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1-1

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1. FUEL SYSTEM BLEEDING

1-21-2

2. MAJOR DISASSEMBL Y OF ENGINE2-1. Remava'

1-71-8

1-101-141-181-251-26

3. S R C NG OF MA OR COMPON N P R S

3-1 . Cl de r body and c y l de r l e rs-2. P ons and connectig-rods-3. Cankshaft. bearjgs and flw eel-4 . Cl de r head as s mb l-5. Rckerarm shaft assmbl-6. Cmshaftassembl

1-291-294. MAJOR REASSEMBL Y OF ENGINE COMPONENTS4-1. Reassembly1-365. ENGINE TROUBLE-SHOOTING

BLEEDING OF FUEL SYSTEM1) Loosen the cap on the fuel feed pump and

pump fuel into the injection pump by operat-ing the feed pump. ?'

2) When the fuel system beccmes filled andfeed pump begins t c idle, Iccsen the jcintbclt cf inlet pipe fitted t c the fuel filter, t crelease fueJ with air.

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3) Repeat the above operation unti' air bubblesdisappear fro~ the fue' being pumped out. FIG. 1-1

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4) Similarly, remove air by loosening thebleeder screw on the left side part of the in-jection pump.NOTE: Tighten the'bleeder screw, before

pressurized fuel is completelyreleased.

FIG. 1-2

(2) Removal of left side engine footRemove the engine foot fixing bolts and the en-gine foot and support rubber.

(3) Removal of intake and exhaust manifolds1) Disconnect the breather hose. and vacuumvinyl pipe.2) Remove the 2 bolts and 7 nuts mounting the

intake and exhaust manifolds; then removethe spring. spring eye. engine tianger an~ in-take and exhaust manifolds. /, .

(4) Removal of leak-off pipeRemove the joint bolt and disconnect the lea-k--off pipe.

(5) Removal of fuel pipes and fuel filter1) Remove the joint bolt and return pipe clip

bolt.2) Remove the fuel filter mounting bolt and re-move the fuel filter .

(6) RemovaJ of injection pipesRemove the sleeve nuts and d isconnect the in-jection pipes.

(7) Remcval of injection pumpRemove the bolts fixing the injection pump andremove the injection pump assembly rearward.MAJOR DISASSEMBL y CF ENGINE.

ervice tools: Dia! indicator, feeler gauge, scrapertools: Crankshaft gear remover

9-8521-0074-0 or 9-8521-0062-0Camshaft bearing remover andinstaller 9-8523-1360-0

NOTE: Liquid gasket has been applied t c thebcnding tace cf injecticn pump befcreinstallaticn t c ensure permanent set-ting. Remcve injecticn pump by tappinglightly with a mallet.

Removal of cooling fan and generator1) Remove the 4 bolts and remove the cooling

fan. spacer and pulley.2) Remove the vacuum pump oil pipe and rub-ber hose.

3) Remove the generator adjust plate bolt andfixjng bolt. then remove the generatorassembly.

FIG -4(8) Removal of right side engine footRemove the bolts fixing the engine foot and re-

move the engine foot and support rubber.(9) Removal of oil level gauge and oil filter

1) Remove the oil level gauge.2) Remove the nut and the bolt fixing the clip ofthe guide tube and remove the guide tube.FIG. 1-3

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ENGINE 1-3

2) Remove the glow plug.NOTE: Take care not to lose the nOZZlf

holder washer, corrugated washerheat shield and heat shield washer.

(13) Remaval of thermastat housing1) Remove the 4 bolts fixing the thermosta

housing and remove th'e thermostat housing2) Remove the fuel filter bracket. .

FIG. 1-53) Remove the 4 bolts fixing the oil filter and

remove the oil filter assembly.NOTE: Remove oil filter carefully not to spill

engine oil.

FIG. 1-7(14) Removal of cylinder head cover

Remove the bo:ts fixing the cylinder head coverand remove the cylinder head cover.

(15) Removal of rocker arm shaft assembly1) Remove the 8 bolts fixing the rocker arm

shaft brackets in sequence commencingwith the outer ones.

2) Remove the rocker arm shaft assembly.3) Remove the 8 push-rods.

~

(10) Removal of oil pipes and glow plug connector1) Remove the vacuum pump oil pipe joint bo(t

and cljp bolt, then djsconnect the oil pipe.2) Remove the rocker arm oil feed pipe sleeve

nut, joint bolt and clip bolt, then disconnectthe oil feed pipe.

