove
4.4 Connecting Rod Cap - Remove
Using a socket wrench, remove the connecting rod bolts
through the inspection window on the side of the crankcase, Connecting
rod cap
and remove the connecting rod cap and connecting rod bear-
ings.
Note:(a) Be careful not to damage the connecting rod bear-
ings by dropping them into the oil pan.
(b) Make marks, such as cylinder number and upper or
lower, on the removed connecting rod bearings to
ensure the correct reassembly.
Connecting Rod Cap - Remove
5-18
4.5 Piston - Remove
When holding the connecting rod with your hand to prevent it from swinging, be very careful, as you may suffer
hand injuries from accidental movement of the connecting rod.
(a) When pulling-out the piston, be careful not to drop the upper connecting rod bearing.
(b) When removing piston, be careful not to damage cylinder liner by connecting rod runout.
(c) When only a few pistons remain in the cylinders, the crankshaft tends to turn by weight imbalance. Be sure to
hold the crankshaft to prevent it from rotating while removing pistons.
(d) Make sure that the connecting rod does not interfere with the piston cooling nozzle when removing the piston.
(e) When pulling the piston out of the cylinder liner, hold the piston by hand so that the piston does not rock.If piston
swings, it can result in piston inner surface hitting the connecting rod, causing damage to the piston.
4.5.1 Removing the Piston With Chain Block Lifting

Eyebolt
(1) Remove the connecting rod cap and rotate the crank- P/N:45815-32301
(M10 × 1.5 mm)
shaft to bring the piston to the top dead center position.
(2) Install the eye bolt to the threaded hole on the piston
top, and support the piston to prevent it from falling
down.
(3) Rotate the crankshaft to place the crank pin slightly
near to the inspection window so that the connecting
Weight of piston and
rod big end does not contact the cylinder liner. connecting rod assembly:
(4) Carefully pull-out the piston by making sure that the Crankpin approx 19.8 kg [43.7 lb]
Removing the Piston With Chain Block Lifting (1)
connecting rod big end slides into the cylinder liner.
Eyebolt
P/N:45815-32201
(M8 × 1.25 mm)
Weight of piston and

connecting rod assembly:
Crankpin approx 19.8 kg [43.7 lb]
Removing the Piston With Chain Block Lifting (2)
5-19
4.5.2 Removing the Piston With Pushing-up the Con-

Eyebolt
necting Rod Big End P/N:45815-32301
(M10 × 1.5 mm)
(1) Remove the connecting rod cap and rotate the crank-
shaft to bring the piston to the top dead center position.
(2) Install the eye bolt to the threaded hole on the piston
top, and support the piston to prevent it from falling
down.
(3) Rotate the crankshaft carefully until the crankpin is dis- Weight of piston and
connecting rod
placed from the connecting rod and the lower bolt hole assembly:
can be seen trough the inspection window. Crankpin approx 19.8 kg [44 lb]
Crankshaft - Rotate (1)
(4) Insert a bar wrapped with cloth, and push up the bottom
of connecting rod carefully, with the crankpin as a ful- Eyebolt
crum. P/N:45815-32201
(M8 × 1.25 mm)
Note: Protect the crankpin and connecting rod big end with
cloth or rubber to prevent them from damage with the
bar.
(5) Push-up the connecting rod and piston while adjusting
the supporting position.
When the oil ring is slid out of the cylinder liner, care- Weight of piston and
connecting rod
fully put the piston on the top face of cylinder liner. assembly:
Crankpin approx 19.8 kg [44 lb]
(6) Lift the piston with eye bolt on the piston top, and pull- Crankshaft - Rotate (2)
out the piston from cylinder liner.
Wrap in cloth
Turning bar
Connecting Rod Big End - Push-Up

4.6 Piston Ring - Remove
Ring expander
P/N : 37191-03200
When removing the piston ring, be careful not to be
pinched your hand between the piston and connecting
rod by piston swing.
A free swing of piston and its bump to connecting rod

may result in piston damage.
Hold the piston and connecting rod in a vise, and remove
the piston rings with ring expander. Piston Ring - Remove
5-20
4.7 Piston Pin and Piston - Remove

(1) Remove the snap ring with ring pliers.
(2) Place a piece of wood to piston pin end and lightly tap
Snap ring
with hammer to remove the piston pin, and separate the
piston from connecting rod.
Note:(a) Do not tap the piston pin directly with hammer.
(b) If the piston is stubborn, heat the piston with heater
or in hot water.
Piston Pin and Piston - Remove

4.8 Cylinder Liner Inside Diameter - Measure
Measure the cylinder liner inside diameter, and know the
current condition. Cylinder liner
For the measurement procedure, refer to "Cylinder Liner
Inside Diameter - Measure" of "ASSEMBLY OF BASIC
ENGINE."

4.9 Cylinder Liner Flange Protrusion - Measure
Measure the cylinder liner flange protrusion, and know the
current condition. Bolt
Liner pusher
For the measurement procedure, refer to "Cylinder Liner
Cylinder liner flange
Flange Protrusion - Measure" of "ASSEMBLY OF BASIC protrusion
ENGINE."

4.10 Cylinder Liner - Remove
(1) Set the cylinder liner remover to the cylinder liner.
Nut
Note: Use care not to hit the piston cooling nozzle when set-
Removing stroke
60 mm [2.36 in.]
ting the remover plate to the bottom of cylinder liner. Cylinder liner
(2) Screw the nuts, and remove the cylinder liner. remover
P/N:32591-14100
Cylinder liner
Cylinder Liner - Remove
5-21
5. Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect

efficient work.
any job.
Crankshaft End Play - Measure
Local contact, crack on counterbore,

fretting/corrosion on fitting bore of
cylinder liner
11
Oil jet pipe bend,
deformation
Replace
Scale deposit, flaw,
crack, oil hole clogging Flaw
2
8
Valve operation, Wear Peeling, wear, contact

7
oil hole clogging 10
9
Inner and outer peripheral
face flaw, corrosion, flaking
6
Wear
Wear, flaw, crack
5
Crack
Flaw
4 1
Inner and outer
peripheral face flaw,
corrosion, flaking
3
Crankcase, Crankshaft and Main Bearing - Disassemble and Inspect

1 Main bearing cap bolt 6 Crankshaft (Approx. 300 kg [661 lb.])
2 Side bolt 7 Upper main bearing
3 Main bearing cap 8 Upper thrust plate
4 Lower main bearing 9 Check valve
5 Lower thrust plate 10 Piston cooling nozzle
11 Crankcase (Approx. 1010 kg [2227 lb.])
5-22
5.1 Crankcase - Turn Over (Upend)

Using a turnover machine, turn over the crankcase.When
the turnover machine is not available, hitch slings to the Weight of crankshaft and
crankcase: 1370 kg
crankcase using wood pieces and cloth pads, and raise the [3020 lb]
crankcase with a hoist or crane. Then lay it on the wooden
block with its side facing downward.Then, change the posi-
tions of the slings, and turn over to upend the crankcase.
Crankcase Wood block
Crankcase - Turn Over (Upend)

5.2 Crankshaft End Play - Measure
Measure the crankshaft end play, and know the current con-
dition.
For the measurement procedure, refer to "Crankshaft End

5.3 Piston Cooling Nozzle - Remove
Remove the piston cooling nozzle from the crankcase.
5.4 Main Bearing Cap - Remove
Nozzle remover
P/N:36291-00900 Main bearing cap bolt
When removing the main bearing cap, be careful not
to damage the main bearing or the thrust plate Main bearing cap
attached to the cap. Also be careful not to drop those
parts from the cap, which may result in crankshaft
damage.
Adapter
(1) Remove the main bearing cap bolts and side bolts. Side bolt
P/N:32591-04300
(2) Install the adapter to main bearing cap.
Install the nozzle remover to adapter.
(3) Remove the main bearing cap from the crankcase. Main Bearing Cap - Remove
(4) Remove the lower main bearing from the main bearing
cap.
(5) Remove the lower thrust plate from the rearmost main
bearing cap.
5-23
5.5 Crankshaft - Remove
(a) Before removing the crankshaft, remove the front

side upper thrust plate first, and be careful not to
drop it into crankcase.
(b) When placing the crankshaft onto a pallet or other
stands, be careful not to damage the crankshaft.
Once placed on a pallet, place some support to
prevent the crankshaft from moving.
(1) Push a mating face of the front upper thrust plate, and
rotate the thrust plate to remove. Crankshaft - Remove
(2) Suspend the crankshaft in a horizontal position, and
slowly lift the crankshaft upward.
Note: Do not hitch a chain directly onto crankshaft, as it
could damage the crankshaft. Place cloth belts or pads
in the positions before lifting crankshaft.
(3) Remove the upper main bearing from crankcase, pay-
ing attention to the lug position, and remove the upper
thrust plate on the rear side.
5-24
1. Cylinder Head and Valve Mechanism - Inspect and Repair................................. 6-3
1.1 Bushing Inside Diameter and Shaft Outside Diameter of Rocker - Measure............................ 6-3
1.2 Rocker Bushing - Replace ........................................................................................................ 6-3
1.3 Valve Stem Outside Diameter and Valve Guide Inside Diameter - Measure ........................... 6-4
1.4 Valve Guide - Replace.............................................................................................................. 6-4
1.5 Valve Face - Inspect ................................................................................................................. 6-5
1.6 Valve Face - Reface ................................................................................................................. 6-5
1.7 Valve Seat - Reface.................................................................................................................. 6-6
1.8 Valve Seat - Replace ................................................................................................................ 6-6
1.9 Valve and Valve Seat - Lap ...................................................................................................... 6-8
1.10 Valve Bridge, Bridge Cap, Valve Cotter and Valve Rotator - Inspect ....................................... 6-8
1.11 Squareness and Free Length of Valve Spring - Measure......................................................... 6-9
1.12 Tappet - Inspect........................................................................................................................ 6-9
1.13 Push rod Runout - Measure...................................................................................................... 6-9
1.14 Nozzle Gland Stud Bolt and Bridge Guide - Inspect and Replace............................................ 6-9
1.15 Distortion of Cylinder Head Bottom Surface - Measure.......................................................... 6-10
1.16 Water Director - Inspect and Replace..................................................................................... 6-10
2. Rear Mechanism - Inspect and Repair................................................................. 6-11
2.1 Idler Bushing Inside Diameter and Idler Shaft Outside Diameter - Measure .......................... 6-11
2.2 Idler Bushing - Replace .......................................................................................................... 6-11
2.3 Cam Lift of Cam Shaft Lobe - Measure .................................................................................. 6-11
2.4 Camshaft Runout - Measure................................................................................................... 6-12
2.5 Camshaft Journal Outside Diameter - Measure ..................................................................... 6-12
2.6 Camshaft Bushing - Inspect.................................................................................................... 6-12
2.7 Camshaft Bushing - Replace .................................................................................................. 6-13
3. Front Mechanism - Inspect and Repair................................................................ 6-14
3.1 Damper - Inspect Visually....................................................................................................... 6-14
3.2 Pulley - Inspect ....................................................................................................................... 6-14
4. Piston and Connecting Rod - Inspect and Repair .............................................. 6-15
4.1 Piston - Inspect Visually.......................................................................................................... 6-15
4.2 Piston Weight ......................................................................................................................... 6-15
4.3 Piston Outside Diameter - Measure........................................................................................ 6-15
4.4 Piston Ring Groove - Inspect.................................................................................................. 6-15
4.5 Piston Pin Bore Inside Diameter - Measure............................................................................ 6-16
4.6 Piston Ring - Inspect Visually ................................................................................................. 6-16
4.7 Piston Ring End Gap - Measure ............................................................................................. 6-16
4.8 Piston Pin Outside Diameter - Measure ................................................................................. 6-16
4.9 Connecting Rod Bushing Inside Diameter - Measure............................................................. 6-17
4.10 Connecting Rod Bushing - Replace........................................................................................ 6-17
4.11 Connecting Rod Assembly Weight Rank................................................................................ 6-20
4.12 Bore Diameter and Roundness of Connecting Rod Big End - Measure................................. 6-20
4.13 Side Face Width of Connecting Rod Big End - Measure........................................................ 6-21
4.14 Connecting Rod Big End Serration and Bolt Holes - Inspect.................................................. 6-21
4.15 Connecting Rod Bearing - Inspect.......................................................................................... 6-21
4.16 Connecting Rod Bearing Thickness - Measure ...................................................................... 6-22
4.17 Connecting Rod Bend and Twist - Inspect ............................................................................. 6-22
6-1
5. Crankcase and Crankshaft - Inspect and Repair ................................................ 6-23

5.1 Crankcase Top Surface Distortion - Measure......................................................................... 6-23
5.2 Inside Diameter of Main Bearing Housing Bore - Measure .................................................... 6-23
5.3 Cylinder Liner Fitting Bore in Crankcase - Inspect ................................................................. 6-24
5.4 Counterbore in Crankcase - Repair ........................................................................................ 6-24
5.5 Crankpin and Journal Outside Diameters - Measure.............................................................. 6-24
5.6 Width of Crankpin and Rearmost Crank Main Journal - Measure .......................................... 6-26
5.7 Crankshaft Runout - Measure................................................................................................. 6-27
5.8 Crankshaft Gear - Inspect....................................................................................................... 6-28
5.9 Crankshaft Gear - Replace ..................................................................................................... 6-28
5.10 Oil Seal Slinger - Inspect ........................................................................................................ 6-29
5.11 Oil Seal Slinger - Replace....................................................................................................... 6-29
5.12 Main Bearing - Inspect............................................................................................................ 6-30
5.13 Thickness of Main Bearing Shell - Measure ........................................................................... 6-30
5.14 Thrust Plate - Inspect.............................................................................................................. 6-30
5.15 Thickness of Thrust Plate - Measure ...................................................................................... 6-31
5.16 Piston Cooling Nozzle - Inspect.............................................................................................. 6-31
6-2
1. Cylinder Head and Valve Mechanism - Inspect and Repair

1.1 Bushing Inside Diameter and Shaft Outside Diameter of Rocker - Measure
Measure the inside diameter of the rocker bushing and the
outside diameter of the rocker shaft.If the measurement Measuring
direction
exceeds the limit, replace the rocker bushing or rocker shaft
Measuring
with a new one. position
Measuring
Nominal
Item Standard value Limit value direction
value
32.055 to
Rocker bushing inside ø32 mm 32.100 mm
32.080 mm
diameter [1.26 in.] [1.50 in.]
[1.26 to 1.26 in.]
31.975 to
Rocker shaft outside ø32 mm 31.991 mm 31.950 mm
diameter [1.26 in.] [1.2588 to [1.2578 in.] Bushing Inside Diameter and Shaft Outside Diameter
1.2594 in.] of Rocker - Measure
1.2 Rocker Bushing - Replace
Removal
If rocker bushing notch is not aligned with center axis
of screw hole, oil will not feed from rocker arm to valve, Rocker bushing puller
P/N:32591-02600
resulting in wear of rocker arm and bridge, or seizure
of valve.
(1) Pull out the rocker bushing using the rocker bushing
Rocker arm
puller.
Rocker bushing
Rocker Bushing - Remove

(2) Install a new rocker bushing using the rocker bushing Bushing inside surface
roughness Turn up
puller. the notch.
Ra0.8μm{ٖ3.2S
ٖٖ
}
Face the cut of the rocker bushing upward, and align
Rocker bushing puller
the position indicated in the right figure. Press fit the P/N:32591-02600
rocker bushing from the chamfered side of the rocker Press-fit it from
chamfered side
bushing hole. Rocker bushing
(3) Make sure the rocker arm is at a specified positional

Press-fit
relationship with respect to the rocker bushing.
(4) Measure the inside diameter of rocker bushing that has Rocker arm
bee installed.
Rocker Bushing - Insert
If the value is smaller than the standard, ream the inside
diameter to the standard. Rocker bushing
notch Oil hole Rocker arm
Rocker bushing 8q
3 °
joint
Inner peripheral groove

Rocker bushing
Press-fit so that the rocker bushing notch is aligned
parallel to the center axis of screw hole.
Rocker Bushing - Position
6-3
1.3 Valve Stem Outside Diameter and Valve Guide Inside Diameter - Measure
Measure the outside diameter of valve stem and the inside
diameter of valve guide at the top and bottom sliding ends in Measurement
direction
right-angle directions as shown, as the sliding surface tends
to wear at the top and bottom ends.If the measurement
exceeds the limit, replace the valve guide or valve with a
new one.
Note: Lap the valve and valve seat whenever new valve is in- Measurement
point
stalled.
Nominal Standard
Item Limit value
value value Valve Stem Outside Diameter - Measure
9.940 to
ø10 mm 9.960 mm 9.910 mm
Inlet
[0.39 in.] [0.0010 to [0.3902 in.] Measurement
Valve stem 0.0044 in.] direction
outside diam-
eter 9.910 to
ø10 mm 9.930 mm 9.880 mm Measurement
Exhaust point
[0.39 in.] [0.3902 to [0.3890 in.]
0.3909 in.]
10.000 to
Valve guide inside diam- ø10 mm 10.015 mm 10.060 mm
eter [0.39 in.] [0.3937 to [0.3961 in.]
0.3943 in.]
Valve Guide Inside Diameter - Measure

1.4 Valve Guide - Replace
Valve guide
Be sure to use the guide and seal installer, and press- remover
P/N:36291-04200
in the valve guide to the specified height.
(1) Remove the valve guide with valve guide remover.
Valve Guide - Remove

(2) With guide and seal installer, press-in the new valve
guide slowly.
Guide & seal installer
P/N:32591-10300
Valve guide
27.5 ± 0.1 mm
[1.083 ± 0.004 in.] Cylinder head
Valve Guide - Press-In
6-4
1.5 Valve Face - Inspect

Inspect the valve face after the valve guide is inspected or
replaced.Lap the valve and valve seat whenever valve is Seat width
refaced or replaced.
Valve seat angle

Valve margin
Valve sinkage
Valve Face - Inspect

1.5.1 Valve Margin - Inspect
Measure the valve margin.If the value exceeds the limit,
reface or replace the valve with a new one.
1.5.2 Seat Width - Inspect
Apply a thin lead-free coloring paste on the valve face, and
Valve lapper
tap the valve face against valve seat with valve lapper to P/N:30091-08800
check the contact condition.If the contact is not even, or any
defects are found, or if the value exceeds the specified limit,
Lapping
reface or replace the valve or valve seat. compound
Note: Do not rotate the valve when pressing valve face coat-
ed with lead-free coloring paste against valve seat.

Valve seat angle 30° - Seat Width - Inspect
1.98 to 2.18 mm 2.5 mm
Valve Inlet
Seat [0.0780 to 0.0858 in.] [0.098 in.]
seat
width 1.75 to 1.95 mm 2.3 mm
Exhaust
[0.0689 to 0.0768 in.] [0.09 in.]
2.7 to 3.1 mm
Inlet
[0.1063 to 0.1220 in.] 2.0 mm
Valve margin
2.8 to 3.2 mm [0.078 in.]
Exhaust
[0.1102 to 0.1260 in.]
Good Bad
Contact condition between valve seat and valve

1.6 Valve Face - Reface
When the valve is re-used by refacing, use valve refacer.
Note:(a) Grind the valve face with valve refacer adjusted to Valve refacer
the specified angle.

(b) The valve margin is to be within the specified lim-
it.If the dimensions after refacing does not meet the
specified values, replace the valve with a new one.
Grind valve face
at specified angles.
Valve Face - Reface
6-5
1.7 Valve Seat - Reface

If any damage or inclusions are found, grind the sheet face.
(1) Reface the valve seat with valve seat cutter or valve
seat grinder.After refacing, insert sand paper of approx Socket
(width across flats
400 grit between cutter and valve, and grind valve seat 32 mm [1.26 in.])
lightly.
Valve seat cutter
If the seat width exceeds the standard, grind the valve P/N:37591-06400
37591-06430
inner seat with 44°50′ valve seat cutter.
(2) Lap the valve and valve seat.
Note:(a) Valve seat refacing depth is to be minimal.
(b) If the seat width cannot be repaired to the standard
Valve Seat - Reface
value, or line contact on valve seat outer periphery
is shown, replace the valve seat with a new one.
(c) If the valve sinkage exceeds the specified limit after
refacing, replace the valve seat with a new one.
1.8 Valve Seat - Replace
Select the valve seat with appropriate interfer-

ence.Improper interference can result in dropping out
of valve seat or crack on cylinder head.
Be careful not to damage the machined surface of cylinder
head when removing the valve seat.
1.8.1 Valve Seat - Remove (With Valve Seat Puller)
Remove the valve seat with valve seat puller. Valve seat puller
P/N:32591-04200
Valve Seat - Remove (With Valve Seat Puller)

1.8.2 Valve Seat - Remove (by Welding)
To remove the valve seat, weld a stud to valve seat as
shown. Then, insert a shaft into valve guide hole from the Welding
Shaft
top of cylinder head, and punch out the valve seat with
shaft. Valve seat
Note: Be careful not to allow spatters to adhere to the ma-
chined surface of the cylinder head during welding.
Stud, etc.
Valve Seat - Remove (by Welding)
6-6
1.8.3 Valve Seat - Install
[0.472+0.004 ]
(1) Before installing the valve seat, measure the inside
0
diameter of valve seat counterbore in cylinder head and
12+0.1
the outside diameter of valve seat to make sure that the
0
9 [0.35]
interference is within the range of standard value.If the
3 [0.118]
value exceeds the standard, use the oversize valve
seat.If the inside diameter of valve seat counterbore in
cylinder head exceeds the limit, replace the cylinder 60°± 15' Valve seat fitting
bore inside diameter
head with a new one.
Valve seat
Note: Oversized valve seats are available in 0.03 and 0.06 outside diameter Unit: mm [in.]
Valve seat counterbore
mm [0.0012, 0.0024 in.] sizes.

58.000 to 58.030 mm 58.09 mm
Inside diameter of valve seat counterbore
[2.2835 to 2.2846 in.] [2.2870 in.]
58.100 to 58.130 mm
Standard - Single red line
[2.2874 to 2.2886 in.]
Inlet
Valve seat outside diame- 0.03 mm 58.130 to 58.160 mm
- Double red lines
ter [0.0012 in.] [2.2886 to 2.2898 in.]
0.06 mm 58.160 to 58.190 mm
- Triple red lines
[0.0024 in.] [2.2898 to 2.2909 in.]
54.000 to 54.030 mm 54.09 mm
Inside diameter of valve seat counterbore
[2.1260 to 2.1272 in.] [2.1295 in.]
54.100 to 54.130 mm
Standard - Double blue lines
[2.1299 to 2.1311 in.]
Exhaust
Valve seat outside diame- 0.03 mm 54.130 to 54.160 mm
- Triple blue lines
ter [0.0012 in.] [2.1311 to 2.1323 in.]
0.06 mm 54.160 to 54.190 mm
- Four blue lines
[0.0024 in.] [2.1323 to 2.1335 in.]
0.070 to 0.130 mm
Valve seat interference -
[0.0028 to 0.0051 in.]
Inside diameter of valve seat counterbore Applicable valve seat

58.030 mm [2.2846 in.] or less Standard
Inlet 58.030 [2.2846 in.] or more 0.03 mm [0.0012 in.]
58.060 [2.2858 in.] or more 0.06 mm [0.0024 in.]
54.030 mm [2.1272 in.] or less Standard
Exhaust 54.030 [2.1272 in.] or more 0.03 mm [0.0012 in.]
58.060 [2.1283 in.] or more 0.06 mm [0.0024 in.]
(2) Cool the valve seat at least for 4 minutes in liquid nitro-
Valve seat caulking tool
gen and cool the cylinder head to a room temperature.
P/N:35A91-05010(Inlet)
(3) Install the valve seat into the cylinder head with valve 35A91-05020(Exhaust)
seat caulking tool.
Valve Seat - Install
6-7
1.9 Valve and Valve Seat - Lap

Lap the valve and valve seat whenever valve seat is refaced
or valve is replaced, or the contact surfaces fail to keep a
pressure in the pressure test after assembling.
(1) Apply a thin coat of lapping compound evenly to the
valve face.
Note:(a) Do not allow the compound to adhere to the valve
stem.
Compound
(b) Compound spreads more evenly when it is mixed
with a small amount of engine oil.
(c) Use medium-grain compound (125 to 150 mesh)
Compound - Apply
for initial lapping, then use fine-grain compound
(200 mesh) for finishing.
Valve lapper
(2) Use a valve lapper for lapping. P/N:30091-08800
Tap the valve against valve seat while rotating the valve
little by little.
(3) Clean off the compound using diesel oil.
(4) Apply engine oil to the contact surface of valve, and
finish the lapping.
(5) Apply a thin lead-free coloring paste on the valve face,
and tap the valve face against the valve seat using a
valve lapper to check for contact condition. Valve and Valve Seat - Lap
1.10 Valve Bridge, Bridge Cap, Valve Cotter and Valve Rotator - Inspect
(1) Inspect the contact surfaces between valve bridge and
Bridge cap
valve stem, and the sliding surface between valve
Bridge guide
bridge and bridge guide. If significant wear or uneven Valve bridge
contact is found, replace them with new ones. Valve stem Valve rotator
(2) Check the bridge cap for wear. If significant wear is
Valve cotter
found, replace the bridge cap with a new one.
(3) Check the valve rotator for rotation. If any defect is
found, replace the valve rotator with a new one.
(4) Inspect the contact surfaces between valve cotter and
valve stem, and valve cotter and valve rotator. If signif-
Valve Bridge, Bridge Cap, Valve Cotter and Valve
icant uneven wear or dent is found, replace them with
Rotator - Inspect
new ones.
6-8
1.11 Squareness and Free Length of Valve Spring - Measure

Measure the squareness and free length of valve spring.The
free length or squareness exceeds the specified limit, Spring squareness
replace a valve spring with a new one.
Nominal Standard value

Limit value
value
66.2 mm
Free length 67.5 mm [2.66 in.]
[2.61 in.] Free length
A At full
B A=1.5°
length
Squareness B=1.76 mm [0.069 in.]
Lf B= 2.3 mm
Lf=67.5 mm [2.66 in.]
[0.09 in.]
Squareness and Free Length of Spring - Measure
60.0 mm [2.36 in.]/259 to 286 N
Set length /
{26.41 to 29.16 kgf} [375.64 to 414.75 -
load
psi]
1.12 Tappet - Inspect

Inspect the tappet sliding face to cam for even wear.If the
surface is defective, replace the tappet with a new one. Flaw, local wear
Flaw, local wear
Good Bad Bad
Tappet Sliding Face to Cam - Inspect

1.13 Push rod Runout - Measure
Measure the runout of push rod at TIR.If the runout exceeds
the standard, replace the push rod with a new one.

Push rod runout 0.50 mm [0.020 in.] or less TIR V-block　
Push rod
1/2 1/2
Surface plate
Push rod Runout - Measure

1.14 Nozzle Gland Stud Bolt and Bridge Guide - Inspect and Replace
Inspect the nozzle gland stud bolt for bending or damage at
threaded portion.
Bridge guide
Inspect the bridge guide for uneven wear and damage on the Approx.84 mm
[3.31 in.]
sliding surface.
(48 mm 37 mm
1.14.1 Nozzle Gland Stud - Install Nozzle ground [1.89 in.]) [1.46 in.]
Tighten the nozzle gland stud bolt until it comes to the bot- stud
tom end.
1.14.2 Bridge Guide - Install
Press-in the bridge guide to the specified dimension.
Nozzle Gland Stud Bolt and Bridge Guide -

Install
6-9
1.15 Distortion of Cylinder Head Bottom Surface - Measure
Refacing depth of cylinder head is to be mini-

mum.Excessive grinding of the cylinder head may
result in defects such as contact between piston and
valve.
With a straight edge placed on the bottom face of cylinder
head, measure the bottom face distortion with thickness
gauges.If the value exceeds the limit, replace the cylinder
Cylinder head
head with a new one, or repair by grinding.
Distortion of Cylinder Head Bottom Surface - Measure
After grinding, record the maximum depth of grinding.The
maximum amount of total grinding, which includes both Cylinder head top face
roughness:
grinding amount of the top of crankcase and the bottom of 134.9 to 135.1 mm
Ra 3.2 μ m{12.5S
ٖٖٖ
} [5.311 to 5.319 in.]
cylinder head, must be 0.50 mm [0.020 in.] or less.

Distortion of cylinder head 0.03 mm 0.07 mm
bottom surface [0.0012 in.] or less [0.0028 in.]
The height of cylinder head 134.9 to 135.1 mm
-
(reference value) [5.31 to 5.32 in.]
Height of cylinder head - Measure

1.16 Water Director - Inspect and Replace
(1) Inspect the water director, and if corrosion or damage is
found, replace the water director with a new one. Water director
(2) Orient the pipe and the opening of the water director as
shown in the illustration, and tap the water director
lightly.
A 35° B B
1.0 mm 1.0 mm [0.039 in.]

[0.039 in.]
Section AA Section BB
Water director mounting direction
6-10
2. Rear Mechanism - Inspect and Repair

2.1 Idler Bushing Inside Diameter and Idler Shaft Outside Diameter - Measure
Measure the idler bushing inside diameter and the idler shaft
outside diameter.If the value exceeds the limit, replace the Measurement
idler gear assembly or the idler shaft with a new one. direction
Measurement
Note: After replacing idler bushing, finish the bushing inside point
diameter by reaming.
Nominal Measurement
value direction
Idler bushing ø50 mm 50.000 to 50.025 mm 50.060 mm
inside diameter [1.97 in.] [1.9685 to 1.9695 in.] [1.9708 in.]
Idler shaft out- ø50 mm 49.950 to 49.975 mm 49.900 mm
side diameter [1.97 in.] [1.9665 to 1.9675 in.] [1.9646 in.] Idler Bushing Inside Diameter and Idler Shaft Outside
Diameter - Measure
2.2 Idler Bushing - Replace

(1) Using the removing side of the idler bushing puller,
Idler bushing inner face
remove the idler bushing. roughness:
Ra 0.8μm{ 3.2S } Idler bushing puller
(2) Using the installing side of the idler push puller, press- P/N:32591-02500
fit the idler bushing from the large gear side until it
becomes flush with the end face of gear boss. Idler bushing B
(3) After installing, ream the bore of idler bushing to the ▲
specified dimension shown.
Note: Reaming after press-fit is necessary, as the idler bush-
A
▲
ings are supplied in a semi-finished condition.
[0.16 in.]
4 mm
Idler gear
Ra 0.8μm
▽▽▽
3.2S
ø0.05 S A
ø0.05 S B
Φ50H7( +0.025
0 )mm
Idler Bushing - Replace

2.3 Cam Lift of Cam Shaft Lobe - Measure
Measure the major diameter and minor diameter of cam
lobe to know the cam lift.If the value exceeds the limit,
replace the camshaft with a new one.
Major axis
Cam lift of camshaft 7.71 to 7.76 mm 6.79 mm
(major diam - minor diam) [0.3035 to 0.3055 in.] [0.267 in.]
Minor axis
Cam Lift of Cam Shaft Lobe - Measure
6-11
2.4 Camshaft Runout - Measure

Measure the runout of camshaft at TIR.If the value exceeds
the limit, correct the camshaft using a press, or replace the
V-block
camshaft with a new one.
Note: With a dial gauge set on the camshaft, rotate the cam-
shaft one turn and read the gauge indication.
Item Standard value Limit value Remarks Surface plate

0.05 mm 0.08 mm 1/2 1/2
Camshaft runout TIR
[0.0020 in.] or less [0.0031 in.]
Camshaft Runout - Measure

2.5 Camshaft Journal Outside Diameter - Measure
Measure the diameter of each camshaft journal in two direc-
tions at right angles to each other.If the value exceeds the
limit, replace the camshaft with a new one.
Nominal Standard
Item Limit value
value value
63.920 to Measurement
ø64 mm 63.940 mm 63.870 mm direction
No. 1 journal
[2.52 in.] [2.5165 to [2.5146 in.]
Camshaft 2.5173 in.]
Journal
diameter 67.920 to
No. 2 to No. 7 ø68 mm 67.940 mm 67.870 mm
journal [2.68 in.] [2.6740 to [2.6720 in.]
2.6748 in.] Camshaft Journal Outside Diameter - Measure
2.6 Camshaft Bushing - Inspect
(1) Check the inside surface of each bushing for damage,
corrosion, flaking and other abnormalities. If any defect
is found, replace the camshaft bushing with a new one.
(2) Measure the camshaft bushing inside diameter with
bushing installed in the crankcase.If the value exceeds
the limit, replace the camshaft bushing with a new one.
Note: Be careful not to damage the inner surface of camshaft
bushing when measuring the inside diameter.
Nomi-
Measuring direction
Standard
Item nal Limit value
value
value Camshaft Bushing Inside Diameter - Measure
64.000 to
ø64 mm 64.030 mm 64.090 mm
No. 1 journal
[2.52 in.] [2.5197 to [2.5232 in.]
Camshaft 2.5209 in.]
bushing inside
diameter 68.000 to
No. 2 to No. 7 ø68 mm 68.030 mm 68.090 mm
journal [2.68 in.] [2.6772 to [2.6807 in.]
2.6783 in.]
6-12
2.7 Camshaft Bushing - Replace
Before tightening the set bolt, be sure to check that

the set bolt is in alignment with the set bolt hole in the
Engine
camshaft bushing. front
Make sure that the oil hole in the camshaft bushing is
in alignment with the oil hole from the oil gallery. Set bolt
(1) Remove the camshaft bushing set bolt and remove the Oil hole
Set bolt hole
camshaft bushing.
(2) Before inserting the camshaft bushing to the bushing Camshaft bushing
hole on the crankcase, be sure to check that the oil hole Camshaft Bushing - Install
and set bolt hole.
(3) Before securing the set bolt, be sure to check that the
set bolt is in alignment with the oil hole.
6-13
3. Front Mechanism - Inspect and Repair

3.1 Damper - Inspect Visually
Check the damper for cracks around outer periphery, swell-
ing in end plate, silicone oil leakage, and discoloration and
separation of coating due to overheating.If any defect is
found, replace the damper with a new one.
Damper - Inspect Visually

3.2 Pulley - Inspect
Check the belt groove of pulley for wear.
(1) Check the sinkage of belt.
(2) Fit a new belt tightly in pulley groove.
(3) If the belt sinks 1.6 mm [0.063 in.] or more below pul-
1.6 mm [0.063 in.]
ley rim, replace the pulley with a new one.
or less
Pulley Wear - Inspect
6-14
4. Piston and Connecting Rod - Inspect and Repair

4.1 Piston - Inspect Visually
Check the combustion surface, piston pin bore, ring groove,
sliding surface and bottom surface of piston. If any defect
are found, replace the piston with a new one.
Piston - Inspect Visually

4.2 Piston Weight
Check the piston weight on the top face of piston.
Piston weight mark Engine front
When replacing pistons, be sure that the weight difference direction mark
per engine is within permissible range. [F]
Com-
pres-
Item Part No. ID stamp Standard value
sion ( (
ratio
32517-91101 91101 14 Within ±15 g
Piston
32617-00701 00701 15 [0.53 oz]
weight
differ- 32517-91201 91201 14 Within 20 g Part number (last 5 digits)
ence
32617-00600 00600 15 [0.71 oz]
Piston weight punch mark
4.3 Piston Outside Diameter - Measure
Measure the piston outside diameter of piston skirt at right
[1.18 in.]
30 mm
angle to piston pin.If the value exceeds the limit, replace the
piston with a new one.
Measurement
Nominal Standard point
Item Limit value
value value
149.71 to
Piston outside ø150 mm 149.75 mm 149.68 mm
diameter [5.9 in.] [5.8941 to [5.8929 in.]
5.8957 in.]
Piston Outside Diameter - Measure

4.4 Piston Ring Groove - Inspect
Remove carbon deposits from piston and inspect the Ring carrier
entire circumference of piston.
No.1 compression ring
(1) Remove all deposits such as carbon from each ring groove
groove.
No.2 compression ring
(2) Visually check each ring groove for wear or damage. If groove
faulty, replace the piston with a new one.Inspect the
Oil ring groove
ring insert of No. 1 compression ring groove by dye
penetration test for cracks and separation.
Piston Ring Groove - Inspect
6-15
4.5 Piston Pin Bore Inside Diameter - Measure

Measure the piston pin bore inside diameter.If the value
exceeds the limit, replace the piston with a new one.
Nominal
value
Piston pin bore ø58 mm 58.002 to 58.012 mm 58.040 mm Measurement
inside diameter [2.28 in.] [2.2835 to 2.2839 in.] [2.2850 in.] direction Measurement
point
Piston Pin Bore Inside Diameter - Measure

4.6 Piston Ring - Inspect Visually
Check the sliding surface and top and bottom surfaces for
seizing, abnormal wear, foreign material inclusion and plat-
ing flaking.If any defects are found, replace the piston rings
with new ones.
4.7 Piston Ring End Gap - Measure
Place the piston ring in the gauge or a new cylinder liner,
and measure the end gap.If the value exceeds the limit,
replace piston rings with a new set of rings. Thickness gauge
Note: Using a piston, push the piston ring squarely into
gauge or cylinder liner.

