1-1

1.

FUEL

SYSTEM

BLEEDING

2.

MAJOR 2-1.

DISASSEMBL

Y OF

ENGINE

1-2 1-2

Remava'

1-7
3. SERVICING OF MAJOR COMPONENT PARTS

1-8
3-6. 3-1. 3-2. 3-4. 3-5. 3-3. Cylinder Pistons Crankshaft. Rockerarm Camshaftassembly and head body bearjngs shaft connecting-rods assembly and assembly cylinder and flywheel liners

1-10 1-14 1-18 1-25 1-26

4.

MAJOR 4-1.

REASSEMBL

Y OF

ENGINE

COMPONENTS

1-29 1-29
1-36

Reassembly

5.

ENGINE

TROUBLE-SHOOTING

BLEEDING OF FUEL SYSTEM

1) Loosen the cap on the fuel feed pump and pump fuel into the injection pump by operating the feed pump. 2) When the fuel system beccmes filled and feed pump begins t c idle, Iccsen the jcint bclt cf inlet pipe fitted t c the fuel filter, t c release fueJ with air. 3) Repeat the above operation unti' air bubbles disappear fro~ the fue' being pumped out.

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~~. "~~

FIG.

1-1

1-2

ENGINE

4) Similarly, remove air by loosening the bleeder screw on the left side part of the injection NOTE: pump. Tighten the'bleeder pressurized fuel released. screw, before is completely

(2)

Removal of left side engine foot Remove the engine foot fixing bolts and the engine foot and support rubber. Removal of intake and exhaust manifolds 1) Disconnect the breather hose. and vacuum vinyl pipe. 2) Remove the 2 bolts and 7 nuts mounting the intake and exhaust manifolds; then remove the spring. spring eye. engine tianger an~ intake and exhaust manifolds. /, .

(3)

(4)

Removal of leak-off pipe Remove the joint bolt and disconnect off pipe. Removal of fuel pipes and fuel filter 1) Remove the joint bolt and return bolt. 2) Remove the fuel filter move the fuel filter . mounting

the lea-k--

(5)

pipe

clip

bolt and re-

(6)

RemovaJ of injection pipes Remove the sleeve nuts and d isconnect jection pipes. Remcval of injection pump Remove the bolts fixing the injection remove the injection pump assembly NOTE:

the in-

FIG.

1-2

(7)

2.
Service SpeciaJ

MAJOR
tools: tools:

DISASSEMBL

y CF ENGINE

pump and rearward.

Dia! indicator, feeler gauge, scraper Crankshaft gear remover 9-8521-0074-0 or 9-8521-0062-0 Camshaft bearing remover and installer 9-8523-1360-0

2-1 (1)

Removal Removal of cooling fan and generator 1) Remove the 4 bolts and remove the cooling fan. spacer and pulley. 2) Remove the vacuum pump oil pipe and rubber hose. 3) Remove the generator adjust plate bolt and fixjng bolt. then remove the generator assembly.

Liquid gasket has been applied t c the bcnding tace cf injecticn pump befcre installaticn t c ensure permanent setting. Remcve injecticn pump by tapping lightly with a mallet.

FIG

-4

(8)

Removal of right side engine foot Remove the bolts fixing the engine foot and remove the engine foot and support rubber. Removal of oil level gauge and oil filter 1) Remove the oil level gauge. 2) Remove the nut and the bolt fixing the clip of the guide tube and remove the guide tube.

(9)

FIG. 1-3

ENGINE

1-3

2) Remove the glow plug. NOTE: Take care not to lose the nOZZlf holder washer, corrugated washer heat shield and heat shield washer. (13) Remaval of thermastat housing

1) Remove the 4 bolts fixing the thermosta housing and remove th'e thermostat housing 2) Remove the fuel filter bracket. .

FIG. 1-5 3) Remove the 4 bolts fixing the oil filter remove the oil filter assembly. NOTE: Remove oil filter carefully engine oil. and

not to spill

(10) Removal

of oil pipes

and glow plug connector FIG. 1-7 (14) Removal of cylinder head cover

1) 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 disconnect the oil feed pipe. 3) Remove the nuts fixing the glow plug connector and remove the connector . (11) Removal of water pump

Remove the bo:ts fixing the cylinder head cover and remove the cylinder head cover. (15) Removal of rocker arm shaft assembly

1) Disconnect the bypass hose. 2) Remove the 6 bolts mounting the water pump assembly and remove the water pump assembly and adjust plate.