3) Remove the nuts fixing the glow plug con-nector and remove the connector .(11) Removal of water pump

1) Disconnect the bypass hose.2) Remove the 6 bolts mounting the water

pump assembly and remove the water pumpassembly and adjust plate. "'~"-

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FIG. 1-8(16) Removal of cylinder head assembly

1) Remove the 19 bolts clamping the cylinderhead and remove the cylinder headassembly.

FIG. 1-6(12) Remova! of injection nozzles and glow plugs1) Remove the nozzle holder fixing nut and re-

move the nozzle assembly.

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1-4 ENGINE

2) Remove the cylinder head gasket.NOTE: 1. Loosen the cylinder head bolts in

2 or 3 steps in sequence of coilcommencing with the outer ones.

2. Remove the cyiinder head upwardas it is fitted to the cylinder bodywith dowels. .,.

2) Remove the 3 bolts fixing the rear plate andremove the rear plate.(19) Removal of oil pan and crankcaseRemove the 20 bolts fixing the crankcase andremove the crankcase together with the oil pan.

NOTE: Pry off the crankcase by fitting ascrewdriver :into the slots in thecrankcase. :;(20) Removal of oil pump : .

1) Remove the oil pip"e sleeve nut.2) Removes the 2 bolts fixing the oil pump andremove the oil pump with oil pipe.

FIG. 1-9(17) Removal of tappet chamber cover

1) Remove the 14 bolts fixing the tappetchamber cover and remove the tappetchamber cover assembly.

2) Disconnect the thermostat and ojl pressureunit harnesses.NOTE: To remove tappet chamber cover in-

sert a screwdriver alternately intoslots and pry off cover .

{18) Removal of flywheel assembly and rear plate1) Remove the 6 bolts mounting the flywheel

and remove the flywheel assembly.NOTE: When loosening the flywheel bolts.

hold the crankshaft front nut with awrench to prevent turning of thecrankshaft.

(21) Removal of Crank5haft pulley1) Remove the crankshaft pulley nut by u5ing abar to prevent turning of the crankshaft.2) Remove the crankshaft pulley.

(22) Removal of timing gear case1) Remove the 9 bolts fixing the timing gear

case and remove the gear case.2) Remove the oil thrower.3) Remove the timing gear case oil seal.

(23) Inspection of timing gear5 prior to disassemblyPrior to disa5sembly. check the timing gears inthe following manners to determine whether ornot parts replacement is necessary.1) Inspection of gear backlash.

An excessive timing gear backlash 'Nill de-stroy proper engjne timing and causes ab-normal gear noise.Check the gears for backlash in the fo'lowingmanner: Check the amount of backlash be-tween the crankshaft gear and idle gear. idlegear and camshaft gear using a dial indicatoror by inserting a fuse between the gears inmesh and measuring the thickness of flat-tened fuse after turning the gears carefully innormal direction of rotation.If the amount of backlash is beyond the limit.check the gears and idle gear bushing forwear and replace as necessary.IG. 1-10

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ENGINE 1-5

FIG.1-14

FIG. 1-12(25) Removal of idle gear and idle gear shaft

1) Remove the 2 bolts fixing the idle gear thrustcollar and remove the thrust collar.

2) Remove the idle gear.3) Pry off the idle gear shaft using a

screwdriver.) Inspection of idle gear end play.Measure the clearance between the idle gearand thrust collar using a feeler gauge. If theclearance is in excess of 0.2 mm, replace thethrust co/lar or the gear at the time ofreassembly.

FIG. 1-15

FIG. 1-13(24) Removal of camshaft assembly1) Remove the camshaft gear bolt using a bar to

prevent turning of the crankshaft.2) Remove the bolts fixing the camshaft thrustplate.3) Remove the camshaft together with the gear .NOTE: Remove the camshaft carefully not to

damage the camshaft beari ngs. FIG. 1-16

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(29) Remaval af crankshaft ail seals and spacer1) Remove the crankshaft ail seals.2) Remove the oil seal spacer.

NOTE: Remove oil seal sp.acer carefully notto cause distortion.

(30) Removal of crankshaft ;Prior to removal. check the crankshaft e:nd p'-ayin the following manner to determine whether ornot thrust bearing replacement is necessary.1) Loosen the crankshaft bearing cap blfs insequence commencing with the outer ones.Remove the bolts. bearing caps and

bearings.