No.1 0.6 to 0.8 mm
compression [0.024 to 0.032 in.]
Piston ring No.2 0.5 to 0.7 mm 2.0 mm Gauge diameter:
end gap compression [0.020 to 0.028 in.] [0.078 in.] 150 ± 0 mm [5.91 ± 0 in.] End gap
0.5 to 0.7 mm Piston Ring End Gap - Measure
Oil
[0.020 to 0.028 in.]
4.8 Piston Pin Outside Diameter - Measure

Measure the piston pin outside diameter.
Measurement
If the value exceeds the limit, replace the piston pin with a direction
new one.
Nominal
value
Piston pin out- ø58 mm 57.987 to 58.000 mm 57.970 mm
side diameter [2.28 in.] [2.2830 to 2.2834 in.] [2.2823 in.]
Measurement
point
Piston Pin Outside Diameter - Measure
6-16
4.9 Connecting Rod Bushing Inside Diameter - Measure

Measure the inside diameter of the connecting rod bushing.
If the value exceed the limit, replace the connecting rod Measurement
direction
bushing with a new one.
Measurement
Nominal point
value
Inside diameter
ø58 mm 58.020 to 58.040 mm 58.070 mm
of connecting rod
[2.28 in.] [2.2843 to 2.2850 in.] [2.2862 in.]
bushing
Connecting Rod Bushing Inside Diameter - Measure

4.10 Connecting Rod Bushing - Replace
Using the connecting rod bushing installer, replace the con-
necting rod bushing.
4.10.1 Installer Base and Connecting Rod -
Connecting rod bushing installer
Fix P/N:32591-18010
Base match mark
(1) Align the match mark on base with match mark on Base match mark
(red line mark) (red ø4 mm [0.16 in.])
plate, and install the plate.
(2) Align the match mark on the adapter with the match
mark on the base, and install the adapter.
Adapter Plate
Adapter match mark Base Plate match mark
(red line mark) (red ø4 mm [0.16 in.])
Connecting Rod Bushing Installer - Use (1)
(3) With the connecting rod bearing removed from the con-
Connecting rod cap
necting rod, install the connecting rod cap to plate. Connecting rod Plate
(4) Align the match mark, and install the connecting rod to
plate.
(5) Tighten the connecting rod bolts to the specified torque.
(6) Fix the connecting rod in place with bracket.
Base
Adapter Bracket Mark on the plate
Oil hole of connecting rod
6-17
4.10.2 Connecting Rod Bushing - Remove

(1) Apply engine oil to inner surface of connecting rod
bushing.
(2) Attach the collar A to the mandrel and insert the assem-
Mark on collar A Mandrel
bly into the connecting rod bushing while aligning the (red stamp mark)
match mark (red scribed line) on the collar A with that
Collar A
on the adapter.
(3) With pressing machine, apply pressure slowly on man-
drel head to push-out the connecting rod bushing.
Connecting rod
bushing
Mark on adapter
(red stamp mark)
Adapter
Base
6-18
4.10.3 Connecting Rod Bushing - Press-In
(a) Make sure that the match marks (red lines) on col- Connecting rod bushing
oil hole
lars A and B are align.
(b) Make sure that the oil hole of connecting rod
Collar A
bushing is in alignment with match mark (red ø4 match mark
(ø4 mm [0.16 in.] red)
mm [0.16 in.]) on collar A.
(1) Align the oil hole with match mark on collar A (ø4 mm
[0.16 in.] red), and install a new connecting rod bushing
on collar A. Connecting Rod Bushing Installer - Use (4)
(2) Install the combination of collar A and collar B to man-
drel, and fix them with nut.
Mandrel
Mark on collar A and B
(red stamp marks)
Collar B
Connecting rod
bushing
Nut Collar A
Mark on adapter
(red stamp marks)
Adapter
Base
(3) Apply engine oil to outer surface of connecting rod
Collar A match mark
bushing. Align the match mark (red line) on collar A (ø4 mm [0.16 in.] red) Connecting rod oil hole
with mark of collar B to align the oil hole of connecting
rod bushing and oil hole of connecting rod. Press-in the
bushing into connecting rod with pressing machine.
Connecting rod
oil hole
6-19
(4) Measure the inside diameter of the connecting rod

Bushing inner surface
bushing. roughness Inside diameter of
1.6S
If the value is out of the standard, ream the inside diam- Ra0.4μm ]_
ٖٖٖ connecting rod bushing
eter to the standard. Connecting rod
bushing
Item Standard value
Inside diameter of connecting rod bush- 58.020 to 58.040 mm
ing [2.2843 to 2.2850 in.]
Connecting rod
Connecting Rod Bushing Inside Diameter - Measure
4.11 Connecting Rod Assembly Weight Rank
When replacing a connecting rod, be sure to check the
weight rank of the connecting rod, and use the connecting
rod having the same weight rank mark. All the connecting
rods in one engine must have the same weight rank mark.
Weight rank list

Allowable
Part No. Weight rank Weight
value
7100 g
32619-81110 A
[250 oz.]
Weight rank mark location
7200 g
32619-81210 B
[254 oz.]
Connecting Rod Weight Rank Mark Location
7300 g
32619-81310 C
[257 oz.]
7400 g
32619-81410 D
[261 oz.] ±20g
7500 g [0.71 oz.]
32619-81510 E
[264 oz.]
7600 g
32619-81610 F
[268 oz.]
7700 g
32619-81710 G
[271 oz.]
7800 g
32619-81810 H
[275 oz.]
Note: The weight rank of connecting rod assembled in en-

gine is also stamped on caution plate.
4.12 Bore Diameter and Roundness of Connecting Rod Big End - Measure
Measure the connecting rod bore diameter at front and rear
ends respectively in the directions A, B and C as shown in
illustration.The roundness is determined by subtracting the A
B
minimum value from the maximum value among measure-
ments of A, B and C. C Front Rear
If the value exceeds the limit, replace the connecting rod

with a new one. Measurement
Measurement
point
direction
Nominal Standard Round-
Item Limit value
value value ness limit
Minimum:
Connecting 110.000 to 109.950 mm Connecting Rod Big End Bore Diameter - Measure
rod big end ø110 mm 110.022 mm [4.3287 in.] 0.100 mm
bore diame- [4.33 in.] [4.3307 to Maximum: [0.0039 in.]
ter 4.3316 in.] 110.050 mm
[4.3327 in.]
6-20
4.13 Side Face Width of Connecting Rod Big End - Measure

(1) Inspect the side face of connecting rod big end visu-
ally.If there is any defect such as wear or flaw, replace
the connecting rod with a new one.
(2) Measure the side face width of connecting rod big Connecting rod big end side face (width)
end.If the measured value does not meet the standard,
replace the connecting rod with a new one.
Item Standard value

53.7 to 53.8 mm [2.11
Side face width of connecting rod big end
to 2.12 in.]
Side Face Width of Connecting Rod Big End -

Measure
4.14 Connecting Rod Big End Serration and Bolt Holes - Inspect
Inspect the connecting rod big end serration and bolt holes
with magnetic particle inspection. If there is any defect such
as cracks, fretting and foreign material inclusion, replace the
connecting rod with a new one.
4.15 Connecting Rod Bearing - Inspect
Inspect the sliding surface, back surface and end surface of
connecting rod bearing. If there is any defect such as local
contact, sliding scratches, corrosion and foreign material
inclusion, replace the bearing with a new one.
Scratches
Peeling
Seizure
End face
Connecting Rod Bearing - Inspect
6-21
4.16 Connecting Rod Bearing Thickness - Measure

Measure the thickness of connecting rod at its center.
If the value exceeds the limit, replace both upper and lower
connecting rod bearing shells with new ones as a set.When Measurement
the crankshaft is re-ground due to wear of crank pin, use the at the center
of bearing
undersize bearing.
For the crankshaft grinding procedure, refer to "Crankpin
and Crank Journal - Grind" of "INSPECTION AND
REPAIR OF BASIC ENGINE."
Note: Replacement shells for undersized connecting rod
bearing are available in sizes of 0.25, 0.50, 0.75 and
Bearing thickness - Measure
1.00 mm [0.0098, 0.0197, 0.0295 and 0.0394 in.]
Nominal
Item Size Standard value Limit value
value
3.000 mm 2.987 to 3.000 mm 2.950 mm
Standard
[0.1181 in.] [0.1176 to 0.1181 in.] [0.1161 in.]
0.25 mm 3.125 mm 3.112 to 3.125 mm 3.075 mm
[0.0098 in.] [0.1230 in.] [0.1225 to 0.1230 in.] [0.1211 in.]
Connecting rod bearing 0.50 mm 3.250 mm 3.237 to 3.250 mm 3.200 mm
thickness Under [0.0197 in.] [0.1280 in.] [0.1274 to 0.1279 in.] [0.1260 in.]
size 0.75 mm 3.375 mm 3.362 to 3.375 mm 3.325 mm
[0.0295 in.] [0.1329 in.] [0.1324 to 0.1329 in.] [0.1309 in.]
1.00 mm 3.500 mm 3.487 to 3.500 mm 3.450 mm
[0.0394 in.] [0.1378 in.] [0.1373 to 0.1378 in.] [0.1358 in.]
4.17 Connecting Rod Bend and Twist - Inspect

(1) Measure the dimensions of C and L as shown in illus-
tration to check the bend and twist of connecting C C 0.05 [ 0.0020 ]
L 100 3.94
rod.Straighten the connecting rod with a press so that L C 0.05 [ 0.0020 ]
the measurement value meets the standard. Piston pin L 100 3.94 L
If the value exceeds the limit, replace the connecting
C
rod with a new one.
Note: Tighten the connecting rod cap to the specified torque Connecting rod bend Connecting rod twist
Torque
and check the bend and twist.
343 ± 17.7 N·m
(2) To inspect the connecting rod with the piston installed, {35 ± 1.8 kgf·m} [253 ± 13.0 lbf·ft]
turn the piston upside down and place it on a surface 2-Step tightening [wet] Unit: mm [in.]
Connecting Rod Bend and Twist - Inspect
plate. Insert a round bar having the same diameter as
the crankpin into the big-end bore, and measure the D Unit: mm [in.]
height of the bar with dial gauge.
C
Item Standard value
Connecting rod bend and twist 0.05/100 mm
C 0.05 [0.0020]
(C/L, C/D) [0.0020/3.94 in.] or less
D 100 [3.94]
Surface plate
Deflection of Connecting Rod - Measure
6-22
5. Crankcase and Crankshaft - Inspect and Repair

5.1 Crankcase Top Surface Distortion - Measure
Refacing depth of crankcase is to be minimum.

Excessive grinding of the crankcase may result in
defects such as defective combustion and stamping
between piston and valve.
Apply a straight edge to the top surface of the crankcase and
measure its distortion with thickness gauges.If the value
exceeds the limit, replace the cylinder head with a new one,
or repair by grinding. Straight edge
After grinding, record the maximum depth of grinding.Note Crankcase Top Surface Distortion - Measure
that the total grinding amount, which includes the grinding Crankcase top face roughness:
depth of bottom surface of cylinder head, must be 0.50 mm Ra 1.6 μ m{ٖٖٖ}
[0.020 in.] or less.
Standard
Item Limit value
value
0.1 mm 0.20 mm
Crankcase top surface distortion
[0.004] or less [0.0079 in.] 468.95 to
Height From the Crank Journal 468.95 to 469.05 mm
Center to crankcase Top Surface 469.05 mm [18.4626 to
- 18.4665 in.]
(Reference value) [18.462 to
18.466 in.]
From the center of crank journal to the top of
crankcase
5.2 Inside Diameter of Main Bearing Housing Bore - Measure
(1) Assemble the main bearing cap in crankcase in accor-
588 ± 29 N·m
dance with the specified method. {60 ± 3.0 kgf·m}
[434 ± 21.4 lbf·ft]
Note: For tightening procedure for main bearing cap, refer to
[Wet]
"Main bearing cap - Install" of "ASSEMBLY OF BA-
SIC ENGINE."
(2) Measure the housing diameter in vertical and two diag-
onal directions.
147 ± 7.4 N·m ]

Nominal Standard
Item Limit value {15 ± 0.75 kgf·m}
value value
[Wet] [108 ± 5.46 lbf·ft]
137.000 to
Inside diameter of main ø137 mm 137.025 mm 137.045 mm Inside Diameter of Main Bearing Housing Bore -
bearing bore [5.39 in.] [5.3935 to [5.3953 in.] Measure
5.3945 in.]
6-23
5.3 Cylinder Liner Fitting Bore in Crankcase - Inspect

(1) Inspect the counterbore in crankcase. Check for cracks
Fitting bore of cylinder liner Counterbore in crankcase
in edges, uneven contact between counterbore and bot- in crankcase
tom face of cylinder liner flange.If any defect is found,
reface the counterbore in crankcase.
(2) Inspect the cylinder liner fitting section in crankcase.
Check for the defects such as fretting and corrosion.
Cylinder Liner Fitting Bore in Crankcase - Inspect

5.4 Counterbore in Crankcase - Repair
If local contact is shown on counterbore in crankcase, grind
Grinder
and repair.Grind the counterbore with crankcase grinder to
correct the difference in depth at four directions in circum-
ference to be less than 0.05 mm [0.0020 in.]
After the grinding of counterbore in crankcase is completed,
measure the cylinder liner flange protrusion.
Crankcase grinder Crankcase

P/N:32591-04050 counterbore
Counterbore in Crankcase - Repair

5.5 Crankpin and Journal Outside Diameters - Measure
(1) Measure the outside diameter of crankpins and crank
Measurement
journals. point
If the value exceeds the limit, use the undersize bearing,
and grind the crankshaft to fit the undersize bearing.If
the value exceeds the limit even when the -1.00 mm [-
0.0394 in.] undersize bearing is used, replace the crank-
Measurement
shaft with a new one. direction
(2) know the roundness and cylindricity based on measured

values.
Crankpin Outside Diameter - Measure
6-24
5.5.1 Crankpin and Crank Journal - Grind

When using the undersize bearing, grind to the standard
value corresponding to undersize bearing to be used.Do not
change the fillet radius and bearing journal width when
grinding.If a remarkable decrease in hardness is found,
quench the crankshaft again and inspect it with the magnetic Measurement Measurement
direction point
particle inspection.
After grinding, measure the width of crankpin journals and
rearmost crank main journal.
Crank Journal Outside Diameter - Measure
Nominal Size
value
103.900 to 103.920 mm 103.860 mm
Standard
[4.0904 to 4.0912 in.] [0.019 in.]
0.25 mm 103.650 to 103.670 mm 103.610 mm
[0.0098 in.] [4.0806 to 4.0814 in.] [4.0790 in.]
ø104 mm 0.50 mm 103.400 to 103.420 mm 103.360 mm
Crankpin outside diameter
[4.09 in.] Under [0.0197 in.] [4.0708 to 4.0716 in.] [4.0692 in.]
size 0.75 mm 103.150 to 103.170 mm 103.110 mm
[0.0295 in.] [4.0609 to 4.0617 in.] [4.0593 in.]
1.00 mm 102.900 to 102.920 mm 102.860 mm
[0.0394 in.] [4.0511 to 4.0519 in.] [4.0495 in.]
129.880 to 129.900 mm 129.840 mm
Standard
[5.1133 to 5.1140 in.] [5.1117 in.]
0.25 mm 129.630 to 129.650 mm 129.590 mm
[0.0098 in.] [5.1034 to 5.1042 in.] [5.1018 in.]
Crankshaft main journal outside diame- ø130 mm 0.50 mm 129.380 to 129.400 mm 129.340 mm
ter [5.1180 in.] Under [0.0197 in.] [5.0936 to 5.0944 in.] [5.0920 in.]
size 0.75 mm 129.130 to 129.150 mm 129.090 mm
[0.0295 in.] [5.0837 to 5.0845 in.] [5.0822 in.]
1.00 mm 128.880 to 128.900 mm 128.840 mm
[0.0394 in.] [5.0739 to 5.0747 in.] [5.0723 in.]
Deviation of 0.01 [0.0004] or less over 0.03 mm
Parallelism - -
entire pin length [0.0012 in.]
0.03 mm
Roundness - - Diameter difference 0.01 [0.0004] or less
[0.0012 in.]
0.03 mm
Cylindricity - - Diameter difference 0.01 [0.0004] or less
[0.0012 in.]
Pin and
R7 6.8 to 7.0 mm
journal Pin - -
[0.28] [0.268 to 0.276 in.]
Fillet radius
R7 6.8 to 7.0 mm
Journal - -
[0.28] [0.268 to 0.276 in.]
Hardness - - Hv > 620 -
Finishing surface rough-
- - Ra0.2μm -
ness
Angular deviation between pins - - ±0.3° -
6-25
5.6 Width of Crankpin and Rearmost Crank Main Journal - Measure

(1) Inspect the ends of crankshaft for harmful flaw and
Rearmost crank
wear. Crankpin width journal width
(2) Measure the crankpin and rearmost crank main journal
width.
When using oversize thrust plate due to wear of rear-
most crank journal width, grind the crankshaft for use
with oversize thrust plate.
5.6.1 Rearmost Crank Main Journal Width - Grind
When using the oversize thrust plate, grind the rearmost
crank journal width for use with oversize thrust plate.
Width of Crankpin and Rearmost Crank Main Journal -
Do not change the fillet radius when grinding.Quench the Measure
crankshaft if its surface hardness is significantly decreased,
and after quenching do the magnetic particle inspec- 3.2S
ٖٖٖ
tion.Ensure that the finishing surface roughness after grind- 3.2S
ٖٖٖ
ing is in the standard value.
Note: The difference of thickness between front and rear
thrust plates must be 0.25 mm [0.0098 in.] or less.
ٖٖٖٖ
Fillet radius Fillet radius
R7 R7
Rearmost Crank Main Journal Width - Grind

Nominal
Item Size Standard value
value
108 mm -
Crankpin width 108.20 to 108.30 mm [4.2597 to 4.2637 in.]
[4.25 in.]
Standard 58.00 to 58.03 mm [2.2834 to 2.2846 in.]
0.25 mm [0.0098 in.] 58.25 to 58.28 mm [2.2932 to 2.2944 in.]
0.50 mm [0.0197 in.] 58.50 to 58.53 mm [2.3031 to 2.3043 in.]
Rearmost crank jour- 58 mm
nal width [2.28 in.] Over 0.75 mm [0.0295 in.] 58.75 to 58.78 mm [2.3129 to 2.3141 in.]
Size 1.00 mm [0.0394 in.] 59.00 to 59.03 mm [2.3228 to 2.3240 in.]
1.25 mm [0.0492 in.] 59.25 to 59.28 mm [2.3327 to 2.3339 in.]
1.50 mm [0.0591 in.] 59.50 to 59.53 mm [2.3425 to 2.3437 in.]
6-26
5.7 Crankshaft Runout - Measure

Support the crankshaft at front and rear main journals with
V-blocks, and measure the crankshaft runout at the center V-block
main journal with dial gauge.If the runout deviates slightly
from the standard, correct the crankshaft by grinding.If the
value exceeds the standard considerably, straighten the
crankshaft with pressing machine.
If the value exceeds the limit, replace the crankshaft with a
Surface plate
new one. 1/2 1/2
If the crankshaft is repaired by grinding or pressing, inspect
the crankshaft for cracks and other harmful damage with
Crankshaft Runout - Measure
magnetic particle inspection.

0.04 mm 0.10 mm
Crankshaft runout TIR
[0.0016 in.] or less [0.0039 in.]
6-27
5.8 Crankshaft Gear - Inspect

If there is any defect on the crankshaft gear teeth, such as
flaking, wear, or local contact, replace the crankshaft gear
with a new one.
5.9 Crankshaft Gear - Replace
Use protective gloves when you touch hot parts.

Handling with bear hands could result in burns.
5.9.1 Crankshaft Gear - Remove

Using a gear puller, remove the gear from crankshaft.
Note: When removing the crankshaft gear by heating, the
heating temperature is 180°C [356 °F] or less.
Crankshaft gear
Crankshaft Gear - Remove

5.9.2 Crankshaft Gear - Install
Gear engaged position
(a) Check the correct installing direction and position

of crankshaft gear.
(b) To shrinkage-fit the crankshaft gear to crankshaft,
heat the crankshaft gear evenly to the specified
temperature.
(1) Measure the outside diameter of crankshaft and inside

diameter of crankshaft gear, and check the interference. Match mark side
(2) Heat the crankshaft gear evenly to the specified temper- Crankshaft Gear - Install
ature.After checking gear direction and position, install
Shrink fit temperature: 180㷄 [356㷊] or below
the crankshaft gear. Crankshaft gear
7 mm
[0.28 in.]
Dowel pin
Interference standard:
0.106 to 0.171 mm
[0.0042 to 0.0067 in.]
Crankshaft Gear Installation Direction
6-28
5.10 Oil Seal Slinger - Inspect

If any defect such as dent, damage, wear and backlash that
Front Rear
could lead to oil leakage are found on the rear oil seal Timing
slinger, replace the rear oil seal slinger with a new one. gear case
Front
Note: Whenever the front cover is replaced, the front side cover
slinger must be replaced with a new one, as the front Oil seal
slinger is a cassette (assembling) type having oil seal.
Oil seal
slinger
Oil seal
Oil Seal Slinger - Inspect
5.11 Oil Seal Slinger - Replace
Use protective gloves when you touch hot parts. Oil seal slinger
Handling with bear hands could result in burns.

5.11.1 Oil Seal Slinger - Remove
(1) Using a gear puller, pull out the rear side oil seal slinger
from the crankshaft.
(2) Remove the front side oil seal slinger with a screw-
driver by prying it out.
Note: When removing the oil seal slinger by heating, the
heating temperature is 100°C [212°F] or less. Oil Seal Slinger (Rear) - Remove
5.11.2 Oil Seal Slinger - Install
(1) Measure the outside diameter of crankshaft and inside ID mark
diameter of oil seal slinger, and check the interference. (32511-05200)
(2) Heat the rear side oil seal slinger evenly under 110ºC
[230 °F].After checking the correct direction and posi-
tion of slinger, install the slinger.
Crankshaft
Note: The front side slinger is a cassette type with integrated rear end
Tight contact with gear
oil seal, therefore, the front slinger must be installed Interference standard value:
together with the oil seal after the front cover is mount- 0.210 to 0.294 mm
ed.
Oil seal slinger - Install (1)
For installation, refer to "Front Oil Seal - Install" of
"ASSEMBLY OF BASIC ENGINE".
Slinger
Installer
Oil seal slinger - Install (2)
6-29
5.12 Main Bearing - Inspect

main bearing. If any defect such as local contact, sliding
scratches, corrosion and foreign material inclusion is found,
replace the main bearing with a new one.
Flaw, corrosion, peeling
End face
Main Bearing - Inspect

5.13 Thickness of Main Bearing Shell - Measure
Measure the thickness of main bearing shell at its center.
If the value exceeds the limit, replace both upper and lower
main bearing shells with new ones as a set. Measurement
When the crankshaft is re-ground due to wear of crank jour- at the center
of bearing
nal, use the undersize bearing.
For the crankshaft grinding procedure, refer to "Crankpin
and Crank Journal - Grind" of "INSPECTION AND
Note: Replacement shells for undersized main bearing are
available in sizes of 0.25, 0.50, 0.75 and 1.00 mm
Thickness of Main Bearing Shell - Measure
[0.0098, 0.0197, 0.0295 and 0.0394 in.]
Nominal
value
3.500 mm 3.482 to 3.500 mm 3.450 mm
Standard
[0.1378 in.] [0.1370 to 0.1378 in.] [0.1358 in.]
0.25 mm 3.625 mm 3.607 to 3.625 mm 3.575 mm
[0.0098 in.] [0.1427 in.] [0.1420 to 0.1427 in.] [0.1407 in.]
Main bearing thickness at cen- 0.50 mm 3.750 mm 3.732 to 3.750 mm 3.700 mm
ter [0.0197 in.] [0.1476 in.] [0.1469 to 0.1476 in.] [0.1457 in.]
Under size
0.75 mm 3.875 mm 3.857 to 3.875 mm 3.825 mm
[0.0295 in.] [0.1526 in.] [0.1518 to 0.1526 in.] [0.1506 in.]
1.00 mm 4.000 mm 3.982 to 4.000 mm 3.950 mm
[0.0394 in.] [0.1575 in.] [0.1568 to 0.1575 in.] [0.1555 in.]
5.14 Thrust Plate - Inspect

thrust plate. If any defect such as local contact, sliding
scratches, corrosion and foreign material inclusion is found, End face
replace the thrust plate with a new one.
Flaw, corrosion, peeling
Thrust Plate - Inspect
6-30
5.15 Thickness of Thrust Plate - Measure

Measure the thickness of thrust plate.
If the value exceeds the limit, replace the thrust plate with a
new one.When the crankshaft is re-ground due to wear, use
the oversize thrust plate.
For the crankshaft grinding procedure, refer to "Rearmost
Crank Journal Width - Grind" of "INSPECTION AND
Note:(a) Replacement thrust plates are available in three
oversizes of 0.25, 0.50, 0.75 mm [0.0098, 0.0197,
0.0295 in.]
Thickness of Thrust Plate - Measure
(b) Because the oversize thrust plate can be used in
only one side (a set of upper and lower), the end
play can be adjusted with a minimum crankshaft
grinding.
Nominal
value
5.00 mm 4.83 to 4.90 mm 4.76 mm
Standard
[0.1969 in.] [0.1902 to 0.1929 in.] [0.1874 in.]
0.25 mm 5.25 mm 5.08 to 5.15 mm 5.01 mm
[0.0098 in.] [0.2067 in.] [0.2000 to 0.2028 in.] [0.1972 in.]
Thickness of thrust plate
0.50 mm 5.50 mm 5.33 to 5.40 mm 5.26 mm
Over size
[0.0197 in.] [0.2165 in.] [0.2098 to 0.2126 in.] [0.2071in.]
0.75 mm 5.75 mm 5.58 to 5.65 mm 5.51 mm
[0.0295 in.] [0.2264 in.] [0.2197 to 0.2224 in.] [0.2169 in.]
5.16 Piston Cooling Nozzle - Inspect
Spray hole
If oil jet pipe of piston cooling nozzle is bent or
deformed, it will reduce the cooling performance, and
can lead to piston seizure.
Inspect the piston cooling nozzle.
If there is any defect such as valve malfunction and oil hole
clogging, replace the piston cooling nozzle with a new one.
Valve
Item Standard value
0.26 to 0.32 MPa Piston Cooling Nozzle - Inspect
Valve opening pressure of piston
{2.7 to 3.3 kgf/cm2}
cooling nozzle
[38 to 47 psi]
6-31
1. Crankshaft and Main Bearing - Install ................................................................... 7-3
1.1 Crankcase - Turn Over (Upend) ............................................................................................... 7-3
1.2 Piston Cooling Nozzle - Install .................................................................................................. 7-3
1.3 Upper Main Bearing - Install ..................................................................................................... 7-4
1.4 Crankshaft - Install.................................................................................................................... 7-5
1.5 Upper thrust plates - Install....................................................................................................... 7-5
1.6 Lower Main Bearing Shell and Lower Thrust Plate - Install ...................................................... 7-5
1.7 Main Bearing Cap - Install ........................................................................................................ 7-6
1.8 Crankshaft End Play - Measure................................................................................................ 7-7
1.9 Crankcase - Turn Over ............................................................................................................. 7-7
2. Cylinder Liner, Piston and Connecting Rod - Assemble ..................................... 7-8
2.1 Cylinder Liner Protrusion - Measure ......................................................................................... 7-8
2.2 Cylinder Liner Flange Protrusion - Calculate (When Cylinder Liner Not Installed) ................... 7-8
2.3 Cylinder Liner - Install ............................................................................................................. 7-10
2.4 Cylinder Liner Flange Protrusion - Measure (When Cylinder Liner Installed)......................... 7-10
2.5 Cylinder Liner Inside Diameter - Measure .............................................................................. 7-11
2.6 Piston and Connecting Rod - Assemble ................................................................................. 7-11
2.7 Piston Ring - Install................................................................................................................. 7-12
2.8 Crankshaft - Turn.................................................................................................................... 7-12
2.9 Piston Installation - Prepare.................................................................................................... 7-13
2.10 Upper Connecting Rod Bearing - Install ................................................................................. 7-13
2.11 Piston - Install ......................................................................................................................... 7-14
2.12 Connecting Rod Cap - Install.................................................................................................. 7-16
2.13 Connecting Rod End Play - Measure ..................................................................................... 7-17
2.14 Piston Protrusion - Measure ................................................................................................... 7-17
3. Front Mechanism - Assemble............................................................................... 7-18
3.1 Front Cover - Install ................................................................................................................ 7-18
3.2 Front Oil Seal - Install ............................................................................................................. 7-18
3.3 Crankshaft Pulley, Damper and Front Pulley - Install ............................................................. 7-19
3.4 Damper Face and Radial Runout - Measure .......................................................................... 7-19
3.5 Pointer - Install and Adjust...................................................................................................... 7-19
4. Rear Mechanism - Assemble ................................................................................ 7-20
4.1 Rear Plate - Install .................................................................................................................. 7-20
4.2 Idler Shaft - Install................................................................................................................... 7-20
4.3 Camshaft - Install.................................................................................................................... 7-21
4.4 Camshaft Gear - Install........................................................................................................... 7-21
4.5 Camshaft End Play - Measure................................................................................................ 7-21
4.6 Governor Drive and Fuel Injection Pump Accessory Drive - Install ........................................ 7-22
4.7 Fuel injection pump gear - Install............................................................................................ 7-22
4.8 Idler Gear - Install ................................................................................................................... 7-23
4.9 Idler Gear End Play - Measure ............................................................................................... 7-23
4.10 Timing Gear Backlash - Measure ........................................................................................... 7-24
4.11 Timing Gear Case - Install ...................................................................................................... 7-24
4.12 Rear Oil Seal - Install.............................................................................................................. 7-25
4.13 Flywheel - Install ..................................................................................................................... 7-25
4.14 Flywheel Face and Radial Runout - Measure......................................................................... 7-25
4.15 Pickup - Install ........................................................................................................................ 7-26
7-1
5. Cylinder Head and Valve Mechanism - Assemble .............................................. 7-27

5.1 Cylinder Head - Assemble ...................................................................................................... 7-27
5.2 Valve Sinkage - Measure........................................................................................................ 7-28
5.3 Tappet - Install ........................................................................................................................ 7-28
5.4 Liquid Gasket - Apply.............................................................................................................. 7-28
5.5 Cylinder Head Gasket - Install ................................................................................................ 7-29
5.6 Cylinder Head Assembly - Install............................................................................................ 7-29
5.7 Cylinder Head Bolt - Tighten................................................................................................... 7-30
5.8 Bridges and Bridge Caps - Install ........................................................................................... 7-31
5.9 Valve Bridge and Adjusting Screw - Adjust ............................................................................ 7-31
5.10 Clearance Between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect. 7-31
5.11 Rocker shaft assembly - Assemble ........................................................................................ 7-32
5.12 Rocker Shaft Assembly - Install.............................................................................................. 7-32
5.13 Valve Clearance - Check and Adjust ...................................................................................... 7-33
5.14 Fuel Injection Timing - Check and Adjust ............................................................................... 7-33
5.15 Valve Timing - Inspect ............................................................................................................ 7-35
5.16 Fuel Injection Nozzle Assembly - Install ................................................................................. 7-36
5.17 Fuel pipe - Install .................................................................................................................... 7-36
7-2
1. Crankshaft and Main Bearing - Install

1.1 Crankcase - Turn Over (Upend)
the turnover machine is not available, hitch slings to the Crankcase
crankcase using wood pieces and cloth pads, and raise the weight:1010 kg [2227 lb]
block with its side facing downward.Then, change the posi-
tions of the slings, and turn over to upend the crankcase.
Crankcase Wood block
Crankcase - Turn Over (Upend)

1.2 Piston Cooling Nozzle - Install
34 ± 1.7 N·m
Be sure to tighten the piston cooling nozzle to the {3.5 ± 0.17 kgf·m}
specified torque using a torque wrench.If it is exces- [25 ± 0.13 lbf·ft]
sively tightened, it can lead to check valve operation