1) Remove the 8 bolts fixing the rocker arm shaft brackets in sequence commencing with the outer ones. 2) Remove the rocker arm shaft assembly. 3) Remove the 8 push-rods. ~
"'~"i,C:c..:

."", ':.~j;

FIG. 1-8
FIG. 1-6 (12) Remova! of injection nozzles and glow plugs 1) Remove the nozzle holder fixing nut and remove the nozzle assembly. (16) Removal of cylinder head assembly clamping the cylinder the cylinder head

1) Remove the 19 bolts head and remove assembly.

1-4

ENGINE

2) Remove NOTE:

the cylinder

head gasket.

1. Loosen the cylinder head bolts in 2 or 3 steps in sequence of coil commencing with the outer ones. 2. Remove the cyiinder head upward as it is fitted to the cylinder body with dowels. . ,.

2) Remove the 3 bolts fixing the rear plate and remove the rear plate. (19) Removal of oil pan and crankcase Remove the 20 bolts fixing the crankcase and remove the crankcase together with the oil pan. Pry off the crankcase by fitting a screwdriver :into the slots in the crankcase. :; (20) Removal of oil pump : . 1) Remove the oil pip"e sleeve nut. 2) Removes the 2 bolts fixing the oil pump and remove the oil pump with oil pipe. NOTE:

FIG. 1-9 (17) Removal of tappet chamber cover 1) Remove the 14 bolts fixing the tappet chamber cover and remove the tappet chamber cover assembly. 2) Disconnect the thermostat and ojl pressure unit harnesses. NOTE: To remove tappet chamber cover insert a screwdriver alternately into slots and pry off cover .

(21) Removal of Crank5haft pulley 1) Remove the crankshaft pulley nut by u5ing a bar to prevent turning of the crankshaft. 2) Remove the crankshaft pulley. (22) Removal of timing gear case 1) Remove the 9 bolts fixing the timing case and remove the gear case. 2) Remove the oil thrower. 3) Remove the timing gear case oil seal. gear

{18) Removal of flywheel assembly and rear plate 1) Remove the 6 bolts mounting the flywheel and remove the flywheel assembly. NOTE: When loosening the flywheel bolts. hold the crankshaft front nut with a wrench to prevent turning of the crankshaft.

(23) Inspection of timing gear5 prior to disassembly Prior to disa5sembly. check the timing gears in the following manners to determine whether or not parts replacement is necessary. 1) Inspection of gear backlash. An excessive timing gear backlash 'Nill destroy proper engjne timing and causes abnormal gear noise. Check the gears for backlash in the fo'lowing manner: Check the amount of backlash between the crankshaft gear and idle gear. idle gear and camshaft gear using a dial indicator or by inserting a fuse between the gears in mesh and measuring the thickness of flattened fuse after turning the gears carefully in normal direction of rotation. If the amount of backlash is beyond the limit. check the gears and idle gear bushing for

FIG.

1-10

wear and replace

as necessary.

ENGINE

1-5

FIG.1-14
(25) Removal of idle gear and idle gear shaft 1) Remove the 2 bolts fixing the idle gear thrust collar and remove the thrust collar. 2) Remove the idle gear. 3) Pry off the idle gear shaft using a screwdriver.

FIG. 1-12
2) Inspection of idle gear end play. Measure the clearance between the idle gear and thrust collar using a feeler gauge. If the clearance is in excess of 0.2 mm, replace the thrust co/lar or the gear at the time of reassembly.

FIG. 1-15

FIG. 1-13
(24) Removal of camshaft assembly 1) Remove the camshaft gear bolt using a bar to prevent turning of the crankshaft. 2) Remove the bolts fixing the camshaft thrust plate. 3) Remove the camshaft together with the gear . NOTE: Remove the camshaft carefully not to damage the camshaft beari ngs.

FIG.