Removal of crankshaft gear and front plate1) Remove the crankshaft gear using specialtool; gear remove.r (9-8521-0074-0 or9-8521-0062-0). .2) Remove tbe 3 bolts fixing the front plate and

remove the front plate.Removal of tappetsWith the vallte lapper handle, push out the tap-pet toward tf1e oil pan~ide. "

(28) Removal of" pjston and connecting-rodassembly1) Remove carbon from .,per part of the cylin-

der wall with a scraper to facilitate smoothremoval of the piston.

2) Remove the connecting-rod bearing capbolts, then remove the bearing cap.:'; , ---" ..;) .._:~. .;f~~~,~ .~ --, ,..

-."'c::,~~-;:~%t ";;~r~i;,::,"':::f:"

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FIG. 1-19

2) Move the crankshaft ali the way forward witha pry bar and measure the crankshaft endplay of the thrust bearing fitted to the No.3bearing using a feeler gauge. If the crank-shaft end play is beyond the limit. be sure toreplace the thrust bearing at the time ofreassembly.

3) Remove the crankshaft and take out thebearings.REFERENCE: Scribe the bearing capnumber on the rear face of

the bearings to insure reas-sembly of them to their orig-inaI positions.

IG. 1-18

C.'."'."' ...:'~.~".;"'i:i':;"'i;:ii..:,:c:;;..,;:."",,FIG. 1-173) RemoVe the piston and connecting-rod as-

sembly upward by pushing on theconnecting-rod big-end with a hammerhandle.N,OTE: 1. When removing piston and

connecting-rod assembly. ho1dthe connecting-rod in parallel.with the cylinder bore.

2. 00 not scratch connecting-rodbearing.3.. With a marking pen. apply cylin-der number mark to rear face of

~ each Connecting-ro~d bearing.

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-,.r ,-,' ENGINE 1-'

(31) Remava' af camshaft bearingsRemcve the plug plate from rear cf the cylinderbody, then remcve the camshaft bearings usingspecial tccl; camshaft bearing remcver and in-stalJer (9-8523-1360-9).

NOTE: Removaf of camshaft bearings is neces-sary only when the clearance betweenbearing and journal is found to be in ex-;cess of the value indicating need for.servicing (0.12 mm or more). ,

F/G. 1-211. CYLINDER BODY2. CYLINDER LINER3. DOWEL4. CYLINDER BODY REAR PLATE5. SEALING CAP6. SEALING CAP7. REAMER BOL T8. CRANKSHAFT OIL SEAL9. CRANKSHAFT OIL SEAL SPACER10. BOL T

11. BREATHER PtPE12. PACKtNG

25. RUBBeR HOSe26. PACKING27. CAMSHAFT BeARING PLATe PLUG28. TAPpeT CHAMBeR PLUG29. OIL GALLeRY PLATe PLUG30. BeARING CAP BOL T31. WATeR DRAIN COCK32. WA TeR DUCT33. CAMSHAFT BeARING34. -GASKeT35. CYLINDeR BODY FRONT PLATe36. OIL GALLeRY TAPeR PLUG

13. NIPPLE14. CLIP15. RUBBER HOSE16. CLIP17. BOLT18. BAFFLE FIXING SCREW19. WASHER20. BREATHER BAFFLE (A)21. BREATHER BAFFLE (B)22. CLIP23. TAPPET CHAMBER COVER24. CLIP

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1-8 ENGINE

3-1 Cylinder Body and Cylinder LinersService tools: Cylinder bore indicator, feefer gauge,straight edge, hydraulic tester.Special tools: Cylinder liner remover (9-8523-2552-0),cylinder liner grip (9-8522-1148-0), cylinder liJlerinstalfer (9-8523-2551-0).

(1) Inspection of cylinder liners for wearMeasure the cylinder liner bore diamerer with acylinder bore indicator.Measurements should be taken at the portionapproximately 15 mm below the top end of thecylinder liners where the amount of wear is gen-erally largest.

The cromard cylinder liners cannot be re-conditioned by means of reboring and honingsince their inner wall is chrome plated. Thecromard cylinder liner should therefore be re-placed with a new one if the inner wall has atrace of seizure or has been scuffed or if theamount of wear is beyond the limit for use.

FIG. 1-23(3) Cromard liner handling precautions1) Handle the cromard cylinder liners carefully

not to cause distortion, damage or dents asthey are only 1.0 mm in thickriess of the wall.