Piston cooling nozzle
malfunction, resulting in piston seizure.
Install the piston cooling nozzle onto the crankcase and
tighten the check valve to the specified torque.
Piston Cooling Nozzle - Install
7-3
1.3 Upper Main Bearing - Install
(a) Do not apply engine oil to the back face of the main bearing shell and main bearing fitting bore in the crank-
case when installing the main bearing.Install the main bearing only after cleaning off foreign material, oil and
grease from these surface using cleaning solvent.
(b) When installing main bearings, be careful not to confuse the upper shell with lower shell.
The upper main bearing shell is identified by machined oil hole. The lower main bearing shell has no oil hole
nor groove.Be careful not to install the main bearing upside down.
(c) Be careful not to damage the bearing when installing.
(1) Clean the main bearing fitting bore and main bearing
cap mating surfaces using cleaning solvent, and make
sure that these surfaces are free from any foreign mate-
rial.
(2) Make sure that the main bearing is free from damage
Oil hole
and contamination.
(3) Fit the upper main bearing shell in the crankcase bore
aligning the lug on the shell with the lug slot in the
Lug slot
crankcase.
Main bearing upper
Note:(a) Make the main bearing crush heights even at both
Upper Main Bearing - Install
ends.
(b) The oil hole in the upper main bearing shell is
aligned with the oil hole in the crankcase by align-
ing the lug on upper shell with the lug slot in the
crankcase.
(4) Apply an even coat of clean engine oil to the sliding
surface of upper main bearing shell.
7-4
1.4 Crankshaft - Install

(1) Make sure that the sliding surfaces of the upper main
Apply engine oil to
bearing shells installed in the crankcase are evenly the crank journal
coated with clean engine oil. after cleaning.
(2) Thoroughly clean the crankshaft with cleaning oil, and
blow off the oil with compressed air. Then, apply an
even coat of clean engine oil to the crankshaft journals.
Note: When cleaning crankshaft, be sure to thoroughly clean
Blow compressed
the crank journals, crankpins, and oil holes and make air after cleaning.
sure that the crankshaft is free from foreign material
such as machining chips and dirt.Make sure that oil
Crankshaft - Clean
holes are free from burrs.
(3) Lift the crankshaft keeping in a horizontal attitude, and
slowly install into the crankcase.
Note: When lifting the crankshaft, use fiber slings or pads to
avoid any damage to he crankshaft.
(4) Slowly rotate the crankshaft to verify smooth rotation
of the crankshaft.
Crankshaft - Install
1.5 Upper thrust plates - Install
Upper thrust plate

Do not damage the thrust plate when installing. Oil groove
(1) Apply engine oil evenly to the sliding surface of the

upper thrust plate.
(2) Install the upper thrust plates onto the front and back of
rearmost journal through the clearances between the
crankcase and crankshaft.
Note: Install the thrust plate oil groove to face outward of
each journal. Oil groove
Upper thrust plates - Install
1.6 Lower Main Bearing Shell and Lower Thrust Plate - Install
(1) Install the lower main bearing shell, aligning the lug
with the lug slot in the main bearing cap. Lower main
Note: Make the crush heights even. bearing
(2) Apply an even coat of clean engine oil to the sliding
surfaces of lower main bearing shells. Lower thrust
plate Lug slot
(3) Install the lower thrust plates aligning with the dowel Lower thrust
pins to the rearmost main bearing cap. plate
Note: Install the lower thrust plates so that the oil groove fac-
es outer side of the cap. Main bearing cap
Oil groove Dowel pin
Lower Main Bearing and
Lower Thrust Plates - Install
7-5
1.7 Main Bearing Cap - Install
Be sure to observe the specified tightening sequence

when tightening the main bearing cap bolts and side
bolts.
(1) Make sure that the main bearings and thrust plates
installed to main bearing caps are evenly coated with
clean engine oil.
(2) Install the main bearing cap so that its number stamp
lines up in numerical order from the front to rear of the
engine, and also the embossed part number side faces
toward the engine front (so that all rug grooves are
Main bearing cap
aligned on the same side).
(3) Apply oil to the main bearing cap bolts and washers and
hand tighten them.
Main Bearing Cap - Install
(4) Tap the main bearing caps with a soft-head hammer
evenly to install them in position.
(5) Apply oil to the side bolts and O-ring and hand tighten
them.
(6) Snug tighten the main bearing cap bolts and side bolts First time:
Tighten to the specified
except the rearmost ones, to the half of specified torque torque in the numerical
Main bolt 1, 2: 294 ± 15 N·m
{30 ± 1.5 kgf·m}
in the specified tightening sequence as shown in the order in two steps. [217 ± 11.1 lbf·ft]
[Wet] Side bolt 3, 4: 74 ± 3.7 N·m
illustration. {7.5 ± 0.38 kgf·m}
1 2 [54.6 ± 2.73 lbf·ft]
(7) Tighten the main bearing cap bolts and side bolts Bottom
Second time:
except the rearmost ones to the specified torque in the Main bolt 1, 2: 588 ± 29 N·m
{60 ± 3.0 kgf·m}
specified sequence shown in the illustration. 3 4 [434 ± 21.7 lbf·ft]
(8) Hand tighten the rearmost cap bolts and side bolts to Side bolt 3, 4: 147 ± 7.4 N·m
{15 ± 0.75 kgf·m}
Top
make the rearmost main bearing be lightly seated. [108.4 ± 5.46 lbf·ft]
Measure the crankshaft end play in this condition. Right Left View from engine rear side
Tightening Sequence of Main Bearing Cap Bolts
Side bolt
147 ± 7.4 N·m
N
{15 ± 0.75 kgf·m}
kgf m}
[108 ± 5.4 lbf·ft]
lbf ft]
[Wet]
Main bolt
588 ± 29.4 N·m
{60 ± 3.0 kgf·m}
[434 ± 21.7 lbf·ft]
[Wet]
Main bearing cap bolt - Install
7-6
1.8 Crankshaft End Play - Measure

(1) Verify the smooth rotation of the crankshaft.
(2) Apply a dial gauge probe to the rear end face of crank-
shaft.
(3) Using a bar, move the crankshaft fully to the front and
rear to read the each measurement. The end play is the
difference between the front and rear measurements.
If the value exceeds the standard value, inspect the
thrust plates and the crankshaft.
If the end play is less than the standard value, loosen
the rear most bearing cap bolts and move the crankshaft
back and forth, and measure the end play again.
(4) After tightening the rearmost main bearing cap to the
specified torque, measure the end play again to verify.
(5) Again, verify the crankshaft smooth rotation.
(6) Verify again all main bearing cap bolts and side bolts to
make sure that they are tightened properly.

0.200 to 0.395 mm 0.500 mm
Crankshaft end play
[0.0079 to 0.0156 in.] [0.0197 in.]
1.9 Crankcase - Turn Over

Weight of crankcase and crankshaft assembly:
the turnover machine is not available, hitch slings to the approx. 1370 kg [3020 lb]
crankcase using wood pieces and cloth pads, and raise the
block with its side facing downward.Then, change the sling
positions. Turn over the crankcase on the wooden blocks to
turn it to the normal position.
Crankcase - Turn Over
7-7
2. Cylinder Liner, Piston and Connecting Rod - Assemble

2.1 Cylinder Liner Protrusion - Measure
(1) Place the dial gauge probe on the top surface of cylin-
Height of protrusion
der liner flange, and adjust the dial gauge to zero.
(2) Slide the probe to measure the protrusion of the cylin-
der liner at four places.
(3) If the value exceeds the limit, or if the ridge is cracked, Cylinder liner
replace the cylinder liner with a new one. top face
Item Standard value

0.16 to 0.24 mm
Cylinder liner protrusion
[0.0063 to 0.0094 in.]
Cylinder Liner Protrusion - Measure

2.2 Cylinder Liner Flange Protrusion - Calculate (When Cylinder Liner Not Installed)
If the amount of protrusion is not enough, the contact

pressure of cylinder head gasket is low, and it can
result in gas and water leakage.
(1) Inspect the cylinder liner contact surface on the crank-
case.If uneven contact is shown, reface the counterbore
with the crankcase grinder to correct the depth differ- Projection plate
P/N:37598-09201
ence at four places in circumference to be less than 0.05
mm [0.0020 in.]
Counterbore depth
For repair procedure, refer to "Counterbore in Crank-
case - Repair" of "INSPECTION AND REPAIR OF
BASIC ENGINE."
(2) Make sure that the top and bottom faces of cylinder
liner flange, the top surface of crankcase and the fitting
Depth of counterbore in crankcase - Measure
surfaces of cylinder liner are clean before measure-
ment.
(3) Measure the depth of counterbore in crankcase.
Item Part No. Standard value

32608-00200 12.00 to 12.05 mm
Depth of counterbore in (S12A2-1) [0.4724 to 0.4744 in.]
crankcase 32608-00300 15.00 to 15.05 mm
(S12A2-2) [0.5906 to 0.5925 in.]
(4) Measure the thickness of cylinder liner flange.
Item Part No. Standard value

32507-62400 12.15 to 12.19 mm
Thickness of cylinder liner (S12A2-1) [0.4783 to 0.4799 in.]
flange Cylinder liner
32607-03400 15.15 to 15.19 mm
(S12A2-2) [0.5965 to 0.5980 in.]
Thickness of cylinder liner flange
7-8
(5) Calculate the cylinder liner flange protrusion by sub-

tracting the depth of counterbore in crankcase from the Crankcase
Shim
thickness of the cylinder liner flange.
Cylinder liner
If the value exceeds the limit, insert a shim under the
cylinder liner flange.Select a shim which makes the
cylinder liner flange protrusion the largest within the
tolerance of the standard.
Note:(a) Shims are available in thicknesses of 0.05, 0.10,
0.15, 0.20, 0.25, 0.30, 0.35, 0.40 mm [0.0020,
0.0039, 0.0059, 0.0079, 0.0098, 0.0118, 0.0138,
and 0.0157 in.]. Shim - Insert
(b) Do not double the shims.
Item Standard value

Cylinder liner flange 0.10 to 0.19 mm
protrusion [0.0039 to 0.0075 in.]
Shim thickness Part No.

0.05 mm [0.0020 in.] 35A07-17500
0.10 mm [0.0039 in.] 35A07-17100
0.15 mm [0.0059 in.] 35A07-17600
0.20 mm [0.0079 in.] 35A07-17200
0.25 mm [0.0098 in.] 35A07-17700
0.30 mm [0.0118 in.] 35A07-17300
0.35 mm [0.0138 in.] 35A07-17800
0.40 mm [0.0157 in.] 35A07-17400
7-9
2.3 Cylinder Liner - Install
Apply engine oil to the O-ring sliding surfaces to prevent O-rings from twisting.
Do not apply engine oil to the O-ring grooves on cylinder liner.
(1) Install the O-rings to the cylinder liner.
(2) Insert the shim to the cylinder which needs the adjust-
ment of cylinder liner flange protrusion.
(3) Apply engine oil to the O-ring fitting bore in Crankcase
and cylinder liner O-ring sliding surfaces.
Application of
engine oil
Cylinder Liner O-Rings - Install

(4) Slowly insert the cylinder liner into the bore in the
crankcase.With a correct cylinder liner installer, lightly
tap the cylinder liner until its flange contacts snugly on
the seating surface of the crankcase.Then, lightly tap Installer
the liner several times to verify the stable seating. P/N:32591-01800
Note: To verify the correct O-rings installation, measure the
roundness of inside diameter of the cylinder liner (es- Cylinder liner
pecially O-ring installing position.)
Cylinder Liner - Install

2.4 Cylinder Liner Flange Protrusion - Measure (When Cylinder Liner Installed)
(1) Remove dust and dirt from the crankcase top face and
the cylinder liner top end face to measure. Bolt
Liner pusher
(2) Place the liner pusher on equally spaced 4 positions of
the cylinder liner upper rim and tighten the pusher bolts protrusion
evenly to make a close contact of the cylinder liner and
the crankcase.
(3) Apply a dial gauge probe to the top face of the crank-
case, and the dial gauge to zero.
(4) Slide the probe to measure the flange protrusion at four
places on the top of the cylinder liner, and calculate the
mean value.
(5) If the mean value of the protrusion is smaller than the
standard, insert a shim under the cylinder liner flange.
For shim and standard value, refer to "Cylinder Liner
Flange Protrusion - Calculate (When Cylinder Liner
Not Installed)" of "ASSEMBLY OF BASIC ENGINE."
7-10
2.5 Cylinder Liner Inside Diameter - Measure

Measure the inside diameter of the cylinder liner at three
levels, i.e., upper (position of No.1 compression ring when Cylinder liner
piston is at the top dead center), liner middle position, and
O-ring installed position, in both parallel and perpendicular
directions to the piston pin direction.
Replace the cylinder liner if the value exceeds the limit.If
the liner is distorted, pull-out the liner and re-install paying
attention to O-rings.
Nominal
value
ø150 mm 150.000 to 150.040 mm 150.140 mm
Inside diameter
[5.9 in.] [5.9054 to 5.9069 in.] [5.9109 in.] Direction traverse to piston pin
0.02 mm Direction parallel
Roundness - -
[0.0008 in.] or less
[1.18 in.]
to piston pin
[3.93 in.]
100 mm
30 mm
0.02 mm
250 mm [9.84 in.]

Cylindricity - -
[0.0008 in.] or less
Cylinder liner dimension measuring position

2.6 Piston and Connecting Rod - Assemble
(1) Apply engine oil to the piston pin, and assemble the
Right bank View A Piston Left bank
piston and the connecting rod.The orientation of piston weight
and connecting rod is shown in the illustration. A A
Note: The piston and piston pin are made for a clearance fit.
However, the piston pin is more easily inserted into the Camshaft
(
piston if the piston is warmed up with a heater or with

Part No.
hot water. Match mark
Direction mark
(2) Install the snap ring with ring pliers.Make sure that the “F (Front)”
snap ring is fully inserted into the ring groove. means
engine front
Assembling Orientation of Piston and Connecting Rod
Snap ring
Piston and Connecting Rod - Assemble
7-11
2.7 Piston Ring - Install
Ring expander
P/N:37191-03200
Every piston ring has a top mark near the end
gap.Install piston rings with the marks facing upward. Up mark
Be careful not to install piston rings upside down. If No.1
compression ring
piston rings are assembled incorrectly, it results in
defects such as engine seizure. No.2
compression ring
(1) Install the piston rings to piston with ring expander.
Oil ring
(2) Install the oil ring with its end gap 180° away from the
joint of the coil spring, as shown in the illustration. Coil spring
Piston and Piston Ring - Install
Coil spring joint
180°
Oil ring ends
Oil Ring and Coil Spring Assembling

2.8 Crankshaft - Turn
(1) Install two bolts to the flywheel mounting holes of the
crankshaft.
(2) Using the bolts, turn the crankshaft with a bar.
M22 × 1.5 mm
Crankshaft - Turn
7-12
2.9 Piston Installation - Prepare

(1) Turn the crankshaft to a position where the connecting
rod big end does not hit the crankpin on the piston
installing.
Crankpin Position so that connecting

rod big-end does not
hit crankpin
Position of Crankpin - Adjust
(2) Clean the cylinder liner inner surface and the crankpin,
and apply engine oil to the cylinder liner.
Piston Installation - Prepare

2.10 Upper Connecting Rod Bearing - Install
Upper connecting rod bearing
Be careful not to put engine oil on the back face of Lug groove
upper connecting rod bearing.
Install the upper connecting rod bearing into connecting rod
big end aligning the lug and lug slot. Apply engine oil to the
sliding surface.Verify the alignment of the oil hole of con-
necting rod and the oil hole of bearing.
Oil hole
Upper Connecting Rod Bearing - Install
7-13
2.11 Piston - Install
Eyebolt
P/N:45815-32201
When installing the piston, install the eye bolt to the (M8 × 1.25 mm)
Eyebolt
threaded hole on the piston top, and lift the piston with P/N:45815-32301
chain block.When the installation work is done by (M10 × 1.5 mm)
hand, be sure to take preventive measures so that pis-

ton does not falling down, and be very careful not to
(
hurt your hands and fingers or not to damage the
Engine front
parts. “F” mark
Camshaft Be careful not to bump.
Piston and Connecting Rod - Install
(a) Make sure that the "F" mark on top of the piston
faces the front of the engine.
No. 1 compression ring joint
(b) Checking through the inspection window on the Coil spring joint
side of crankcase, make sure that the connecting

rod does not hit the piston cooling nozzle when
installing piston. Piston pin
(c) To prevent the oil ring from impact damaging,

slowly insert the piston.
(1) Insert the connecting rod into the cylinder liner care- No. 2 compression ring joint Oil ring joint
fully not to damage the liner, and slowly lower the pis-
ton to the upper surface of crankcase. Piston Ring End Gaps - Place
(2) Apply engine oil to the piston rings. Compression ring

Place the end gaps equally spaced each other, avoiding
piston pin and thrust/anti-thrust directions.
Oil ring
(3) Hold the compression ring position of piston with
hands, and slowly insert the piston skirt into cylinder
liner.
Piston Skirt - Insert

(4) Verify again the positions of piston ring gaps.
Apply engine oil to the piston rings.
Apply engine oil to the inner surface of piston installer.
Verify the oil ring placed in the groove. Then, compress
the piston rings with piston installer.
Note: For piston ring placing, see above (2).
Piston installer
P/N:37191-07100
Piston Ring - Compress
7-14
(5) Install piston into cylinder liner by tapping the piston

head with soft-head hammer.
Note: Make sure that the piston is not caught in the cylinder
liner, or the connecting rod big end does not hit the
crank pin.
Use of a soft hammer
handle
Piston- Install
(6) Verify the proper placing of upper connecting rod bear-
Verification of connecting
ing shell through the inspection window on crankcase rod bearing position
side.If the bearing shell is not placed properly, push the
bearing upward with your hand to correct the position.
Connecting Rod Bearing - Installation Check

(7) If the upper connecting rod bearing is displaced from
connecting rod big end, rotate the crankshaft to make a
space between the connecting rod big end and crank-
pin.Then, insert the connecting rod bearing, sliding on
the crankpin, and make sure that the lug on the bearing
shell is correctly positioned in the lug slot of the rod.
Upper connecting
rod bearing
Lug Groove - Align
7-15
2.12 Connecting Rod Cap - Install

Lower connecting rod
Connecting rod bolt bearing
(a) Make sure that the matching numbers on the con-
Lug groove
necting rod and the connecting rod cap are on the
Threaded
same side and in alignment. portion
(b) When installing the connecting rod cap, make sure
that dust or metal particles are not caught in the
Serrated portion
serrations, bolt seating surfaces and the bolt
threads. Connecting rod cap
Bolt's seat face
(1) Install the lower connecting rod bearing, aligning its
lug with the lug slot of the connecting rod bearing cap. Connecting Rod Cap - Install (1)
(2) Apply engine oil to the connecting rod bolt threads and
seating surface, and the sliding surface of the lower
connecting rod bearing shell.
(3) Install the connecting rod cap to the connecting rod so
that that the matching numbers on the connecting rod
cap and the connecting rod are the same and on the
same side.
(4) Hand tighten the connecting rod bolts.
Connecting Rod Cap - Install (2)

(5) Align the connecting rod and rod cap side faces to
ensure the rod end play.
Note: To ensure the minimum end play, the connecting rod
gauge may be inserted between the two connecting
rods for adjustment.
Ensure the end play
(6) Measure the connecting rod end play, and adjust the with a connecting
end play to the range of the standard value. rod gauge
Connecting rod gauge

P/N 0.5 mm [0.020 in.] : 32691-01500
0.6 mm [0.024 in.] : 32691-01600
(7) Tighten the connecting rod bolts to the specified
torque.After tightening to the specified torque, loosen
the bolts completely and tighten again to the specified
torque.(2-time tightening method)
Measure the end play again.
Note: To tighten the connecting rod bolts with the angle con-
trol tightening, follow the steps below.
(a)Tighten the bolt to a snug torque of 147±7.4 N•m 343±17 N·m {35±1.8 kgf·m}
{15± 0.75kgf•m} [108±5.46 lbf•ft]. [148±13 lbf·ft] [Wet]
2 times tightening method
(b)Further rotate the bolt 45±3 degrees.
(c)Loosen all bolts, and then angle controlled tighten
them again.(2-time tightening method)
7-16
2.13 Connecting Rod End Play - Measure

Measure the end play of the connecting rod.
If the value exceeds the limit, find the causal parts, and Connecting rod
replace them with new ones.

0.6 to 0.9 mm 1.0 mm
[0.024 to 0.035 in.] [0.040 in.]

2.14 Piston Protrusion - Measure
Piston protrusion must always meet the standard, as

Piston protrusion
the amount of protrusion not only influences engine
performance, but it also prevents valve from stamping.
Measure the protrusion of each piston, following the
instructions below.If the value exceeds the limit, inspect the
clearances between various parts involved.
(1) Move the piston to the top dead center.
(2) Apply the dial gauge probe to the top face of crankcase,
and adjust the dial gauge to zero. Piston protrusion - Measure
(3) Move the dial gauge to the top face of piston, measure
Top clearance
the maximum protrusion by turning the crankshaft near Cylinder head gasket Piston protrusion
top dead center. thickness
Cylinder head
Note: The crankshaft position that indicates the maximum
protrusion is defined as the correct top dead center. Cylinder liner
(4) Measure the protrusion at four places on the piston top
face, and calculate the mean value. Cylinder liner flange
Crankcase Piston
Note: The top clearance (clearance between the piston top protrusion
and cylinder head) can be calculated by the piston pro-

trusion, cylinder liner flange protrusion and cylinder
Top clearance
head gasket thickness.
Top clearance = Cylinder head gasket thickness + Cyl-
inder liner flange protrusion - Piston protrusion
Item Standard value

Piston protrusion 0.229 to 0.839 mm [0.0090 to 0.0330 in.]
0.10 to 0.19 mm [0.0039 to 0.0075 in.]
protrusion
Thickness of cylin-
1.77 to 1.83 mm [0.0697 to 0.0720 in.]
der head gasket
Top clearance 1.191 to 2.031 mm [0.0469 to 0.0800 in.]
7-17
3. Front Mechanism - Assemble

3.1 Front Cover - Install
(1) Apply sealant (ThreeBond 1211) to the packing mount-
ing surface of the crankcase, and install the packing.
(2) Apply sealant (ThreeBond 1211) to the packing for
front cover mounting surface, and install the front
cover.
(3) Tighten the bolt.
(4) Check that the lower face of front cover is flush with
the bottom of crankcase.
Cut off any excessive packing neatly.
Front Cover - Install

3.2 Front Oil Seal - Install
The font seal is a cassette combining seal lip and slinger
Insert bolt
(assembling type).Do not forcibly separate the oil seal from
Guide flange
the slinger.
With the front seal installer assembly, install the front oil Insert
seal. Swing washer

(1) Apply clean engine oil evenly to the oil seal lip.
Bolt
Note: Pay attention to the installing side of oil seal, and be
careful not to damage the oil seal. Front seal
(2) Install the guide flange to the crankshaft front end, and installer assembly
Socket bolt P/N:32691-00042
secure it with the insert bolts.
Front Oil Seal - Install (1)
(3) Set the oil seal to insert and install it to the guide flange.
(4) Tighten the bolt on guide flange to insert the oil seal
Front cover
into the front cover.
(5) Remove the installer assembly.
Oil seal
Crankshaft
From crankshaft end face to

slinger end face
68.5 mm [2.697 in.]
Front Oil Seal - Install (2)
7-18
3.3 Crankshaft Pulley, Damper and Front Pulley - Install

(1) Install the guide bolt to damper mounting thread on the
crankshaft. 539 ± 27 N·m
(2) Put the crankshaft pulley, belt and damper to the guide {55 ± 2.8 kgf·m}
[397.5 ± 19.9 lbf·ft]
bolt, and install them aligning with the dowel pin.
(3) Tighten the bolts to the specified torque.
Guide bolt
Crankshaft Pulley, Damper and Front Pulley - Install

3.4 Damper Face and Radial Runout - Measure
Measure the face and radial runouts of damper.
If the value exceeds the limit, check the assembling condi-
tion such as loose bolt or foreign material collection on the
mounting faces.
Note: For measurement, avoid the punch mark position.
Item Standard value

Face runout
Face runout (reference) 0.5 mm [0.020 in.] or less
Radial runout (reference) 0.5 mm [0.020 in.] or less
Radial runout

3.5 Pointer - Install and Adjust
(1) Install the pointer to the front gear case.
(2) Turn the crankshaft to the top dead center of No. 1 cyl-
inder. Align the stamped line of top dead center of No.
1 cylinder on the periphery of damper with the pointer.
Timing gear case
(3) To make sure the No.1 cylinder top dead center, mea-
sure the flywheel punch mark positioning at the same
Flywheel
distance from the two punch marks stamped on the tim-
ing gear case.
Note: For checking procedure of the top dead center by pis-
ton movement, refer to "Piston Protrusion - Measure"
Top Dead Center of Punch Marks - Check
of "ASSEMBLY OF BASIC ENGINE."
7-19
4. Rear Mechanism - Assemble

4.1 Rear Plate - Install
(1) Make sure that plugs that block the oil gallery of the
crankcase are installed (3 places). Plug
(2) Apply sealant (ThreeBond 1211) to the packing mount-
ing surface of the crankcase, and install the packing.
(3) Apply the same sealant (ThreeBond 1211) to the pack-
ing, and then install the rear plate.
(5) Make sure that the bottom face of the rear plate is flush
with the bottom face of the crankcase.Cut off excessive
packing carefully.
Plug - Mounting location
Dowel pin 98 ± 4.9 N·m

{10 ± 0.5 kgf·m}
[72.3 ± 3.6 lbf·ft]
Rear Plate - Install
4.2 Idler Shaft - Install
(1) Tap-in the idler shaft into position using a bolt as guide.
54 ± 2.7 N·m
{5.5 ± 0.28 kgf·m}
[39.8 ± 1.99 lbf·ft]
Idler Shaft - Install
7-20
4.3 Camshaft - Install

Sling
Install the camshaft through the posh rod hole in the

Crankcase by supporting it with a lifting sling.Be care-
ful not to bump the camshaft to avoid the damage to
cam lobe and bushing.
(1) Apply engine oil to the inner surface of camshaft bush-
ing.
(2) Apply engine oil to the camshaft oil galleries, journals
and lobes. Camshaft Thrust plate
(3) Slowly insert the camshaft into the crankcase while Camshaft - Install
supporting it with a lifting sling.
(4) Install the thrust plate.
(5) Make sure that the camshaft rotates.
4.4 Camshaft Gear - Install
(1) Install the camshaft gear by aligning it with the cam-
Woodruff key
shaft Woodruff key.
(2) Using a socket, tighten the nut (left-hand thread) to the
specified torque by turning counterclockwise.
(3) Verify the camshaft smooth rotation.
Nut
(Left-hand
thread)
Camshaft gear
Camshaft Gear - Install (1)
Socket
P/N:32591-02800
(Left-hand thread)
294 ± 15 N·m
{30 ± 1.5 kgf·m}
[217 ± 11 lbf·ft]
Camshaft Gear - Install (2)
4.5 Camshaft End Play - Measure
Measure the camshaft end play.If the value exceeds the
limit, find the causal parts, and replace them with new ones.

0.20 to 0.30 mm 0.40 mm
Camshaft end play
[0.0079 to 0.0118 in.] [0.0157 in.]
Camshaft gear
Camshaft End Play - Measure
7-21
4.6 Governor Drive and Fuel Injection Pump Accessory Drive - Install
4.6.1 Fuel Injection Pump Accessory Drive - Install
(1) Install the O-ring to the mounting surface of the fuel Accessory drive
injection pump accessory drive case.Apply a thin coat

of ThreeBond 1212 to the flange.
Electronic
(2) Install the fuel injection pump accessory drive to the governor spec Governor drive
rear plate.
4.6.2 Governor Drive - Install (Oil Pressure Governor
Spec)
(1) Apply a thin coat of ThreeBond 1212 to the packing Oil pressure
governor spec
mounting surface of the governor drive, and attach the
Governor Drive and Fuel Injection Pump and
packing to the surface. Accessory Drive - Install
Apply a thin coat of ThreeBond 1212 on the packing.
(2) Install the governor drive to the rear plate.
4.7 Fuel injection pump gear - Install

(1) Align the match mark on the camshaft with the Wood-
Align the mark「3」on the
ruff key on the drive shaft, and install the fuel injection camshaft gear with the mark「3」on
Camshaft gear the fuel injection pump gear.
pump gear to the shaft.
(2) Tighten the nuts to the specified torque.
Fuel injection pump gear

Nut
294 ± 15 N·m
{30 ± 1.5 kgf·m}
Woodruff key [217 ± 11.1 lbf·ft]
Fuel injection pump gear - Install
7-22
4.8 Idler Gear - Install

(1) Turn the crankshaft to move the No. 1 cylinder to the
Camshaft gear
top dead center.
(2) Apply engine oil to the idler shaft. 㪈㪋㪋
(3) Install the idler gear, aligning it with the match marks.
㪊
㪊
㪉
㪊㪊
㪉
㪊㪊
(4) Install the thrust plate to the idler shaft.
㪉
㪉
㪋
㪉
㪉
㪈
㪋
㪈
㪊㪋
(5) Tighten the bolts to the specified torque. Fuel 㪊
㪈
㪊㪊
injection
(6) Make sure that the match marks on timing gears are pump gear (Z51) Crankshaft gear
properly aligned as shown in the illustration.
Idler gear Oil pump
gear
Timing Gear Train
Thrust plate
39 ± 3.9 N·m
{4 ± 0.4 kgf·m}
[29 ± 2.9 lbf·ft]
Idler gear
Idler Gear - Install
4.9 Idler Gear End Play - Measure
Measure the end play of the idler gear.If the value exceeds
the limit, find the causal parts, and replace them with new
ones.