1-16

1-6

ENGINE

(26) Removal of crankshaft gear and front plate 1) Remove the crankshaft gear using special tool; gear remove.r (9-8521-0074-0 or 9-8521-0062-0). . 2) Remove tbe 3 bolts fixing remove the front plate. the front plate and

(29) Remaval 1) Remove 2) Remove NOTE:

af crankshaft

ail seals

and spacer

the crankshaft ail seals. the oil seal spacer. Remove oil seal sp.acer carefully to cause distortion. not

(27) Removal of tappets With the vallte lapper handle, push out the tappet toward tf1e oil pan~ide. " (28) Removal of" pjston and connecting-rod assembly 1) Remove carbon from .,per part of the cylinder wall with a scraper to facilitate smooth removal of the piston. 2) Remove the connecting-rod bearing cap bolts, then remove the bearing cap. :'; , ---" ..;) .._:~. .;f~~~
. ~

(30) Removal of crankshaft

Prior to removal. check the crankshaft e:nd p'-ay in the following manner to determine whether or not thrust bearing replacement is necessary. 1) Loosen the crankshaft bearing cap blfs in sequence commencing with the outer ones. Remove the bolts. bearing caps and bearings.

,~

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;,::
,"': ::f:"

-,

,.. "

-."'c::, ~~-;:~%t

~~i~~

~ti~

C.'."'."' ...:'~.~".;"'i:i':;"'i;:ii..:,:c:;;..,;:."",, FIG. 1-17 3) RemoVe the piston and connecting-rod assembly upward by pushing on the connecting-rod big-end with a hammer handle. N,OTE: 1. When removing piston and connecting-rod assembly. ho1d the connecting-rod in parallel .with the cylinder bore. 2. 00 not scratch connecting-rod bearing. 3.. With a marking pen. apply cylinder number mark to rear face of ~ each Connecting-ro~d bearing.

FIG.

1-19

2) Move the crankshaft ali the way forward with a pry bar and measure the crankshaft end play of the thrust bearing fitted to the No.3 bearing using a feeler gauge. If the crankshaft end play is beyond the limit. be sure to replace the thrust bearing at the time of reassembly.

3) Remove bearings.

the

crankshaft

and

take

out

the

REFERENCE:

FIG.

1-18

Scribe the bearing cap number on the rear face of the bearings to insure reassembly of them to their originaI positions.

-, .r

-,'

ENGINE 1-'

(31) Remava' af camshaft Remcve the plug plate body, then remcve the special tccl; camshaft stalJer (9-8523-1360-9).

bearings from rear cf the cylinder camshaft bearings using bearing remcver and in-

NOTE:

Removaf of camshaft bearings sary only when the clearance bearing and journal is found to cess of the value indicating servicing (0.12 mm or more).

is necesbetween be in ex-; need for. ,

F/G. 1-21
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. CYLINDER BODY CYLINDER LINER DOWEL CYLINDER BODY REAR PLATE SEALING CAP SEALING CAP REAMER BOL T CRANKSHAFT OIL SEAL CRANKSHAFT OIL SEAL SPACER BOL T BREATHER PtPE PACKtNG 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. NIPPLE CLIP RUBBER HOSE CLIP BOLT BAFFLE FIXING SCREW WASHER BREATHER BAFFLE (A) BREATHER BAFFLE (B) CLIP TAPPET CHAMBER COVER CLIP 25. RUBBeR HOSe 26. PACKING 27. CAMSHAFT BeARING PLATe PLUG 28. TAPpeT CHAMBeR PLUG 29. OIL GALLeRY PLATe PLUG 30. BeARING CAP BOL T 31. WATeR DRAIN COCK 32. WA TeR DUCT 33. CAMSHAFT BeARING 34. -GASKeT 35. CYLINDeR BODY FRONT PLATe 36. OIL GALLeRY TAPeR PLUG

1-8

ENGINE

3-1 Service straight Special cylinder instalfer (1)

Cylinder tools:

Body Cylinder

and tester.