2) It is important to use the specified pressurewhen measuring the outside diameter of thecyfinder liner wth an outside micrometer, asthe use of excess pressure will cause distor-tion of the thin wall of the liner and gives afalse indication of the diameter.3) Wash clean the outer and inner wall of thecromard liner carefully with clean oil aspresence of foreign matter or damage couldcause various troubles.4) Before installation. invert the liner and posi-tion it over the cylinder bore in the cyfinderbody and check that its ffanged end fits intothe stepped portion of the cylinder bore.

5) Keep hands off the cromard liners unlesswhen installing them as they are treated withrust-proofing materiaf.

(4) Cylinder liner installation precautionsThere should be provided an appropriate fittinginterference between the cylinder liner and bodysince too small a fitting interference betweenthese parts will adversely affect the cooling ofthe cylinder liner while too large a fitting inter-ference makes installation of the cylinder linerextremely difficult or impossible.It is therefore advisable to measure the cylinderbore diameter and outside diameter of the cyl-inder liner to make certain there exists a normalfitting interference before installing the cyfinderliner.

FIG. 1-22(2) Cramard liner remava!Press cut the cylinder liner frcm the Icwer side

cf the cylinder body using a bench press andspecial tccl; remcver (9-8523-2552-0), grip(9-8522-1148-0).

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ENGINE 1-9

Measure the cylinder bore diameter after clean-ing the bore carefully to determjne the size ofthe cromard liner to be installed. When thegrade of the Ijner s d~termined, wash clean theliner and cylinder bore, then app(y spindle oil tothe outer wall of the liner.NOTE: Reference value .

NOTE: Variance in prcjecticn cf adjacent liner5shculd be held within 0.015 mm.

CrQmard liner length (mm) :; 178

'.(5) Cromard liner jnstallationInstall the cromard liner into the cylinder borewith a bench press by aligning the centers of thecylinder bore, liner and bench press spindle.First apply a pressure of 500 kg to the liner withspecial tool; installer (9-8523-2551-0), then applythe final load of 2,500 kg to set it in position ofinstallation.

FIG. 1-25(8) Inspection of cylinder body upper face for

distortionWhen the dowels and cromard liners are re-moved from the cylinder body. check the upperface of the cylinder body for distortion in 6 di-rections using a straight edge and a feelergauge.If the amount of distortion is beyond the valueindicating need for servicing. correct with a sur-face grinder.

FIG. 1-24(6) Inspection of cylinder liners after installation

Measurement of cylinder liner bore diameterand selection of piston grade. When the cylinderliner is installed into the cylinder body, measurethe cyfinder liner t?ore diameter and select thepiston grade.It is strong(y advisable to use piston of gradecarefully selected by referring to the measurecylinder liner bore diameter as the use of pistonse(ected at random may resultin piston seizure.

(7) Projection of cylinder linersWhen the liner is installed. check the amount ofprojection of the liner in the following manner:Ho(d a straight edge against the upper face ofthe (iner and measure the clearance betweenthe straight edge and upper face of the cylinderwith a feeler gauge.

FJG. 1-26

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1.10 ENGINE

Service taals: Micrameter, cylinder bare indicatorfeeler gauge, connecting-rod align~r.pull scale.Special taols: Piston ring remover and instaIler.

: FIG. 1-27(9) Inspection and cleaning of cylinder body1) Inspection. ~

1. Wash clean the cylinder body and checkfor cracking or damage using a dye pene-trant flow detector.

2. Hydraulic test.Perform a hydraulic water test on the cyl-inder body by applying pressurized waterof 3 kg/cm2 into the cylinder body con-tinuousfyfor 5 minutes.2) Cleaning of water and oil ports.

Remove rust and scales and check for corro-sion and restrictions paying particular atten-tion to the water passages between thecylinders. Wash the oil gallery and cle~n theoil ports with compressed air and check tobe certain they are free from restrictions.

FIG. 1-29

Pistons and connecting-rods-2(1) Disassembly of piston and connecting-rod

assembly1) Remove the piston rings using piston ringremover and installer .NOTE: Keep the piston rings and pistonfrom each cylinder separate to pre-vent interchanging.4

5

FIG. 1-30

1. Piston2. Piston pin3. Snap ring4. Piston ring kit

5. Connecting-rod a~embly6. Connecting-rod bolt7. Connecting-rod bushing8. Connecting-rod bearing

2) Remove the piston pin snap rings from thepiston.3) Removal of piston pin.Tap out the piston pin using a bar and ahammer.NOTE: Keep the piston. piston pin and con-necting-rod from each cylinder sepa-

rate to prevent interchanging.