0.2 to 0.4 mm 0.6 mm
Idler gear end play
[0.008 to 0.016 in.] [0.024 in.]
Idler gear
Idler Gear End Play - Measure
7-23
4.10 Timing Gear Backlash - Measure

Measure the backlash of timing gears using either method:
measure the gear backlash with a dial gauge applying its
probe to a tooth flank on the pitch circle at a right angle to
the tooth axis, or measure the clearance between gears by Camshaft gear
inserting thickness gauges between the engaging gear
teeth.If the value exceeds the limit, replace the gears with
new ones. Fuel injection
pump gear
Backlash between crank 0.11 to 0.25 mm 0.50 mm Idler gear
gear and idler gear [0.0043 to 0.0098 in.] [0.0197 in.]
Backlash between fuel
injection pump gear and
camshaft gear
Backlash between idler
0.12 to 0.18 mm 0.50 mm
gear and fuel injection
[0.0047 to 0.0071 in.] [0.0197 in.]
pump gear
Backlash between crank-
shaft gear and oil pump
gear
4.11 Timing Gear Case - Install
Eyebolt
P/N:05930-00200
Be careful not to drop or bump the timing gear case.It (M12 × 1.25 mm)
will result in personnel injury as well as damage of the
timing gear case.
(1) Apply sealant (ThreeBond 1211) to the rare plate pack- M12:
N
98 ± 4.9 N·m
ing mating surface, and install the packing. kgf m}
{10 ± 0.5 kgf·m}
lbf tt]
[72.3 ± 3.61 lbf·tt]
(2) Apply sealant (ThreeBond 1211) to the packing mating M16:
N
255 ± 12.8 N·m
surface to timing gear case. kgf m}
{26 ± 1.3 kgf·m}
(3) Set the eye bolt to timing gear case, align it with the Timing gear case lbf ft]
[188.1 ± 9.44 lbf·ft]
dowel pins, and install the timing gear case. Timing Gear Case - Install
(5) Cut off excessive packing carefully from the bottom of
crankcase.
7-24
4.12 Rear Oil Seal - Install

Use the rear seal installer assembly to install the rear oil
seal. Insert bolt
(1) Apply clean engine oil evenly to the oil seal lip. Guide flange
Note: Pay attention to the installing side of oil seal, and be Insert
careful not to damage the oil seal. Swing washer
(2) Install the guide flange to the crankshaft rear end face,
Bolt
and fix it with insert bolts.
(3) Set the oil seal to insert and install it to the guide flange. Rear seal installer
(4) Tighten the bolt on the guide flange to insert the oil seal assembly
P/N:32591-07012 Socket bolt
into timing gear case.
Rear Oil Seal - Install (1)
(5) Remove the installer assembly.
12.5 mm
[0.492 in.]
Timing gear case
Oil seal
Slinger
3.5 ± 0.1 mm
[0.138 ± 0.004 in.]
Rear Oil Seal - Install (2)

4.13 Flywheel - Install
Be careful not to drop or bump the flywheel.It will result

in personnel injury as well as damage of the flywheel.
(1) Check the mounting surfaces of flywheel and crank-
shaft to make sure that they are free from any foreign
material or damage.
539 ± 27 N·m
(2) Hitch a sling to the flywheel. {55 ± 2.8 kgf·m}
(3) Install the flywheel by aligning its hole with dowel pin [397.5 ± 19.9 lbf·ft]
[Wet]
on crankshaft.
(4) Apply engine oil to the bolt threads and bolt seat sur- Flywheel - Install
faces, then tighten the bolts to the specified torque.
4.14 Flywheel Face and Radial Runout - Measure
Measure the face and radial runouts of the flywheel.
If the measured value extremely deviates from the standard,
check the assembling condition such as loose bolt or foreign Face runout
measuring plane
material collection on mounting faces.
Radial runout
measuring plane
Item Standard value
Face runout (reference) 0.285 mm [0.0112 in.] or less
Radial runout (reference) 0.127 mm [0.0050] or less
7-25
4.15 Pickup - Install

(Electronic governor spec)
Timing gear case
(1) Turn the crankshaft to move the ring gear teeth top to
the center line of pickup installing hole.
(2) Insert the pickup into the hole slowly and carefully by
hand.
(3) When the tip of pickup contacts with the ring gear tooth Lock nut
top, loosen the pickup to adjust the clearance to stan- One back-turn after
dard value. bottoming end App
rox 1
.4 m
m
(4) Fix the pickup with lock nut. [0.06
in.]
Ring gear
Pickup - Install
7-26
5. Cylinder Head and Valve Mechanism - Assemble

5.1 Cylinder Head - Assemble
Guide and seal installer Valve stem

(a) Be careful when inserting the valve through stem
P/N:32591-10300
seal, as the edge of stem can cause damage to
Stem seal
the stem seal lip.
(b) Do not apply oil or liquid sealant to the fitting faces Valve guide
between stem seal and valve guide.
(c) Always replace the stem seal with a new one.Stem
30.3 ± 0.1 mm
Cylinder head
seal can not be re-used. [1.193 ± 0.04 in.]
(1) Apply engine oil to the valve stem, and insert valve into
valve guide. Stem Seal - Install
Note: The inlet valve and exhaust valve are different. Make
Valve cotter
sure the correct mounting position.
Valve rotator
(2) Install the stem seal to valve guide with guide and seal
installer.
Valve spring
Note: Place the valve in valve guide before installing the
stem seal. The valve stem seal is centered with valve
stem. Stem seal
(3) Apply engine oil to the lip of stem seal.
Valve and Valve Spring - Install

(4) Install the valve spring and rotator to the valve guide,
and then install the valve cotter with valve spring Valve spring pusher
P/N:33591-04500
pusher.
Application of engine oil

Valve Cotter - Install
(5) Tap the top of valve stem lightly several times with a
soft-head hammer to slightly open the valve, and make Valve stem head
sure that the valve spring and valve cotters are properly
installed and seated firmly.
Valve - Install
7-27
5.2 Valve Sinkage - Measure

Measure the valve sinkage.
If the value exceeds the limit, replace the valve or valve seat Seat width
with a new one.Lap the valve and valve seat whenever valve
or valve seat is refaced or replaced.
Valve seat angle

-0.1 to 0.1 mm 0.5 mm
Valve sinkage
[-0.004 to 0.004 in.] [0.019 in.]
Valve margin
Valve sinkage
Valve Sinkage - Measure

5.3 Tappet - Install
Apply engine oil to the tappet outside face, insert tappet into
tappet hole and place the tappet softly on camshaft.
Apply engine oil

Tappet - Install
5.4 Liquid Gasket - Apply
(a) Do not apply liquid gasket excessively.It results in

10 mm Never allow liquid
O-ring deformation.Be careful to apply gasket to [0.39 in.] gasket to adhere to
portions A and B. The space to O-ring is very nar- this area.
row.
(b) Do not apply liquid gasket around the periphery of 5 to 8 mm A
[0.20 to
cylinder bore.It results in gas leakage. Liquid gasket:
0.32 in.]
ThreeBond 1211
(1) Wipe off oil, grease and other contamination from the P/N:37594-01300
cylinder head gasket, cylinder head bottom surface and Liquid gasket coating area
crankcase top surface. Liquid Gasket - Area of Application (Head Side)
(2) Apply a thin coat of liquid gasket to both sides of cylin-
der head gasket around tappet holes and oil pas-
sages.Beads of liquid gasket is 5 to 8 mm [0.20 to 0.31 10 mm Never allow liquid
in.] from the cylinder head gasket outer edge with a [0.39 in.] gasket to adhere to
this area.
thickness of 0.2 to 0.5 mm [0.008 to 0.020 in.]The area
5 to 8 mm
of application is shown on the right. [0.20 to 0.32 in.]
B
Note: After the application of liquid gasket to cylinder head Liquid gasket:
gasket install the cylinder head before liquid gasket ThreeBond 1211
P/N:37594-01300
dries.
Liquid gasket coating area
Liquid Gasket - Area of Application (Crankcase Side)
7-28
5.5 Cylinder Head Gasket - Install

(1) Wipe off oil, grease and other contamination from the
cylinder head bottom surface and crankcase top sur-
Dowel pin
face.
(2) Install the cylinder head gasket coated with liquid gas-
ket onto crankcase with dowel pin and hole in align-
ment.
Cylinder Head Gasket - Install

5.6 Cylinder Head Assembly - Install
(1) Apply engine oil to the cylinder head bolt threads, bolt
Eye nut
seats and washer surfaces. P/N:08014-00003 Application of
(M12 × 1.25 mm) engine oil
Note: Do not apply excessive amount of engine oil. Remove
the excess before assembling.
(2) Install the eye nut to stud bolt, and lift the cylinder head
assembly.
(3) Slowly lower the cylinder head, and place the cylinder
head properly by aligning the holes with the dowel
pins, and tentatively tighten the cylinder head bolts
except long ones.
Cylinder Head Assembly - Install
7-29
5.7 Cylinder Head Bolt - Tighten

Because the cylinder head bolts (long) are used to tighten
Tightening torque of torque method:
both the cylinder head and the rocker shaft bracket, the long 392 ± 20 N·m {40 ± 2.0 kgf·m} [289 ± 14.5 lbf·ft]
cylinder head bolts should be tightened after the rocker shaft [Wet] 2-time tightening
Snug torque of 4 2
bracket is installed.Two methods of cylinder head bolt tight- angle method:
ening, torque tightening and angle controlled tightening, are Short bolt:
available. 118 ± 5.9 N·m
{12 ± 0.6 kgf·m}
Note: If the standard socket tool interferes with the rocker [87 ± 4.3 lbf·ft] 6 5
bracket, use the socket wrench (special tool). Long bolt:
196 ± 9.8 N·m 1 3
5.7.1 Torque tightening method {20 ± 1.0 kgf·m}
[145 ± 7.2 lbf·ft] Cylinder head bolts (Long)
(1) Tighten the cylinder head bolts progressively to the
Cylinder Head Bolts - Tightening Sequence
specified torque in the sequence shown in illustration.
(2) Tighten all the bolts, and then loosen them, and tighten
them again according to this torque method.(2-time
tightening method)
5.7.2 Angle controlled tightening method
(1) Tighten the cylinder head bolts to the specified snug
torque in the sequence shown the illustration.
(2) Tighten the cylinder head bolts to the specified angle in
the sequence shown the illustration. Socket wlench
(3) Loosen all bolts, and then angle controlled tighten them P/N:32591-01100
again.(2-time tightening method) Cylinder Head Bolt - Tighten
Angle
Tightening position Snug torque
method
118±5.9 N·m
Cylinder head bolt
{12±0.6 kgf·m} 75±3°
(short)
[87±4 lbf·ft]
S12A2-1
196±9.8 N·m
Cylinder head bolt
{20±1.0 kgf·m} 60±3°
(long)
[145±7 lbf·ft]
118±5.9 N·m
Cylinder head bolt
{12±0.6 kgf·m} 110±3°
(short)
[87±4 lbf·ft]
S12A2-2
196±9.8 N·m
Cylinder head bolt
{20±1.0 kgf·m} 110±3°
(long)
[145±7 lbf·ft]
7-30
5.8 Bridges and Bridge Caps - Install

(1) Apply engine oil to the bridge guide.
Bridge cap
(2) Install the bridge on bridge guide. Place the screw-fit-
ted end of bridge to exhaust manifold side.
(3) Apply engine oil to the bridge contact area of bridge
Application of
cap, and install the bridge cap.Be careful not to drop the engine oil
bridge cap inside crankcase through push rod hole.
Bridges and Bridge Caps - Install

5.9 Valve Bridge and Adjusting Screw - Adjust
Adjust the contact of valve stem top faces to ensure bridge
Hold down the top of
smooth sliding on bridge guide and balanced pushing to bridge by hand. 55 ± 5.5 N·m
valves. {5.6 ± 0.56 kgf·m}
[41 ± 4.1 lbf·ft]
Tighten an
(1) Loosen the adjusting screw so that its top face protrudes additional 10゜
from top face of nut by 6 to 7 mm [0.23 to 0.27 in.]

(2) Press the top of bridge by hand so that the top face of
Valve
valve stem on bridge plane end contacts closely to the bridge-valve
bridge pushing face. contact
(3) Turn the adjusting screw slowly until screw contacts

the top face of valve stem. Then, turn the screw further
Valve Bridge and Adjusting Screw - Adjust
by 10°, and tighten lock nut to the specified torque.
5.10 Clearance Between Bottom Face of Valve Bridge and Top Face of Valve Rotator - Inspect
Hold down the top
Bridge cap of bridge by hand. Clearance between
Be sure to keep the standard clearance between
Valve bridge valve bridge bottom
valve bridge and valve rotator.If the clearance is face and valve
rotator top face
smaller than the standard, the valve cotter may Valve rotator
come off or get damage.
Push the valve bridge by hand to make close contact of the
top end face of valve stem. Then, check the clearance
between bottom face of valve bridge and top face of valve
rotator.If the value deviates from the standard, find the
causal parts, and replace them with new ones. Clearance Between Bottom Face of Valve Bridge and
Top Face of Valve Rotator - Inspect
Item Standard value
Adjusting screw 2.5 mm
Clearance Between the Bottom side [0.098 in.]
Face of Valve Bridge and the Top
Face of Valve Rotator Non adjusting 1.5 mm
side [0.0591 in.]
7-31
5.11 Rocker shaft assembly - Assemble

(1) Insert the rocker shaft bracket to the rocker shaft
Rocker shaft bracket
bracket.Match the chipped parts of the rocker shaft and
the head bolt hole of rocker shaft bracket.
Notch Rocker shaft

Rocker Shaft - Assemble
(2) Install the rocker arm to the rocker shaft, and tighten
them with washers and snap rings. Rocker shaft bracket
Rocker shaft
Rocker arm
Washer
Cylinder head
bolt (long)
Snap ring
Adjusting Screw
Rocker shaft assembly - Assemble

5.12 Rocker Shaft Assembly - Install
(1) Install the push rod to the tappet hole from the cylinder
Cylinder head bolt (long)
head.
(2) Install a new O-ring to the cylinder head bolt (long), Rocker bracket bolt
and tentatively install the rocker shaft assembly to the 49 ± 2.5 N·m
{5 ± 0.25 kgf·m}
cylinder head.
[36 ± 1.84 lbf·ft]
(3) Insert the rocker bracket bolt to the rocker shaft
bracket.
(4) With the bracket mounting bolt loosely tightened,
adjust the bracket position so that the ends of both rock- O-ring
ers come into contact equally with the respective bridge
Rocker Shaft Assembly - Install
cap tops.
(5) Tighten the cylinder head bolts.
For tightening procedure, refer to "Cylinder Head Bolt -
Tighten" of "ASSEMBLY OF BASIC ENGINE".
(6) Tighten the rocker bracket bolts to the specified torque.
7-32
5.13 Valve Clearance - Check and Adjust

Adjust the valve clearance when the engine is cold.
Note:(a) The inlet valves are on the left side and exhaust
valves are on the right when the cylinder head is
viewed from camshaft side. 8#.8'%.'#4#0%'
%1.&
(b) The valve clearance standard values are shown on +0.'6 OO ':*#756 OO
(+4+0) 14&'4
the caution plate on the No. 1 cylinder rocker cover.
(7'.+0,'%6+106+/+0) q
$6&%
%1041&4#0-
Item Standard value
Inlet 0.4 mm [0.016 in.]
Valve clearance
Exhaust 0.5 mm [0.019 in.]
Valve Clearance Label - Location

(1) Adjust the valve clearance in the firing order at TDC of
compression stroke by turning crankshaft in the normal
direction.
(2) On each cylinder, the piston is at the top dead center on
compression stroke, when corresponding cylinder num-
ber stamped on damper is aligned with pointer, and
inlet valves and exhaust valves are not pushed with
push rod. 1・6
(3) Insert a thickness gauge between rocker arm and bridge
cap to measure the clearance. Tighten or loosen the Cylinder firing order:
Pointer
1-12-5-8-3-10-6-7-2-11-4-9
screw to adjust the clearance where the movement of No. 1 Cylinder Compression Top Dead Center - Check
thickness gauge becomes slightly restricted.
(4) After the adjustment tighten the lock nut firmly to the
specified torque. Then, check the clearance again.
Screw
Lock nut
64 ± 6.4 N·m
{6.5 ± 0.65 kgf·m}
[47 ± 4.7 lbf·ft]
Valve Clearance - Adjust

5.14 Fuel Injection Timing - Check and Adjust
5.14.1 Specified Value of Fuel Injection Timing - Check
The fuel injection timing varies depending on the engine
output, speed and specifications. Be sure to check the plate
on the No. 1 rocker cover for the fuel injection timing. 8#.8'%.'#4#0%'
%1.&
+0.'6 OO ':*#756 OO
(+4+0) 14&'4

(7'.+0,'%6+106+/+0) q
$6&%
%1041&4#0-
Specified Value of Fuel Injection Timing - Check
7-33
5.14.2 Fuel Injection Timing - Check

(1) Turn the crankshaft in normal direction, and stop the
turning when the No. 1 cylinder is positioned at approx
10° before the specified fuel injection timing.
Also, make sure that the line stamped on the fuel injec-
tion pump coupling is positioned before and close to the
pointer.
1・6
Note: In this condition, the clearances of inlet and exhaust
valves are as specified, and valves are not pushed Cylinder firing order:
Pointer
down. 1-12-5-8-3-10-6-7-2-11-4-9
No. 1 Cylinder Compression Top Dead Center - Check
In case of the exhaust stroke top dead center, valves are
pushed down.
(2) Turn the crankshaft to the normal direction progres-
sively, align the fuel injection timing mark on damper
with engine pointer.
If the fuel injection timing is adjusted to the specified
timing, the line stamped on the fuel injection pump
coupling (or timer) will align with the pointer.
If the line does not align with the pointer, adjust the fuel Pointer
injection timing. Fuel injection pump

coupling punch mark
Note: For the left fuel injection pump, rotate the crankshaft Fuel Injection Timing - Check
in No.7 cylinder to before compression top dead cen-
ter, and then follow a procedure described above.
5.14.3 Fuel Injection Timing - Adjust

88 ± 5 N·m
(1) Turn the crankshaft to the normal direction progres- {9 ± 0.5 kgf·m}
[65 ± 3.7 lbf·ft]
sively, align the fuel injection timing mark on damper
with engine pointer.
(2) Loosen the bolts of the driving coupling, and align the
line with the pointer by rotating the fuel injection pump
only. Then tighten the bolts.
(3) From the specified fuel injection timing, turn the crank- Pointer
shaft in the reverse direction by approx 10°. Fuel injection pump
(4) Turning the crankshaft to the normal direction progres- coupling (punch) mark
Fuel Injection Timing - Adjust
sively again, align the line mark of fuel injection timing
with the pointer.
Then, make sure that the line on the fuel injection pump
coupling (or timer) aligns with the pointer.
Repeat the step (2) until the proper alignment is made.
7-34
5.15 Valve Timing - Inspect

The specified valve timing is automatically made, when
gears are assembled by aligning match marks and valve
clearance is adjusted to the specified value.To make sure,
check the valve timing as follows:
5.15.1 Valve timing at normal valve clearance (no Top dead center
thickness gauge insertion) q 55
55 q
Exhaust valve
(1) Check that the valve clearance is adjusted to the specifi- Inlet valve
open closes
cation.
Direction of
(2) Insert the thickness gauge, which has the same thick- rotation
ness as the specified valve clearance, between bridge
cap and rocker arm.(valve clearance 0 mm)
Inlet valve Exhaust valve
(3) Turn the crankshaft in the normal direction little by lit- closes open
tle, and find a position where thickness gauge is tightly 65 q
q 65
gripped (valve open position) and a position where Bottom dead center
Valve Timing When Valve Clearance is 0 mm
thickness gauge is released (valve closed position.)
(4) Verify the value to the specification. Rocker arm
Standard valve clearance
Thickness
Bridge cap gauge
Valve clearance 0 mm
5.15.2 Valve Timing When Valve Clearance is 2 mm
Top dead center 11°11°
[0.08 in.] Exhaust valve
Inlet valve
Valve timing open closes
Adjust the clearance to 2.5 mm [0.098 in.] for reliable Direction of
rotation
inspection, where the valve motion changes rapidly.
(1) Insert a thickness gauge of 0.5 mm [0.020 in.] between
bridge cap and rocker arm.(Valve clearance 2 mm [0.08
in.]) Inlet valve Exhaust valve
(2) Turn the crankshaft in the normal direction little by lit- closes 21° 21°open
tle, and find a position where thickness gauge is tightly Bottom dead center
Valve Timing When Valve Clearance is 2 mm [0.08 in.]
gripped (valve open position) and a position where
thickness gauge is released (valve closed position.) Rocker arm
(3) Check that the obtained angle meets the angle shown in
the illustration.
(4) Readjust valve clearance to the correct value. Valve clearance 2 mm [0.08 in.]
0.5 mm [0.020 in.]
Thickness
Bridge cap gauge
Valve clearance 2 mm [0.08 in.]
7-35
5.16 Fuel Injection Nozzle Assembly - Install

(1) Apply a thin coat of grease to the gasket and install it to
fuel injection nozzle. Fuel leak off pipe
Eye bolt
(2) Insert the fuel injection nozzle to the cylinder head, and
Fuel injection pipe
temporarily tighten the nozzle gland.
(3) Tighten the nozzle gland nut to the specified torque so Gasket
that the inlet connector of fuel injection nozzle does not Nut
contact the valve spring. 59 ± 2.9 N·m
Note: Do not forget to install the gasket when installing fuel {6 ± 0.3 kgf·m}
[43 ± 2.2 lbf·ft]
injection nozzle assembly.
Nozzle gland
Fuel Injection Nozzle - Install
5.17 Fuel pipe - Install
(1) Tighten the fuel injection pipe.
17.5 ± 2.5 N·m
(2) Tighten the eyebolt of fuel leak-off pipe with the speci- {1.8 ± 0.3 kgf·m}
[12.9 ± 1.8 lbf·ft] Fuel injection pipe
fied torque.
(3) Fix the fuel injection pipe and fuel leak-off pipe with a Sealing Clamp
clamp. washer
Fuel leak off pipe
Fuel pipe - Install
7-36
1. Fuel System - Remove and Inspect ....................................................................... 8-3
1.1 Fuel Injection Pipe - Remove and Inspect ................................................................................ 8-3
1.2 Fuel Leak-off Pipe and Fuel Pipe - Remove and Inspect ......................................................... 8-4
1.3 Fuel Filter and Fuel Pipe - Remove and Inspect ...................................................................... 8-6
1.4 Stop Solenoid - Remove and Inspect ....................................................................................... 8-7
1.5 Fuel Control Link - Remove and Inspect .................................................................................. 8-9
1.6 Fuel Injection Pump - Remove and Inspect............................................................................ 8-12
2. Fuel System - Disassemble, Inspect and Assemble .......................................... 8-14
2.1 Fuel Filter (Wire Element) - Disassemble, Inspect and Assemble.......................................... 8-14
2.2 Fuel Filter (Paper Element) - Disassemble, Inspect and Assemble ....................................... 8-15
2.3 Fuel Injection Nozzle - Disassemble and Inspect ................................................................... 8-18
2.4 Fuel Injection Nozzle - Inspect and Adjust.............................................................................. 8-20
2.5 Fuel Injection Nozzle - Assemble ........................................................................................... 8-23
2.6 Fuel Injection Pump Accessory Drive - Disassemble and Inspect.......................................... 8-25
2.7 Outside Diameter and Inside Diameter of Accessory Drive Bearing Fit - Inspect .................. 8-26
2.8 Fuel Injection Pump Accessory Drive - Assemble .................................................................. 8-27
2.9 Governor Drive - Disassemble and Inspect ............................................................................ 8-28
2.10 Outside Diameter and Inside Diameter of Bearing Fit ............................................................ 8-29
2.11 Governor Drive - Assemble .................................................................................................... 8-31
3. Fuel System - Install .............................................................................................. 8-33
3.1 Fuel Injection Pump - Install ................................................................................................... 8-33
3.2 Fuel Control Link - Install ........................................................................................................ 8-37
3.3 Stop Solenoid - Install............................................................................................................. 8-44
8-1
1. Fuel System - Remove and Inspect

1.1 Fuel Injection Pipe - Remove and Inspect
Standard spec PTA2 spec
4
4
7
Leak, crack, contact
7
Replace Replace
Double pipe spec
Replace 5
8
Replace
4
1
Leak, crack, contact
6
Replace
Fuel Injection Pipe - Remove and Inspect

Removing Sequence
1 Leak-off pipe (Double pipe) 5 Leak-off connector (Double pipe)
2 Leak-off pipe (Double pipe) 6 Left leak-off pipe
3 Right leak-off pipe (Double pipe) 7 No. 7 to 12 fuel injection pipe
4 No.1 to 6 fuel injection pipe 8 Leak-off connector (Double pipe)
8-3
1.2 Fuel Leak-off Pipe and Fuel Pipe - Remove and Inspect
Return to fuel tank
Replace A
12 11
A
Replace
Replace 1
7
5
8
2
9 3
Replace
6
With fuel filter (wire element) spec
10 Replace
Fuel Leak-off Pipe and Fuel Pipe - Remove and Inspect

Removing Sequence
1 Left leak-off pipe 8 Fuel pipe
2 Left leak-off pipe 9 Leak-off connector
3 Leak-off pipe 10 Fuel filter (wire mesh element)
4 Right leak-off pipe (Fuel filter [wire mesh element] spec)
5 Right leak-off pipe 11 Left leak-off pipe
6 Fuel pipe 12 Right leak-off pipe
7 Fuel pipe
8-4
Return to fuel injection pump
Replace 5
7
Replace
With fuel filter (wire element) spec
1
4 1
Replace
Fuel Leak-off Pipe and Fuel Pipe - Remove and Inspect

Removing Sequence
1 Fuel pipe 5 Leak-off pipe
2 Fuel pipe 6 Left leak-off pipe
3 Fuel pipe 7 Right leak-off pipe
4 Fuel filter (wire mesh element)
(Fuel filter [wire mesh element] spec)
8-5
1.3 Fuel Filter and Fuel Pipe - Remove and Inspect
Change over type fuel filter spec Standard fuel filter spec
4
Standard fuel filter
3 spec
6
2
6
3
4 6
5
1
5 5
Change over type fuel filter spec
Fuel Filter and Fuel Pipe - Remove and Inspect

Removing Sequence
1 Left fuel pipe 4 Right fuel pipe
2 Left fuel pipe 5 Fuel filter assembly
3 Right fuel pipe 6 Fuel filter bracket
8-6
1.4 Stop Solenoid - Remove and Inspect
Stop solenoid RUN ON spec
6
11
Looseness, bend 7
9
8
1
10
Rotation
4 5
Stop Solenoid - Remove and Inspect

Removing Sequence
1 Link 5 Lever 9 Snap ring
2 Bolt, Spacer, Rubber cushion 6 Spring pin 10 Ball bearing
3 Stop solenoid 7 Lever 11 Bracket
4 Spring pin 8 Shaft
8-7
Stop solenoid RUN OFF type
7 6
11
Looseness, bend 10
Rotation
1
4 5
Stop Solenoid - Remove and Inspect

Removing Sequence
1 Link 5 Lever 9 Snap ring
2 Bolt 6 Spring pin 10 Ball bearing
3 Stop solenoid 7 Lever 11 Bracket
4 Spring pin 8 Shaft
8-8
1.5 Fuel Control Link - Remove and Inspect
Woodward PSG type governor spec

TOHO SEISAKUSHO SG4017 type actuator spec
a. PSG spec 2
A
4
Looseness, bend
6
6 Rotation a. PSG spec
A 8
Contact face wear, bend
3
7
Flaw, wear, bend
Rotation
Looseness, bend 6
b. SG4017 spec
Rotation 6
6
6 Rotation
8 1
3 7
4 Flaw, wear, bend 5
6
Looseness, bend
Contact face wear, bend
A b. SG4017 spec Rotation
a. Woodward PSG type governor

b. TOHO SEISAKUSHO SG4017 type actuator
Fuel Control Link - Remove and Inspect

Removing Sequence
1 Right link 4 Cancel lever 7 Control shaft
2 Left link 5 Right lever 8 Timing gear case pipe
3 Governor link 6 Bearing cover, ball bearing
8-9
Woodward PROACT type actuator spec
Looseness, bend 6
Looseness, bend 5
9
10
Rotation
8 Rotation 7
1
4
Looseness, bend 3
Looseness, bend
11
13 11
Contact face wear, bend Rotation

12
Flaw, wear, bend Rotation

2
Looseness, bend

Removing Sequence
1 Right link 6 Left link 10 Left lever
2 Right link 7 Left lever 11 Bearing cover, ball bearing
3 Right lever 8 Governor link 12 Control shaft
4 Right stay 9 Cancel lever 13 Timing gear case
5 Left link
8-10
TOHO SEISAKUSHO SG4017 type actuator

PTA2 spec
Looseness, bend 6
Looseness, bend 5
9
10
Rotation
8 Rotation 7
1
4
Looseness, bend
3
Looseness, bend
11
13
11
Contact face wear, bend Rotation

12
Flaw, wear, bend

Rotation
2
Looseness, bend

Removing Sequence
1 Right link 6 Left link 10 Left lever
2 Right link 7 Left lever 11 Bearing cover, ball bearing
3 Right lever 8 Governor link 12 Control shaft
4 Right stay 9 Cancel lever 13 Timing gear case
5 Left link
8-11
1.6 Fuel Injection Pump - Remove and Inspect
With back stay spec

16
12 13 16
14
PTA,PTA2,PTK spec 8
15
8
17
7
10
11
A
9
6
11
4
A
PTA,PTK,MTK,MPTA,
MPTK spec
1
Drive case 2
Fuel Injection Pump - Remove and Inspect

Removing Sequence
1 Right stay 9 Right injection pump bracket
2 Right coupling cover 10 Left stay
3 Right cover stay 11 Left coupling cover
4 Pump mounting bolt 12 Pump mounting bolt
6 Right fuel injection pump (Approx 43 kg [95 lb]) 14 Left fuel injection pump (Approx 43 kg [95 lb])
7 Right fuel injection pump stay 15 Left fuel injection pump stay
(With back stay spec) (With back stay spec)
8 Stay (with back stay spec) 16 Stay (with back stay spec)
17 Left fuel injection pump stay
Note: The shape of left coupling cover differs in accordance with the customization and specification.
8-12
Tamper proof attachment spec

16 16
12 13
15
11 10
8
8
14 7
17
4
A
5
3
A
1
6
2 9
Y2PTAW
Y2PTAW Crankcase
Y2PTAW
Fuel Injection Pump - Remove and Inspect

Removing Sequence
1 Right stay 10 Right stay
2 Right coupling cover 11 Left coupling cover
5 Right fuel injection pump (Approx 43 kg [95 lb]) 14 Left fuel injection pump
6 Right tamper plate 15 Left fuel injection pump stay
7 Right injection pump stay 16 Stay
8 Stay 17 Left injection pump stay
9 Right injection pump bracket
8-13
2. Fuel System - Disassemble, Inspect and Assemble

2.1 Fuel Filter (Wire Element) - Disassemble, Inspect and Assemble
Replace
Replace
2
10
Replace
Cracks, flaw 3
20 N·m
Replace
{2.0 kgf·m}
[14.7 lbf·ft]
5 6
1
4
Replace
Fuel Filter (Wire Element) - Disassemble, Inspect and Assemble

1 Plug, packing 6 Element
2 Bolt, spring washer, plain washer 7 Rod, O-ring
3 Flange, lower case, packing 8 Snap ring, washer, handle
4 Nut 9 Air vent plug
5 Plate, scraper, collar, O-ring 10 Cover
8-14
2.2 Fuel Filter (Paper Element) - Disassemble, Inspect and Assemble
Standard fuel filter spec
Air vent plug

9 ± 1 N·m
{0.9 ± 0.1 kgf·m}
[6.6 ±0.7 lbf·ft]
Filter wrench
Use the filter wrench to remove
the fuel filter.
(Use only when removing)
Crack, flaw
2
Dent
Fuel Filter (Paper Element) - Disassemble, Inspect and Assemble

1 Fuel filter cartridge 2 Fuel filter bracket
8-15
Changeover spec
Replace Air vent plug

9 ± 1 N·m
{0.9 ± 0.1 kgf·m}
[6.6 ±0.7 lbf·ft]
Filter wrench
Crack, flaw Use the filter wrench to remove
the fuel filter cartridge.
(Use only when removing)
5
4 2
Replace
1
3
Dent
Fuel Filter (Paper Element) - Disassemble, Inspect and Assemble

1 Fuel filter cartridge 4 Cock
2 Pin 5 Fuel filter bracket
3 Cover
8-16
2.2.1 Fuel Filter Cartridge - Install
(a) Make sure that there is no flame around the area before handling fuel.
(b) Wipe any spilled fuel to prevent a fire.
(c) Do not use the fuel filter cartridge that has a dent on the case. If the case has a dented, it can cause damage
to the fuel filter cartridge, leading to fuel leaks during operation, and results in a fire.
(a) When installing the fuel filter cartridge, do not use a filter wrench. Tighten it with your hand.
(b) Be careful not to dent or damage the surface of fuel filter cartridge.
(1) Remove dust and contaminants on the filter cartridge mating face.
(2) Apply clean fuel on the fuel filter gasket.
(3) After the fuel filter gasket comes into contact with the base, tighten the cartridge by 3/4 to 1 turn by hand.
Note: After the installation bleed air from the fuel system.
(4) Start the engine, and make sure that there is no fuel leaks.
8-17
2.3 Fuel Injection Nozzle - Disassemble and Inspect

efficient work.
any job.
Fuel Injection Start Pressure - Inspect
Fuel Injection Nozzle Spray - Inspect
Shim adjustment type spec
Deformation, deterioration, 9
flaw
8
1
6
7
Replace
5
4
Worn contact of needle valve

10
3
Carbon deposit,
nozzle hole clogging,
needle valve sticking
Fuel Injection Nozzle - Disassemble and Inspect

1 Connector, gasket 5 Spacer 9 Shim
2 Retaining nut 6 Pin 10 Nozzle holder body
3 Nozzle tip 7 Push rod
4 Pin 8 Nozzle spring
8-18
Screw adjust type
1
2
Replace
Replace
3
Deformation, deterioration, flaw
4
7
5
Carbon deposit,
nozzle hole clogging,
needle valve sticking
Fuel Injection Nozzle - Disassemble and Inspect

1 Inlet connector, gasket 4 Nozzle spring 7 Nozzle tip
2 Connector, gasket 5 Push rod 8 Nozzle holder
3 Adjusting screw 6 Retaining nut
8-19
2.4 Fuel Injection Nozzle - Inspect and Adjust

2.4.1 Fuel Injection Start Pressure - Inspect and
Nozzle tester
Adjust
P/N:04239-00050
Never touch fuel spray during fuel injection nozzle

test.
(Screw adjust type)

(1) Install the fuel injection nozzle to the nozzle tester.
(2) Push down the handle at a speed of one stroke a second
and measure the pressure when injection starts. If the
pressure is out of the standard, adjust it to the standard. Fuel Injection Start Pressure - Inspect
(3) To adjust the injection start pressure, remove the set
44 ± 5 N·m
screw on the nozzle holder and the cap nut, and turn the {4.5 ± 0.5 kgf·m}
adjusting screw with a screwdriver. [33.2 ± 3.7 lbf·ft]
Cap nut
(4) After adjustment, tighten the cap nut and set screw to
the specified torque.
(5) After tightening the set screw, inspect the injection start Pressure Pressure
- increase - decrease
pressure again to make sure it is within the standard
value.
Adjusting screw
Item Nominal value Standard value
21.6 MPa 22.1 to 22.6 MPa Fuel Injection Start Pressure - Adjust
Fuel injection start-
{220 kgf/cm2} {225 to 230 kgf/cm2}
ing pressure
[3129 psi] [3200 to 3271 psi]
(Shim adjust type) Pressure adjustment

(1) Install the fuel injection nozzle to the nozzle tester. by shim combinations
(2) Push down the handle at a speed of one stroke a second

and measure the pressure when injection starts. If the
pressure is out of the standard, adjust it to the standard.
(3) Adjust the injection start pressure by increasing or
68.5 ± 9.5 N·m
N·m
decreasing the number of shims. Shims are available in {7 ± 1 kgf·m}
kgf·m}
5 thicknesses from 0.40 to 0.70 mm [0.0157 to 0.0275 [50.5 ± 7.01 lbf·ft]
in]. Valve opening pressure difference of 0.1 MPa can
be achieved by using a shim having a thickness of
Valve Opening Pressure of Fuel Injection Nozzle -
approximately 0.0045 to 0.0083 mm [0.0002 to 0.0003
Adjust
in.].
(4) After the adjustment, tighten the retaining nut to the
specified torque.
(5) After tightening the retaining nut to the specified
torque, inspect again the injection start pressure to see
that it is as specified.