Cylinder

Liners feefer gauge,

bore indicator,

edge, hydraulic

tools: Cylinder liner remover (9-8523-2552-0), liner grip (9-8522-1148-0), cylinder liJler (9-8523-2551-0). of cylinder liners for wear

Inspection

Measure the cylinder liner bore diamerer with a cylinder bore indicator. Measurements should be taken at the portion approximately 15 mm below the top end of the cylinder liners where the amount of wear is generally largest. (3)

FIG. 1-23 Cromard liner handling precautions 1) Handle the cromard cylinder liners carefully not to cause distortion, damage or dents as they are only 1.0 mm in thickriess of the wall. 2) It is important to use the specified pressure when measuring the outside diameter of the cyfinder liner wth an outside micrometer, as the use of excess pressure will cause distortion of the thin wall of the liner and gives a false indication of the diameter. 3) Wash clean the outer and inner wall of the cromard liner carefully with clean oil as presence of foreign matter or damage could cause various troubles. 4) Before installation. invert the liner and position it over the cylinder bore in the cyfinder body and check that its ffanged end fits into the stepped portion of the cylinder bore. 5) Keep hands off the cromard liners unless when installing them as they are treated with rust-proofing (4) materiaf. Cylinder liner installation precautions There should be provided an appropriate fitting interference between the cylinder liner and body since too small a fitting interference between these parts will adversely affect the cooling of the cylinder liner while too large a fitting interference makes installation of the cylinder liner extremely difficult or impossible. It is therefore advisable to measure the cylinder bore diameter and outside diameter of the cylinder liner to make certain there exists a normal fitting interference before installing the cyfinder liner.

The cromard cylinder liners cannot be reconditioned by means of reboring and honing since their inner wall is chrome plated. The cromard cylinder liner should therefore be replaced with a new one if the inner wall has a trace of seizure or has been scuffed or if the amount of wear is beyond the limit for use.

FIG. 1-22
(2) Cramard liner remava! Press cut the cylinder liner frcm the Icwer side cf the cylinder body using a bench press and special tccl; remcver (9-8523-2552-0), grip (9-8522-1148-0).

ENGINE

1-9

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

NOTE:

Variance in prcjecticn shculd be held within

cf adjacent 0.015 mm.

liner5

CrQmard liner length

(mm)

:; 178

(5)

Cromard liner jnstallation Install the cromard liner into the cylinder bore with a bench press by aligning the centers of the cylinder bore, liner and bench press spindle. First apply a pressure of 500 kg to the liner with special tool; installer (9-8523-2551-0), then apply the final load of 2,500 kg to set it in position of installation.

'.

FIG. 1-25
(8) Inspection of cylinder body upper face for distortion When the dowels and cromard liners are removed from the cylinder body. check the upper face of the cylinder body for distortion in 6 directions using a straight edge and a feeler gauge. If the amount of distortion is beyond the value indicating need for servicing. correct with a surface grinder.

FIG. 1-24
(6) Inspection of cylinder liners after installation Measurement of cylinder liner bore diameter and selection of piston grade. When the cylinder liner is installed into the cylinder body, measure the cyfinder liner t?ore diameter and select the piston grade. It is strong(y advisable to use piston carefully selected by referring to the cylinder liner bore diameter as the use se(ected at random may resultin piston (7) of grade measure of piston seizure.

Projection of cylinder liners When the liner is installed. check the amount of projection of the liner in the following manner: Ho(d a straight edge against the upper face of the (iner and measure the clearance between the straight edge and upper face of the cylinder with a feeler gauge.

FJG. 1-26

1.10 ENGINE

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

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

1. Wash clean the cylinder body and check for cracking or damage using a dye penetrant flow detector. 2. Hydraulic test. Perform a hydraulic water test on the cylinder body by applying pressurized water of 3 kg/cm2 into the cylinder body continuousfyfor 5 minutes. 2) Cleaning of water and oil ports. Remove rust and scales and check for corrosion and restrictions paying particular attention to the water passages between the cylinders. Wash the oil gallery and cle~n the oil ports with compressed air and check to be certain they are free from restrictions.

FIG. 1-29 (1) Disassembly of piston and connecting-rod assembly 1) Remove the piston rings using piston ring remover and installer . NOTE: Keep the piston rings and piston from each cylinder separate to prevent interchanging.

3-2

Pistons

and connecting-rods

~4

FIG. 1-30

2) Remove the piston pin snap rings from the piston. 3) Removal of piston pin. Tap out the piston pin using a bar and a hammer. NOTE: Keep the piston. piston pin and connecting-rod from each cylinder separate to prevent interchanging.

1. 2. 3. 4.

Piston Piston pin Snap ring Piston ring kit

5. 6. 7. 8.

Connecting-rod Connecting-rod Connecting-rod Connecting-rod

a~embly bolt bushing bearing