29.4 MPa 29.9 to 30.7 MPa
Fuel injection start-
{300 kgf/cm2} {304 to 313 kgf/cm2}
ing pressure
[4267 psi] (the value when it is new)
8-20
2.4.2 Fuel Injection Nozzle Spray - Inspect

When adjusting the nozzle opening pressure with the nozzle
tester, inspect for nozzle orifice clogging, fuel spray pattern
Good Faulty spray
and dripping. If spray condition is faulty, clean or replace
the nozzle tip.
Checking points of fuel spray are as follows:
Injection spray is straight.
Large After Intermittent Whirling
The spray is of fine fuel droplets without big drops. angel dribble spray spray
No dripping is shown after injection. spray
Fuel Injection Nozzle Spray - Inspect
2.4.3 Nozzle Tip - Clean and Replace
(a) Be careful not to hit the nozzle tip. Nozzle tip end
(b) The needle valve and body are precision parts.
Retaining nut
Handle them carefully, and do not change the
original valve and body combination.
(1) Remove the retaining nut.
(2) Remove the nozzle tip.
Nozzle Tip - Remove

(3) Clean the needle valve and body of nozzle tip.
When cleaning the needle valve and nozzle tip body,
use clean wash oil. Assemble the needle valve and body
in clean diesel fuel after cleaning.
(4) Tighten the nozzle tip tightening retainer nut to the
specified torque.
Needle valve
(5) If the spray pattern is still faulty after cleaning and
Body
adjusting, change the nozzle tip with a new one.
New nozzle tips are coated with anti-corrosive agent.
Wash the nozzle tips before use. First wash them in
wash oil, and wash it again with clean diesel fuel before Nozzle Tip - Clean
installation.
2.4.4 Push Rod - Inspect

Shim adjust type Screw adjust type
Inspect the push rod visually. If its spring seat wears Spring seating face
unevenly, or its needle valve contact surface wears remark- local wear
ably, or the cavitation occurs on its tapered area, replace the
push rod with a new one.
Cavitation
Needle valve
contact surface wear
Push Rod - Inspect
8-21
2.4.5 Spacer - Inspect

High pressure
(Shim adjust type) seal face
Inspect the spacer visually. If its needle valve contact sur-
face or high pressure seal surface wears remarkably, replace
the spacer with a new one.
Note: When the nozzle tip is replaced, replace the spacer and
nozzle spring with new ones.
High pressure seal
face Needle valve contact portion
ø3 mm [0.12 in.]
Spacer - Inspect
8-22
2.5 Fuel Injection Nozzle - Assemble
Shim adjust type
Do not hit with a hammer when

installing into cylinder head.
44 ± 5 N·m {4.5 ± 0.5 kgf·m}

[32.5 ± 3.69 lbf·ft]
Application of engine oil to

gasket top and bottom faces
68.5 ± 9.5 N·m {7 ± 1 kgf·m}

[50.5 ± 7 lbf·ft]
Fuel Injection Nozzle - Assemble
Be sure to tighten the retaining nut to the specified torque. Excessive tightening of retaining nut can harm smooth
movement of the needle valve and result in abnormal exhaust smoke or needle valve sticking.
Note: When assembling the nozzle tip on the nozzle holder, make sure to align the nozzle tip knock pin with the nozzle holder
hole.
8-23
Screw adjust type
Do not hit with a hammer, etc.

when installing into cylinder head.
44 ± 5 N·m
{4.5 ± 0.5 kgf·m}
74 ± 5 N·m [32.5 ± 3.69 lbf·ft]
{7.5 ± 0.5 kgf·m}
[54.5 ± 3.69 lbf·ft]
Application of engine oil to

gasket top and bottom faces
68.5 ± 9.5 N·m

{7 ± 1 kgf·m}
[50.5 ± 7.01 lbf·ft]
Fuel Injection Nozzle - Assemble
Be sure to tighten the retaining nut to the specified torque. Excessive tightening of retaining nut can harm smooth
movement of the needle valve and result in abnormal exhaust smoke or needle valve sticking.
8-24
2.6 Fuel Injection Pump Accessory Drive - Disassemble and Inspect
Fuel injection pump S7S spec
Fuel injection pump

S3S spec Deformation, lip surface wear
10
Rotation
5
Wear, flaw
Wear, flaw 8
9
7
Fuel injection pump

5 S7S spec
10
Wear, flaw
6 Rotation
4
2 Peeling, wear
1 3
Fuel Injection Pump Accessory Drive - Disassemble and Inspect

1 Nut 5 Drive shaft 9 Sleeve
2 Washer 6 Ball bearing 10 Drive case
3 Fuel injection pump gear 7 Ball bearing
4 Snap ring 8 Oil seal
8-25
2.7 Outside Diameter and Inside Diameter of Accessory Drive Bearing Fit - Inspect
(1) Turn the bearing and if the turning is not smooth,
replace the bearing with a new one.
(2) Inspect the fit of drive shaft and bearing. If significant
wear is found, replace them with new ones.
(3) Inspect the fit of drive case and bearing. If significant
wear is found, replace them with new ones.
(4) Inspect the driveshaft and oil seal, and if any defect is
found, replace them with new ones.
Nominal
Item Standard value
value
ø72 mm 71.988 to 72.018 mm
Inside diameter of case bear- [2.83 in.] [2.8341 to 2.8353 in.]
ing housing ø90 mm 89.985 to 90.020 mm
[3.54 in.] [3.5426 to 3.5440 in.]
ø72 mm 71.987 to 72.000 mm
Small
Outside [2.83 in.] [2.8341 to 2.8346 in.]
diameter ø90 mm 89.985 to 90.000 mm
S3S spec Large
(Drive case [3.54 in.] [3.5427 to 3.5433 in.]
Bearing
P/N: 34.988 to 35.000 mm
32625-10300) Small ø35 mm
Inside [1.3774 to 1.3779 in.]
Large
[1.57 in.] [1.5743 to 1.5748 in.]
35.002 to 35.013 mm
ø35 mm
Outside diameter of drive [1.3780 to 1.3785 in.]
shaft bearing fit ø40 mm 40.002 to 40.013 mm
[1.57 in.] [1.5748 to 1.5753 in.]
ø80 mm 79.988 to 80.018 mm
Inside diameter of case bear- [3.15 in.] [3.1491 to 3.1502 in.]
ing housing ø100 mm 99.987 to 100.022 mm
[3.94 in.] [3.9365 to 3.9379 in.]
ø80 mm 79.987 to 80.000 mm
Small
Outside [3.15 in.] [3.1490 to 3.1495 in.]
S7S spec Large
(Drive case [3.94 in.] [3.9364 to 3.9370 in.]
Bearing
P/N: ø40 mm 39.988 to 40.000 mm
32625-09100) Small
Inside [1.57 in.] [1.5743 to 1.5748 in.]
Large
[1.77 in.] [1.7712 to 1.7717 in.]
ø40 mm 40.002 to 40.013 mm
Outside diameter of drive [1.57 in.] [1.5748 to 1.5753 in.]
shaft bearing fit ø45 mm 45.002 to 45.013 mm
[1.77 in.] [1.7717 to 1.7722 in.]
8-26
2.8 Fuel Injection Pump Accessory Drive - Assemble
294 ± 15 N·m
{30 ± 1.5 kgf·m}
[216.8 ± 11.06 lbf·ft] Application of
engine oil to lip portion
294 ± 15 N·m
{30 ± 1.5 kgf·m} Application of
[216.8 ± 11.06 lbf·ft] engine oil to lip portion
Fuel Injection Pump Accessory Drive - Assemble
8-27
2.9 Governor Drive - Disassemble and Inspect
Oil pressure governor spec

S3S spec Replace
13
8
8
S7S spec
9
Wear of tooth
Settling
Rotation
S3S spec S7S spec

2
3
12
4
11
10
10
Rotation
Rotation
Replace
1 Wear of tooth Wear of tooth
Rotation Rotation
5
6
7
Governor Drive - Disassemble and Inspect

1 Drive case cover, packing, oil seal 9 Ball bearing, snap ring
2 Ball bearing, snap ring 10 Ball bearing, snap ring
3 Idler gear 11 Washer
4 Ball bearing, snap ring 12 Drive shaft, drive gear, rubber, pin, sleeve
5 Ball bearing, snap ring 13 Drive case, packing
6 Driven gear
7 Ball bearing, snap ring
8 Injection pump gear, nut, washer, key
8-28
2.10 Outside Diameter and Inside Diameter of Bearing Fit

Rotate the bearing and if the rotation is not smooth, replace the bearing with a new one.
Inspect the fit of drive shaft, idler shaft and bearing. If significant wear is found, replace them with new ones.
Inspect the fit of drive case and bearing. If significant wear is found, replace them with new ones.
Nominal
Item Standard value
value
ø47 mm 46.989 to 47.014 mm
[1.85 in.] [1.8500 to 1.8509 in.]
ø80 mm 79.988 to 80.018 mm
[3.15 in.] [3.1491 to 3.1502 in.]
ø90 mm 89.987 to 90.022 mm
[3.54 in.] [3.5428 to 3.5442 in.]
ø47 mm 46.989 to 47.014 mm
[1.85 in.] [1.8500 to 1.8509 in.]
Inside diameter of case cover bearing hous- ø62 mm 61.988 to 62.018 mm
ing [2.44 in.] [2.4404 to 2.4416 in.]
ø72 mm 71.988 to 72.018 mm
[2.83 in.] [2.8341 to 2.8353 in.]
ø47 mm 46.890 to 47.000 mm
Small
[1.85 in.] [1.8461 to 1.8504 in.]
Outside ø80 mm 79.987 to 80.000 mm
Middle
diameter [3.15 in.] [3.1490 to 3.1495 in.]
ø90 mm 89.985 to 90.000 mm
Large
[3.54 in.] [3.5427 to 3.5433 in.]
Drive case bearing
ø20 mm 19.990 to 20.000 mm
S3S spec Small
[0.79 in.] [0.7870 to 0.7874 in.]
(Drive case
P/N: 32625-15100) Inside ø40 mm 39.988 to 40.000 mm
Middle
diameter [1.57 in.] [1.5743 to 1.5748 in.]
ø40 mm 39.988 to 40.000 mm
Large
[1.57 in.] [1.5743 to 1.5748 in.]
ø47 mm 46.890 to 47.000 mm
Small
[1.85 in.] [1.8461 to 1.8504 in.]
Middle
diameter [2.44 in.] [2.4404 to 2.4409 in.]
ø72 mm 71.987 to 72.000 mm
Large
Drive case cover bear- [2.83 in.] [2.8341 to 2.8346 in.]
ing ø20 mm 19.990 to 20.000 mm
Small
[0.79 in.] [0.7870 to 0.7874 in.]
Inside ø30 mm 29.990 to 30.000 mm
Middle
diameter [1.18 in.] [1.1807 to 1.1811 in.]
ø35 mm 34.988 to 35.000 mm
Large
[1.38 in.] [1.3774 to 1.3779 in.]
ø35 mm 35.002 to 35.013 mm
[1.38 in.] [1.3780 to 1.3785 in.]
Outside diameter of drive shaft bearing fit
ø40 mm 40.002 to 40.013 mm
[1.57 in.] [1.5748 to 1.5753 in.]
8-29
Nominal
Item Standard value
value
ø47 mm 46.989 to 47.014 mm
[1.85 in.] [1.8500 to 1.8509 in.]
ø80 mm 79.988 to 80.018 mm
[3.15 in.] [3.1491 to 3.1502 in.]
ø100 mm 99.987 to 100.022 mm
[3.94 in.] [3.9365 to 3.9379 in.]
ø47 mm 46.989 to 47.014 mm
[1.85 in.] [1.8500 to 1.8509 in.]
Inside diameter of case cover bearing hous- ø62 mm 61.988 to 62.018 mm
ing [2.44 in.] [2.4404 to 2.4416 in.]
ø80 mm 79.988 to 80.018 mm
[3.15 in.] [3.1491 to 3.1502 in.]
ø47 mm 46.890 to 47.000 mm
Small
[1.85 in.] [1.8461 to 1.8504 in.]
Middle
diameter [3.15 in.] [3.1490 to 3.1495 in.]
ø100 mm 99.985 to 100.000 mm
Large
[3.94 in.] [3.9364 to 3.9370 in.]
Drive case bearing
ø20 mm 19.990 to 20.000 mm
S7S spec Small
[0.79 in.] [0.7870 to 0.7874 in.]
(Drive case
P/N: 32625-09200) Inside ø40 mm 39.988 to 40.000 mm
Middle
diameter [1.57 in.] [1.5743 to 1.5748 in.]
ø45 mm 44.988 to 45.000 mm
Large
[1.77 in.] [1.7712 to 1.7717 in.]
ø47 mm 46.890 to 47.000 mm
Small
[1.85 in.] [1.8461 to 1.8504 in.]
Middle
diameter [2.44 in.] [2.4404 to 2.4409 in.]
ø80 mm 79.987 to 80.000 mm
Large
Drive case [3.15 in.] [3.1490 to 3.1495 in.]
cover bearing ø20 mm 19.990 to 20.000 mm
Small
[0.79 in.] [0.7870 to 0.7874 in.]
Inside ø30 mm 29.990 to 30.000 mm
Middle
diameter [1.18 in.] [1.1807 to 1.1811 in.]
ø40 mm 39.988 to 40.000 mm
Large
[1.57 in.] [1.5743 to 1.5748 in.]
ø40 mm 40.002 to 40.013 mm
[1.57 in.] [1.5748 to 1.5753 in.]
Outside diameter of drive shaft bearing fit
ø45 mm 45.002 to 45.013 mm
[1.77 in.] [1.7717 to 1.7722 in.]
8-30
2.11 Governor Drive - Assemble
Backlash
0.12 to 0.18 mm
Apply engine oil [0.0047 to 0.0071 in.]
Apply engine oil to the lip
Backlash
0.12 to 0.18 mm Fuel injection pump
[0.0047 to 0.0071 in.] S7S spec
Apply engine oil
Apply engine oil to the lip Fuel injection pump Apply engine oil
S3S spec
294±15 N·m
{30±1.5 kgf·m}
[217±11 Ibf·ft]
294±15 N·m
{30±1.5 kgf·m}
[217±11 Ibf·ft]
Governor Drive - Assemble
2.11.1 Backlash - Measure

Measure the backlash between each gear. If the value exceeds the limit, replace the gears with new ones.

Backlash between drive gear and 0.12 to 0.18 mm 0.50 mm
idler gear [0.0047 to 0.0071 in.] [0.0197 in.]
Backlash between driven gear 0.12 to 0.18 mm 0.50 mm
and idler gear [0.0047 to 0.0071 in.] [0.0197 in.]
8-31
2.11.2 Rubber - Install

Insert the drive gear to the drive shaft, then assemble the pin
and rubber.
Rubber - Install
2.11.3 Drive gear and Case - Assemble
Insert the drive shaft assembly to the drive case.
Drive shaft - Install
8-32
3. Fuel System - Install

Install the parts in the reverse order of the disassemble sequence. (Refer to the illustration for disassembling.)
Clean and dry well the fuel passage.
3.1 Fuel Injection Pump - Install
With back stay spec

58 ± 5.8 N·m
{5.9 ± 0.59 kgf·m}
[42.8 ± 4.28 lbf·ft] 108 ± 11 N·m
58 ± 2.9 N·m {11 ± 1.1 kgf·m}
{5.9 ± 0.3 kgf·m} [79.6 ± 8 lbf·ft]
[42.8 ± 2.14 lbf·ft]
34 ± 3.4 N·m
{3.5 ± 0.35 kgf·m}
[25.3 ± 2.53 lbf·ft]
58 ± 5.8 N·m
108 ± 11 N·m {5.9 ± 0.59 kgf·m}
PTA,PTA2,PTK spec {11 ± 1.1 kgf·m} [42.8 ± 4.28 lbf·ft]
[79.6 ± 8 lbf·ft]
34 ± 3.4 N·m
{3.5 ± 0.35 kgf·m}
[25.3 ± 2.53 lbf·ft]
A
PTA,PTK,MTK,MPTA,
MPTK spec 58 ± 5.8 N·m
{5.9 ± 0.59 kgf·m}
[42.8 ± 4.28 lbf·ft]
58 ± 5.8 N·m
{5.9 ± 0.59 kgf·m}
[42.8 ± 4.28 lbf·ft] 58 ± 2.9 N·m
Drive case {5.9 ± 0.3 kgf·m}
[42.8 ± 2.14 lbf·ft]
Fuel Injection Pump - Install
8-33
58 ± 5.8 N·m Tamper proof attachment spec

33 ± 3.3 N·m 58 ± 5.8 N·m {5.9 ± 0.59 kgf·m}
{3.4 ± 0.34 kgf·m} {5.9 ± 0.59 kgf·m} [42.8 ± 4.28 lbf·ft] 108 ± 11 N·m
[24.3 ± 2.43 lbf·ft] [42.8 ± 4.28 lbf·ft] {11 ± 1.1 kgf·m}
35 ± 5.0 N·m [79.6 ± 8 lbf·ft]
{3.6 ± 0.51 kgf·m}
[25.8 ± 3.69 lbf·ft] 34 ± 3.4 N·m
{3.5 ± 0.35 kgf·m}
[25.3 ± 2.53 lbf·ft]
34 ± 3.4 N·m 58 ± 5.8 N·m

{3.5 ± 0.35 kgf·m} {5.9 ± 0.59 kgf·m}
[25.3 ± 2.53 lbf·ft] [42.8 ± 4.28 lbf·ft]
108 ± 11 N·m 35 ± 5.0 N·m
{11 ± 1.1 kgf·m} {3.6 ± 0.51 kgf·m}
[79.6 ± 8 lbf·ft] [25.8 ± 3.69 lbf·ft]
58 ± 5.8 N·m
{5.9 ± 0.59 kgf·m}
[42.8 ± 4.28 lbf·ft]
35 ± 5.0 N·m
{3.6 ± 0.51 kgf·m}
[25.8 ± 3.69 lbf·ft]
33 ± 3.3 N·m
{3.4 ± 0.34 kgf·m}
[24.3 ± 2.43 lbf·ft]
A
58 ± 2.9 N·m
{5.9 ± 0.3 kgf·m}
[42.8 ± 2.14 lbf·ft] A
Y2PTAW 58 ± 2.9 N·m

{5.9 ± 0.3 kgf·m} 33 ± 3.3 N·m
[42.8 ± 2.14 lbf·ft] {3.4 ± 0.34 kgf·m}
Y2PTAW
Y2PTAW 35 ± 5.0 N·m [24.3 ± 2.43 lbf·ft]
{3.6 ± 0.51 kgf·m}
Crankcase [25.8 ± 3.69 lbf·ft]
Fuel Injection Pump - Install
8-34
3.1.1 Checking before installing fuel injection pump

(1) When installing the right bank fuel injection pump,
rotate the crankshaft so that No. 1 piston is at the top
dead center of compression stroke, and when installing
the left bank fuel injection pump, rotate the crankshaft
so that No. 7 piston is at the top dead center of com-
pression stroke.
(2) Remove the tentatively installed drive coupling and Pointer
laminated plates set on the drive coupling from the fuel Fuel injection pump
injection pump. Install the coupling and the set to the coupling punch mark
Pointer and Line Mark - Align
accessory drive shaft with the woodruff key. Push the
drive coupling to the accessory drive as close as possi-
Fuel injection pump
ble, and leave the tightening bolts loose.
accessory drive
(3) Align the line mark on the fuel injection pump coupling
(or timer) with the pointer. Drive coupling
(the injection start timings of cylinder No. 1 and No. 7)

Laminated plate set
Shaft tightening bolt
Drive Coupling - Install

(4) Make sure that the driving coupling and laminated plate
are coupled as shown in the illustration. Coupling key 19°30’±3
groove
Assembling Position of Fuel Injection Pump Coupling

(Viewed From Rear Side i.e. From Drive Side)
8-35
3.1.2 Fuel Injection Pump - Install
(a) Wash the bolt, bushing and washer before using. Foreign material on the contact surface of drive coupling and
laminated plates can cause the slipping or damage of coupling.
(b) After the tightening of couplings check the laminated plates for distortion. If the plates are distorted loosen and
retighten the bolts.
(1) Lift the fuel injection pump. Slowly lower the fuel
injection pump, and install the pump aligning with the Nut 88 ± 5N·m
{9.0 ± 0.5kgf·m}
dowel pin on bracket. [65 ± 3.7 lbf·ft]
(2) Couple the drive coupling to the cross coupling and ten- Drive coupling
tatively tighten the bolt.
Cross coupling
Then, make sure that the line mark on the fuel injection
Laminated plate
pump coupling (or timer) is at a position close to the
pointer when the No. 1 and No. 7 cylinders are at the Coupling tightening bolt
88 ± 5N·m
top dead center on compression. {9 ± 0.5kgf·m}
(3) Adjust the distance between couplings to the specified [65 ± 3.7 lbf·ft]
Couplings and plates - assemble
value.
For adjustment procedure, refer to "Coupling Distance -
Adjust" of "FUEL SYSTEM."
(4) Tighten all bolts and nuts, which have been installed
tentatively to the couplings, to the specified torque.
(5) Install the stay in between the fuel injection pump case
and the crankcase.
(6) Refill engine oil through the oil drain pipe mounting
hole of cam chamber. Refill the engine oil to the
(7) Install the oil pipe and fuel pipe. intake hole on the oil drain
pipe.
Engine Oil - Refill
3.1.3 Coupling Distance - Adjust

Fuel injection pump side
Adjust the position of coupling so that the distance between S3S : 63 mm [2.48 in.]
S7S : 64 mm [2.52 in.]
couplings meet the specified value, and tighten the bolt to
Adjust so that the distance
the specified torque.
between the coupling end faces
meets the specified value.
Drive coupling
88 ± 5 N·m
{9 ± 0.5 kgf·m}
[65 ± 3.7 lbf·ft]
Coupling
Coupling Distance - Adjust
8-36
3.2 Fuel Control Link - Install

3.2.1 Control shaft - Install
If the bearings at both ends of control shaft are not properly installed, or if the bearings do not rotate smoothly, it
could result in a hunting or other malfunctions.
Stop lever Bearing cover Control shaft

Link lever
O-ring Control lever
To governor Pipe
Left side of engine Right side of engine

Control shaft - Install
(1) Insert the pipe with O-ring to the timing gear case.
(2) Insert the control shaft to the pipe.
(3) Press-in bearings to control shaft both ends.
(4) Install the snap ring to left control shaft. (Mechanical governor spec, PSG governor spec)
(5) Install the bearing cover.
(6) With a plastic head mallet, tap the both ends of control shaft alternately for snug fitting.
(7) Rotate the control shaft by hand, and verify the smooth rotation.
3.2.2 Control Link Lever - Install
(1) Install the link levers of both banks (stamped mark : L and R) together with ball bearing, snap ring and bearing cover to the
stay.
(2) Tentatively install the control lever having a serrated hole to the right end of control shaft.
(3) Tentatively install the link lever, which is connected to the governor, together with the ball bearing, snap ring, and stop
lever to the left end of control shaft.
8-37
3.2.3 Fuel Control Link - Install and Adjust
Woodward PGS governor spec
Control lever
Adjustable length control link B-1
Fuel Adjustable length
injection pump Fixed length
control link B-2
(208.5 ± 1.0 mm [11.97 ± 0.0394 in.])
control rink A-2
Control rack
[6.22
158 ± 0.59 in.]
1±
95.5 mm
1.5 m
[3.760 in.]
m
Stop lever
Distance between the end face of fuel injection pump
and the center of hole at control rack end: 78 mm [3.07 in.]
Control rack position ‫ޟ‬0‫ޠ‬:: 67.5mm [2.99 in.]
Play: approx. 2 mm [0.08 in.]
Governor lever
Toho Seisakusho SG4017 actuator spec

Distance from the end of
pump to the
fuel injection pumptothe
hole center of rack end
Rack "0": 67.5 mm [2.60 in.] Adjustable length control link B-3
Play: approx. 2 mm [0.12 in.] Stop lever
Governor lever
Fixed length
561
(208.5 ± 1.0 mm
2
[11.97 ± 0.0394 in.])

control rink A-3 Approx.
25q
Control lever
B-4
Adjustable length control link B-2
Fuel injection pump
Left-bank linkage - Overall view
8-38
Woodward PSG governor spec

Toho Seisakusho SG4017 actuator spec
Control shaft
Control lever
Fuel injection pump
Fixed length
(304 ± 1.0 mm [11.97 ± 0.0394 in.])control rink A-1
Control rack
Distance between the end face of fuel injection pump

and the center of hole at control rack end: 78 mm [3.07 in.]
Control rack position 「0」:: 67.5mm [2.99 in.]
Right-bank linkage - Overall view
If the play of fuel injection pump rack is in excess, fuel can not be stopped even when the governor brings the link to
engine stop position, and engine over-running may results.
Common
Left bank fixed length control link
(1) Install the fixed-length (304±1.0 mm [12±0.04 in.])
208.5 ± 1.0 mm
control link A-1 in between the fuel injection pump
[8.209 ± 0.039 in.]
control rack and the control lever on the right bank. Welding
PSG type governor spec
Welding
(2) Adjust the variable-length control link B-1 on the left
bank to 95.5 mm [3.76 in.], and tentatively tighten it. Right bank fixed length control link
Then fix it to the fixed-length (208.5±1.0 mm 304 ± 1.0 mm [11.97 ± 0.039 in.]
Welding
[8.21±0.04 in.]) control link A-2.
(3) Assemble the variable-length control link B-1 into the
Fixed-length control links of right and left banks
stop lever having a serrated hole. Install the fixed-
length (208.5±1.0 mm [8.21±0.04 in.]) control link A-2 Left bank variable length control link
to the fuel injection pump control rack. Left-hand thread Right-hand thread
Check that the fuel injection pump racks of both banks

are at the no-injection position, then install the stop
lever together with the spacer and cancel spring to the Make the length of engagements even.
serration on the control shaft. Left-hand Right-hand
thread thread
Note: Adjust the engagement lengths even on right and left-
handed threads.
(4) Fine adjust the variable-length control link B-1 for the Make the length of engagements even.
left bank so that movement of the fuel injection pump Left bank variable-length control link
rack becomes the same on both banks.
8-39
(5) Adjust the variable-length control link B-2 to 158±1.5

mm [6.2±0.06 in.], and install it in between the control
lever and the governor lever.
Fine adjust so that the distance between fuel injection
pump end face and the center of hole at the end of rack
becomes 67.5 mm [2.66 in.] with 2mm [0.079 in.] play
when the governor output shaft is at zero (no injection).
Note: Insert the reverse threaded portions of the variable-
length link, right and left equally, so that the length of
thread engagement becomes 10mm [0.39] or more.
(6) Make sure that the distance between the center of hole
locating at the end of fuel injection pump rack and the
fuel injection pump end face is 6735 mm [2.66 in.] with
a 2mm [0.08 in.] play when the stop lever is fully
pulled to the stop side (rack "0" position).
SG4017 type actuator spec
Left bank fixed length control link
(2) Assemble the variable-length control link B-3 on the
208.5 ± 1.0 mm
left bank to the fixed-length (208.5±1.0 mm [8.21±0.04
[8.209 ± 0.039 in.]
in.]) control link A-3. Welding
(3) Assemble the variable-length control link B-3 into the
Welding
stop lever having a serrated hole. Install the fixed-
length (208.5±1.0 mm [8.21±0.04 in.]) control link A-3 Right bank fixed length control link
to the fuel injection pump control rack. 304 ± 1.0 mm [11.97 ± 0.039 in.]
Check that the fuel injection pump racks of both banks Welding

Fixed-length control links of right and left banks
lever together with the spacer and cancel spring to the
serration on the control shaft. Left bank variable length control link
Note: Adjust the engagement lengths even on right and left- Left-hand thread Right-hand thread
handed threads.
(4) Fine adjust the variable-length control link B-3 for the
left bank so that movement of the fuel injection pump Make the length of engagements even.
rack becomes the same on both banks. Left-hand Right-hand
thread thread
(5) Install the variable-length control link B-4 between the
control lever and the governor lever.
The installing angle of governor lever must be 25º to Make the length of engagements even.
the variable-length control link B-4. Left bank variable-length control link
when the governor output shaft is at zero (no injection).
Note: Insert the reverse threaded portions of the variable-
length link, right and left equally, so that the length of
thread engagement becomes 10mm [0.39] or more.
8-40
3.2.4 Fuel Control Link - Install and Adjust
Woodward ProAct actuator spec

fuel injection pump
to the holecenter of rack end
Rack "0": 67.5 mm [2.60 in.]
Play: approx. 2 mm [0.12 in.] 147m
[5.78 m
7 in.]
Adjustable length
control link B-2
126.5 ± 0.3 mm
[4.980 ± 0.012 in.]
Stop lever
5612
39.
7°
Control lever
8°
124
[4.88 mm
Adjustable length Governor lever 2 in.
control rink A ]
Adjustable length
control rink C
Fuel injection pump
Distance from the end of Toho Seisakusho SG4017 actuator PTA2 spec
fuel injection pump to
the hole center of rack end
Rack "0": 67.5 mm [2.60 in.]
Adjustable length
control link B-2
147
126.5 ± 0.3 mm
16.1° [5.7 mm
87 in
[4.980 ± 0.012 in.] .] Stop lever
5612
Control lever
Adjustable length
control rink A 8°
Adjustable length
control rink C
Fuel injection pump
Governor lever
Left-bank linkage - Overall view
8-41
Woodward ProAct actuator spec

Toho Seisakusho SG4017 actuator PTA2 spec

mm fuel injection pump to
± 0.3 2 in.] the hole center at rack end
.5 01
140 2± 0. Rack "0": 67.5 mm [2.60 in.]
5 3
[5. Play: approx. 2 mm [0.12 in.]
Control lever
126.5 ± 0.3 mm
[4.980 ± 0.012 in.]
Control link lever
Control shaft
Adjustable length control link B-1 Control rack
Adjustable length control rink A

4°
Fuel injection pump
Right-bank linkage - Overall view
If the play of fuel injection pump rack is in excess, fuel can not be stopped even when the governor brings the link to
engine stop position, and engine over-running may results.
(1) Set the length of the link A between the fuel injection
pump rack and the control link lever (for both right and
left banks) to 126.5±0.3 mm [4.98±0.012 in.], and
install the link A to the right and left banks respectively.
(2) Install the right-bank variable length control link B-1
Left-hand thread Right-hand thread
(140.5±0.3 mm [5.53±0.012 in.]) between the control
link lever and control lever.
(3) Set the left-bank variable-length control link B-2 to
147 mm [5.79 in.], and fit the link to the stop lever hav- Make the length of engagements even.
ing a serration hole. Left-hand thread Right-hand thread

Check that the fuel injection pump racks of both banks
lever together with the spacer and cancel spring to the
Make the length of engagements even.
serration on the control shaft.
Right and left-bank control links
Note: Adjust the engagement lengths even on right and left-
handed threads.
(4) Fine adjust the left-bank variable-length control link C

so that both right and left-bank fuel injection pump
racks move the same distance.
8-42
(5) Install the variable-length control link B-1 for the left
bank C between the control lever and the governor
lever.
when the angle scale of actuator output shaft is at zero
(no injection).
Note: Adjust the engagement lengths even and 8 mm [0.32
in.] or more on right and left-handed threads of the
variable-length control link.
Woodward PROACT type actuator spec only
Stopper - Install
Install the stopper bolt to the plate.
When the actuator output shaft angle scale reads "0" (no
0
injection), screw the stopper bolt until it comes into contact
with the top face of the governor lever. 10
Zero scale mark
Governor actuator output shaft - Angle scale
Stopper bolt
39.7
°
STOP
Governor lever stopper - Adjust
8-43
3.3 Stop Solenoid - Install

3.3.1 Stop solenoid
RUN-ON type:
Turned ON during operation, when turned OFF, the solenoid is deactivated to stop the engine.
RUN-OFF type:
Turned OFF during operation, when turned ON, the solenoid is activated to stop the engine.
3.3.2 Stop solenoid (RUN ON type) - Adjust
RUN ON stop system spec

Stop solenoid OFF:
118.5 ± 0.5 mm [2.697 ± 0.020 in.]
Stop lever
Adjustable length control link

Follower
OFF
Engine stop
condition Clearance: 0 mm (contact)
Engine
running condition
Stop solenoid
Stop solenoid (RUN ON type) - Adjust

(1) Turn off the stop solenoid (engine stop).
(2) Adjust the variable-length control link so that the distance between the follower and stop lever is 0 mm (contact).
Note: When the power of governor actuator is OFF, the fuel injection pump rack is at the no injection (engine stop) position. In
this state, the distance between the fuel injection pump case end face and the follower center is 118.5±0.5 mm
[4.665±0.019 in.].
8-44
3.3.3 Stop solenoid (RUN OFF type) - Adjust
Stop solenoid RUN OFF stop system spec

ON: 99 ± 0.5 mm [2.697 ± 0.020 in.]
Clearance: 0 mm (contact)
Follower
Stop lever
Adjustable length control link
Engine
running condition
ON
Engine
stop condition
Stop solenoid
Stop solenoid (RUN OFF type) - Adjust

(1) Pull the stop solenoid manually to the stop solenoid ON position (engine stop.)
(2) Adjust the variable-length control link so that the distance between the follower and stop lever is 0 mm (contact).
Note: When the power of governor actuator is OFF, the fuel injection pump rack is at the no injection (engine stop) position. In
this state, the distance between the fuel injection pump case end face and the follower center is 99±0.5 mm [3.898±0.019
in.].
3.3.4 Solenoid Function - Verify
Make sure the solenoid functions of start, running and emergency stop of the engine and check the fuel injection pump rack
positions.
Stop solenoid
Specification Item Engine starting Engine running Engine emergency stop
Plunger position (spring condition) Compressed Stretched
Stop solenoid Activation ON OFF
RUN ON
Distance from the fuel injection pump
- 118.5±0.5 mm [4.6653±0.019 in.]
end face to follower center
Plunger position (spring condition) Stretched Compressed
Stop solenoid Activation OFF ON
RUN OFF
Distance from the fuel injection pump
- 99±0.5 mm [3.898±0.019 in.]
end face to follower center
Note:(a) If the distance to the follower center of fuel injection pump is the standard value (with 3.5 mm [0.138 in.] play to the
rack 0) or more, the engine may not be stopped.
(b) If the distance to the follower center of fuel injection pump is the 116 mm (4.57 in.) at RUN ON and 97 mm (3.82 in.)
at RUN OFF (rack 0 contacting to the stopper), fuel injection pump rack stopper may be damaged. Ensure the correct
play of 2 to 3 mm [0.08 to 0.12 in.]
8-45
1. Lubrication System - Remove and Inspect ........................................................... 9-3
1.1 Oil Pipe - Remove..................................................................................................................... 9-3
1.2 Oil Pipe for Fan Drive - Remove............................................................................................... 9-4
1.3 Oil Cooler and Oil Filter - Remove and Inspect ........................................................................ 9-5
1.4 Breather - Remove and Inspect................................................................................................ 9-8
1.5 Oil Level Gauge and Oil Filler - Remove and Inspect............................................................... 9-9
1.6 Oil Filter for Governor - Remove and Inspect ......................................................................... 9-10
1.7 Oil Pan, Oil Strainer and Oil Pump - Remove and Inspect ..................................................... 9-11
2. Lubrication System - Disassemble, Inspect and Assemble .............................. 9-13
2.1 Oil strainer - Disassemble and Inspect ................................................................................... 9-13
2.2 Oil Pump and Safety Valve - Disassemble and Inspect ......................................................... 9-14
2.3 Oil Pump and Safety Valve - Inspect ...................................................................................... 9-15
2.4 Oil Pump and Safety Valve - Assemble.................................................................................. 9-17
2.5 Oil Cooler, Oil Filter, and Relief Valve - Disassemble and Inspect......................................... 9-18
2.6 Oil Filter - Inspect.................................................................................................................... 9-19
2.7 Oil Filter Alarm - Inspect ......................................................................................................... 9-19
2.8 Relief valve opening pressure - Measure ............................................................................... 9-19
2.9 Relief Valve - Inspect.............................................................................................................. 9-19
2.10 Bypass Valve - Inspect ........................................................................................................... 9-20
2.11 Oil Cooler - Inspect ................................................................................................................. 9-20
2.12 Oil Filter, Relief Valve and Oil Cooler - Assemble .................................................................. 9-20
2.13 Oil Filter Cartridge - Install ...................................................................................................... 9-20
2.14 Bypass Oil Filter - Disassemble and Inspect .......................................................................... 9-21
2.15 Governor Oil Filter - Disassemble and Inspect ....................................................................... 9-22
3. Lubrication System - Install.................................................................................. 9-23
3.1 Oil pump, Oil strainer and Oil pan - Install .............................................................................. 9-23
9-1
1. Lubrication System - Remove and Inspect

1.1 Oil Pipe - Remove
Distributor
11
10
Crankcase
8
7
6 11
9
7
4 5 9
Electronic Crankcase
governor spec
Drive case
Drive case
2 1
Right side
injection pump 4
3 Replace: Gasket
Electronic governor spec O-ring
Oil Pipe - Remove

Removing Sequence
1 Right drain pipe 5 Left oil pipe 9 Oil drain pipe
2 Right oil pipe 6 Left drain pipe 10 Oil pipe
3 Right oil pipe 7 Oil pipe 11 Oil drain pipe
4 Left oil pipe 8 Oil pipe
9-3
1.2 Oil Pipe for Fan Drive - Remove
Crankcase
3 Crankcase
Crankcase
1
Fan drive bracket
2
Front cover
Fan drive bracket
Top positioning bypass filter spec Ribbed belt spec
4 3
Crankcase
Fan drive bracket
Front cover
Replace: sealing washer
Oil Pipe for Fan Drive - Remove

Removing Sequence
1 Flexible pipe 3 Flexible pipe 4 Oil pipe
2 Oil drain pipe
9-4
1.3 Oil Cooler and Oil Filter - Remove and Inspect
Land use standard spec

3
8
Front cover
7
6 6
5
5
2
Crankcase
Replace: Gasket, O-ring Continuous generator
Oil Cooler and Oil Filter - Remove and Inspect

Removing Sequence
1 Oil filter 4 Oil cooler 7 Oil pipe
2 Oil pipe 5 Stay 8 Bypass oil filter assembly
3 Oil pipe 6 Stay 9 Oil filter bracket
9-5
MPTA, MPTK spec
9
3
A
A
Front cover 8
Front cover
7 7
MTK spec
9
6 1
5 2
Crankcase

Removing Sequence
9-6
Bypass oil filter downward spec
7
9
3
9
7
A
MTK, MPTA, MPTK, spec
8
3
A
4
PTA2,Y2PTAW spec
6
5 6
2
5
Crankcase
6
5 2
2 PTA2 spec
MPTA, MPTK, C2MPTK spec Replace: Gasket, O-ring

Removing Sequence
9-7
1.4 Breather - Remove and Inspect
4
4 4
5 5 5
3 3
1 1 3 1
3 2 2 2
Marine standard spec MPTA spec MPTK spec
3
5
1
2
Upward spec
Downward spec
Replace: Gasket
O-ring
Breather - Remove and Inspect

Removing Sequence
1 Oil drain pipe 3 Stay 5 Breather assembly
2 Breather pipe 4 Rubber hose
9-8
1.5 Oil Level Gauge and Oil Filler - Remove and Inspect
Land use standard spec

PTA, PTA2, PTAW spec
2
Standard type oil pan spec
MPTA, MPTK spec (MEE)
2
PTA, Marine standard spec
1
3
Deep type oil pan spec
2
MPTA(SKL), MPTK spec(VOLVO) Replace: packing
Oil Level Gauge and Oil Filler - Remove and Inspect

Removing Sequence
1 Oil level gauge 2 Oil filler 3 Spacer
9-9
1.6 Oil Filter for Governor - Remove and Inspect
Oil pressure governor spec
Drive case
Crankcase
6 2
4
Replace: sealing washer

*Woodward PSG type governor
Oil Filter for Governor - Remove and Inspect
Removing Sequence
1 Oil pipe 3 Oil pipe 5 Oil filter assembly for governor
2 Oil pipe 4 Oil pipe 6 Oil filter bracket
9-10
1.7 Oil Pan, Oil Strainer and Oil Pump - Remove and Inspect
Land
2 Deep
1
5
Deep
Oil Pan, Oil Strainer and Oil Pump - Remove and Inspect
Removing Sequence
1 Oil pan 3 Strainer support 5 Oil strainer
(Standard type: approx. 48 kg [105 lb]) 4 Oil pump assembly 6 Oil pipe
(Deep type: approx. 80 kg [176 lb]
2 Packing
9-11
Marine spec
MPTK, MPTA spec
MTK, MPT spec
Oil Pan, Oil Strainer and Oil Pump - Remove and Inspect
Removing Sequence
1 Oil pan (Deep type: approx. 83 kg [183 3 Strainer support 5 Oil strainer
lb.]) 4 Oil pump assembly 6 Oil pipe
2 Packing
9-12
2. Lubrication System - Disassemble, Inspect and Assemble

2.1 Oil strainer - Disassemble and Inspect
Replace
Replace
Replace
Replace
Clogged strainer hole:

Wash with diesel fuel
Oil strainer - Disassemble and Inspect

1 Oil strainer 2 Oil pipe
9-13
2.2 Oil Pump and Safety Valve - Disassemble and Inspect
5
Flaw, crack
1 9
Flaw, wear
Replace
6
Settling, breakage, wear
10
4
Flaw, crack 3
8
2 Contact, peeling, wear
7
Contact, peeling, wear
Flaw, wear
Oil Pump and Safety Valve - Disassemble and Inspect

1 Safety valve assembly 5 Washer, nut 9 Oil pump case
2 Oil pump cover 6 Oil pump gear 10 Shim
3 Bushing 7 Drive gear
4 Driven gear 8 Bushing
9-14
2.3 Oil Pump and Safety Valve - Inspect

2.3.1 Drive Gear and Driven Gear Backlash - Mea-
sure
Measure the backlash between drive gear and driven gear.If
the value exceeds the limit, replace the gears with new ones.

Drive gear and driven 0.100 to 0.200 mm 0.400 mm
gear backlash [0.0039 to 0.0079 in.] [0.0157 in.]
2.3.2 Clearance Between the Gear Teeth and Case -

Measure
Measure the top clearance between drive/driven gear teeth
and case housing.If the value exceeds the limit, replace the
gear or case with a new one.

Tip clearance
Top clearance between 0.150 to 0.230 mm
0.350 mm
gear teeth and case [0.0059 to 0.0091 in.]
[0.0138 in.]
Clearance Between the Gear Teeth and Case -

Measure
2.3.3 Side Clearance Between Gear Width and Case
- Measure
Measure the side clearance between the gear width and case
depth.If the value exceeds the limit, replace the gear or case
with a new one.
Side clearance P/N: 0.130 to 0.200 mm 0.250 mm

between gear 32635-20010 [0.0051 to 0.0079 in.] [0.0098 in.]
width and case P/N: 0.130 to 0.300 mm 0.350 mm
depth 32635-10020 [0.0051 to 0.0118 in.] [0.0138 in.]
Side Clearance Between Gear Width and Case -
Measure
2.3.4 Drive/Driven Gear Shaft Outside Diameters and
Bushing Inside Diameters - Measure
(1) Check the gear teeth.If any defect is found, replace the
gear with a new one.
(2) Measure the drive/driven gear shaft outside diameters
and bushing inside diameters.If any of the gear or bush-
ing exceeds the limit, replace them as a set with new
ones.
Nominal
value
Gear shaft out- 33.944 to 33.960 mm 33.920 mm
side diameter ø34 mm [1.3363 to 1.3370 in.] [1.3354 in.]
Bushing inside [1.34 in.] 34.000 to 34.025 mm 34.055 mm
diameter [1.3385 to 1.3395 in.] [1.3407 in.]
9-15
2.3.5 Oil Pump Bushing - Replace

Oil pump
(1) Use the oil pump bushing puller to replace oil pump bushing puller
bushings. P/N:32691-02700 Bushing inside
(2) Replace the oil pump bushing in a timely manner. If the diameter
ø34 +0.025
0 mm
bushing is too stubborn to remove, replace the bushing [ø1.34 0
+0.001
in.]
as an assembly of the oil pump case or oil pump cover. Surface roughness
Ra: 0.4 μm
[0.016 μin.]
Removing Press-fitting
Oil pump bushing - Insert
(3) When press-fitting a bushing in the oil pump cover, ori-
ent the bushing such that its joint is positioned as illus-
trated (it is not aligned with the oil groove).
15±5º
Bushing joint
15±5º
Oil pump bushing joint position

2.3.6 Oil Pump Safety Valve - Inspect
Valve Plug
Item Standard value
1.42 MPa
Safety valve opening pressure
{14.5 kgf/cm2} [206 psi]
(1) Inspect the oil pump safety valve spring, and if any
deformation, wear, or breakage is found, or if the speci-
fied limit is exceeded, replace it with a new one. Spring
Fatigue, breakage, wear
Item Standard value
Safety valve spring 97 mm [3.82 in.]/833.6 N Safety Valve - Inspect
Set length / load {85 kgf} [187.4 lbf]
Free length of safety valve
120 mm [4.72 in.]
spring
(2) Inspect the valve and stopper. If significant wear or

malfunction of sliding parts is found, replace them with
new ones.
9-16
2.4 Oil Pump and Safety Valve - Assemble
294 ± 15 N·m
{30 ± 1.5 kgf·m}
[217 ± 11 lbf·ft]
Oil Pump and Safety Valve - Assemble
9-17
2.5 Oil Cooler, Oil Filter, and Relief Valve - Disassemble and Inspect
11 6
7
Replace 8
9
10
Replace
Fatigue, breakage, wear

Replace 12
Replace 13 Clogging, rupture, crack
Crack, deformation
Without With
oil filter alarm oil filter alarm
Replace
14
2 4 4
3 3 Replace
5
Changeover-type No changeover
Replace
Replace
Replace
1
Plug
Replace
Oil Cooler, Oil Filter, and Relief Valve - Disassemble and Inspect
1 Oil filter 5 Drain cock 10 Relief valve
2 Bypass valve 6 Relief valve plug 11 Oil cooler case
3 Connector 7 O-ring 12 Gasket
Oil filter alarm 8 Relief valve sleeve 13 Oil cooler element
4 Sealing washer 9 Relief valve spring 14 Oil cooler cover
9-18
2.6 Oil Filter - Inspect

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

2.7 Oil Filter Alarm - Inspect
(1) Use a tester to check the alarm for insulation and conti-
nuity. If the alarm is defective, replace it with a new
one.
(2) If the filter alarm activation pressure is out of the stan-
dard, replace the alarm with a new one.
Item Standard value

Oil filter alarm 0.165 ± 0.015 MPa
Turn on start pressure
(differential pressure)
{1.68 ± 0.15 kgf/cm2}
[24 ± 2 psi]
ǡ
Oil Filter Alarm - Inspect
2.8 Relief valve opening pressure - Measure
(1) Remove the taper plug (R1/8) on the upper surface of
the oil filter bracket, and set a pressure gauge.
(2) Warm-up the engine until the oil temperature reaches
70 to 90 °C [158 to 194 °F].
(3) Measure the oil pressure at idle and maximum speed
respectively.
Note: When the oil temperature is low, the oil pressure may
rise above the set pressure, but it returns to the set pres-
sure as the oil temperature rises.
Item Standard value Relief valve opening pressure - Measure

0.55 MPa
Relief valve opening pressure
{5.6 kgf/cm2} [80 psi]
2.9 Relief Valve - Inspect

(1) Inspect the relief valve spring for settling and damage.
If significant settling, wear, or damage is found, replace
it with a new one.
Item Standard value

Free length of relief valve spring 147 mm [5.79 in.] Spring
Valve
(2) Inspect the valve. If significant wear or sliding mal-
function is found, replace it with a new one.
Relief Valve - Inspect

9-19
2.10 Bypass Valve - Inspect

Inspect the bypass valve opening pressure. If limit is
exceeded, replace it with a new one.
Item Standard value

0.44 ± 0.05 MPa
Bypass valve opening pressure {4.49 ± 0.51 kgf/cm2}
[64 ± 7 psi]
2.11 Oil Cooler - Inspect

Check the oil passages of element for flaws or cracks by
Air
applying compressed air of 1.5 MPa {15 kgf/cm2} [217 psi]. Leak, flaw, crack check
If any leakage or damage is found, replace the element with
a new one.
Oil Cooler - Inspect

2.12 Oil Filter, Relief Valve and Oil Cooler - Assemble
To assemble, follow the disassembly sequence in reverse.
Thoroughly clean oil passages with wash oil, and dry the
cleaned parts with compressed air.
2.13 Oil Filter Cartridge - Install
(a) When installing oil filter cartridge, tighten it by

hand. (Do not use filter wrench.)
(b) Be careful not to dent or damage the surface of
cartridge.
(1) Remove dust and contamination on oil filter cartridge
mating face.
(2) Apply clean engine oil on oil filter gasket.
(3) After the oil filter gasket contacts with base surface,
tighten the cartridge by 3/4 to 1 turn by hand.
(4) Start the engine, and make sure that there is no fuel
leaks.
9-20
2.14 Bypass Oil Filter - Disassemble and Inspect
Replace:
every 250 hours 2
Remove with oil filter wrench

Replace
Replace
3
Replace
3
Replace:
every 250 hours Replace:
every 250 hours
1 2
2
MTK, MPTA, MPTK spec PTA2,Y2PTAW spec

Bypass Oil Filter - Disassemble and Inspect
1 Bypass filter bracket 2 Cartridge element 3 Bracket
9-21
2.15 Governor Oil Filter - Disassemble and Inspect
Governor Oil Filter - Disassemble and Inspect

1 Element 2 Bracket
9-22
3. Lubrication System - Install

Install the parts in the reverse order of the disassemble sequence.(Refer to the illustration for disassembling.)
Thoroughly clean and dry the oil passage.
3.1 Oil pump, Oil strainer and Oil pan - Install
3.1.1 Backlash When Installing Oil Pump - Adjust
After installing the oil pump to crankcase, measure the
backlash of crankshaft gear and oil pump gear.
If the backlash is out of the standard, insert shims to oil Shim
t = 0.1 mm
pump mounting portion to adjust the backlash.
[0.004 in.]
P/N: 32635-00900
Item Standard value
Backlash between oil pump gear and 0.12 to 0.18 mm
crankshaft gear [0.0047 to 0.0071 in.]
Backlash When Installing Oil Pump - Adjust

3.1.2 Oil Pan - Install
ThreeBond Apply ThreeBond Rear plate
(1) Apply sealant (ThreeBond 1211) to the bottom surface 1211 1211
of mating place between the front cover and crankcase. Timing gear
case
(2) Apply Heldite to the bottom surfaces of mating places Crankcase
between crankcase, rear plate and timing gear case.
(3) Apply sealant (ThreeBond 1212) to the parting places Front Rear
of oil pan packing (4 places), and install the packing to
the oil pan. Packing
(4) Tighten the oil pan mounting bolts to the specified
torque. Front cover Crankcase
Oil Pan - Install (1)
Replace
Application of
ThreeBond 1211
at parting surface
39 ± 3.9 N·m
{4 ± 0.4 kgf·m}
[29 ± 2.9 lbf·ft]
Oil Pan - Install (2)
9-23
1. Cooling System - Remove and Inspect ............................................................... 10-3
1.1 Tension Pulley - Remove and Inspect (Water pump side) ..................................................... 10-3
1.2 Tension Pulley - Remove and Inspect (Fan side)................................................................... 10-4
1.3 Thermostat Case and Water Pipe - Remove and Inspect ...................................................... 10-5
1.4 Water Pipe - Remove and Inspect.......................................................................................... 10-6
1.5 Heat Exchanger and Water Pipe - Remove and Inspect ...................................................... 10-11
1.6 Sea Water Pump and Water Pipe - Remove and Inspect .................................................... 10-12
1.7 Expansion Tank and Water Pipe - Remove and Inspect ...................................................... 10-13
1.8 Water pump and Water Pipe - Remove and Inspect ............................................................ 10-14
2. Cooling System - Disassemble, Inspect and Assemble .................................. 10-15
2.1 Tension Pulley - Disassemble and Inspect (Water pump side) ............................................ 10-15
2.2 Tension Pulley - Disassemble and Inspect (Water pump side for Air cooler)....................... 10-18
2.3 Tension Pulley - Disassemble and Inspect (Water pump side PTA2 spec).......................... 10-21
2.4 Tension Pulley - Disassemble and Inspect (Fan side PTA2 spec) ....................................... 10-23
2.5 Thermostat - Disassemble and Inspect ................................................................................ 10-25
2.6 Thermostat - Inspect............................................................................................................. 10-26
2.7 Heat Exchanger - Disassemble and Inspect......................................................................... 10-27
2.8 Water pump - Disassemble and Inspect............................................................................... 10-28
2.9 Water pump - Inspect ........................................................................................................... 10-30
2.10 Water pump - Assemble ....................................................................................................... 10-31
2.11 Water pump for Air cooler Cooling - Disassemble and Inspect ............................................ 10-33
2.12 Water pump for Air cooler Cooling - Assemble..................................................................... 10-36
2.13 Sea Water Pump - Disassemble and Inspect ....................................................................... 10-38
2.14 Sea Water Pump - Assemble ............................................................................................... 10-40
2.15 Fan Drive Assembly - Disassemble and Inspect .................................................................. 10-44
2.16 Fan Drive - Inspect ............................................................................................................... 10-45
2.17 Oil Seal Sleeve - Inspect ...................................................................................................... 10-46
2.18 Oil Seal Sleeve - Replace..................................................................................................... 10-46
2.19 Fan Drive - Assemble ........................................................................................................... 10-47
3. Cooling System - Install ...................................................................................... 10-50
3.1 Water Pipe (Air cooler) - Install............................................................................................. 10-50
3.2 Tension Pulley - Install.......................................................................................................... 10-50
3.3 Water Outlet Pipe - Install..................................................................................................... 10-50
10-1
1. Cooling System - Remove and Inspect

1.1 Tension Pulley - Remove and Inspect (Water pump side)
PTAW spec
Crack, wear
PTA2 spec
9 5
10
2
12
11 4
Crack, wear
Tension Pulley - Remove and Inspect (Water pump side)

Removing Sequence
1 Tension bolt 7 Belt
2 Mounting bolt 8 Tension pulley assembly
3 Belt 9 Tension bolt
4 Tension pulley assembly 10 Mounting bolt
10-3
1.2 Tension Pulley - Remove and Inspect (Fan side)
PTA2 spec
Crack, wear
Tension Pulley - Remove and Inspect (Fan side)

Removing Sequence
10-4
1.3 Thermostat Case and Water Pipe - Remove and Inspect
Replace
Replace
MTK spec PTA,PTA2,PTK, MPTA,

PTAW spec MPTK spec MPTA,MPTK spec PTA,PTAW spec
4 4
4
Replace
Replace 1 2
MTK spec PTA,PTA2,PTK, MPTA,
PTAW spec MPTK spec 3
4 4
4
Thermostat Case and Water Pipe - Remove and Inspect

Removing Sequence
1 Coupling 3 Water outlet pipe
2 Water outlet pipe 4 Thermostat
10-5
1.4 Water Pipe - Remove and Inspect
PTA,PTA2 spec
14
Replace Replace
14
Air Air 12 13
cooler cooler
13
PTA spec PTA2 spec 15
PTA spec
11 14
10
Replace
Air cooler Air cooler

3
Replace 8 PTA2 spec
1
Replace 14
9
Replace Replace
Replace
Replace
Air cooler
Replace
3
2 Air cooler
PTA spec 1 Replace
7 Replace
6 2
2 Replace
PTA2 spec 2
PTA2 spec PTA spec
PTA spec PTA2 spec
5
5
4 4
Water Pipe - Remove and Inspect

Removing Sequence
1 Coupling 6 Coupling 11 Water pipe
2 Water pipe 7 Bypass pipe 12 Coupling
3 Water pipe 8 Coupling 13 Coupling
4 Coupling 9 Water pipe 14 Water pipe
5 Bypass pipe 10 Water pipe 15 Water pipe
10-6
PTK spec
Replace
7
Air cooler
Cooling water inlet

8
9 7
8
Replace
Air cooler
Replace
Air cooler Replace
2 6
1
2
4
5
1 Air cooler
3 Replace

Removing Sequence
1 Coupling 6 Bypass pipe
2 Water pipe 7 Coupling
3 Coupling 8 Water pipe
4 Bypass pipe 9 Water pipe
5 Coupling
10-7
MPTA,C2MPTK spec
Replace
Air cooler
13 14
15 15
14
16
12
MPTA spec C2MPTK spec Air

11 cooler
11
9
Air cooler
4 10
Replace Replace
2
Replace
Replace
Replace
4
3 1
Replace
2 3
Air
cooler
8
6
7

Removing Sequence
1 Water outlet pipe 7 Coupling 13 Coupling
2 Coupling 8 Bypass pipe 14 Coupling
3 Water pipe 9 Coupling 15 Water pipe
4 Water pipe 10 Water pipe 16 Water pipe
10-8
MPTK spec
Replace
10
Air cooler
Cooling water inlet

11
12 10
9
11
8 Replace
Air cooler
8
Replace
7 Replace
Replace
6
Air cooler
2 4
5
Cooling water outlet

Air cooler
3
Replace
1 2

Removing Sequence
1 Coupling 7 Bypass pipe
3 Water pipe 9 Water outlet pipe
4 Coupling 10 Coupling
10-9
PTAW spec
10 11
9
Air cooler
Replace 9
10
B
Motor pump
6 Air cooler
5
7 Replace
Replace
Air cooler 4
2 8
1
3
A
3
B
4 1
Air cooler
Replace
2

Removing Sequence
1 Coupling 7 Rubber hose
2 Water pipe 8 Water pipe
5 Rubber hose 11 Water pipe
6 Water pipe
10-10
1.5 Heat Exchanger and Water Pipe - Remove and Inspect
MPTK spec 2
Replace
Replace 5
8
Replace
3
1
10
Replace
Water pump
4
Heat Exchanger and Water Pipe - Remove and Inspect

Removing Sequence
1 Strap coupling 6 Strap coupling
4 Water pipe 9 Bypass pipe
5 Coupling 10 Heat exchanger (approx. 71 kg [157 lb])
10-11
1.6 Sea Water Pump and Water Pipe - Remove and Inspect
MTK,MPTK spec
4
Replace
5 Heat exchanger
Replace 3
2
6
Replace
1 Replace
MPTK spec Replace

Replace
Replace 5
Air cooler
Replace
13
12
Replace
Replace
Replace
MTK spec 6 11
Replace
9
7
Replace
10 Replace
8
Replace
Sea Water Pump and Water Pipe - Remove and Inspect
Removing Sequence
1 Sea water pipe 8 Sea water pipe
6 Sea water pipe 13 Sea water pump
7 Coupling
10-12
1.7 Expansion Tank and Water Pipe - Remove and Inspect
MTK spec
Replace
Replace
7
3
1
2 6 5
8
4
Water pump
Replace
Replace
1
2
Expansion Tank and Water Pipe - Remove and Inspect

Removing Sequence
1 Strap coupling 5 Bypass pipe
3 Water pipe 7 Bypass pipe
4 Coupling 8 Expansion tank
10-13
1.8 Water pump and Water Pipe - Remove and Inspect
PTAW spec
Replace
11
4 3
Replace
Replace 9
Replace
2
PTA,PTA2,PTAW,PTK,
MTK,MPTA,MPTK spec
8
6
Replace
MTK,MPTK spec
10 7
1
Replace
PTA2 spec
Water pump and Water Pipe - Remove and Inspect

Removing Sequence
1 Water pipe 5 Stay 9 Oil pipe
2 Joint 6 Connector 10 Water pump (Approx 33 kg [73 lb])
3 Water pipe 7 Water pipe 11 Water pump for air cooler
4 Joint 8 Oil drain pipe
1.8.1 Oil Drain Pipe - Remove

The oil drain pipe is located at a hard-to-access position
behind the water pump. Use the water pump wrench to
remove the oil drain pipe.
Water pump wrench
P/N:32691-01200
Oil drain pipe

Water pump
Oil Drain Pipe - Remove
10-14
2. Cooling System - Disassemble, Inspect and Assemble

2.1 Tension Pulley - Disassemble and Inspect (Water pump side)
Crack, flaw,
deflection of shaft, 8
oil hole clogging
Belt groove wear

7
6
5
4
1
Rotation
Tension Pulley - Disassemble and Inspect (Water pump side)

1 Bolt 4 Ball bearing 7 Tension pulley
2 Thrust plate 5 Spacer 8 Bracket
3 Snap ring 6 Ball bearing
2.1.1 Tension Pulley - Inspect

Measure the bearing fit in tension pulley and on shaft. If abnormal wear or damage is shown, replace the bearing, pulley or ten-
sion bracket.
Item Standard value Standard value

Inside diameter of tension pulley bearing fit ø80 [3.15] 79.961 to 79.991 mm [3.1480 to 3.1492 in.]
Outside diameter ø80 [3.15] 79.987 to 80.000 mm [3.1490 to 3.1495 in.]
Bearing
Inside diameter ø35 [1.38] 34.988 to 35.000 mm [1.3774 to 1.3779 in.]
Outside diameter of bracket bearing fit ø35 [1.38] 34.984 to 35.000 mm [1.3773 to 1.3779 in.]
10-15
2.1.2 Tension pulley - Assemble

(1) Apply engine oil to the fitting faces of bearing and ten-
sion pulley. ø78 [3.07]
Special jig
(2) Fabricate a special press-fitting jig. Fit the bearing in 54 ø38
the tension pulley using the jig and a hand-press. [2.13] [1.5] Bearing
Note: The bearing is a grease-filled type. Do not wash the
bearing.
Tension pulley
Unit: mm [in.]
Inner ball bearing - Insert
(3) Fit the inner ball bearing onto the bracket using a hand-
press.
Special jig
Bracket
Tension pulley - Insert

(4) Install the spacer.
Spacer
(5) Screw two bolts into the extracting bolt holes in the
bracket from the inside to hold the tension pulley
lightly.
Bolt
M12×1.25 (2 pcs.)
Spacer and Bolt - Install
(6) Fit the outer ball bearing into the tension pulley using
the special jig and a hand-press.
Special jig
Outer ball bearing - Insert
10-16
(7) Fit the snap ring in the groove on the inner periphery of
the tension pulley. Snap ring
Snap Ring - Install

(8) Install the thrust plate with bolt.
Thrust plate
Thrust plate - Install

(9) Tighten the bolt.
Note: After assembly, confirm that the tension pulley rotates
Bolt
smoothly.
Bolt - Tighten
10-17
2.2 Tension Pulley - Disassemble and Inspect (Water pump side for Air cooler)
PTAW spec
Belt groove wear
7
6
5
4
3
2
Crack, flaw,
deflection of shaft,
Rotation oil hole clogging
Tension Pulley - Disassemble and Inspect (Water pump side for Aircooler)
1 Bolt 4 Snap ring 7 Ball bearing
2 Thrust plate 5 Ball bearing 8 Tension pulley
3 Spacer 6 Spacer 9 Bracket

sion bracket.

Bearing
10-18

(1) Apply engine oil to the fitting faces of bearing and ten-
sion pulley. ø 52 [2.05]
Special jig
(2) Fabricate a special press-fitting jig. Fit the bearing in
the tension pulley using the jig and a hand-press. 34 ø 20
[1.34] [0.8]
Note: The bearing is a grease-filled type. Do not wash the Bearing
bearing.
Tension pulley
Unit: mm [in.]
(3) Fit the inner ball bearing onto the bracket using a hand-
press.
Special jig
Bracket

(4) Install the inside spacer.
(5) Screw two bolts into the extracting bolt holes in the Umit: mm [in.]
Spacer
bracket from the inside to hold the tension pulley
lightly.
Bolt
M12×1.25 (2 pcs.)
Spacer and Bolt - Install
(6) Fit the outer ball bearing into the tension pulley using
the special jig and a hand-press.
Special jig
10-19
(7) Fit the snap ring in the groove on the inner periphery of
the tension pulley.
Snap ring
Snap Ring - Install

(8) Install the outside spacer.
Spacer
Outer Spacer - Install

(9) Install the thrust plate with bolt.
Thrust plate
Thrust plate - Install

(10)Tighten the bolt.
Note: After assembly, confirm that the tension pulley rotates
Bolt 98 N·m
smoothly. {10 kgf·m}
[72 lbf·ft]
Bolt - Tighten
10-20
2.3 Tension Pulley - Disassemble and Inspect (Water pump side PTA2 spec)
PTA2 spec
Lip surface wear,

flaw, deterioration
Belt groove wear 7

8
6
5
4
Replace 3
2
Crack, flaw,
1 oil hole clogging
Rotation
Tension Pulley - Disassemble and Inspect (Water pump side PTA2 spec)
1 Bearing cover 4 Plain washer 7 Oil seal
2 Snap ring 5 Ball bearing 8 Oil seal sleeve
3 Ball bearing 6 Tension pulley 9 Bracket

sion bracket.

Bearing
10-21

Apply grease
(1) Before pressing-fit the tension pulley, apply grease to Ball bearing
both ball of ball bearing and ball-cage.
(2) Apply grease to the inside tension pulley, and press-fit
the lower ball bearing.
(3) Install the plain washer, and press-fit the upper ball
bearing.
Plain washer Pulley
Note: Load the outer ring when pressing-fit the ball bearing. inner face
Tension pulley Ball bearing

Ball Bearing - Press-fit
(4) Apply sealant (ThreeBond 1215) to the inside surface
Apply sealant
of the oil seal installation part of tension pulley.
(5) Apply grease to the oil seal lip and dust seal lip, and
press-fit the oil seal to the tension pulley.
Fill grease Oil seal

Oil Seal - Install
(6) Press-fit the oil seal sleeve to the tension shaft.
(7) Press-fit the tension pulley that installed the ball bear- Snap ring Bearing cover
ing and oil seal to the tension shaft. 13 ± 1.3 N·m
O-ring {1.3 ± 0.13 kgf·m}
(8) Fix the tension shaft and ball bearing with snap ring. [9.6 ± 0.96 lbf·ft]
Note: Check that the clearance to the shaft after installing the
snap ring.
(9) Install the bearing cover that mounted O-ring, and
tighten the bolt to specified torque.
(10)Remove the taper plug, and fill the specified grease to
the oil hole of tension shaft.
Oil seal sleeve
Inject grease 50 cm3

Tension shaft P/N:37594-01600
10-22
2.4 Tension Pulley - Disassemble and Inspect (Fan side PTA2 spec)
PTA2 spec
10
Lip surface wear,
flaw, deterioration
Belt groove wear 8

9
7
6
5
4
Replace
3
2 Crack, flaw,
oil hole clogging
1
Rotation
Tension Pulley - Disassemble and Inspect (Fan side PTA2 spec)

1 Bearing cover 5 Tension spacer 9 Oil seal sleeve
2 Snap ring 6 Ball bearing 10 Bracket
3 Plain washer 7 Tension pulley
4 Ball bearing 8 Oil seal

sion bracket.

Inside diameter of tension pulley bearing fit ø120 [4.72 in.] 119.972 to 119.994 mm [4.7233 to 4.7242 in.]
Outside diameter ø120 [4.72 in.] 119.985 to 120.000 mm [4.7238 to 4.7244 in.]
Bearing
10-23

Ball bearing Apply grease
(1) Before pressing-fit the tension pulley, apply grease to
both ball of ball bearing and ball-cage.
(2) Apply grease to the inside tension pulley, and press-fit
the lower ball bearing.
(3) Install the plain washer, and press-fit the upper ball
bearing.
Note: Load the outer ring when pressing-fit the ball bearing. Tension Pulley inner
spacer face
Tension pulley Ball bearing
Ball Bearing - Press-fit
(4) Apply sealant (ThreeBond 1215) to the inside surface
of the oil seal installation part of tension pulley. Apply sealant
(5) Apply grease to the oil seal lip and dust seal lip, and
press-fit the oil seal to the tension pulley.
Fill grease Oil seal

Oil Seal - Install
(6) Press-fit the oil seal sleeve to the tension shaft.
Bearing cover
(7) Press-fit the tension pulley that installed the ball bear- 30 ± 3.0 N·m
Snap ring {3.0 ± 0.3 kgf·m}
ing and oil seal to the tension shaft. [22.1 ± 2.21 lbf·ft]
(8) Fix the tension shaft and ball bearing with snap ring. O-ring
Note: Check that the clearance to the shaft after installing the
snap ring.
(9) Install the bearing cover that mounted O-ring, and
tighten the bolt to specified torque.
(10)Remove the taper plug, and fill the specified grease to
the oil hole of tension shaft.
Oil seal sleeve
Inject grease 50 cm3 Tension shaft

P/N:37594-01600
10-24
2.5 Thermostat - Disassemble and Inspect
PTA,PTA2,PTK, MTK spec MPTA,

PTAW spec MPTK spec
30 ± 3.0 N·m
{3.0 ± 0.3 kgf·m}
[22.1 ± 2.2 lbf·ft]
1 1
1
2 2
2
Replace 3
Replace
Thermostat - Disassemble and Inspect

1 Thermostat cover 3 Thermostat
2 Packing 4 Thermostat case
10-25
2.6 Thermostat - Inspect
Stir the water with a stick.

Be very careful with hot water and flames.
Or, you may get burned or cause a fire.
(1) Immerse the thermostat in a container filled with water.
(2) Heat the water while measuring water temperature.
Record the temperature at which valve start to open,
and at which valve lift becomes to the standard
value.Replace the thermostat if a deviation from the
standard temperature is unusual.
Note:(a) Stir the water to maintain uniform temperature dur- Thermostat Operation - Inspect
ing the test.
(b) At assembling, be sure to check the valve opening 10
[0.39]
temperature marked on the side of thermostat valve.
Item Standard value

Temperature at which primary valve starts to 69 to 73 ºC 85˚C [185.0˚F]
0
open [157 to 163 ºF] Lift Secondary valve opening
(mm [in.]) Temperature: 72 to 76˚C
Temperature at which secondary valve starts 72 to 76ºC
to open [161 to 168ºF] [161.6 to 168.8˚F]
Primary valve opening
Temperature at which valve lift becomes 10 temperature: 69 to 73˚C
85 ºC [185 ºF]
mm [0.35 in.] or more
[156.2 to 163.4˚F]
Thermostat motion diagram
10-26
2.7 Heat Exchanger - Disassemble and Inspect
MTK spec
2
1
4
Cleaning: every 2000 hours
or within 24 months
3 Replace: every 500 hours

Replace or within 12 months
Replace
Replace
2
Heat Exchanger - Disassemble and Inspect

1 U-bolt 3 Zinc
2 Cover 4 Heat exchanger
2.7.1 Heat Exchanger Element - Clean

(1) Clean the pipe outside pouring water with wire brush or
the like. Inspect the element for corrosion and cracks.
(2) Remove deposits from inside of pipes inserting a bar.
Heat Exchanger Element - Clean
10-27
2.8 Water pump - Disassemble and Inspect
Replace
3
4
5
13
12
11
9
2 Corrosion,
crack, flaw
10
Corrosion, flaw
8
7
6
2 Replace
1
Corrosion, crack, damage
Replace
Rotation
Replace
V-belt groove wear, damage
Water pump - Disassemble and Inspect

1 Nut and lock washer 6 Spacer 11 Ball bearing
2 Water pump pulley, key 7 Oil seal 12 Oil seal
3 Water pump cover, packing 8 Snap ring 13 Water pump case
4 Water pump impeller 9 Water pump shaft (Approx 17.5 kg [38.6 lb])
5 Unit seal 10 Ball bearing
10-28
2.8.1 Water pump Mounted on Engine - Inspect

With fingers, touch the drain pipe located at bottom center
of the water pump case.If water is oozing out, the unit seal is
defective, and if oil is oozing out, the oil seal is defective.
Water pump Mounted on Engine - Inspect

2.8.2 Water pump Pulley - Remove
Install the pulley puller to the holes on the water pump pul-
ley, and remove the water pump pulley. Water pump
pulley
Pulley puller
M10×1.5mm
Water pump Pulley - Remove

2.8.3 Impeller - Remove
Socket
Width across flat:
32 mm [1.26 in.] Impeller
When removing the impeller from the water pump
shaft, be careful not to damage the water pump shaft
and impeller.
(1) Install two nuts to the water pump shaft on the opposite
side of impeller to prevent the shaft from rotating.
Water pump
(2) Hold the two nuts with a wrench. Loosen the impeller shaft
with a socket (width across flats: 32 mm [1.26 in.]) and
remove it.
Double nuts
to hold the
shaft
Impeller - Remove
2.8.4 Water pump Shaft - Remove
(1) Remove the snap ring from the ball bearing on the
water pump pulley side.
Ball bearing
(2) Remove the shaft and ball bearings by pushing the end
face of water pump shaft on the impeller side. Water pump
shaft
Ball bearing
Water pump Shaft - Remove
10-29
2.9 Water pump - Inspect

Measure the bearing fit diameters of water pump bearing housing and shaft, and the inside and outside diameters of bearing.If
any of the measurements is out of the standard, replace the part with a new one.

ø62 mm [2.44 in.] 61.988 to 62.018 mm [2.4404 to 2.4416 in.]
ø72 mm [2.83 in.] 71.988 to 72.018 mm [2.8341 to 2.8353 in.]
Outside diameter ø72 mm [2.83 in.] 71.987 to 72.000 mm [2.8341 to 2.8346 in.]
Large
Inside diameter ø30 mm [1.18 in.] 29.988 to 30.000 mm [1.1806 to 1.1811 in.]
Bearing
Small
Outside diameter of shaft fit to bearing ø30 mm [1.18 in.] 30.002 to 30.011 mm [1.1812 to 1.1815 in.]
Impeller front clearance 0.6 to 1.4 mm [0.0236 to 0.0551 in.]
Impeller back clearance 1.0 mm [0.040 in.]
10-30
2.10 Water pump - Assemble
12.3 ± 2.5 N·m

{1.3 ± 0.3 kgf·m} Replace
[9.07 ± 1.84 lbf·ft]
196 ± 29.6 N·m

{20 ± 3.0 kgf·m}
260 ± 12 N·m [144.6 ± 21.83 lbf·ft]
{26 ± 1.2 kgf·m}
[191.8 ± 8.9 lbf·ft]
44 ± 4.9 N·m
{4.5 ± 0.5 kgf·m}
[32.5 ± 3.61 lbf·ft]
31.9 ± 2.5 N·m

{3.3 ± 0.3 kgf·m}
Apply sealant. [23.53 ± 1.84 lbf·ft]
Unit seal (stationary side)
Unit seal (rotating side)
Apply LLC to the floating portion when

installing the unit seal (rotating side) into the ring.
Apply sealant (ThreeBond 1102) to
outer periphery of unit seal (stationary side).
Apply engine oil to the oil seal lip and
the balls of ball bearing.
Water pump - Assemble
10-31
2.10.1 Oil Seal - Install

(1) Using installer, press-fit the oil seal, making sure that
Oil seal installer Apply engine oil
oil seal surface is flush with the water pump case face. P/N:32591-03200 to oil seal lip
(2) Apply engine oil to the oil seal lip.
Water pump case
Inner oil seal - Install

2.10.2 Unit Seal (Stationary Side) - Install
(1) Apply sealant (ThreeBond 1102) to the outer circum- Water pump case
ference of unit seal (stationary side.) Unit seal installer

P/N:37191-06300
(2) Tap-in the unit seal into water pump case with unit seal
installer.
Apply ThreeBond
1102 to the unit seal
fitting face
Unit Seal (Stationary Side) - Install

2.10.3 Ball Bearing - Install
(1) Apply engine oil to the balls of the ball bearing. Water pump shaft Bearing installer
P/N:32591-03600
(2) Press-fit the ball bearing to the water pump shaft.(3
places) Apply engine oil
(3) Install the thread cover to the big end of water pump
shaft with the ball bearing.
(4) Using a bearing installer, press fit the water pump shaft Thread cover
P/N: 37191-06600
gently until the end of ball bearing comes into contact
with water pump case.
Ball Bearing - Install

2.10.4 Outer oil seal - Install
(1) Press-fit the oil seal using the installer so that the oil Oil seal installer
seal surface is flush with the water pump case face. P/N:32591-03100
Apply engine oil

to oil seal lip face
Outer oil seal - Install
10-32
2.11 Water pump for Air cooler Cooling - Disassemble and Inspect
PTAW spec
2
3
4 Corrosion, flaw
11
Replace
Replace
10 7
Corrosion, crack, flaw
6 5
1
9
Rotation 8
Rotation
Wear, flaw
Water pump for Air cooler Cooling - Disassemble and Inspect

1 Water pump pulley 5 Snap ring 9 Ball bearing
2 Snap ring 6 Water pump shaft 10 Unit seal
3 Cover 7 Ball bearing 11 Water pump case (Approx 15 kg [33 lb])
4 Impeller 8 Spacer
10-33
2.11.1 Water pump for Air cooler Cooling Mounted on

Engine - Inspect
Touch the drain port at the bottom center of water pump
case with a finger.If water or oil is oozing out, the unit seal
is defective.
Water pump for Air cooler Cooling Mounted on Engine

- Inspect
2.11.2 Impeller - Remove
Install a puller to impeller pull-out holes, and remove the
impeller. Puller
M8 × 1.25 mm Impeller
Impeller - Remove
2.11.3 Water pump Shaft - Remove
Remove the shaft and ball bearings as a set by pushing the
impeller end face of water pump shaft with hand press or the
like. Impeller side
Ball bearing
Water pump Ball bearing

shaft
Water pump Shaft - Remove
10-34
2.11.4 Water pump for Air cooler Cooling - Inspect

Measure the bearing fit diameters of water pump bearing housing and shaft, and the inside and outside diameters of bearing.If
any of the measurements is out of the standard, replace the part with a new one.

Pump case ø62 mm [2.44 in.] 61.988 to 62.018 mm [2.4404 to 2.4416 in.]
Inside diameter of bearing fit
Bearing cover ø68 mm [2.68 in.] 67.961 to 67.991 mm [2.6760 to 2.6768 in.]
Bearing
Impeller front clearance 0.8 mm [0.031 in.] 0.5 to 1.1 mm [0.020 to 0.043 in.]
10-35
2.12 Water pump for Air cooler Cooling - Assemble
Replace
Application of grease
Make it flush
0.5 to 1.1 mm
Fill with 31 grams grease. [0.020 to 0.043 in.]
Application of Loctite
22.5 ± 2.25 N·m Application of sealant
{2.29 ± 0.23 kgf·m} (ThreeBond 1102)
[16.6 ± 1.66 lbf·ft]
Apply sealant (ThreeBond 1102) to

outer peripheral surface of unit seal.
Water pump for Air cooler Cooling - Assemble
10-36
2.12.1 Unit Seal - Install

(1) Apply sealant (ThreeBond 1102) to the circumference
of the unit seal.
(2) Press-in the unit seal into water pump case with unit
seal installer. Unit seal
Note: Replace the unit seal with a new one whenever it is re-
moved from water pump case. Apply sealant
11.3 ± 0.3 mm (ThreeBond 1102)
[0.445 ± 0.012 in.] to outer peripheral
surface.
Unit Seal - Install

2.12.2 Water pump Shaft - Install
Water pump shaft
Be careful not to damage the water pump shaft by oil Spacer
seal and unit seal when press-fitting the water pump Fill with 31 grams
grease.
shaft. Apply grease to
ball bearing rolling
portion.
(1) Press-in the water pump shaft slowly into pump case
until the end face of ball bearing comes into contact
Shield plate
with pump case. portion faces
(2) Install the spacer to water pump shaft. inward (down).
(3) Apply grease on ball bearing rolling faces. Water pump Shaft - Install
(4) Fill grease of 31g [1.09 oz] into space among spacer,
ball bearing and pump case.
2.12.3 Ball Bearing - Install

(1) Apply grease on ball bearing rolling faces and press fit Water pump shaft Snap ring
the bearing to Water pump shaft.
Note: Place the sealed plate outside to fit the outer bearing to
the shaft. Apply grease to Shield plate portion
ball bearing rolling faces outward (up).
(2) Securely install the snap ring to pump case groove.
portion.
Ball Bearing - Install
10-37
2.13 Sea Water Pump - Disassemble and Inspect
MTK,MPTK spec
14
Lip face wear, deterioration

13
12
Rotation
11
12
10 Spline wear
9
8 1
3
Rotation
15
2
4 Replace
5
6
Wear, deterioration
7
Settling, crack, flaw
Replace
Wear, flaw
Sea Water Pump - Disassemble and Inspect

1 Cover 6 Bushing, unit seal 11 Shaft, key
2 Impeller, impeller cover 7 Slinger 12 Bearing
3 Case 8 Nut, washer 13 Oil seal
4 Plate 9 Pulley 14 Holder
5 Snap ring 10 Snap ring 15 Cam
10-38
2.13.1 Outside Diameter and Inside Diameter of Bearing Fit - Inspect

Turn the bearing and if turning is not smooth, replace the bearing with a new one.Inspect the fit of bearing case and bearing. If
heavy wear is found, replace them with new ones.Inspect the fit of shaft and bearing. If heavy wear is found, replace them with
new ones.

Inside diameter of case bearing housing ø72 mm [2.83 in.] 71.985 to 72.004 mm [2.8340 to 2.8348 in.]
Bearing
10-39
2.14 Sea Water Pump - Assemble
MTK spec
7.5 ± 0.5 N·m

Apply grease to rolling surface {0.75 ± 0.05 kgf·m}
[5.53 ± 0.37 lbf·ft]
196 ± 10 N·m
{20 ± 1 kgf·m}
[144.6 ± 7.38 lbf·ft]
15 ± 1 N·m
{1.5 ± 0.1 kgf·m}
Apply ThreeBond 1102 to mating faces
[11.1 ± 0.74 lbf·ft]
Sea Water Pump - Assemble
10-40

(1) Press-fit the oil seal to the holder with the installer.
Note: Always replace the oil seal with a new one.
Installer
(2) Apply grease to the oil seal groove and lips.
Apply grease Oil seal
Oil Seal - Install

2.14.2 Cam - Install
Apply ThreeBond
(1) Apply sealant (ThreeBond 1102) to the mating surfaces Cam
1102 to mating faces
of cam and case.
(2) Install the cam to case, and tighten the bolt to the speci-
Case
fied torque.
15 ± 1.0 N·m
{1.5 ± 0.1 kgf·m}
[11.1 ± 0.74 lbf·ft]
Cam - Install
2.14.3 Unit Seal (Stationary Side) - Install
(1) Apply sealant (ThreeBond 1102) to the outer circum-
ference of unit seal (stationary side.)
(2) Hand-press the unit seal slowly into the bushing with
the unit seal installer.
Note:(a) Do not use a hummer or mallet to install.
(b) Do not damage the sliding surface of the unit seal.
Bushing
Unit Seal (Stationary Side) - Install

2.14.4 Bearing - Install
(1) Tap-in the bearing squarely along the shaft center line.
(2) Apply grease on bearing rolling faces.
Shaft
Bearing
Bearing - Install
10-41
2.14.5 Shaft and Bearing - Install

(1) Press-fit the ball bearing to the water pump shaft with
the installer. Shaft
Installer
(2) Press-fit the ball bearing and water pump shaft to the
holder with the installer.
Holder
Bearing
Shaft and Bearing - Install

2.14.6 Snap Ring - Install
Install the snap ring to the holder.
Snap ring
Snap Ring - Install

2.14.7 Bushing - Install
Install the slinger to the shaft. Bush
Install the bushing and unit seal assembly to the holder.
Clean the seat side sliding face of the unit seal with ethyl
alcohol, and apply turbine oil.
Insert the shaft to the seat side, and fix it with the snap ring.
Unit seal
Slinger Sliding part seat side
Bushing - Install
2.14.8 Case - Install
(1) Apply sealant (ThreeBond 1102) to the mating surfaces
of holder and case.
Application of
(2) Install the holder to the case, and tighten the bolts to the ThreeBond 1102
specified torque.
Case - Install
10-42
2.14.9 Impeller - Install

(1) Tap-in the impeller to shaft.
Blade tip
Note: Place the impeller to bend its impellers in following di- Impeller
rection to the Water pump rotation.
Rotation
direction
Impeller - Install
(2) Install the impeller cover.
Impeller cover
Impeller cover - Install

2.14.10Cover - Install
Install the cover to the case, and tighten the bolts to the 7.5 ± 0.5 N·m
specified torque. {0.75 ± 0.05 kgf·m}
[5.5 ± 0.37 lbf·ft]
Cover
Cover - Install
10-43
2.15 Fan Drive Assembly - Disassemble and Inspect
Fan
Rotation 12
Belt groove wear 11

PTA2 spec Crack, flaw
10
3
9
PTA2 spec
6
5
12
4
Replace
Rotation
2 Wear
1
Replace
Fan Drive Assembly - Disassemble and Inspect

1 Fan spacer 5 Oil seal 9 Ball bearing
2 Cap nut 6 Snap ring 10 Spacer
3 Fan pulley 7 Cap 11 Ball bearing
4 Sleeve 8 Fan drive shaft 12 Drive shaft bracket
If one blade of the fan is damaged, be sure to replace the fan with a new one, as such defects as the other blade
damage or abnormal wear of bearing due to the vibration will result.
10-44
2.16 Fan Drive - Inspect

Inspect the fit between the fan drive shaft and fan drive case bearing, and if unusual wear is found, replace with new one.

ø100 [3.94] 99.987 to 100.022 mm [3.9365 to 3.9379 in.]
ø110 [4.33] 109.987 to 110.022 mm [4.3302 to 4.3316 in.]
Large
V-belt Bearing
outside diameter ø100 [3.94] 99.985 to 100.000 mm [3.9364 to 3.9370 in.]
Small
ø45 [1.77] 45.002 to 45.013 mm [1.7717 to 1.7722 in.]
ø40 [1.57] 40.002 to 40.013 mm [1.5748 to 1.5753 in.]
ø110 [4.33] 109.987 to 110.022 mm [4.3302 to 4.3316 in.]
ø120 [4.72] 119.987 to 120.022 mm [4.7239 to 4.7253 in.]
Large
Ribbed belt Bearing
Small
ø50 [1.97] 50.002 to 50.013 mm [1.9686 to 1.9690 in.]
ø45 [1.77] 45.002 to 45.013 mm [1.7717 to 1.7722 in.]
10-45
2.17 Oil Seal Sleeve - Inspect

If any defects such as dents, scars, wear and looseness that
can lead to oil leakage are found, replace the oil seal sleeve
with a new one.
2.18 Oil Seal Sleeve - Replace
Use protective gloves when you touch hot parts.Han-

dling with bear hands could result in burns.
2.18.1 Oil Seal Sleeve - Remove
Place a chisel vertically to the sleeve end face and tap three
places with a hammer. When the sleeve is loosened, remove
the sleeve.
If the sleeve can not be removed by the above procedure,
hold the chisel against the sleeve in the axial direction and
tap on it lightly to make the sleeve expand. Once the inter-
ference between crankshaft and sleeve is reduced, the sleeve
will be removed easily.
2.18.2 Oil Seal Sleeve - Install
Heat the oil seal sleeve to a temperature of 180 to 200 °C Fan pulley
[356 to 392 ºF] with a heater.
Insert the oil seal sleeve to drive shaft.
Oil seal sleeve
Oil Seal Sleeve - Install
10-46
2.19 Fan Drive - Assemble
Apply engine oil to the oil seal lip.

Flush with the case face.
178 ± 8.9 N·m

108 ± 10.8 N·m
108 ± 10.8 N·m {18 ± 0.9 kgf·m}
{11 ± 1 .1 kgf·m}
{11 ± 1 .1 kgf·m} [131.3 ± 6.6 lbf·ft]
[79.7 ± 8.0 lbf·t]
[79.7 ± 8.0 lbf·t]
441 ± 22 N·m Apply engine oil to rolling surface

{45 ± 2.2 kgf·m}
[325.3 ± 16.2 lbf·ft]
Apply
LOCTITE 262 to threads.
Fan Drive - Assemble
10-47
2.19.1 Inner ball bearing - Insert

(1) Apply engine oil to the rolling surface of the ball bear-
ing.
(2) Press-in the bearing to drive shaft with bearing installer.
Bearing installer
P/N: 32691-04200

2.19.2 Outer ball bearing - Insert
(1) Apply engine oil to the rolling surface of the ball bear-
ing.
(2) Install the drive shaft to fan drive case.
(3) Press-in the bearing to drive shaft with bearing installer.
Bearing installer
P/N: 32691-04300
Application
of engine oil

(1) Press-in the oil seal to drive shaft bracket with oil seal
installer.
Oil seal installer

P/N: 32591-03100
Application of
engine oil
Oil Seal - Install
10-48
2.19.4 Fan - Assemble

108 ± 10.8 N·m Fan Fan pulley
Installation the fan at the final step of assembling work.
{11 ± 1 .1 kgf·m}
(1) Install the key to the fan end of fan drive shaft.
Key
(2) Install the fan pulley to the key of fan drive shaft.
(3) Install the fan pulley adapter, and lock the fan pulley.
Fan spacer
(4) Tighten the cap nut to the specified torque.
Note: Ensure the proper fan orientation (wind direction: 441 ± 22 N·m
pusher) when installing. {45 ± 2.3 kgf·m}
(5) Install the fan spacer to the fan pulley, and tighten the Fan drive shaft
bolts to the specified torque.
Fan - Assemble
(6) Install the fan to the fan spacer, and tighten the bolts to
the specified torque. Fix with bolt
to hold fan pulley.
Fan pulley
Cap nut
Fan pulley adapter

P/N:32691-07100
Fan Pulley - Lock
When using
pusher fan,
attach the
wraparound
face of the
blade forward.
Fan drive
Front (engine)side
Direction of the wind

(Pusher fan)
Fan installation direction
10-49
3. Cooling System - Install

Clean and dry well the cooling water passage.
3.1 Water Pipe (Air cooler) - Install
Apply silicone sealant to the both sides of packings between
air cooler in/out connectors and water pipes.
3.2 Tension Pulley - Install
Tighten the tension pulley mounting bolts to the specified
torque. Fan tension pulley
108 ± 10.8 N·m

Water pump
{11 ± 1 .1 kgf·m} tension pulley
[79.7 ± 7.97 lbf·ft]
Tension Pulley - Install
3.3 Water Outlet Pipe - Install
Tighten the water outlet pipe mounting bolts to the specified
torque.
Water outlet pipe
54 ± 5 N·m
{5.5 ± 0.5 kgf·m}
[39.8 ± 3.69 lbf·ft]
Water Outlet Pipe - Install
10-50
1. Inlet and Exhaust Systems - Remove and Inspect ............................................. 11-3
1.1 Air Duct and Air cooler - Remove and Inspect........................................................................ 11-3
1.2 Pre-cleaner and Paper Type Air Cleaner - Remove and Inspect ........................................... 11-6
1.3 Exhaust Pipe - Remove and Inspect ...................................................................................... 11-9
1.4 Exhaust Manifold - Remove and Inspect .............................................................................. 11-10
2. Inlet and Exhaust Systems - Disassemble, Inspect and Assemble ................ 11-11
2.1 Air cooler - Disassemble, Inspect and Assemble ................................................................. 11-11
2.2 Pre-cleaner - Clean............................................................................................................... 11-15
3. Inlet and Exhaust Systems - Install.................................................................... 11-16
3.1 Exhaust Manifold - Install...................................................................................................... 11-16
11-1
1. Inlet and Exhaust Systems - Remove and Inspect

1.1 Air Duct and Air cooler - Remove and Inspect
PTA,PTK,MPTA spec
Crack, flaw, deformation
2 Crack, flaw,
Replace Replace deformation
Replace 1
1 Turbocharger 2
4 Replace
Turbocharger
Replace 4
Replace
Replace 3
Air Duct and Air cooler - Remove and Inspect

Removing Sequence
1 Connector 3 Air cooler (approx. 57 kg [125 lb.])
2 Air duct 4 Spacer
11-3
PTA2 spec
3
Replace Replace
2 1 2
Replace
Turbocharger Replace
1
4
Turbocharger
Replace
4
3
Replace
Replace

Removing Sequence
1 Connector 3 Air cooler (approx. 64 kg [141 lb.])
2 Air duct 4 Spacer
11-4
MTK,MPTK spec
2
Turbocharger
Replace
Turbocharger
3 1 1
2
3
Replace
Crack, flaw,
deformation
9
Replace Replace
6
Replace Replace
8 8
6 5 Crack, flaw,
Replace 7
deformation
Crack, flaw,
7
deformation 4
Replace
Crack, flaw,
4 deformation
Replace

Removing Sequence
1 Coupling 4 Oil pipe 7 Air duct
2 Duct 5 Inlet manifold (Approx 36.4 kg [80 lb]) 8 Air duct
3 Duct 6 Spacer 9 Air cooler (approx. 180 kg [397 lb.])
11-5
1.2 Pre-cleaner and Paper Type Air Cleaner - Remove and Inspect
With pre-cleaner MTK,MPTA,MPTK spec

Replace 5
Replace
Replace 4
Replace
1
3
2
Crack, flaw,
deformation 4
1 2
With pre-cleaner PTA,PTA2,PTK spec
Pre-cleaner - Remove and Inspect

Removing Sequence
1 Silencer assembly 4 Inlet pipe
2 Silencer cover (PTA, PTA2, PTK spec) 5 Duct
3 Stay
11-6
With air cleaner PTA spec 1

1
Crack, flaw 2
4
Replace
Crack, flaw
Replace
5
6
Crack, flaw,
deformation
Air cleaner - Remove and Inspect

Removing Sequence
1 Air cleaner (approx. 23 kg [51 lb.]) 4 Rubber hose 7 Air pipe
2 Elbow hose 5 Air pipe
3 Air pipe 6 Elbow hose
11-7
With air cleaner PTA spec 2

Crack, flaw
1 2
Crack, flaw
2
Crack, flaw
3
4
Replace
Crack, flaw
Replace
7
9
8
Air cleaner - Remove and Inspect
Removing Sequence
1 Air cleaner (approx. 23 kg [51 lb.]) 4 Air pipe 7 Air pipe
2 Rubber hose 5 Elbow hose 8 Elbow hose
3 Rubber hose 6 Air duct 9 Air pipe
11-8
1.3 Exhaust Pipe - Remove and Inspect
With flexible pipe spec

Replace Crack, flaw, deformation
4
6 5
3
7
5 6
Replace
4
Replace
Exhaust Pipe - Remove and Inspect

Removing Sequence
1 Flexible pipe 4 Ring 7 Exhaust pipe (approx. 21 kg [46 lb])
2 Flange 5 Exhaust joint
3 Turbocharger (approx. 25 kg [55 lb]) 6 Ring
11-9
1.4 Exhaust Manifold - Remove and Inspect
Replace: Gasket
Exhaust Manifold - Remove and Inspect

Removing Sequence
1 Coupling 3 Exhaust manifold
2 Flexible joint
11-10
2. Inlet and Exhaust Systems - Disassemble, Inspect and Assemble

2.1 Air cooler - Disassemble, Inspect and Assemble
PTA,PTK,PTAW,MPTA spec
Replace
1
Replace
Replace
Replace
3
The gap between the element

and plate must be sealed with
KE45-W (Shin-Etsu Chemical Co.)
or equivalent silicon sealant. (2 places)
Air cooler - Disassemble, Inspect and Assemble

1 Air cooler cover 3 Plate
2 Air cooler element (approx. 30 kg [66 lb.]) 4 Inlet manifold (approx. 15 kg [33 lb])
11-11
PTA2 spec

or equivalent silicon sealant.
Replace
Replace 1
Replace
3
2
Replace

or equivalent silicon sealant.

1 Air cooler cover 2 Air cooler element 3 Inlet manifold
(approx. 33 kg [73 lb]) (approx. 18 kg [40 lb])
11-12
MTK,MPTK spec
Replace
1
2
3 Replace

1 Air duct 2 Air cooler assembly 3 Center duct
(One piece approx. 74 kg [163 lb])
11-13
2.1.1 Air cooler - Inspect
The air cooler differs in material and structure depend-

ing on the application (fresh water or seawater). Pay
attention to the difference when handling the air
cooler.
2.1.2 Air cooler - Clean
Blow compressed air (at a pressure of 0.29 to 0.49 MPa {3 Intake side
to 5 kgf/cm2} [43 to 71 psi] or less) through the air cooler in
the opposite direction to the normal air flow to remove the
accumulation of dust and dirt. Then, inspect for corrosion
and cracks.
Compressed air
PTA, PTA2, PTAW, PTK, MPTA spec

Air cooler - Clean
Intake side
Compressed air
MTK and MPTK Spec Air cooler - Clean
11-14
2.1.3 Air cooler - Inspect for Leakage

Immerse the air cooler in water. In this condition, blow
compressed air (at a pressure of 0.39 MPa {4 kgf/cm2} [57
psi]) to the coolant passage to check for air leakage.
Air leakage
PTA, PTA2, PTAW, PTK, MPTA spec

Air cooler - Check for Leakage
Air leakage
MTK and MPTK Spec Air cooler - Check for Leakage

2.1.4 Air cooler - Assemble
To assemble, follow the disassembly sequence in reverse.
Seal the clearance between the PTA, PTA2, PTAW, PTK,
and MPTA spec air cooler element and plate with KE45-W
(Shin-Etsu Chemical Co., ltd.) or equivalent silicone seal-
ant.
2.2 Pre-cleaner - Clean
(1) Remove the pre-cleaner from the silencer, and hand-
wash the pre-cleaner using neutral detergent. Mild
detergent
(2) Rinse with fresh water.
(3) Dry it thoroughly, and install it to the silencer.
Note: If the pre-cleaner is damaged or torn, replace it with a Water
(Wash) (Rinse)
new one.
Install
(Dry)
Pre-cleaner - Clean
11-15
3. Inlet and Exhaust Systems - Install

Thoroughly clean and dry the inlet and exhaust passages.
3.1 Exhaust Manifold - Install
3.1.1 Cautions during installation of exhaust manifold
(1) Make sure that the centers of exhaust manifold and cou-
pling are aligned when installing.The misalignment of
exhaust manifold and coupling causes gas leakage.
(2) Install the exhaust gasket so that the side having letters
is on the exhaust manifold side.
(3) When installing the exhaust gaskets, always replace all
TOP
the gaskets with new ones.
Install so that the side having letters is
positioned on the exhaust manifold side.
Cautions during installation of exhaust manifold
3.1.2 Exhaust Manifold Coupling - Tighten
Do not distort the exhaust manifold coupling.
(1) Apply MOLYKOTE (molybdenum disulfide anti-seize)

or equivalent to the bolt.
(3) Lightly shake the outer circumference of exhaust mani- 9 ± 0.45 N·m
fold coupling to make a snug contact between exhaust {0.9 ± 0.05 kgf·m}
[6.6 ± 0.3 lbf·ft]
manifold mating face and exhaust manifold coupling
taper face. Exhaust Manifold Coupling - Tighten
(5) Lightly shake again to verify the snug fitting.
11-16
1. Air Start System - Remove and Inspect............................................................... 12-3
1.1 Magnetic Valve - Remove and Inspect ................................................................................... 12-3
1.2 Air Pipe, Starter Valve and Distributor Valve - Inspect ........................................................... 12-4
1.3 Air Starter - Remove and Inspect ........................................................................................... 12-5
2. Air Start System - Disassemble, Inspect and Assemble.................................... 12-6
2.1 Starter Valve - Disassemble and Inspect................................................................................ 12-6
2.2 Starter Valve - Inspect ............................................................................................................ 12-7
2.3 Starter Valve - Assemble ........................................................................................................ 12-8
2.4 Distributer Valve - Disassemble and Inspect .......................................................................... 12-9
2.5 Distributer Valve - Inspect..................................................................................................... 12-10
2.6 Distributer Valve - Assemble ................................................................................................ 12-11
3. Air Start System - Install ..................................................................................... 12-11
12-1
1. Air Start System - Remove and Inspect

1.1 Magnetic Valve - Remove and Inspect
Air direct starting spec
Clean internal element with

light oil: every 500 hours
8
Abnormality of seat
surface, broken line
5
1 6 7
Magnetic Valve - Remove and Inspect

Removing Sequence
1 Air pipe 5 Air pipe
2 Elbow 6 Air filter
3 Bracket 7 Flexible pipe
4 Magnetic valve 8 Bracket
12-3
1.2 Air Pipe, Starter Valve and Distributor Valve - Inspect
Replace: Gasket
3
O-ring
Air Pipe, Starter Valve and Distributor Valve - Inspect
Removing Sequence
1 No.1 thru 6 pilot air pipes 3 Distributer valve
2 Main air pipe 4 Starter valve
12-4
1.3 Air Starter - Remove and Inspect
Air starter motor starting spec
Air Starter - Remove and Inspect

Removing Sequence
1 Clamp 4 Bracket
2 Air motor (approx. 60 kg [132 lb]) 5 Bracket
3 Auto-muffler
12-5
2. Air Start System - Disassemble, Inspect and Assemble

2.1 Starter Valve - Disassemble and Inspect
Replace
1 7
Replace
Replace
5
6
2
Settling, crack
3
4
Seat face defect, wear
Starter Valve - Disassemble and Inspect

1 Retaining screw 5 Packing
2 Nut 6 Starter valve
3 Retainer 7 Packing
4 Spring 8 Starter valve guide
2.1.1 Starter Valve - Remove

Nozzle remover
(1) Remove the retaining screw. P/N:36291-00900
(2) Attach the starter valve adapter and nozzle remover to
starter valve, and pull-out. Starter valve adapter
P/N:32591-01200
Starter valve
Starter Valve - Remove
12-6
2.2 Starter Valve - Inspect

2.2.1 Clearance Between Starter Valve and Starter
Valve Guide - Measure
(1) Measure the starter valve outside diameter and starter
valve guide inside diameter, and calculate the clear-
ance.
(2) If the value exceeds the limit, replace the starter valve
or starter valve guide with a new one. Change the part
with larger difference value to the standard.
Nominal
Item Standard value Limit value Clearance Between Starter Valve and Starter Valve
value
Starter valve ø13 mm 12.973 to 12.984 mm
Guide - Measure
-
outside diameter [0.51 in.] [0.5107 to 0.5112 in.]
Starter valve ø13 mm 13.000 to 13.018 mm
-
inside diameter [0.51 in.] [0.5118 to 0.5125 in.]
Clearance between
0.016 to 0.045 mm 0.100 mm
valve and valve
[0.0006 to 0.0018 in.] [0.0039 in.]
guide
2.2.2 Free Length of Valve Spring - Measure

Measure the free length of valve spring.
If the value exceeds the limit, replace the valve spring with
a new one.

Valve spring free length 30 mm [1.18 in.] 28 mm [1.10 in.]
Free Length of Valve Spring - Measure
12-7
2.3 Starter Valve - Assemble
147 ± 7.35 N·m

{15 ± 0.75 kgf·m}
[108.4 ± 5.42lbf·ft]
19 ± 0.95 N·m
{1.94 ± 0.09 kgf·m}
[14 ± 0.7lbf·ft]
to valve sliding portion. Valve lift
3.5 ± 0.3 mm
[0.138 ± 0.012 in.]
Lapping:
Using lapping compound,
make sure that valve seat face
shows a uniform contact all
around the circumference.
Be sure to attach gasket.
Starter Valve - Assemble
12-8
2.4 Distributer Valve - Disassemble and Inspect
Replace
Replace
Settling
Crack, wear
9
Crack, wear
Replace 4 2
5
6
Distributer Valve - Disassemble and Inspect

1 Case cover 6 Bushing
2 Packing 7 Distributer case
3 Distributer valve, lock pin 8 Distributer spacer
4 Snap ring 9 Packing
5 Distributer shaft
12-9
2.5 Distributer Valve - Inspect

2.5.1 Distributer Valve Height - Measure
Measure the distributer valve height. If the value exceeds
the limit, replace the valve with a new one.
Nominal
value
Distributer valve 22 mm 21.8 to 21.9 mm 21.5 mm
height [0.87 in.] [0.858 to 0.862 in.] [0.846 in.]
Distributer Valve Height - Measure

2.5.2 Clearance Between Distributer Shaft and Bush-
ing - Measure
(1) Measure the distributer shaft outside diameter and
bushing inside diameter, and calculate the clearance.
(2) If the value exceeds the limit, replace the distributer
shaft or bushing with a new one. Change the part with
larger difference value to the standard.
Nominal
value
Distributer shaft ø20 mm 19.959 to 19.980 mm Clearance Between Distributer Shaft and Bushing -
-
outside diameter [0.79 in.] [0.7858 to 0.7866 in.] Measure
Bushing inside ø20 mm 20.000 to 20.021 mm
-
diameter [0.79 in.] [0.7874 to 0.7882 in.]
Clearance between 0.020 to 0.062 mm 0.150 mm
shaft and bushing [0.0008 to 0.0024 in.] [0.0059 in.]
12-10
2.6 Distributer Valve - Assemble
Application of oil Air direct starting spec
Match mark
Rotation
direction
No.1 cylinder top Fitting

3° (No.6)
A
ir
in f
9°
lo w
126°
120° 120°
Overlap
6° 120°
3°
9° 3°
(65°) 9° No.1 exhaust valve open
No.3 cylinder top 14°
(No.4)
No.5 cylinder top
Starting air blowing timing diagram (No.2)
Distributer Valve - Assemble

Note: Align the match marks to assemble the distributer. The wrong assembling results in 360° timing error of air blow and the
engine will not start.
3. Air Start System - Install

Install the parts in the reverse order of the disassemble sequence. (Refer to the illustration for disassembling.)
12-11
1. Engine - Adjust ...................................................................................................... 13-3
1.1 Valve Bridge and Adjusting Screw - Check ............................................................................ 13-3
1.2 Valve Clearance - Check ........................................................................................................ 13-3
1.3 Fuel Injection Timing - Check ................................................................................................. 13-3
1.4 Fuel System - Bleed Air .......................................................................................................... 13-3
1.5 Belt and Belt Tension - Inspect and Adjust............................................................................. 13-6
2. Break-in Operation .............................................................................................. 13-10
2.1 Preparation Before Engine Starting ...................................................................................... 13-10
2.2 Engine Start-up..................................................................................................................... 13-10
2.3 Break-in Operation................................................................................................................ 13-10
3. Engine-Test and Adjustment .............................................................................. 13-12
3.1 Engine Performance Test ..................................................................................................... 13-12
3.2 Emission Gas Test................................................................................................................ 13-12
3.3 Governor Performance Test ................................................................................................. 13-12
3.4 Alarm Action and Emergency Stop Tests ............................................................................. 13-12
3.5 Maximum Fuel Injection Volume - Set .................................................................................. 13-12
3.6 Seal ...................................................................................................................................... 13-13
13-1
1. Engine - Adjust
1.1 Valve Bridge and Adjusting Screw - Check
Check the adjustment of valve bridge and adjusting screw.If
it is not adjusted, adjust it to the standard value.
For the adjusting procedure, refer to "Valve Bridge and
Adjusting Screw - Adjust" of "ASSEMBLY OF BASIC
ENGINE."
1.2 Valve Clearance - Check
Check the valve clearance.
If it is not adjusted, adjust it to the standard value.
For the adjusting procedures, refer to "Valve Clearance -
Inspect and Adjust" of "ASSEMBLY OF BASIC
ENGINE. "
1.3 Fuel Injection Timing - Check
Check the fuel injection timing.
If it is not adjusted, adjust the timing to the specified value.
For the adjusting procedures, refer to "Fuel Injection Timing
- Check and Adjust" of "ASSEMBLY OF BASIC
ENGINE. "
1.4 Fuel System - Bleed Air
[Unlock] [Prime] [Lock]

(a) Thoroughly wipe off fuel spilled out of air vent plug Move cap Turn clockwise
Turn counterclockwise up and down while pressing
to prevent a fire.
(b) After air bleeding, ensure the lock of priming pump
cap.If locking is insufficient, it could cause damage
to the priming pump and result in fuel leak and a
fire.
To bleed air from fuel system, start air bleeding at the place
nearest to fuel tank, from fuel filter to injection pump, while
feeding fuel with priming pump. Priming Pump - Operate
1.4.1 Fuel Filter (Wire Mesh Element Spec) - Bleed

air Air vent plug
Priming pump
cap
If the air vent plugs, threads of bracket or sealing
washers are damaged, replace them with new ones.
(1) Loosen the air vent plug of fuel filter by approx 1.5
turns.
(2) Feed fuel by moving the priming pump up and down.
(3) When fuel flowing from vent holes no longer contains
air bubbles, tighten the air vent plugs to the specified Fuel Filter (Wire Mesh Element Spec) - Bleed air
torque.
13-3
1.4.2 Fuel Filter (Standard Spec) - Bleed Air

Priming pump Air vent plug
8 to 10 N·m
cap {0.8 to 1.0 kgf·m}
If the air vent plugs, threads of bracket or sealing [5.9 to 7.4 lbf·ft]
(1) Loosen the air vent plug of fuel filter by approx 1.5
turns.
air bubbles, tighten the air vent plugs to the specified
torque. Fuel Filter (Standard Spec) - Bleed Air
1.4.3 Air Filter (Change Over Spec) - Bleed Air Air vent plug Changeover cock
9 ±1 N·m {0.9 ± 0.1 kgf·m}
[ 6.6 ± 0.7 lbf·ft] Position during
operation
If the air vent plugs, threads of bracket or sealing
Pin B A Pin
(1) Switch the filter to bleed air, and loosen the air vent
plug of fuel filter by approx 1.5 turns. Right side
Left side filter
(2) Feed fuel by moving the priming pump up and down. filter Changeover cock
A: Air vent location of left side filter
air bubbles, tighten the air vent plugs to the specified B: Air vent location of right side filter
torque. Air Filter (Chnge Over Spec) - Bleed Air
(4) Turn the changeover cock to the position during opera-
tion.
1.4.4 Fuel Injection Pump - Bleed Air
(1) Loosen the air vent plugs of fuel injection pump by
approx 1.5 turns.
air bubbles, tighten a air vent plug leaving one plug un-
Air vent plug
tightened. Lock the priming pump by turning the cap Priming pump 6 ± 1 N·m
clockwise while pushing it down. Then tighten the last cap {0.6 ± 0.1 kgf·m}
[4.4 ± 0.7 lbf·ft]
air vent plug.
Note:(a) To check the function of check valve, tighten the all
Fuel Injection Pump - Bleed Air
air vent plugs, then lock the priming pump cap.The
priming pump cap resists the push-in, but the check
valve opening pressure is stabilized and the valve
function is verified with this procedure.
(b) Thoroughly wipe off fuel spilled out of air vent
plug.
13-4
1.4.5 Priming Pump Cap - Lock

Gently tighten 90 ± 10°
the priming cap
by hand until Priming pump
If the priming pump cap is not locked sufficiently, the the tightening
force suddenly
screw in cap wears due to engine vibration, which can increases.
result in the priming pump cap to pop-off and fuel to
leak. When over tightened
If it is over-tightened, the head of priming pump can be (120° or more),
damage of head or
damaged. Make sure to tighten the cap to the correct packing can results.
angle.
Priming Pump Cap - Lock
Check the head packing of priming pump for deforma-

tion and damage.If any deformation or damage is
Head packing
found, replace the priming pump with a new one.
(1) Gently tighten the priming cap by hand until the tight-
ening force suddenly increases. Then, mark the priming
pump cap in this position.
(2) Using a wrench, further tighten the priming pump cap
by 90 ± 10° from the mark position.
(3) Check the mounting condition of head packing. If any
defects such as deformation or dent are found, replace Priming Pump Cap Packing
the priming pump with a new one.
13-5
1.5 Belt and Belt Tension - Inspect and Adjust
If any defects such as cuts or surface separations are found during inspection, replace the belt with a new one.
Keep the belt free from oil and grease.Oil or grease causes the belt to slip and shorten the service life.
Excessive belt tension can cause rapid wear of alternator bearing and shorten the service life of belt. Adjust the belt
tension correct following the procedures below:
1.5.1 Belt - Inspect

(1) Inspect the belt visually for separation or damage.If any defect is found, replace the belt with a new one.
(2) Inspect the tension (deflection) and pressing force of belt.
V-belt
Inspect the V-belt deflection by pressing it with approx 98 to 147 N {10 to 15 kgf} [22 to 33 lbf] force at the center of its span.
The belt deflection of 10 to 15 mm [0.39 to 0.59 in.] is normal.
If the deflection is out of standard, adjust the belt tension.
Ribbed belt
Refer to the table below. If the pressing force is not meet the standard, when pushing in the middle of pulleys with the gauge
and the belt deflection is 15 mm [0.59 in.], adjust the belt tension.
1.5.2 Belt Tension (Fan) - Adjust
V-belt drive
Lock nut
(1) Remove the belt cover. Fan pulley
(2) Loosen all the fixing bolts of fan bracket. 10 to 15 mm Tension bolt
(3) Turn the tension bolt to adjust the belt tension. [0.39 to 0.59 in.] Fixing bolt (4 places)
(4) Secure the tension bolt with lock nut.

(5) Tighten all the fixing bolts of fan bracket.
(6) Install the belt cover.
Fan Belt (V-belt Drive) Tension - Adjust

Ribbed belt drive
(1) Remove the belt cover. Tension pulley Fixing bolt (4 places)
(2) Loosen all the fixing bolts of tension bracket. Fan pulley
Lock nut
(3) Turn the tension bolt to adjust the belt tension.
Tension bolt
(5) Tighten all the fixing bolts of tension bracket. Gauge width
approx. 10 mm [0.39 in.]
15 mm
[0.59 in.]
Thrust force
Gauge
Ribbed belt Crankshaft pulley

Fan Belt (Ribbed Belt Drive) Tension - Adjust
13-6
1.5.3 Belt tension (water pump) - Adjust

V-belt drive
(1) Remove the belt cover. Lock nut
10 to 15 mm
(2) Loosen all the fixing bolts of tension bracket. [0.39 to 0.59 in.]
Tension bolt
(5) Tighten all the fixing bolts of tension bracket.
Water pump
Fixing bolt (3 places) pulley
Water pump Belt (V-belt Drive) Tension - Adjust
Ribbed belt drive
Gauge width
(1) Remove the belt cover. approx. 10 mm [0.39 in.]
(2) Loosen all the fixing bolts of tension bracket. Tension bolt
(3) Turn the tension bolt to adjust the belt tension. Lock nut
Fixing bolt
(4) Secure the tension bolt with lock nut. 15 mm
(5) Tighten all the fixing bolts of tension bracket. Fixing bolt [0.59 in.]
Thrust force
(6) Install the belt cover. Tension pulley Gauge
Ribbed belt
Water pump
pulley
Crankshaft pulley
Water pump Belt Tension - Adjust
(Ribbed belt drive)
1.5.4 Belt Tension - Adjust
(Water pump for Air cooler) 10 to 15 mm
[0.39 to 0.59 in.]
(1) Remove the belt cover.
(2) Loosen all the fixing bolts of tension bracket. Air cooler water
pump pulley
(5) Tighten all the fixing bolts of tension bracket.
(6) Install the belt cover. Fixing bolt (3 places)
Tension bolt
Tension pulley Lock nut
Water pump Belt for Air cooler Tension - Adjust
13-7
1.5.5 Belt Tension (Alternator) - Adjust

V-belt drive
Alternator pulley
(1) Remove the belt cover. 10 to 15 mm
[0.39 to 0.59 in.] Fixing bolt
(2) Loosen all the fixing bolts of alternator.
(3) Adjust the belt tension by shifting the alternator with
bar.
(4) Tighten all the fixing bolts of alternator.
Fixing bolt
Alternator Belt (V-belt Drive) Tension - Adjust

Ribbed belt drive
(1) Remove the belt cover.
Ribbed belt Gauge width
(2) Loosen all the fixing bolts of alternator. approx. 10 mm [0.39 in.]
Pressing force Fixing bolt
(4) Secure the tension bolt with lock nut. 15 mm
[0.59 in.] Alternator pulley
(5) Tighten all the fixing bolts of alternator.
(6) Install the belt cover. Fixing bolt
Gauge
Tension bolt
Fixing bolt Lock nut
Alternator Belt (Ribbed Belt Drive) Tension - Adjust
13-8
Ribbed belt tension (N) table

Belt straight distance (mm) [in.]
Number
Item 300 [11.81] or more than 300 to 400 more than 400 to 500 more than 500 to 600 more than 600
of ribs
below [11.81 to 15.75] [15.75 to 19.69] [16.69 to 23.62] [23.62]
74 N {7.55 kgf} 49 N {5.00 kgf} 37 N {3.77 kgf} 29 N {2.96 kgf} 25 N {2.55 kgf}
3
[16.64 lbf] [11.02 lbf] [8.32 lbf] [6.52 lbf] [5.62 lbf]
4
103 N {10.50 kgf} 69 N {7.04 kgf} 51 N {5.20 kgf} 41 N {4.18 kgf} 34 N{3.47 kgf}
5
6
132 N {13.46 kgf} 88 N {8.97kgf} 66 N {6.73 kgf} 53 N {5.40 kgf} 44 N {4.49 kgf}
7
When a new [29.67 lbf] [19.78 lbf] [14.84 lbf] [11.91 lbf] [9.89 lbf]
belt is installed: 147 N {14.99 kgf} 98 N {9.99 kgf} 74 N {7.55 kgf} 59 N {6.02 kgf} 49 N {5.00 kgf}
8
9
10
11
12
51 N {5.20 kgf} 34 N{3.47 kgf} 26 N {2.65 kgf} 21 N {2.14 kgf} 17 N {1.73 kgf}
3
4
5
6
7
When re- [20.91 lbf] [13.94 lbf] [10.34 lbf] [8.32 lbf] [6.97 lbf]
adjusted: 103 N {10.50 kgf} 69 N {7.04 kgf} 51 N {5.20 kgf} 41 N {4.18 kgf} 34 N{3.47 kgf}
8
9
10
11
12
The force when the middle of belt straight line is pushed and deflected by 15 mm [0.59 in.]
13-9
2. Break-in Operation
2.1 Preparation Before Engine Starting
Check the levels of fuel, engine oil, and coolant, and also bleed air from fuel system and cooling system.
Inspect the link between governor output lever and the fuel injection pump rack.Check that the fuel control rack is at the no-
injection position when the engine is stopped. Check that the control rack is at the "0" position when the stop lever is pulled.
Check the wiring of electrical system (sensor, meter alarm panel, starter, alternator, stop solenoid, and battery). Turn ON the
controller main switch to check for abnormality.
Set the governor speed lever so that the engine may run at a low idling speed after start-up.
Operate the stop solenoid, and make sure that the fuel injection pump rack moves to the no injection position.
Install the pressure gauge, thermometer and flow meter as required.
2.2 Engine Start-up

(1) Pull the stop lever to the no injection position, and crank for approx 10 seconds with starter to circulate engine oil in the
engine. Repeat this 2 or 3 times with one minute intervals between them.
Check that there is no defect such as abnormal noise or rotation speed fluctuation.
(2) Start the engine in the normal procedure.
Check that the engine can run at a low idling speed after start-up.
(3) Check that the oil pressure increases immediately, and the coolant circulates.
(4) Check for leakage of oil, coolant, fuel and gas (air), and abnormal noise and vibration.
(5) After checking the engine low idling without any problem, turn the key switch to OFF position, and make sure that the
engine stops.
2.3 Break-in Operation
Be prepared to activate the emergency stop for unexpected trouble of engine operation.
2.3.1 Break-in operation load and time

The load during break-in operation is to be increased progressively as shown in the table.
Note that the time shown in the table is the minimum time required to check the engine in a stable condition.
Break-in Operation
Classi-
Generator Marine main
fication
Item Rotating speed (min-1) Load (PS) Time (min) Rotating speed (min-1) Load (PS) Time (min)
Low rotating Low rotating
1 600 to 900 No-load 20 600 to 900 No-load 20
speed speed
Medium Medium
2 1000 to 1200 No-load 10 1000 to 1200 No-load 10
rotating speed rotating speed
High rotating High rotating
3 1400 to rated speed No-load 10 1400 to rated speed No-load 10
speed speed
4 25 % 20 Equivalent to 25 % output 25 % 20
Marine
5 50 % 20 engine speed Equivalent to 50 % output 50 % 20
Rated speed at partial load
6 75 % 30 Equivalent to 75 % output 75 % 30
7 100 % 20 Rated speed 100 % 20
13-10
2.3.2 Inspection while the engine is running

During the break-in operation, pay attention to followings and make sure that there is no abnormality.
Oil pressure and oil temperature Exhaust temperature
Coolant temperature and level Differences between right and left banks
Leakage of oil, water, fuel and gas; especially oil from tur- Blow-by gas (amount and color)
bocharger pipe connection of lubricating oil. Rotational fluctuation
Noise and vibration Face and radial runouts of rotating parts
Intake air pressure and temperature Indication and operation of meter and alarm
Exhaust color and odor
2.3.3 Inspection and adjustment after break-in opera-
tion
Valve clearance Belt tension
Fuel injection timing Defects such as oil leakage - inspect and repair
Bolts and nuts around the engine - retighten
13-11
3. Engine-Test and Adjustment
(a) Engine test, adjustment and seal shall be performed at the certified maintenance shop only.
When the seal of engine is to be done at a service shop other than the certified shops, ask a certified shop for
the presence of qualified person for the test, adjustment and seal.
(b) Performance check and adjustment of the engine shall be conducted when the water and oil temperatures
become stable after sufficient warm-up operation.
After the break-in operation is completed, and the engine runs normally, check and adjust the performance and functions of the
engine.
Record the test results referring to the engine data of delivery time.
3.1 Engine Performance Test
Fuel consumption rate, various temperatures and pressures,
and exhaust color
3.2 Emission Gas Test
Exhaust gas analyses
3.3 Governor Performance Test
Minimum speed at no-load (low idle) - set
Maximum speed at no-load (high idle) - set
Load sudden application and rejection tests
Governor droop, hunting, and rotational fluctuation - check
Setting conditions of governor controller and others - check
3.4 Alarm Action and Emergency Stop Tests
Oil pressure decrease, water temperature increase, and over-
speed
3.5 Maximum Fuel Injection Volume - Set
Left side pump
Maximum load
(1) Run the engine under the maximum rated speed. rack position Stopper
(2) Loosen the lock nut located on the edge of rack stopper. Pump rack Lock nut
(3) Fix the lock nut in a position where the stopper comes zero position
in contact with the end face of rack plate.
Rack plate
Decrease
Increase
Left
Maximum Fuel Injection Volume (Left Side) - Set
Right side pump
Maximum load
(1) Run the engine under the maximum rated speed. rack position
(2) Remove the cap, and loosen the outer nut.
(3) Loosen or tighten the inner nut until it is firmly engaged Rack Increase Decrease Cap
in place with a clicking sound.
(4) Tighten the outer nut, and install the cap.
Right Inner nut Outer nut

Maximum Fuel Injection Volume (Right Side) - Set
13-12
3.6 Seal
After all performance tests and adjustments are completed, stop the engine, and seal the specified part between governor actua-
tor and fuel injection pump rack.
3.6.1 Tamper Proof - Remove
Tamper proof nut is composed of double structure, and can-
not be removed by rotating.
To remove, cut the outer cylinder nut and remove the inner
nut.
Inner nut
Self-locking nut
Outer cylinder nut
(Tamper proof nut)
Tamper Proof (Left) - Remove
Inner nut
Self-locking nut
Outer cylinder nut
(Tamper proof nut)
Tamper Proof (Right) - Remove
3.6.2 Tamper Proof - Install
Tamper proof nut
(1) Tighten the tamper proof nut to the specified torque, (Outer cylinder nut)
35 ± 5.0 N·m
and make sure that the inner nut is separated. {3.6 ± 0.51 kgf·m}
(2) Tighten the self lock nut to the specified torque, and [25.8 ± 3.69 lbf·ft]
caulk the end of the nut. Caulking
Self-locking
33 ± 3.3 N·m {3.4 ± 0.34 kgf·m}
[24.3 ± 2.43 lbf·ft]
Tamper Proof - Install
13-13
Engine inspection record sheet (SA series)
No. 1 Cylinder liner bore inside diameter - measure

No. 2 Cylinder liner flange protrusion - measure
No. 3 Valve guide inside diameter and Vale stem diameter - measure
No. 4 Cylinder head valve sinkage, seat width, and valve margin - measure
No. 5 Cylinder head bottom face distortion - measure
No. 6 Connecting rod bushing inside diameter and connecting rod big-end bore diameter
- measure
No. 7 Rocker bushing inside diameter and rocker shaft outside diameter - measure
No. 8 Piston pin bore inside diameter and piston pin outside diameter - measure
No. 9 Valve clearance - measure
No. 10 Fuel injection nozzle injection pressure - measure
Camshaft bushing inside diameter and camshaft journal outside diameter (right
No. 11
side) - measure
Camshaft bushing inside diameter and camshaft journal outside diameter (left side)
No. 12
- measure
No. 13 Crankshaft end play - measure
INSPECTION RECORD SHEET No.1
SA
Engine Model
Customer Serial No.
Date
Item Cylinder liner bore inside diameter - measure Unit mm[in.]
Measuring location Standard

Item to be
Nominal Standard Limit
measured
Cylinder liner 䃥150 150.000 to 150.040 150.140
inside diameter [5.91] [5.9055 to 5.9071] [5.9110]
Location
a 30 [1.18]
b 100 [3.94]
c 250 [9.84]
Measured value
Item Cylinder liner bore inside diameter Item Cylinder liner bore inside diameter
No. Direction A B C No. Direction A B C
X X
1 7
Y Y
X X
2 8
Y Y
X X
3 9
Y Y
X X
4 10
Y Y
X X
5 11
Y Y
X X
6 12
Y Y
Remark Approved by Checked by Measured by

No.2 INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Item Cylinder liner bore flange protrusion - measure Unit mm[in.]

Item to be measured Standard
0.10 to 0.19
Cylinder liner flange protrusion
[0.0039 to 0.0075]
Measured value
Item Cylinder liner bore flange protrusion

No. A B C D Average value
1
2
3
4
5
6
7
8
9
10
11
12

INSPECTION RECORD SHEET No.3(1/2)
SA
Engine Model
Customer Serial No.
Date
Valve guide inside diameter and Valve stem diameter -
Item measure (1/2)
Unit mm[in.]
Measuring Standard
location
Item to be measured Nominal Standard Limit
Valve guide inside diameter 䃥10 10.000 to 10.015 10.060
(same for inlet and exhaust) [0.39] [0.3937 to 0.3943] [0.3961]
Valve stem 䃥㻝㻜 9.940 to 9.960 9.910
Inlet 㼇㻜㻚㻟㻥㼉 [0.3913 to 0.3921] [0.3902]
outside
䃥㻝㻜 9.910 to 9.930 9.880
diameter Exhaust 㼇㻜㻚㻟㻥㼉
[0.3902 to 0.3909] [0.3890]
Measured value
Item Valve guide inside diameter Valve stem outside diameter Clearance
A B A B A B
No. Direction
X Y X Y X Y X Y Max. Min. Max. Min.
a
Inlet
b
1
Exhaust
a
b
a
Inlet
b
2
Exhaust
a
b
a
Inlet
b
3
Exhaust
a
b
a
Inlet
b
4
Exhaust
a
b
a
Inlet
b
5
Exhaust
a
b
a
Inlet
b
6
Exhaust
a
b

No.3(2/2) INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Valve guide inside diameter and Valve stem diameter -
Item measure (2/2)
Unit mm[in.]
Measuring Standard
location
Valve guide inside diameter 䃥10 10.000 to 10.015 10.060
(same for inlet and exhaust) [0.39] [0.3937 to 0.3943] [0.3961]
Valve stem 䃥㻝㻜 9.940 to 9.960 9.910
Inlet 㼇㻜㻚㻟㻥㼉 [0.3913 to 0.3921] [0.3902]
outside
䃥㻝㻜 9.910 to 9.930 9.880
diameter Exhaust 㼇㻜㻚㻟㻥㼉
[0.3902 to 0.3909] [0.3890]
Measured value
Item Valve guide inside diameter Valve stem outside diameter Clearance
A B A B A B
No. Direction
X Y X Y X Y X Y Max. Min. Max. Min.
a
Inlet
b
7
Exhaust
a
b
a
Inlet
b
8
Exhaust
a
b
a
Inlet
b
9
Exhaust
a
b
a
Inlet
b
10
Exhaust
a
b
a
Inlet
b
11
Exhaust
a
b
a
Inlet
b
12
Exhaust
a
b

INSPECTION RECORD SHEET No.4(1/2)
SA
Engine Model
Customer Serial No.
Date
Cylinder head valve sinkage, seat width, and valve margin -
Item measure(1/2)
Unit mm[in.]

Item to be measured Standard Limit
Valve seat angle 30° -
-0.1 to 0.1 0.5
Valve sinkage
[-0.039 to 0.039] [0.020]
1.98 to 2.18 2.5
Inlet [0.0780 to 0.0858]
Seat [0.098]
Valve
width 1.75 to 1.95 2.3
seat Exhaust
[0.0689 to 0.0768] [0.091]
2.7 to 3.1
Inlet [0.106 to 0.122]
Valve Reface up to
margin 2.0 [0.079]
2.8 to 3.2
Exhaust
[0.110 to 0.126]
Measured value
Item Item
Valve seat Valve Valve seat Valve
Seat width Seat width
No. Direction angle sinkage No. Direction angle sinkage
a a
Inlet
Inlet
b b
1 4
Exhaust
Exhaust
a a
b b
a a
Inlet
Inlet
b b
2 5
Exhaust
Exhaust
a a
b b
a a
Inlet
Inlet
b b
3 6
Exhaust
Exhaust
a a
b b

No.4(2/2) INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Cylinder head valve sinkage, seat width, and valve margin -
Item measure(2/2)
Unit mm[in.]

Valve seat angle 30° -
-0.1 to 0.1 0.5
Valve sinkage
[-0.039 to 0.039] [0.020]
1.98 to 2.18 2.5
Inlet [0.0780 to 0.0858]
Seat [0.098]
Valve
width 1.75 to 1.95 2.3
seat Exhaust
[0.0689 to 0.0768] [0.091]
2.7 to 3.1
Inlet [0.106 to 0.122]
Valve Reface up to
margin 2.0 [0.079]
2.8 to 3.2
Exhaust
[0.110 to 0.126]
Measured value
Item Item
Valve seat Valve Valve seat Valve
Seat width Seat width
No. Direction angle sinkage No. Direction angle sinkage
a a
Inlet
Inlet
b b
7 10
Exhaust
Exhaust
a a
b b
a a
Inlet
Inlet
b b
8 11
Exhaust
Exhaust
a a
b b
a a
Inlet
Inlet
b b
9 12
Exhaust
Exhaust
a a
b b

INSPECTION RECORD SHEET No.5
SA
Engine Model
Customer Serial No.
Date
Item Cylinder head bottom face distortion - measure Unit mm[in.]
Item to be
Standard Limit
measured
Distortion of
0.03 [0.0012] 0.70
cylinder head
or less [0.0276]
bottom surface
Measured value
Item Cylinder head bottom face distortion

No. A B C D E F G
1
2
3
4
5
6
7
8
9
10
11
12

No. 6(1/2) INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Connecting rod bushing inside diameter and connecting rod
Item big-end bore diameter - measure (1/2)
Unit mm[in.]
Measuring
location
Standard Item to be measured Nominal Standard Limit

Connecting rod bushing 䃥58 58.020 to 58.040 58.070
Connecting rod big end 䃥110 110.000 to 110.022 Minimum: 109.950 [4.3287]
bore diameter [4.33] [4.3307 to 4.3316] Maximum: 110.050 [4.3327]
Measured value
Item Connecting rod bushing inside diameter Connecting rod big-end bore diameter
No. Direction X Y A B C
a
1
b
a
2
b
a
3
b
a
4
b
a
5
b
a
6
b

INSPECTION RECORD SHEET No. 6(2/2)
SA
Engine Model
Customer Serial No.
Date
Connecting rod bushing inside diameter and connecting rod
Item big-end bore diameter - measure (2/2)
Unit mm[in.]
Measuring
location
Standard Item to be measured Nominal Standard Limit

Connecting rod bushing 䃥58 58.020 to 58.040 58.070
Connecting rod big end 䃥110 110.000 to 110.022 Minimum: 109.950 [4.3287]
bore diameter [4.33] [4.3307 to 4.3316] Maximum: 110.050 [4.3327]
Measured value
Item Connecting rod bushing inside diameter Connecting rod big-end bore diameter
No. Direction X Y A B C
a
7
b
a
8
b
a
9
b
a
10
b
a
11
b
a
12
b

No. 7(1/2䠅
INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Rocker bushing inside diameter and rocker shaft outside
Item diameter - measure(1/2)
Unit mm[in.]

Rocker bushing 䃥32 32.055 to 32.080 32.100
Rocker shaft 䃥32 31.975 to 31.991 31.950
outside diameter [1.26] [1.2589 to 1.2595] [1.2614]
Measured value
Item Rocker bushing inside diameter Rocker shaft outside diameter Clearance
No. Direction X Y X Y Maximum Minimum
a
1
b
a
2
b
a
3
b
a
4
b
a
5
b
a
6
b

No. 7(2/2䠅
INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Rocker bushing inside diameter and rocker shaft outside
Unit mm[in.]

Rocker bushing 䃥32 32.055 to 32.080 32.100
Rocker shaft 䃥32 31.975 to 31.991 31.950
Measured value
Item Rocker bushing inside diameter Rocker shaft outside diameter Clearance
a
7
b
a
8
b
a
9
b
a
10
b
a
11
b
a
12
b

No. 8(1/2) INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Piston pin bore inside diameter and piston pin outside
Unit mm[in.]

Piston pin bore 䃥58 58.002 to 58.012 58.040
Piston pin 䃥58 57.987 to 58.000 57.970
Measured value
Item Piston pin bore diameter Piston pin outside diameter Clearance
A
1 B
C - - - -
A
2 B
C - - - -
A
3 B
C - - - -
A
4 B
C - - - -
A
5 B
C - - - -
A
6 B
C - - - -

INSPECTION RECORD SHEET No. 8(2/2)
SA
Engine Model
Customer Serial No.
Date
Piston pin bore inside diameter and piston pin outside
Unit mm[in.]

Piston pin bore 䃥58 58.002 to 58.012 58.040
Piston pin 䃥58 57.987 to 58.000 57.970
Measured value
Item Piston pin bore diameter Piston pin outside diameter Clearance
A
7 B
C - - - -
A
8 B
C - - - -
A
9 B
C - - - -
A
10 B
C - - - -
A
11 B
C - - - -
A
12 B
C - - - -

No. 9 INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Item Valve clearance - measure Unit mm[in.]

Item to be measured Standard
Valve Inlet 0.4 [0.016]
clearance (A) Exhaust 0.5 [0.020]
Measured value
Valve clearance Valve clearance
No. Inlet Exhaust No. Inlet Exhaust
Before Before
adjustment adjustment
1 After
7 After
Before Before
2 After
8 After
Before Before
3 After
9 After
Before Before
4 After
10 After
Before Before
5 After
11 After
Before Before
6 After
12 After

INSPECTION RECORD SHEET No. 10
SA
Engine Model
Customer Serial No.
Date
Item Fuel injection nozzle injection pressure - measure Unit MPa{kgf/cm2}[psi]

Item to be measured Nominal Standard
21.6 22.1 to 22.6
Valve opening
{220} {225 to 230}
pressure [3133] [3205 to 3278]
Measured value
Injection pressure Service hours Injection pressure Injection pressure Service hours Injection pressure
No. (h)
No. (h)
Before adjustment After adjustment Before adjustment After adjustment
1 7
2 8
3 9
4 10
5 11
6 12

No. 11 INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Camshaft bushing inside diameter and camshaft journal
Item outside diameter (right side) - measure
Unit mm[in.]

䃥64 64.000 to 64.030 64.090
No.1
Camshaft bushing [2.52] [2.5197 to 2.5209] [2.5232]
inside diameter 䃥68 68.000 to 68.030 68.090
No.2䡚7
[2.68] [2.6772 to 2.6783] [2.6807]
䃥64 63.920 to 63.940 63.870
Camshaft journal No.1
[2.52] [2.5165 to 2.5173] [2.5146]
bore outside
䃥68 67.920 to 67.940 67.870
diameter No.2䡚7
[2.68] [2.6740 to 2.6748] [2.6720]
Measured value
Item Camshaft bushing inside diameter Camshaft journal outside diameter Clearance
No. Direction X Y X Y Minimum Maximum
a
1
b
a
2
b
a
3
b
a
4
b
a
5
b
a
6
b
a
7
b

INSPECTION RECORD SHEET No. 12
SA
Engine Model
Customer Serial No.
Date
Camshaft bushing inside diameter and camshaft journal
Item outside diameter (left side) - measure
Unit mm[in.]

䃥64 64.000 to 64.030 64.090
No.1
Camshaft bushing [2.52] [2.5197 to 2.5209] [2.5232]
inside diameter 䃥68 68.000 to 68.030 68.090
No.2䡚7
[2.68] [2.6772 to 2.6783] [2.6807]
䃥64 63.920 to 63.940 63.870
Camshaft journal No.1
[2.52] [2.5165 to 2.5173] [2.5146]
bore outside
䃥68 67.920 to 67.940 67.870
diameter No.2䡚7
[2.68] [2.6740 to 2.6748] [2.6720]
Measured value
Item Camshaft bushing inside diameter Camshaft journal outside diameter Clearance
No. Direction X Y X Y Minimum Maximum
a
1
b
a
2
b
a
3
b
a
4
b
a
5
b
a
6
b
a
7
b

No.13 INSPECTION RECORD SHEET
SA
Engine Model
Customer Serial No.
Date
Item Crankshaft end play - measure Unit mm[in.]
Measuring location
Standard

0.200䡚0.395 0.500
Crankshaft end play
[0.0079 to 0.0156] [0.0197]
Measured value
Before disassembly After reassembly

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SERVICE MANUAL

HOW TO USE THIS MANUAL

Terms used in this manual

Abbreviations and Standards

Stay Away From Rotating and Moving Parts

Install Protective Covers Over Rotating Lockout and Tagout

Work tion and maintenance. Lockout and tagout are effec-

Be Careful of Exhaust Gas Poison- Be Careful of Falling

Do not Climb Onto the Engine

Always Prepare a Stable Footing

Be Careful When Handling Fuel, Be Careful of Burns

Be Careful of Burns When Changing Oil

Battery When Abnormality Occurs

Be Careful with Battery Do Not Add Cooling Water Immediately

Do Not Tamper Never Break the Seals

Observe Safety Rules at Work Site Cautions for Engine Transportation

Do Not Turn Off the Battery Switch During

Maintenance of Warning Labels

Points on Disassembling and As- Points on Assembling

Chapter 2 SERVICE DATA

Chapter 3 SERVICE TOOLS

Chapter 4 OVERHAUL INSTRUCTIONS

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Chapter 6 INSPECTION AND REPAIR OF BASIC ENGINE

Chapter 7 ASSEMBLY OF BASIC ENGINE

Chapter 9 LUBRICATION SYSTEM

Chapter 10 COOLING SYSTEM

Chapter 11 INLET AND EXHAUST SYSTEMS

Chapter 12 AIR START SYSTEM

Chapter 13 ADJUSTMENT AND OPERATION

Note: Configuration may differ depending

Exhaust gas outlet S12A2-PTA

Note: Configuration may differ depending Oil pan

Cooling Fuel injection pump

Air cooler Governor oil filter

Fuel filter Stop lever

Fuel feed pump

Starter Oil filter

Water drain cock

Right Side View

Note: Configuration may differ depending on the customization and specifications.

Exhaust gas outlet S12A2-PTA2

Note: Configuration may differ depending Oil pan

Cooling Fuel injection pump

Fuel filter Stop lever

Fuel feed pump

Bypass oil filter

Starter Oil filter

Water drain cock

Water pump side

Note: Configuration may differ depending

Exhaust gas outlet S12A2-Y1PTA2

Note: Configuration may differ depending Oil pan

Air cooler Fuel filter S12A2-Y1PTA2

Cooling water outlet

Fan Fuel injection pump

Water drain cock

Air cooler Oil cooler

Fuel injection pump

Fuel feed pump

Bypass oil filter

Note: Configuration may differ depending

Exhaust gas outlet